CN105269751A - 齿轮及其制造方法 - Google Patents

齿轮及其制造方法 Download PDF

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CN105269751A
CN105269751A CN201510409765.5A CN201510409765A CN105269751A CN 105269751 A CN105269751 A CN 105269751A CN 201510409765 A CN201510409765 A CN 201510409765A CN 105269751 A CN105269751 A CN 105269751A
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gear
metal pattern
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国岛武史
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JTEKT Corp
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Abstract

本发明提供齿轮及其制造方法，制造方法是在金属模的与套筒对应的区域放置有由强化纤维构成的圆环状预制件的状态下，向上述金属模的上述区域和与齿部对应的区域填充树脂。齿轮通过上述工序制造。

Description

齿轮及其制造方法
技术领域
本发明涉及树脂制的齿轮及其制造方法。
背景技术
例如在电动动力转向装置中，经由减速机使转向操纵辅助用的电动马达的旋转减速并且将输出增幅而传递至转向机构，从而对由驾驶员操作的转舵机构的动作进行扭矩辅助。减速机通常使用具备相互啮合的蜗杆与蜗轮的构造。而且，蜗轮例如一般是在铁制的套筒的外周通过注射模塑成型(嵌件成型)等形成圆环状的树脂部件后，切削加工树脂部件的外周等而形成齿来制造。
树脂部件例如由聚酰胺(PA6、PA66、PA46等)、芳香族聚酰胺、聚甲醛、PEEK、PPS等形成。根据近几年减少环境负荷的要求，汽车用部件需要进一步轻型化。在电动动力转向装置中，蜗轮的铁制的套筒所占的重量比很大。因此，需要在保持必要强度以及刚性的基础上使包含上述金属芯的蜗轮的整体轻型化。
近几年，逐渐将轻型且高强度、高刚性的纤维强化复合件应用于汽车用部件。作为纤维强化复合件，例如可举出使用碳纤维作为强化纤维并使用热固性树脂的CFRP材(CarbonFiberReinforcedPlastics：碳纤维增强塑料)、或使用热塑性树脂的CFRTP材(CarbonFiberReinforcedThermoPlastics：碳纤维增强热塑性塑料)等。
为了应用上述纤维强化复合件使蜗轮等齿轮轻型化，例如考虑下述的方法。
(1)将使强化纤维的薄片浸入热固性树脂而得的半固化片卷绕为圆环状。接着，通过使热固性树脂固化反应的薄片卷绕成型，制作由纤维强化复合件构成且与齿轮的整体形状对应的圆板状的成型体。并且，切削加工其外周等从而形成齿。
(2)通过上述薄片卷绕成型制作由纤维强化复合件构成的套筒。接着，与以往相同，通过嵌件成型等在该套筒的外周形成圆环状的树脂部件。而且，对树脂部件的外周进行切削加工等形成齿(日本特开2001-304379号公报等)。
然而，通过(1)的方法形成的齿轮一直到齿的前端都是由纤维强化复合件形成的。因此，刚性高、韧性低，所以例如对于蜗轮的情况会有在与蜗杆啮合并旋转时容易产生所谓的噪音(齿轮噪音)的问题。而且在通过切削加工形成齿时，连续的强化纤维被切断，树脂与强化纤维剥离。上述情况成为破坏源从而还存在齿轮的耐冲击性、机械强度降低的问题。
另一方面，通过(2)的方法形成的齿轮的套筒与齿部的粘合部的可靠性、耐热冲击性等不足。另外，若为了提高上述特性并进行齿部与套筒之间的防脱、止转等而对与齿部接触的套筒的外周进行滚花加工、喷砂加工、蚀刻处理等，则连续的强化纤维被切断、或者树脂与强化纤维剥离。上述情况成为破坏源从而存在齿轮的耐冲击性、机械强度降低的问题。
而且，在上述(1)、(2)的方法中，用于纤维强化复合件的树脂限定于在固化前具有适度粘着性的柔软的环氧树脂等。然而，使用上述粘着性好的柔软的环氧树脂等的纤维强化复合件若一直存在到流动化时间为止，则到固化反应结束要大致5个小时以上较长的时间。因此，还存在齿轮以及具备该齿轮的电动动力转向装置等生产率大幅降低之类的问题。
发明内容
本发明的目的之一在于提供能够不使连续的强化纤维产生切断、剥离等并以较高的生产率高效地制造轻型齿轮的齿轮的制造方法、和由此方法制造出的齿轮，上述齿轮是将由纤维强化复合件构成的高强度且高刚性的套筒、和由不含有上述强化纤维的树脂构成从而柔软且韧性优异并难以产生噪音等进而耐冲击性优异的齿部牢固地形成为一体而得到的。
本发明的一实施方式的齿轮的制造方法在结构上的特征是包含如下工序：对于在最外周具备与齿部对应的圆环状的区域、和与该区域的径向内侧接触地具备与套筒对应的区域的金属模而言，在该金属模内的与所述套筒对应的区域，放置由强化纤维构成的圆环状预制件的工序、以及使放置的上述圆环状预制件中浸入树脂，并且将上述树脂填充到上述金属模的与上述齿部及上述套筒对应的整个区域的工序。
通过以下参照附图对本发明的实施方式示例进行的详细描述，本发明的上述及其他特征和优点会变得更加清楚，其中，相同的附图标记表示相同的要素。
附图说明
图1(a)是表示在本发明的齿轮的制造方法的一个例子中，在放置于金属模的圆环状预制件中浸入树脂并且向各区域填充树脂而形成的、在外周形成齿前的成型体的立体图，图1(b)是表示在从金属模取出的上述成型体的外周形成齿而完成的齿轮的一个例子的立体图。
图2(a)是说明在使用上述例子的制造方法的金属模中收纳圆环状预制件并且填充树脂的区域的配置的立体图，图2(b)是表示在上述金属模中与套筒对应的区域放置有圆环状预制件的状态的立体图。
图3(a)～(d)分别是表示放置于金属模的圆环状预制件的一个例子的立体图。
具体实施方式
参照图1(a)，作为齿轮1的基体的成型体2在最外周具有圆环状的齿部3、与该齿部3的径向内侧接触地具有厚壁圆板状的套筒4。在该套筒4的中心，形成有用于插通和固定未图示的轴的通孔5。上述的套筒4由在形成被埋设于内部的圆环状预制件6的强化纤维中浸入树脂的纤维强化复合件构成。齿部3由不含有上述强化纤维的树脂构成。上述齿部3与套筒4通过上述树脂的连续相牢固地形成为一体。
通孔5和齿部3的外周7分别形成为直径一定的圆筒状。外周7与通孔5配设为同心状。埋设于套筒4内的圆环状预制件6也与上述通孔5配设为同心状。参照图2(a)，用于制造上述成型体2的金属模8具备第一区域9和第二区域10。第一区域9与齿部3的立体形状对应。第二区域10与第一区域9的径向内侧接触并与套筒4的立体形状对应。在第二区域10的中心插通有与通孔5对应且直径一定的圆柱状的销11。
第一区域9的内周12形成为与上述齿部3的外周7对应且直径一定的圆筒状。由于成型体2的外周7与通孔5配设为同心状，所以上述内周12与销11配设为同心状。通孔5的内径的精度由销11的外径的精度决定。因此，提高销11的外径的精度，能够提高轴压入通孔5的精度。但也可以在成型后对通孔5内进行切削加工来精加工至规定的精度。
参照图2(b)，在该例的制造方法中，首先在上述金属模8的第二区域10放置圆环状预制件6。作为圆环状预制件6，使用如图所示的内径与销11的外径大致一致的部件。由此，能够将该圆环状预制件6如之前说明那样配设为与通孔5呈同心状。
作为圆环状预制件6，例如可以使用图3(a)～(d)例示的部件等。例如使由强化纤维构成的开孔圆板13成为规定的厚度，并如图中的实线箭头所示那样在厚度方向层叠多张而形成图3(a)的圆环状预制件6。而且，作为开孔圆板13，例如可举出将强化纤维织成开孔圆板状的纺织品、将片状的纺织品或者单向材料穿孔为开孔圆板状的结构等。
将织造强化纤维而成并具有一定厚度和宽度的编织带14如图中的实线箭头所示那样两端连结为圆环状而形成图3(b)的圆环状预制件6。另外，在编织带14的厚度不足的情况下，可以与图3(a)的开孔圆板13相同，在厚度方向层叠多张。图3(c)的圆环状预制件6形成为将强化纤维织造为立体状的三维纺织品15。
而且，织造强化纤维形成筒16，将该筒16如图中的实线箭头所示那样沿长度方向卷绕而形成图3(d)的圆环状预制件6。作为形成上述圆环状预制件6的强化纤维，例如可举出碳纤维、玻璃纤维、芳香族聚酰胺纤维各种纤维。为了尽可能使齿轮1的套筒4高强度并且高刚性，特别优选碳纤维。而且，考虑进一步提高上述效果，碳纤维优选拉伸强度在3000MPa以上、拉伸弹性率在200GPa以上的纤维。
为了确保碳纤维的表面与树脂的良好紧贴，例如优选利用聚氨酯类、环氧类、丙烯酸类、双马来酰亚胺类等施胶剂进行处理。
接着，在该例的制造方法中，向上述金属模8的第一以及第二区域9、10注入树脂。这样，注入的树脂浸入被放置于上述第二区域10的圆环状预制件6中并且填充于第一以及第二区域9、10的整体从而形成图1(a)所示的成型体2。
树脂例如通过注射模塑成型，即将利用注射模塑成型机加热并熔融的流动状态的树脂通过未图示的浇口注入，从而能够填充到金属模8的上述两区域9、10内。上述浇口例如可以采用与金属模8的第一或者第二区域9、10的任意多个位置连通的针点浇口、在第一区域9以及/或者第二区域10的整周连通的盘形浇口等任意形式的浇口。
在树脂为热塑性树脂的情况下，冷却所填充的树脂使其固化，从而形成成型体2。而且，在树脂为热固性树脂的情况下，在填充后加热使其进行固化反应从而形成成型体2。热塑性树脂可以使用能够进行注射模塑成型的各种热塑性树脂。优选在机械领域采用特别多的例如聚酰胺(PA6、PA66、PA46等)等工程塑料、或芳香族聚酰胺(PA6T、PA9T、PPA)、聚甲醛、PEEK、PPS等超级工程塑料。
而且，热固性树脂可以使用能够进行注射模塑成型并且固化时间短的各种热固性树脂。作为上述热固性树脂，例如可举出酚醛树脂(甲阶酚醛树脂、酚醛清漆)、不饱和聚酯树脂等。而且可以使用代替粘着性、柔软性等而具有即时固化性的环氧树脂。可以在树脂中配合填充物。若配合填充物，则能够特别维持不含强化纤维的齿部3的很好的柔软性并且能够进一步提高该齿部3的高的韧性、强度、耐磨性、耐冲击性等。而且，使填充物浸透于形成圆环状预制件6的强化纤维间，从而能够进一步提高套筒4以及齿轮1整体的强度、刚性。
作为填充物，例如可举出玻璃纤维、碳纤维等纤维状的填充物、玻璃片等板状的填充物、或碳纳米管、碳纳米纤维等能够进行细微强化的填充物等1种或者2种以上。在不含上述填充物的情况下的树脂本身、或者在包含填充物的情况下的状态的注射模塑成型时(熔融时)的树脂的熔体流动速率优选为30g/10min以上，特别优选为50g/10min以上。
在熔体流动速率不到该范围时，无法通过注射模塑成型将树脂或者树脂与填充物无间隙且很好地浸入圆环状预制件6中。其结果，产生成为破坏源的树脂的未浸入部分而降低齿轮1的机械强度，无法将树脂充分填充到区域9、10的各个角落，可能产生成型不良。
另外，为了将熔体流动速率调整到上述范围，可以向树脂中适当地添加减粘剂、分散剂、用于减小固化速度的非晶质树脂等。
另外，特别在使用注射模塑成型时的熔融粘度高的树脂的情况下，为了使该树脂、或树脂与填充物无间隙且很好地浸入圆环状预制件6中、充分填充到区域9、10的各个角落，可以将金属模8内抽真空，在减压下进行注射模塑成型。而且在该例的制造方法中，例如可以通过RTM(ResinTransferMolding：树脂传递模塑)、VaRTM(VacuumResinTransferMolding：真空树脂传递模塑)等树脂注入成型将树脂的液态的前驱体(precursor)或者液态的树脂填充至上述两区域9、10内。
作为在上述方法中使用的树脂的液态的前驱体，可举出在上述单体浇铸尼龙等作为热塑性树脂的基体的单体、低聚物中配合重合催化剂、重合助催化剂、反应引发剂等。而且，作为液态的树脂，可以使用能够通过树脂注入成型注入到金属模8内并且固化时间短的液态的热固性树脂。作为上述热固性树脂，可以使用上述酚醛树脂(甲阶酚醛树脂、酚醛清漆)、不饱和聚酯树脂或代替粘着性、柔软性等而具有即时固化性的环氧树脂中在固化前呈液态的树脂、配合反应性稀释剂等而成为液态的树脂等。
而且，可以在树脂的液态的前驱体、液态的树脂中以与之前注射模塑成型的情况相同的理由配合相同的填充物。例如通过RTM法并利用合模力+泵压将上述液态的前驱体或者树脂注入金属模8内，通过VaRTM法将金属模8内抽真空进行吸引注入。而且，若在液态的前驱体的情况下根据需要加热，则单体等通过聚合反应生成树脂而固化，从而形成成型体2。而且，在液态的热固性树脂的情况下，在填充后加热使其固化反应从而形成成型体2。
接着参照图1(a)、(b)，将通过上述任意方法形成的成型体2从金属模8取出。之后，与以往相同地切削加工齿部3的外周7来形成齿17，完成齿轮1。通过上述工序制造的图1(a)的例的齿轮1如上所述由纤维强化复合件构成。齿轮1由高强度、高刚性的套筒4、和不含上述强化纤维的树脂构成，所以柔软且韧性优异，难以产生噪音等。并且，齿轮1由于耐冲击性也优异的齿部3与树脂的连续相而牢固地形成为一体并且为轻型。
因此，将上述制造的齿轮1例如作为蜗轮组装于电动动力转向装置的减速机，由此，能够使该减速机以及电动动力转向装置的大幅度轻型化。本发明的结构不限定于以上说明的图中的例子。例如可以在金属模8的销11的位置放置轴进行嵌件成型。由此，能够在成型的同时形成插通固定有轴的成型体2。
而且，可以在金属模8的与齿部3对应的区域的外周7，形成与齿17对应的凹凸，通过树脂的注入而在上述齿部3的外周7直接形成齿17。另外，在不脱离本发明的宗旨的范围内可以进行各种改变。
本申请主张于2014年7月16日提出的日本专利申请2014-146022号的优先权，并在此引用其全部内容。

Claims (10)

1.一种齿轮的制造方法，包含如下工序：
对于在最外周具备与齿部对应的圆环状的区域、和与该区域的径向内侧接触地具备与套筒对应的区域的金属模而言，在该金属模内的与所述套筒对应的区域，放置由强化纤维构成的圆环状预制件的工序、以及
使放置的所述圆环状预制件中浸入树脂，并且将所述树脂填充到所述金属模的与所述齿部及所述套筒对应的整个区域的工序。
2.根据权利要求1所述齿轮的制造方法，其中，
将由强化纤维构成的开孔圆板层叠而形成所述圆环状预制件。
3.根据权利要求1所述的齿轮的制造方法，其中，
将由强化纤维构成的编织带连结为圆环状从而形成所述圆环状预制件。
4.根据要求1所述的齿轮的制造方法，其中，
所述圆环状预制件形成为由强化纤维构成的三维纺织品。
5.根据要求1所述的齿轮的制造方法，其中，
将由强化纤维构成的筒沿长度方向卷绕从而形成所述圆环状预制件。
6.根据要求1～5中任一项所述的齿轮的制造方法，其中，
通过将加热熔融的状态下的所述树脂注入所述金属模内的注射模塑成型，使所述树脂浸入所述圆环状预制件中，并且向与所述齿部以及所述套筒对应的整个区域填充所述树脂。
7.根据要求1～5中任一项所述的齿轮的制造方法，其中，
通过将所述树脂的液态的前驱体或者液态的树脂注入所述金属模内的树脂注入成型使所述树脂的液态的前驱体或者液态的树脂浸入所述圆环状预制件中，并且向与所述齿部以及所述套筒对应的整个区域填充所述树脂的液态的前驱体或者液态的树脂。
8.根据要求1～5中任一项所述的齿轮的制造方法，其中，
所述齿部的外周形成为圆筒状，在将所述外周从所述金属模取出后再进行切削加工而形成齿。
9.根据要求7所述的齿轮的制造方法，其中，
所述齿部的外周形成为圆筒状，在将所述外周从所述金属模取出后再进行切削加工而形成齿。
10.一种齿轮，通过如下方法来制造，
即，对于在最外周具备与齿部对应的圆环状的区域、和与该区域的径向内侧接触地具备与套筒对应的区域的金属模而言，在该金属模内的与所述套筒对应的区域，放置有由强化纤维构成的圆环状预制件的状态下，使所述圆环状预制件中浸入树脂，并且将所述树脂填充到所述金属模的与所述齿部以及所述套筒对应的整个区域来制造所述齿轮。
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