JP2021169853A - Method for manufacturing resin gear and resin gear - Google Patents

Method for manufacturing resin gear and resin gear Download PDF

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JP2021169853A
JP2021169853A JP2020073873A JP2020073873A JP2021169853A JP 2021169853 A JP2021169853 A JP 2021169853A JP 2020073873 A JP2020073873 A JP 2020073873A JP 2020073873 A JP2020073873 A JP 2020073873A JP 2021169853 A JP2021169853 A JP 2021169853A
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mold
base portion
resin
annular portion
gear
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JP7431397B2 (en
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勝 藤生
Masaru Fujiu
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Mitsuba Corp
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Abstract

To enhance productivity of a resin gear.SOLUTION: A method for manufacturing a resin gear 1 includes the step of: (a) forming a disc-like base part 2 by injecting a resin into a die; (b) forming an annular part 3 including a gear part 3a around the outer periphery thereof by injecting a resin into a die and having an inner diameter that is larger than an outer diameter of the base part 2; (c) arranging the base part 2 and the annular part 3 inside a die so that the base part 2 is positioned inside the annular part 3; and (d) forming a junction part 4 for joining the base part 2 to the annular part 3 by injecting a resin into the die. The method for manufacturing a resin gear includes a cycle comprising the (a) to (d) steps and repeats the cycle multiple times. The cycle repeated multiple times includes a cycle where the (a) step and the (b) step are performed at the same time.SELECTED DRAWING: Figure 3

Description

本発明は、樹脂製ギヤの製造方法及び樹脂製ギヤに関する。 The present invention relates to a method for manufacturing a resin gear and a resin gear.

自動車のワイパーなどの動力源となるモータの回転軸の回転に伴って動力を伝達するギヤの一例として、樹脂製ギヤが知られている。 A resin gear is known as an example of a gear that transmits power with the rotation of a rotating shaft of a motor that is a power source for an automobile wiper or the like.

上記樹脂製ギヤの製造方法として、特許文献１および２に、樹脂製ギヤを複数の部分に分けて該部分ごとに順次樹脂成形して製造することが開示されている。 As a method for manufacturing the resin gear, Patent Documents 1 and 2 disclose that the resin gear is divided into a plurality of parts and sequentially resin-molded for each part.

特開２００４−５２７９１号公報Japanese Unexamined Patent Publication No. 2004-52791 特公平４−１４８６１号公報Tokusho 4-14861 Gazette

樹脂製ギヤにおいて、外周に配置されるギヤ部とその内側に配置される本体部とが一体で樹脂成形され、さらに本体部に肉厚が異なる部分が存在すると、肉厚が厚い部分と薄い部分とで樹脂の熱収縮差が発生し、この熱収縮差によってギヤ部の寸法精度が低下する。 In a resin gear, the gear portion arranged on the outer circumference and the main body portion arranged inside the resin gear are integrally molded with resin, and if there is a portion having a different wall thickness in the main body portion, the thick portion and the thin portion are formed. A difference in heat shrinkage of the resin is generated between the two, and the difference in heat shrinkage reduces the dimensional accuracy of the gear portion.

上記樹脂の熱収縮差のギヤ部への影響を回避する方法として、上記特許文献１および２に記載された樹脂製ギヤの製造方法のように、ギヤ部と本体部とを分けて、まず一方を樹脂成形し、その後、他方を樹脂成形して樹脂製ギヤを製造することが考えられる。 As a method of avoiding the influence of the heat shrinkage difference of the resin on the gear portion, as in the method of manufacturing a resin gear described in Patent Documents 1 and 2, the gear portion and the main body portion are separated, and one of them is first. Is resin-molded, and then the other is resin-molded to manufacture a resin gear.

しかしながら、樹脂製ギヤを２つの部分に分けて、まず一方を樹脂成形し、その後、他方を樹脂成形して製造すると、樹脂製ギヤの生産性が低くなる。 However, if the resin gear is divided into two parts, one of which is first resin-molded and then the other is resin-molded, the productivity of the resin gear is lowered.

本発明の目的は、生産性が高められた樹脂製ギヤの製造方法および樹脂製ギヤを提供することにある。 An object of the present invention is to provide a method for manufacturing a resin gear and a resin gear with improved productivity.

本発明の一態様は、（ａ）金型内に樹脂を射出して円板状のベース部を成形する工程と、（ｂ）金型内に樹脂を射出して外周に歯形部を備え、かつ、前記ベース部の外径よりも大きな内径の環状部を成形する工程と、（ｃ）前記環状部の内側に前記ベース部が位置するように前記ベース部と前記環状部とを金型内に配置する工程と、（ｄ）金型内に樹脂を射出して前記ベース部と前記環状部とを接合する接合部を前記ベース部と前記環状部との間に成形する工程と、を有し、前記（ａ）工程〜前記（ｄ）工程を１サイクルとし、これを複数回繰り返す樹脂製ギヤの製造方法であって、複数回繰り返される前記１サイクルには、前記（ａ）工程と前記（ｂ）工程とを同時に実施する前記１サイクルが含まれる。 One aspect of the present invention includes (a) a step of injecting resin into a mold to form a disk-shaped base portion, and (b) injecting resin into a mold to provide a tooth profile portion on the outer periphery. In addition, a step of forming an annular portion having an inner diameter larger than the outer diameter of the base portion, and (c) the base portion and the annular portion are placed in a mold so that the base portion is located inside the annular portion. There are a step of arranging in the mold and a step of (d) forming a joint portion for joining the base portion and the annular portion between the base portion and the annular portion by injecting resin into the mold. A method for manufacturing a resin gear in which the steps (a) to (d) are set as one cycle and repeated a plurality of times. In the one cycle repeated a plurality of times, the step (a) and the step (a) are described. (B) The one cycle in which the step is carried out at the same time is included.

本発明の他の態様は、樹脂製の円板状のベース部と、外周に歯形部を備え、かつ、前記ベース部の外径よりも大きな内径の樹脂製の環状部と、前記ベース部と前記環状部とを接合する樹脂製の接合部と、を有し、前記ベース部は、前記環状部の内側に配置され、前記接合部は、前記環状部と前記ベース部との間に配置されている。 Another aspect of the present invention includes a resin disc-shaped base portion, a resin annular portion having a tooth profile portion on the outer circumference and an inner diameter larger than the outer diameter of the base portion, and the base portion. It has a resin joint portion for joining the annular portion, the base portion is arranged inside the annular portion, and the joint portion is arranged between the annular portion and the base portion. ing.

本発明によれば、樹脂製ギヤの生産性及び樹脂製ギヤの真円度などの精度を高めることができる。 According to the present invention, it is possible to improve the productivity of the resin gear and the accuracy of the roundness of the resin gear.

本発明の実施の形態１の射出成形装置の構成を示す概略図である。It is the schematic which shows the structure of the injection molding apparatus of Embodiment 1 of this invention. 図１に示す射出成形装置を含む射出成形システムの構成を示す概略図である。It is the schematic which shows the structure of the injection molding system including the injection molding apparatus shown in FIG. 本発明の実施の形態１の樹脂製ギヤの構造を示す斜視図である。It is a perspective view which shows the structure of the resin gear of Embodiment 1 of this invention. 図３に示す樹脂製ギヤの構造を示す平面図である。It is a top view which shows the structure of the resin gear shown in FIG. 図４に示すＡ−Ａ線に沿う切断面を示す拡大断面図である。It is an enlarged cross-sectional view which shows the cut surface along the line AA shown in FIG. 図２に示す射出成形システムを用いた樹脂製ギヤの組立ての手順を示す組立て手順図である。It is an assembly procedure diagram which shows the procedure of assembling the resin gear using the injection molding system shown in FIG. 本発明の実施の形態２の樹脂製ギヤの構造を示す斜視図である。It is a perspective view which shows the structure of the resin gear of Embodiment 2 of this invention. 図７に示す樹脂製ギヤの構造を示す平面図である。It is a top view which shows the structure of the resin gear shown in FIG. 図８に示すＢ−Ｂ線に沿う切断面を示す拡大断面図である。It is an enlarged cross-sectional view which shows the cut surface along the line BB shown in FIG.

以下、本発明の実施の形態について図面を用いて詳細に説明する。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

（実施の形態１）
図１に示す本実施の形態１の射出成形装置の構造について説明する。図１に示す射出成形装置２０は、ターンテーブル５上に配置された複数の金型内に樹脂を射出して同時に複数の成形部材を成形することが可能な装置である。 (Embodiment 1)
The structure of the injection molding apparatus of the first embodiment shown in FIG. 1 will be described. The injection molding device 20 shown in FIG. 1 is a device capable of injecting resin into a plurality of molds arranged on a turntable 5 to mold a plurality of molding members at the same time.

本実施の形態１では、射出成形装置２０によって成形される成形品として、例えば、自動車のリヤワイパーの動力源となるモータの回転軸に係合する図３に示す樹脂製ギヤ１を取り上げて説明する。 In the first embodiment, as the molded product molded by the injection molding apparatus 20, for example, the resin gear 1 shown in FIG. 3 that engages with the rotating shaft of the motor that is the power source of the rear wiper of the automobile will be taken up and described. do.

まず、図１に示す本実施の形態1の射出成形装置２０について説明する。射出成形装置２０は、射出成形が行われる第１回転位置と、射出成形が行われ、かつ回転中心Ｃ（図２参照）の周上において上記第１回転位置に対して所定の角度で位置する第２回転位置と、に往復回転するターンテーブル５を備えている。本実施の形態１では、上記所定の角度が１２０°の場合について説明する。すなわち、上記第１回転位置と上記第２回転位置とは、ターンテーブル５の回転中心Ｃの周上において互いに１２０°の角度を成す位置となっている。 First, the injection molding apparatus 20 of the first embodiment shown in FIG. 1 will be described. The injection molding apparatus 20 is located at a predetermined angle with respect to the first rotation position where injection molding is performed and the first rotation position where injection molding is performed and the rotation center C (see FIG. 2). It is provided with a second rotation position and a turntable 5 that reciprocates to. In the first embodiment, the case where the predetermined angle is 120 ° will be described. That is, the first rotation position and the second rotation position are positions that form an angle of 120 ° with each other on the circumference of the rotation center C of the turntable 5.

また、図１に示すように、射出成形装置２０は、回転自在に設けられたターンテーブル５上に、このターンテーブル５の回転中心Ｃに対して所定間隔（等間隔）で配置された第１金型６、第２金型７および第３金型８を備えている。本実施の形態１では、ターンテーブル５の回転中心Ｃの周上において互いが１２０°を成す角度で配置された第１金型６、第２金型７および第３金型８を備えている場合について説明する。つまり、第１金型６、第２金型７および第３金型８は、ターンテーブル５上にターンテーブル５の回転方向に沿って１２０°間隔で配置されており、第１金型６、第２金型７および第３金型８は、それぞれ下型である。なお、図２に示すように、ターンテーブル５上の１２０°毎に区画された領域である成形位置（射出位置）をそれぞれＸ成形位置、Ｙ成形位置、Ｚ成形位置とすると、例えば、Ｘ成形位置に第１金型６が配置され、Ｙ成形位置に第２金型７が配置され、Ｚ成形位置に第３金型８が配置されている。 Further, as shown in FIG. 1, the injection molding apparatus 20 is first arranged on a rotatably provided turntable 5 at predetermined intervals (equal intervals) with respect to the rotation center C of the turntable 5. A mold 6, a second mold 7, and a third mold 8 are provided. The first embodiment includes a first mold 6, a second mold 7, and a third mold 8 arranged at an angle of 120 ° on the circumference of the rotation center C of the turntable 5. The case will be described. That is, the first mold 6, the second mold 7, and the third mold 8 are arranged on the turntable 5 at intervals of 120 ° along the rotation direction of the turntable 5, and the first mold 6, The second mold 7 and the third mold 8 are lower molds, respectively. As shown in FIG. 2, assuming that the molding positions (injection positions), which are regions divided by 120 ° on the turntable 5, are the X molding position, the Y molding position, and the Z molding position, respectively, for example, X molding. The first mold 6 is arranged at the position, the second mold 7 is arranged at the Y molding position, and the third mold 8 is arranged at the Z molding position.

そして、図１に示すように、射出成形装置２０は、第１金型６、第２金型７および第３金型８に対して型開きおよび型締めをする第４金型９、第５金型１０および第６金型１１を備えている。第４金型９、第５金型１０および第６金型１１は、それぞれ上型である。さらに、射出成形装置２０は、型締めされた金型内に樹脂を射出する第１射出装置１２、第２射出装置１３および第３射出装置１４を備えている。第１射出装置１２は、射出筒１２ａを有し、かつ、第４金型９の上部に配置され、第２射出装置１３は、射出筒１３ａを有し、かつ、第５金型１０の上部に配置され、第３射出装置１４は、射出筒１４ａを有し、かつ、第６金型１１の上部に配置されている。 Then, as shown in FIG. 1, the injection molding apparatus 20 opens and fastens the first mold 6, the second mold 7, and the third mold 8, and the fourth mold 9, the fifth mold. A mold 10 and a sixth mold 11 are provided. The fourth mold 9, the fifth mold 10, and the sixth mold 11 are upper molds, respectively. Further, the injection molding device 20 includes a first injection device 12, a second injection device 13, and a third injection device 14 that inject the resin into the molded mold. The first injection device 12 has an injection cylinder 12a and is arranged on the upper portion of the fourth mold 9, and the second injection device 13 has the injection cylinder 13a and is arranged on the upper portion of the fifth mold 10. The third injection device 14 has an injection cylinder 14a and is arranged on the upper part of the sixth mold 11.

すなわち、射出成形装置２０においては、第４金型９に第１射出装置１２が取り付けられ、第５金型１０に第２射出装置１３が取り付けられ、さらに第６金型１１に第３射出装置１４が取り付けられている。そして、第１射出装置１２は、射出口１２ｂを有する射出筒１２ａを備えている。また、第２射出装置１３は、射出口１３ｂを有する射出筒１３ａを備えており、さらに、第３射出装置１４は、射出口１４ｂを有する射出筒１４ａを備えている。 That is, in the injection molding device 20, the first injection device 12 is attached to the fourth mold 9, the second injection device 13 is attached to the fifth mold 10, and the third injection device is further attached to the sixth mold 11. 14 is attached. The first injection device 12 includes an injection cylinder 12a having an injection port 12b. Further, the second injection device 13 includes an injection cylinder 13a having an injection port 13b, and the third injection device 14 further includes an injection cylinder 14a having an injection port 14b.

そして、射出成形装置２０では、ターンテーブル５の往復回転（旋回）動作や金型の型開きおよび型締めの動作、さらに各射出装置からの射出動作等が図示しない制御部によって制御される。具体的には、下型である第１金型６、第２金型７および第３金型８の何れかに対して、上型である第４金型９、第５金型１０および第６金型１１を接近させたり、離反させたりする動作、使用する各射出装置、使用する樹脂および射出のタイミングなどの射出動作が上記制御部によって制御される。さらに、第１射出装置１２、第２射出装置１３および第３射出装置１４に対して、必要なタイミングで必要な樹脂をそれぞれの射出筒の射出口から射出するようになっている。 In the injection molding apparatus 20, the reciprocating rotation (swivel) operation of the turntable 5, the mold opening and mold clamping operations, the injection operation from each injection device, and the like are controlled by a control unit (not shown). Specifically, with respect to any one of the lower molds 1, 1, 2, and 3, the upper molds 9, the fourth mold 9, the fifth mold 10, and the third mold 8. 6 The control unit controls an operation of bringing the mold 11 closer to or further away from the mold 11, an injection device to be used, a resin to be used, an injection timing, and the like. Further, the required resin is injected from the injection port of each injection cylinder to the first injection device 12, the second injection device 13, and the third injection device 14 at a necessary timing.

また、ターンテーブル５の位置制御として、上記制御部は、例えば、ターンテーブル５に対して第１の位置制御および第２の位置制御を実行する制御を行う。上記第１の位置制御が実行されると、第１金型６と第４金型９とが対向し、第２金型７と第５金型１０とが対向し、かつ、第３金型８と第６金型１１とが対向する第１回転位置にターンテーブル５が回転する。一方、上記第２の位置制御が実行されると、第１金型６と第５金型１０とが対向し、第２金型７と第６金型１１とが対向し、かつ、第３金型８と第４金型９とが対向する第２回転位置にターンテーブル５が回転する。 Further, as the position control of the turntable 5, the control unit controls, for example, to execute the first position control and the second position control on the turntable 5. When the first position control is executed, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the third mold The turntable 5 rotates at the first rotation position where the 8 and the 6th mold 11 face each other. On the other hand, when the second position control is executed, the first mold 6 and the fifth mold 10 face each other, the second mold 7 and the sixth mold 11 face each other, and the third mold 3 The turntable 5 rotates at the second rotation position where the mold 8 and the fourth mold 9 face each other.

次に、図２に示す本実施の形態1の射出成形システム２１について説明する。射出成形システム２１では、ターンテーブル５の周囲に、各金型に対して部品や成形品の搬入および搬出（取り出し）を行うハンドリング用の第１ロボット１５、第２ロボット１６および第３ロボット１７が設けられている。 Next, the injection molding system 21 of the first embodiment shown in FIG. 2 will be described. In the injection molding system 21, a first robot 15, a second robot 16, and a third robot 17 for handling that carry in and out (take out) parts and molded products for each mold are arranged around the turntable 5. It is provided.

さらに、第１ロボット１５の近傍には、部品を供給可能な供給機１９が設置されている。また、第２ロボット１６および第３ロボット１７それぞれの近傍には、射出成形された成形品等を梱包可能な梱包機１８が設置されている。 Further, a feeder 19 capable of supplying parts is installed in the vicinity of the first robot 15. Further, in the vicinity of each of the second robot 16 and the third robot 17, a packing machine 18 capable of packing injection-molded molded products and the like is installed.

以上の構成により、射出成形システム２１では、樹脂製ギヤ１の製造が行われる。 With the above configuration, the injection molding system 21 manufactures the resin gear 1.

次に、本実施の形態１の樹脂製ギヤ１の構造について、図３〜図５を用いて説明する。 Next, the structure of the resin gear 1 of the first embodiment will be described with reference to FIGS. 3 to 5.

樹脂製ギヤ１は、樹脂製の円板状のベース部２と、外周にギヤ部（歯形部）３ａを備え、かつ、ベース部２の外径よりも大きな内径の樹脂製の環状部３と、ベース部２と環状部３とを接合する樹脂製の接合部４と、を有している。つまり、図４に示すように、環状部３は、その内径Ｑがベース部２の外径Ｐよりも大きい（Ｑ＞Ｐ）ため、ベース部２は、環状部３の内側に配置されている。また、接合部４は、ベース部２と環状部３とを接合する樹脂であるため、環状部３とベース部２との間に配置されている。 The resin gear 1 includes a resin disk-shaped base portion 2 and a resin annular portion 3 having a gear portion (tooth profile portion) 3a on the outer circumference and an inner diameter larger than the outer diameter of the base portion 2. It has a resin joining portion 4 for joining the base portion 2 and the annular portion 3. That is, as shown in FIG. 4, since the inner diameter Q of the annular portion 3 is larger than the outer diameter P of the base portion 2 (Q> P), the base portion 2 is arranged inside the annular portion 3. .. Further, since the joint portion 4 is a resin that joins the base portion 2 and the annular portion 3, it is arranged between the annular portion 3 and the base portion 2.

樹脂製ギヤ１の中央部に位置するベース部２は、その中心部にはギヤフレームに設けられたピン等が挿通される貫通孔２ａを有している。また、貫通孔２ａの周りには、図３に示すように、ベース部２の表面から厚さ方向に凹んだ複数の凹部２ｂが設けられている。これら複数の凹部２ｂには、この樹脂製ギヤ１と係合するピン部材（図示せず）が配置される。そして、貫通孔２ａおよび複数の凹部２ｂの周囲には、複数のリブ２ｃや複数の溝２ｄが設けられている。これら複数のリブ２ｃは、ベース部２を全域に亘って補強するものであり、さらに複数の溝２ｄは、凹部２ｂを形成する壁部の厚さや複数のリブ２ｃのそれぞれの厚さを略均一な厚さにするものである。これにより、ベース部２の全域に亘る肉厚が略等しくなるようになっており、その結果、ベース部２の樹脂の熱収縮を低減することができる。 The base portion 2 located at the central portion of the resin gear 1 has a through hole 2a in the central portion through which a pin or the like provided in the gear frame is inserted. Further, as shown in FIG. 3, a plurality of recesses 2b recessed in the thickness direction from the surface of the base portion 2 are provided around the through hole 2a. A pin member (not shown) that engages with the resin gear 1 is arranged in the plurality of recesses 2b. A plurality of ribs 2c and a plurality of grooves 2d are provided around the through holes 2a and the plurality of recesses 2b. The plurality of ribs 2c reinforce the base portion 2 over the entire area, and the plurality of grooves 2d make the thickness of the wall portion forming the recess 2b and the thickness of each of the plurality of ribs 2c substantially uniform. It is intended to be thick. As a result, the wall thickness over the entire area of the base portion 2 becomes substantially equal, and as a result, the heat shrinkage of the resin of the base portion 2 can be reduced.

また、複数の凹部２ｂには、ベース部２の中心からの距離が２通りまたは３通りあり、中心からの距離が遠い方の凹部２ｂは、その壁部の一部（図４のＲ部）がベース部２の外周より外側に突出している。この突出した部分の壁部（Ｒ部）は、ベース部２の直径方向に対する肉厚が薄くなるため、その補強として接合部４に、図３および図４に示す凸部４ａが設けられている。つまり、凸部４ａは、接合部４の肉厚部分であり、ベース部２における２つの凹部２ｂのベース部２の外周より外側に突出した部分（Ｒ部）を補強するため、円弧状となっている。 Further, the plurality of recesses 2b have two or three distances from the center of the base portion 2, and the recess 2b farther from the center is a part of the wall portion (R portion in FIG. 4). Projects outward from the outer periphery of the base portion 2. Since the wall thickness (R portion) of this protruding portion becomes thinner in the diameter direction of the base portion 2, the joint portion 4 is provided with the convex portion 4a shown in FIGS. 3 and 4 as reinforcement thereof. .. That is, the convex portion 4a is a thick portion of the joint portion 4, and has an arc shape in order to reinforce the portion (R portion) of the two concave portions 2b in the base portion 2 that protrudes outward from the outer circumference of the base portion 2. ing.

ベース部２の外側に配置された環状部３は、外周側面に複数の歯が形成されたギヤ部３ａを備えている。なお、環状部３の内周部（内周の壁面）は、接合部４の円弧状の凸部４ａと接している。また、環状部３の内周部と接合部の４の円弧状の凸部４ａとの間に隙間を設けてもよい。 The annular portion 3 arranged on the outside of the base portion 2 includes a gear portion 3a having a plurality of teeth formed on the outer peripheral side surface thereof. The inner peripheral portion (inner peripheral wall surface) of the annular portion 3 is in contact with the arcuate convex portion 4a of the joint portion 4. Further, a gap may be provided between the inner peripheral portion of the annular portion 3 and the arcuate convex portion 4a of the joint portion 4.

接合部４は、ベース部２と環状部３とを接合する樹脂である。したがって、接合部４は、環状部３とベース部２との間に配置されているとともに、環状部３の内周部とベース部２の外周部とに接触している。 The joint portion 4 is a resin that joins the base portion 2 and the annular portion 3. Therefore, the joint portion 4 is arranged between the annular portion 3 and the base portion 2, and is in contact with the inner peripheral portion of the annular portion 3 and the outer peripheral portion of the base portion 2.

なお、ベース部２、環状部３および接合部４は、それぞれ異なる樹脂からなる部材であってもよいし、全てが同一の樹脂からなる部材であってもよいし、あるいは３つのうちの何れか２つが同じ樹脂からなる部材であってもよい。 The base portion 2, the annular portion 3, and the joint portion 4 may be members made of different resins, all of them may be members made of the same resin, or any one of the three. The two may be members made of the same resin.

次に、本実施の形態１の樹脂製ギヤ１の製造方法を、図６に示す組立て手順を用いて説明する。 Next, the method of manufacturing the resin gear 1 of the first embodiment will be described using the assembly procedure shown in FIG.

図６に示す組立て手順では、まず、射出成形装置２０のＸ成形位置で金型内に樹脂を射出して円板状のベース部２を成形し、射出成形装置２０のＹ成形位置で金型内に樹脂を射出して外周にギヤ部（歯形部）３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。さらに、射出成形装置２０のＺ成形位置で金型内に樹脂を射出してベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。その後、ターンテーブル５を時計方向に１２０°旋回させる。 In the assembly procedure shown in FIG. 6, first, resin is injected into the mold at the X molding position of the injection molding apparatus 20 to form the disc-shaped base portion 2, and then the mold is formed at the Y molding position of the injection molding apparatus 20. A resin is injected inside to form an annular portion 3 having a gear portion (tooth profile portion) 3a on the outer periphery and an inner diameter larger than the outer diameter of the base portion 2. Further, a resin is injected into the mold at the Z molding position of the injection molding apparatus 20, and a joint portion 4 for joining the base portion 2 and the annular portion 3 is formed between the base portion 2 and the annular portion 3. After that, the turntable 5 is turned clockwise by 120 °.

図６に示す組立て手順を具体的に説明すると、まず、ターンテーブル５の位置制御として、第１の位置制御を行う。これにより、第１金型６と第４金型９とが対向し、第２金型７と第５金型１０とが対向し、かつ、第３金型８と第６金型１１とが対向する第１回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第１金型６と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第２金型７と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第３金型８と第６金型１１の型閉（型締め）を行う。 To specifically explain the assembly procedure shown in FIG. 6, first, the first position control is performed as the position control of the turntable 5. As a result, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the third mold 8 and the sixth mold 11 face each other. The turntable 5 rotates at the opposite first rotation position. Then, the first mold 6 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the second mold 7 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the third mold 8 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて、第１金型６および第４金型９の内部に樹脂を射出し、図３に示すような樹脂製ギヤ１の円板状のベース部２を成形する。ここでは、樹脂製ギヤ１のベース部２（外周の環状部以外）を成形し、このベース部２を下型である第１金型６に残す。 After tightening each mold, at the X molding position, resin is injected into the first mold 6 and the fourth mold 9 using the first injection device 12, and the resin gear as shown in FIG. The disk-shaped base portion 2 of 1 is formed. Here, the base portion 2 (other than the annular portion on the outer circumference) of the resin gear 1 is molded, and the base portion 2 is left in the first mold 6 which is the lower mold.

また、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第２金型７および第５金型１０の内部に樹脂を射出し、図３に示すような外周にギヤ部（歯形部）３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第５金型１０に残す。 Further, at the Y molding position of the injection molding device 20, resin is injected into the second mold 7 and the fifth mold 10 by using the second injection device 13, and a gear portion is formed on the outer periphery as shown in FIG. An annular portion 3 having an inner diameter (dental portion) 3a and having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the fifth mold 10 which is the upper mold.

そして、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第３金型８および第６金型１１の内部に樹脂を射出し、図３に示すようなベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。ここでは、下型である第３金型８のベース部２と、上型である第６金型１１の環状部３とを接合部４によって接合して樹脂製ギヤ１を成形する。なお、このＺ成形位置で接合されるベース部２と環状部３は、前段の工程で射出成形されて予め準備された部材である。 Then, at the Z molding position of the injection molding device 20, the resin is injected into the inside of the third mold 8 and the sixth mold 11 by using the third injection device 14, and the base portion 2 and the base portion 2 as shown in FIG. A joint portion 4 for joining the annular portion 3 is formed between the base portion 2 and the annular portion 3. Here, the base portion 2 of the third mold 8 which is the lower mold and the annular portion 3 of the sixth mold 11 which is the upper mold are joined by the joint portion 4 to form the resin gear 1. The base portion 2 and the annular portion 3 joined at the Z molding position are members prepared in advance by injection molding in the previous step.

成形完了後、各金型の型開きを行う。そして、第３金型８および第６金型１１から、例えば、図２に示す第３ロボット１７によって完成品である樹脂製ギヤ１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, for example, the resin gear 1 which is a finished product is taken out from the third mold 8 and the sixth mold 11 by the third robot 17 shown in FIG. 2, and is housed in the packing machine 18.

このように本実施の形態１の樹脂製ギヤ１の製造方法では、ベース部２を射出成形する工程、環状部３を射出成形する工程および接合部４を射出成形する工程を、回転自在に設けられたターンテーブル５上に該ターンテーブル５の回転中心Ｃに対して等間隔で配置された複数の金型において実施する。 As described above, in the method for manufacturing the resin gear 1 of the first embodiment, a step of injection molding the base portion 2, a step of injection molding the annular portion 3, and a step of injection molding the joint portion 4 are rotatably provided. This is carried out in a plurality of molds arranged on the turntable 5 at equal intervals with respect to the rotation center C of the turntable 5.

樹脂製ギヤ１を梱包機１８に収容した後、ターンテーブル５を、例えば時計方向に１２０°旋回させる。ここでは、ターンテーブル５の位置制御として、第２の位置制御を行う。これにより、上記第２の位置制御が実行されると、第１金型６と第５金型１０とが対向し、第２金型７と第６金型１１とが対向し、かつ、第３金型８と第４金型９とが対向する第２回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第３金型８と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第１金型６と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第２金型７と第６金型１１の型閉（型締め）を行う。 After the resin gear 1 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, clockwise by 120 °. Here, a second position control is performed as the position control of the turntable 5. As a result, when the second position control is executed, the first mold 6 and the fifth mold 10 face each other, the second mold 7 and the sixth mold 11 face each other, and the second mold The turntable 5 rotates at the second rotation position where the 3 mold 8 and the 4th mold 9 face each other. Then, the third mold 8 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the first mold 6 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the second mold 7 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて第３金型８および第４金型９の内部に樹脂を射出し、円板状のベース部２を成形する。ここでは、樹脂製ギヤ１のベース部２（外周の環状部以外）を成形し、このベース部２を下型である第３金型８に残す。 After molding each mold, at the X molding position, resin is injected into the third mold 8 and the fourth mold 9 using the first injection device 12, and the disk-shaped base portion 2 is molded. .. Here, the base portion 2 (other than the annular portion on the outer circumference) of the resin gear 1 is molded, and the base portion 2 is left in the third mold 8 which is the lower mold.

そして、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第１金型６および第５金型１０の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。この時、ターンテーブル５を時計方向に１２０°旋回させたことで、Ｙ成形位置には、下型としてベース部２を収容した第１金型６が配置され、かつ、上型として環状部３を収容した第５金型１０が配置されている。そして、第１金型６と第５金型１０が型閉（型締め）されたことにより、環状部３の内側にベース部２が位置するようにベース部２と環状部３とが第１金型６および第５金型１０の内部に配置された状態となる。そして、第１金型６および第５金型１０の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４を成形する。これにより、ベース部２と環状部３とを接合部４によって接合し、樹脂製ギヤ１が成形される。 Then, at the Y molding position of the injection molding device 20, the second injection device 13 is used to inject resin into the inside of the first mold 6 and the fifth mold 10 to join the base portion 2 and the annular portion 3. The joint portion 4 to be formed is formed between the base portion 2 and the annular portion 3. At this time, by turning the turntable 5 clockwise by 120 °, the first mold 6 accommodating the base portion 2 as the lower mold is arranged at the Y forming position, and the annular portion 3 is arranged as the upper mold. A fifth mold 10 containing the above is arranged. Then, since the first mold 6 and the fifth mold 10 are mold-closed (mold-tightened), the base portion 2 and the annular portion 3 are first placed so that the base portion 2 is located inside the annular portion 3. It is in a state of being arranged inside the mold 6 and the fifth mold 10. Then, the resin is injected into the inside of the first mold 6 and the fifth mold 10 to form the joint portion 4 that joins the base portion 2 and the annular portion 3. As a result, the base portion 2 and the annular portion 3 are joined by the joining portion 4, and the resin gear 1 is formed.

また、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第２金型７および第６金型１１の内部に樹脂を射出し、外周にギヤ部３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第６金型１１に残す。 Further, at the Z molding position of the injection molding apparatus 20, the third injection apparatus 14 is used to inject resin into the inside of the second mold 7 and the sixth mold 11, and the gear portion 3a is provided on the outer periphery thereof. An annular portion 3 having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the sixth mold 11 which is the upper mold.

成形完了後、各金型の型開きを行う。そして、第１金型６および第５金型１０から、例えば、図２に示す第２ロボット１６によって完成品である樹脂製ギヤ１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, for example, the resin gear 1 which is a finished product is taken out from the first mold 6 and the fifth mold 10 by the second robot 16 shown in FIG. 2, and is housed in the packing machine 18.

樹脂製ギヤ１を梱包機１８に収容した後、ターンテーブル５を、例えば反時計方向に１２０°旋回させる。ここでは、ターンテーブル５の位置制御として、第１の位置制御を行う。これにより、上記第１の位置制御が実行されると、第１金型６と第４金型９とが対向し、第２金型７と第５金型１０とが対向し、かつ、第３金型８と第６金型１１とが対向する第１回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第１金型６と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第２金型７と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第３金型８と第６金型１１の型閉（型締め）を行う。 After the resin gear 1 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, counterclockwise by 120 °. Here, as the position control of the turntable 5, the first position control is performed. As a result, when the first position control is executed, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the second mold The turntable 5 rotates at the first rotation position where the 3 mold 8 and the 6th mold 11 face each other. Then, the first mold 6 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the second mold 7 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the third mold 8 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて、第１金型６および第４金型９の内部に樹脂を射出し、円板状のベース部２を成形する。ここでは、樹脂製ギヤ１のベース部２（外周の環状部以外）を成形し、このベース部２を下型である第１金型６に残す。 After molding each mold, at the X molding position, resin is injected into the first mold 6 and the fourth mold 9 using the first injection device 12, and the disk-shaped base portion 2 is molded. do. Here, the base portion 2 (other than the annular portion on the outer circumference) of the resin gear 1 is molded, and the base portion 2 is left in the first mold 6 which is the lower mold.

また、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第２金型７および第５金型１０の内部に樹脂を射出し、外周にギヤ部３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第５金型１０に残す。 Further, at the Y molding position of the injection molding device 20, the second injection device 13 is used to inject resin into the inside of the second mold 7 and the fifth mold 10, and a gear portion 3a is provided on the outer periphery thereof. An annular portion 3 having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the fifth mold 10 which is the upper mold.

そして、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第３金型８および第６金型１１の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。この時、ターンテーブル５を反時計方向に１２０°旋回させたことで、Ｚ成形位置には、下型としてベース部２を収容した第３金型８が配置され、かつ、上型として環状部３を収容した第６金型１１が配置されている。そして、第３金型８と第６金型１１が型閉（型締め）されたことにより、環状部３の内側にベース部２が位置するようにベース部２と環状部３とが、第３金型８および第６金型１１の内部に配置された状態となる。そして、第３金型８および第６金型１１の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４を成形する。これにより、ベース部２と環状部３とを接合部４によって接合し、樹脂製ギヤ１が成形される。 Then, at the Z molding position of the injection molding device 20, the resin is injected into the inside of the third mold 8 and the sixth mold 11 by using the third injection device 14, and the base portion 2 and the annular portion 3 are joined. The joint portion 4 to be formed is formed between the base portion 2 and the annular portion 3. At this time, by turning the turntable 5 counterclockwise by 120 °, the third mold 8 accommodating the base portion 2 as the lower mold is arranged at the Z molding position, and the annular portion as the upper mold. A sixth mold 11 containing 3 is arranged. Then, by closing (molding) the third mold 8 and the sixth mold 11, the base portion 2 and the annular portion 3 are moved so that the base portion 2 is located inside the annular portion 3. It is in a state of being arranged inside the 3 mold 8 and the 6th mold 11. Then, the resin is injected into the inside of the third mold 8 and the sixth mold 11 to form the joint portion 4 that joins the base portion 2 and the annular portion 3. As a result, the base portion 2 and the annular portion 3 are joined by the joining portion 4, and the resin gear 1 is formed.

成形完了後、各金型の型開きを行う。そして、第３金型８および第６金型１１から、例えば、図２に示す第３ロボット１７によって完成品である樹脂製ギヤ１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, for example, the resin gear 1 which is a finished product is taken out from the third mold 8 and the sixth mold 11 by the third robot 17 shown in FIG. 2, and is housed in the packing machine 18.

樹脂製ギヤ１を梱包機１８に収容した後、ターンテーブル５を、例えば時計方向に１２０°旋回させ、Ｘ，Ｙ，Ｚの各成形位置で図６に示す処理を繰り返して実施する。 After the resin gear 1 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, clockwise by 120 °, and the process shown in FIG. 6 is repeated at each of the X, Y, and Z molding positions.

以上のように、本実施の形態１の樹脂製ギヤ１の製造方法では、ベース部２を射出成形する工程、環状部３を射出成形する工程、ターンテーブル５を１２０°旋回させて環状部３の内側にベース部２を配置する工程、および接合部４を射出成形してベース部２と環状部３とを接合する工程を１サイクルとし、これらの工程が複数回繰り返して実施される。そして、複数回繰り返される１サイクルには、ベース部２を射出成形する工程と環状部３を射出成形する工程とを同時に実施する１サイクルが含まれる。 As described above, in the method for manufacturing the resin gear 1 of the first embodiment, the step of injection molding the base portion 2, the step of injection molding the annular portion 3, and the step of turning the turntable 5 by 120 ° to form the annular portion 3 The step of arranging the base portion 2 inside the base portion 2 and the step of injection molding the joint portion 4 to join the base portion 2 and the annular portion 3 are set as one cycle, and these steps are repeated a plurality of times. The one cycle repeated a plurality of times includes one cycle in which the step of injection molding the base portion 2 and the step of injection molding the annular portion 3 are simultaneously performed.

本実施の形態１では、ベース部２を射出成形する工程と、環状部３を射出成形する工程と、接合部４を射出成形してベース部２と環状部３とを接合する工程とを同時に実施する１サイクルが連続的に実施される場合を説明している。ただし、樹脂製ギヤ１の組立てとしては、上述のように複数回繰り返される上記１サイクルにおいて、ベース部２を射出成形する工程と、環状部３を射出成形する工程とを同時に実施する上記１サイクルを含んでいればよい。 In the first embodiment, the step of injection molding the base portion 2, the step of injection molding the annular portion 3, and the step of injection molding the joint portion 4 to join the base portion 2 and the annular portion 3 at the same time. The case where one cycle to be carried out is carried out continuously is described. However, as the assembly of the resin gear 1, in the above-mentioned one cycle repeated a plurality of times as described above, the above-mentioned one cycle in which the step of injection molding the base portion 2 and the step of injection molding the annular portion 3 are simultaneously performed. Should be included.

本実施の形態１の樹脂製ギヤ１の組立てでは、樹脂製ギヤ１を複数の部分に分けて該部分ごとに射出成形して製造する際に、ベース部２を射出成形する工程と、環状部３を射出成形する工程とを同時に実施することにより、樹脂製ギヤ１の生産性を高めることができる。 In the assembly of the resin gear 1 of the first embodiment, when the resin gear 1 is divided into a plurality of parts and injection-molded for each part, the base portion 2 is injection-molded and the annular portion. By simultaneously performing the step of injection molding 3 can increase the productivity of the resin gear 1.

そして、本実施の形態１では、ベース部２を射出成形する工程と、環状部３を射出成形する工程と、接合部４を射出成形してベース部２と環状部３とを接合する工程とを同時に実施することにより、樹脂製ギヤ１の生産性をさらに高めることができる。 Then, in the first embodiment, there are a step of injection molding the base portion 2, a step of injection molding the annular portion 3, and a step of injection molding the joint portion 4 to join the base portion 2 and the annular portion 3. By simultaneously carrying out the above steps, the productivity of the resin gear 1 can be further increased.

また、樹脂製ギヤ１をベース部２と環状部３とに分けてそれぞれを樹脂成形して製造するため、ベース部２および環状部３のそれぞれの形状の精度を高めることができる。これにより、環状部３の外周のギヤ部３ａの複数の歯の肉厚を均一に成形することができる。その結果、樹脂製ギヤ１において高精度なギヤ形状を実現することが可能になる。これにより、ギヤ形状の精度を確保するためのトライ回数や金型改修費等の見極めまでの費用と時間を削減することができる。 Further, since the resin gear 1 is divided into a base portion 2 and an annular portion 3 and each is manufactured by resin molding, the accuracy of the shapes of the base portion 2 and the annular portion 3 can be improved. As a result, the wall thickness of the plurality of teeth of the gear portion 3a on the outer circumference of the annular portion 3 can be uniformly formed. As a result, it becomes possible to realize a highly accurate gear shape in the resin gear 1. As a result, it is possible to reduce the cost and time required to determine the number of trials and the mold repair cost for ensuring the accuracy of the gear shape.

また、ベース部２の成形と、ギヤ部３ａを含む環状部３の成形と、ベース部２と環状部３との接合と、を独立して同時に実施することが可能なため、成形タクトを改善することができる。 Further, since the molding of the base portion 2, the molding of the annular portion 3 including the gear portion 3a, and the joining of the base portion 2 and the annular portion 3 can be performed independently and simultaneously, the molding tact is improved. can do.

また、ベース部２の成形と、ギヤ部３ａを含む環状部３の成形と、ベース部２と環状部３との接合と、を射出成形装置２０から成形品を取出さずに実施するため、静電気による成形品への異物の付着を防止することができる。これにより、除電処理が不要になるとともに異物の付着がない樹脂製ギヤ１の生産が可能になり、樹脂製ギヤ１の品質の向上化を図ることができる。 Further, in order to perform molding of the base portion 2, molding of the annular portion 3 including the gear portion 3a, and joining of the base portion 2 and the annular portion 3 without removing the molded product from the injection molding apparatus 20. It is possible to prevent foreign matter from adhering to the molded product due to static electricity. As a result, it becomes possible to produce the resin gear 1 in which the static elimination treatment is not required and no foreign matter adheres to the resin gear 1, and the quality of the resin gear 1 can be improved.

また、ベース部２の成形と、ギヤ部３ａを含む環状部３の成形と、ベース部２と環状部３との接合と、を射出成形装置２０のターンテーブル５上で実施するため、中間在庫を発生させることなく、樹脂製ギヤ１を生産することが可能になる。これにより、中間在庫を収容するための収容箱や該収容箱内で成形品を仕切るための仕切り板が不要になり、樹脂製ギヤ１の製造コストの低減化を図ることができる。 Further, since the molding of the base portion 2, the molding of the annular portion 3 including the gear portion 3a, and the joining of the base portion 2 and the annular portion 3 are performed on the turntable 5 of the injection molding apparatus 20, intermediate inventory is provided. It becomes possible to produce the resin gear 1 without generating the above. As a result, a storage box for storing the intermediate inventory and a partition plate for partitioning the molded product in the storage box are not required, and the manufacturing cost of the resin gear 1 can be reduced.

また、ベース部２の成形と、ギヤ部３ａを含む環状部３の成形と、ベース部２と環状部３との接合と、を同時に実施するため、一定の時間で樹脂製ギヤ１を成形することができ、樹脂製ギヤ１の各部分における温度バラツキを無くすことができる。その結果、樹脂製ギヤ１の品質の安定化を図ることができる。 Further, in order to simultaneously perform the molding of the base portion 2, the molding of the annular portion 3 including the gear portion 3a, and the joining of the base portion 2 and the annular portion 3, the resin gear 1 is molded in a fixed time. This makes it possible to eliminate temperature variations in each part of the resin gear 1. As a result, the quality of the resin gear 1 can be stabilized.

また、金型において樹脂製ギヤ１を複数個取りとしても、下型と上型の組み合わせが決まるため、金型の組合わせによる成形品（樹脂製ギヤ１）のバラツキを低減することができる。 Further, even if a plurality of resin gears 1 are taken in the mold, the combination of the lower mold and the upper mold is determined, so that the variation of the molded product (resin gear 1) due to the combination of the molds can be reduced.

（実施の形態２）
本実施の形態２は、金属製シャフト２２をインサート部材として樹脂製ギヤ３１を射出成形するものであり、金属製シャフト２２がベース部２に埋め込まれた樹脂製ギヤ３１を完成品とするものである。 (Embodiment 2)
In the second embodiment, the resin gear 31 is injection-molded using the metal shaft 22 as an insert member, and the resin gear 31 in which the metal shaft 22 is embedded in the base portion 2 is a finished product. be.

したがって、本実施の形態２では、射出成形装置２０によって成形される成形品として、例えば、自動車のフロントワイパーの動力源となるモータの回転軸に係合する図７に示す樹脂製ギヤ３１を取り上げて説明する。 Therefore, in the second embodiment, as the molded product molded by the injection molding apparatus 20, for example, the resin gear 31 shown in FIG. 7 that engages with the rotating shaft of the motor that is the power source of the front wiper of the automobile is taken up. I will explain.

次に、樹脂製ギヤ３１の構造について、図７〜図９を用いて説明する。 Next, the structure of the resin gear 31 will be described with reference to FIGS. 7 to 9.

樹脂製ギヤ３１は、樹脂製の円板状のベース部２と、外周にギヤ部（歯形部）３ａを備え、かつ、ベース部２の外径よりも大きな内径の樹脂製の環状部３と、ベース部２と環状部３とを接合する樹脂製の接合部４と、を有している。つまり、図８に示すように、環状部３は、その内径Ｑがベース部２の外径Ｐよりも大きい（Ｑ＞Ｐ）ため、ベース部２は、環状部３の内側に配置されている。また、接合部４は、ベース部２と環状部３とを接合する樹脂であるため、環状部３とベース部２との間に配置されている。 The resin gear 31 includes a resin disk-shaped base portion 2 and a resin annular portion 3 having a gear portion (tooth profile portion) 3a on the outer circumference and an inner diameter larger than the outer diameter of the base portion 2. It has a resin joining portion 4 for joining the base portion 2 and the annular portion 3. That is, as shown in FIG. 8, since the inner diameter Q of the annular portion 3 is larger than the outer diameter P of the base portion 2 (Q> P), the base portion 2 is arranged inside the annular portion 3. .. Further, since the joint portion 4 is a resin that joins the base portion 2 and the annular portion 3, it is arranged between the annular portion 3 and the base portion 2.

なお、図９に示すように、樹脂製ギヤ３１の中央部に位置するベース部２は、その中心部に金属製シャフト２２が埋め込まれる凹部２ｅを有している。 As shown in FIG. 9, the base portion 2 located at the central portion of the resin gear 31 has a recess 2e in which the metal shaft 22 is embedded in the central portion thereof.

また、ベース部２の外側に配置された環状部３は、外周側面に複数の歯が形成されたギヤ部３ａを備えている。 Further, the annular portion 3 arranged on the outside of the base portion 2 includes a gear portion 3a having a plurality of teeth formed on the outer peripheral side surface thereof.

接合部４は、ベース部２と環状部３とを接合する樹脂である。したがって、接合部４は、環状部３とベース部２との間に配置されているとともに、環状部３の内周部とベース部２の外周部とに接触している。 The joint portion 4 is a resin that joins the base portion 2 and the annular portion 3. Therefore, the joint portion 4 is arranged between the annular portion 3 and the base portion 2, and is in contact with the inner peripheral portion of the annular portion 3 and the outer peripheral portion of the base portion 2.

なお、ベース部２、環状部３および接合部４は、それぞれ異なる樹脂からなる部材であってもよいし、全てが同一の樹脂からなる部材であってもよいし、あるいは３つのうちの何れか２つが同じ樹脂からなる部材であってもよい。 The base portion 2, the annular portion 3, and the joint portion 4 may be members made of different resins, all of them may be members made of the same resin, or any one of the three. The two may be members made of the same resin.

次に、本実施の形態２の樹脂製ギヤ３１の製造方法を、図６に示す組立て手順を用いて説明する。 Next, the method of manufacturing the resin gear 31 of the second embodiment will be described using the assembly procedure shown in FIG.

図６に示す組立て手順では、まず、ターンテーブル５の位置制御として、第１の位置制御を行う。これにより、第１金型６と第４金型９とが対向し、第２金型７と第５金型１０とが対向し、かつ、第３金型８と第６金型１１とが対向する第１回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第１金型６と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第２金型７と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第３金型８と第６金型１１の型閉（型締め）を行う。 In the assembly procedure shown in FIG. 6, first, the first position control is performed as the position control of the turntable 5. As a result, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the third mold 8 and the sixth mold 11 face each other. The turntable 5 rotates at the opposite first rotation position. Then, the first mold 6 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the second mold 7 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the third mold 8 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて、第１金型６および第４金型９の内部に樹脂を射出し、図７に示すような樹脂製ギヤ３１の円板状のベース部２を成形する。その際、図２に示す第１ロボット１５によって供給機１９から図７の金属製シャフト２２を取出し、この金属製シャフト２２を予め下型である第１金型６内に配置しておき、金属製シャフト２２をインサート部材として金属製シャフト２２の周りにベース部２（外周の環状部以外）を一体的に成形する。そして、金属製シャフト２２が埋め込まれたベース部２を下型である第１金型６に残す。 After tightening each mold, at the X molding position, resin is injected into the first mold 6 and the fourth mold 9 using the first injection device 12, and the resin gear as shown in FIG. The disk-shaped base portion 2 of 31 is formed. At that time, the metal shaft 22 of FIG. 7 is taken out from the feeder 19 by the first robot 15 shown in FIG. 2, and the metal shaft 22 is arranged in advance in the first mold 6 which is a lower mold, and the metal is formed. Using the manufactured shaft 22 as an insert member, the base portion 2 (other than the annular portion on the outer periphery) is integrally formed around the metal shaft 22. Then, the base portion 2 in which the metal shaft 22 is embedded is left in the first mold 6 which is a lower mold.

また、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第２金型７および第５金型１０の内部に樹脂を射出し、図７に示すような外周にギヤ部（歯形部）３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第５金型１０に残す。 Further, at the Y molding position of the injection molding device 20, resin is injected into the second mold 7 and the fifth mold 10 by using the second injection device 13, and a gear portion is formed on the outer periphery as shown in FIG. An annular portion 3 having an inner diameter (dental portion) 3a and having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the fifth mold 10 which is the upper mold.

そして、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第３金型８および第６金型１１の内部に樹脂を射出し、図７に示すようなベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。ここでは、下型である第３金型８のベース部２と、上型である第６金型１１の環状部３とを接合部４によって接合して樹脂製ギヤ３１を成形する。なお、このＺ成形位置で接合されるベース部２と環状部３は、前段の工程で射出成形されて予め準備された部材である。 Then, at the Z molding position of the injection molding device 20, the resin is injected into the inside of the third mold 8 and the sixth mold 11 by using the third injection device 14, and the base portion 2 and the base portion 2 as shown in FIG. 7 are formed. A joint portion 4 for joining the annular portion 3 is formed between the base portion 2 and the annular portion 3. Here, the base portion 2 of the third mold 8 which is the lower mold and the annular portion 3 of the sixth mold 11 which is the upper mold are joined by the joint portion 4 to form the resin gear 31. The base portion 2 and the annular portion 3 joined at the Z molding position are members prepared in advance by injection molding in the previous step.

成形完了後、各金型の型開きを行う。そして、第３金型８および第６金型１１から、例えば、図２に示す第３ロボット１７によって完成品である樹脂製ギヤ３１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, the resin gear 31, which is a finished product, is taken out from the third mold 8 and the sixth mold 11 by, for example, the third robot 17 shown in FIG. 2, and is housed in the packing machine 18.

このように本実施の形態２の樹脂製ギヤ３１の製造方法では、金属製シャフト２２が埋め込まれたベース部２を射出成形する工程、環状部３を射出成形する工程および接合部４を射出成形する工程を、回転自在に設けられたターンテーブル５上に該ターンテーブル５の回転中心Ｃに対して等間隔で配置された複数の金型において実施する。 As described above, in the method for manufacturing the resin gear 31 of the second embodiment, the step of injection molding the base portion 2 in which the metal shaft 22 is embedded, the step of injection molding the annular portion 3, and the step of injection molding the joint portion 4 are performed. The step is carried out in a plurality of molds arranged on a turntable 5 rotatably provided at equal intervals with respect to the rotation center C of the turntable 5.

樹脂製ギヤ３１を梱包機１８に収容した後、ターンテーブル５を、例えば時計方向に１２０°旋回させる。ここでは、ターンテーブル５の位置制御として、第２の位置制御を行う。これにより、上記第２の位置制御が実行されると、第１金型６と第５金型１０とが対向し、第２金型７と第６金型１１とが対向し、かつ、第３金型８と第４金型９とが対向する第２回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第３金型８と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第１金型６と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第２金型７と第６金型１１の型閉（型締め）を行う。 After the resin gear 31 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, clockwise by 120 °. Here, a second position control is performed as the position control of the turntable 5. As a result, when the second position control is executed, the first mold 6 and the fifth mold 10 face each other, the second mold 7 and the sixth mold 11 face each other, and the second mold The turntable 5 rotates at the second rotation position where the 3 mold 8 and the 4th mold 9 face each other. Then, the third mold 8 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the first mold 6 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the second mold 7 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて第３金型８および第４金型９の内部に樹脂を射出し、円板状のベース部２を成形する。その際、図２に示す第１ロボット１５によって供給機１９から図７の金属製シャフト２２を取出し、この金属製シャフト２２を予め下型である第３金型８内に配置しておき、金属製シャフト２２をインサート部材として金属製シャフト２２の周りにベース部２（外周の環状部以外）を一体的に成形する。そして、金属製シャフト２２が埋め込まれたベース部２を下型である第３金型８に残す。 After molding each mold, at the X molding position, resin is injected into the third mold 8 and the fourth mold 9 using the first injection device 12, and the disk-shaped base portion 2 is molded. .. At that time, the metal shaft 22 of FIG. 7 is taken out from the feeder 19 by the first robot 15 shown in FIG. 2, and the metal shaft 22 is arranged in advance in the lower mold 3 mold 8 to be metal. Using the manufactured shaft 22 as an insert member, the base portion 2 (other than the annular portion on the outer periphery) is integrally formed around the metal shaft 22. Then, the base portion 2 in which the metal shaft 22 is embedded is left in the third mold 8 which is the lower mold.

また、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第１金型６および第５金型１０の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。この時、ターンテーブル５を時計方向に１２０°旋回させたことで、Ｙ成形位置には、下型として金属製シャフト２２が埋め込まれたベース部２を収容した第１金型６が配置され、かつ、上型として環状部３を収容した第５金型１０が配置されている。そして、第１金型６と第５金型１０が型閉（型締め）されたことにより、環状部３の内側にベース部２が位置するようにベース部２と環状部３とが第１金型６および第５金型１０の内部に配置された状態となる。そして、第１金型６および第５金型１０の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４を成形する。これにより、ベース部２と環状部３とを接合部４によって接合し、かつ、ベース部２に金属製シャフト２２が埋め込まれた樹脂製ギヤ３１が成形される。 Further, at the Y molding position of the injection molding device 20, the second injection device 13 is used to inject resin into the inside of the first mold 6 and the fifth mold 10 to join the base portion 2 and the annular portion 3. The joint portion 4 to be formed is formed between the base portion 2 and the annular portion 3. At this time, by turning the turntable 5 clockwise by 120 °, the first mold 6 accommodating the base portion 2 in which the metal shaft 22 is embedded as the lower mold is arranged at the Y forming position. Moreover, a fifth mold 10 accommodating the annular portion 3 is arranged as the upper mold. Then, since the first mold 6 and the fifth mold 10 are mold-closed (mold-tightened), the base portion 2 and the annular portion 3 are first placed so that the base portion 2 is located inside the annular portion 3. It is in a state of being arranged inside the mold 6 and the fifth mold 10. Then, the resin is injected into the inside of the first mold 6 and the fifth mold 10 to form the joint portion 4 that joins the base portion 2 and the annular portion 3. As a result, a resin gear 31 is formed in which the base portion 2 and the annular portion 3 are joined by the joining portion 4 and the metal shaft 22 is embedded in the base portion 2.

また、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第２金型７および第６金型１１の内部に樹脂を射出し、外周にギヤ部３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第６金型１１に残す。 Further, at the Z molding position of the injection molding apparatus 20, the third injection apparatus 14 is used to inject resin into the inside of the second mold 7 and the sixth mold 11, and the gear portion 3a is provided on the outer periphery thereof. An annular portion 3 having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the sixth mold 11 which is the upper mold.

成形完了後、各金型の型開きを行う。そして、第１金型６および第５金型１０から、例えば、図２に示す第２ロボット１６によって完成品である樹脂製ギヤ３１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, for example, the resin gear 31 which is a finished product is taken out from the first mold 6 and the fifth mold 10 by the second robot 16 shown in FIG. 2, and is housed in the packing machine 18.

樹脂製ギヤ３１を梱包機１８に収容した後、ターンテーブル５を、例えば反時計方向に１２０°旋回させる。ここでは、ターンテーブル５の位置制御として、第１の位置制御を行う。これにより、上記第１の位置制御が実行されると、第１金型６と第４金型９とが対向し、第２金型７と第５金型１０とが対向し、かつ、第３金型８と第６金型１１とが対向する第１回転位置にターンテーブル５が回転する。そして、射出成形装置２０のＸ成形位置で第１金型６と第４金型９の型閉（型締め）を行い、射出成形装置２０のＹ成形位置で第２金型７と第５金型１０の型閉（型締め）を行い、射出成形装置２０のＺ成形位置で第３金型８と第６金型１１の型閉（型締め）を行う。 After the resin gear 31 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, counterclockwise by 120 °. Here, as the position control of the turntable 5, the first position control is performed. As a result, when the first position control is executed, the first mold 6 and the fourth mold 9 face each other, the second mold 7 and the fifth mold 10 face each other, and the second mold The turntable 5 rotates at the first rotation position where the 3 mold 8 and the 6th mold 11 face each other. Then, the first mold 6 and the fourth mold 9 are closed (molded) at the X molding position of the injection molding apparatus 20, and the second mold 7 and the fifth mold are closed at the Y molding position of the injection molding apparatus 20. The mold 10 is closed (molded), and the third mold 8 and the sixth mold 11 are closed (molded) at the Z molding position of the injection molding apparatus 20.

各金型の型締め後、Ｘ成形位置では、第１射出装置１２を用いて、第１金型６および第４金型９の内部に樹脂を射出し、円板状のベース部２を成形する。その際、図２に示す第１ロボット１５によって供給機１９から図７の金属製シャフト２２を取出し、この金属製シャフト２２を予め下型である第１金型６内に配置しておき、金属製シャフト２２をインサート部材として金属製シャフト２２の周りにベース部２（外周の環状部以外）を一体的に成形する。そして、金属製シャフト２２が埋め込まれたベース部２を下型である第１金型６に残す。 After molding each mold, at the X molding position, resin is injected into the first mold 6 and the fourth mold 9 using the first injection device 12, and the disk-shaped base portion 2 is molded. do. At that time, the metal shaft 22 of FIG. 7 is taken out from the feeder 19 by the first robot 15 shown in FIG. 2, and the metal shaft 22 is arranged in advance in the first mold 6 which is a lower mold, and the metal is formed. Using the manufactured shaft 22 as an insert member, the base portion 2 (other than the annular portion on the outer periphery) is integrally formed around the metal shaft 22. Then, the base portion 2 in which the metal shaft 22 is embedded is left in the first mold 6 which is a lower mold.

また、射出成形装置２０のＹ成形位置では、第２射出装置１３を用いて、第２金型７および第５金型１０の内部に樹脂を射出し、外周にギヤ部３ａを備え、かつ、ベース部２の外径よりも大きな内径の環状部３を成形する。ここでは、外周のギヤ部３ａを含む環状部３を成形し、この環状部３を上型である第５金型１０に残す。 Further, at the Y molding position of the injection molding device 20, the second injection device 13 is used to inject resin into the inside of the second mold 7 and the fifth mold 10, and a gear portion 3a is provided on the outer periphery thereof. An annular portion 3 having an inner diameter larger than the outer diameter of the base portion 2 is formed. Here, the annular portion 3 including the outer peripheral gear portion 3a is formed, and the annular portion 3 is left in the fifth mold 10 which is the upper mold.

そして、射出成形装置２０のＺ成形位置では、第３射出装置１４を用いて、第３金型８および第６金型１１の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４をベース部２と環状部３との間に成形する。この時、ターンテーブル５を反時計方向に１２０°旋回させたことで、Ｚ成形位置には、下型として金属製シャフト２２が埋め込まれたベース部２を収容した第３金型８が配置され、かつ、上型として環状部３を収容した第６金型１１が配置されている。そして、第３金型８と第６金型１１が型閉（型締め）されたことにより、環状部３の内側にベース部２が位置するようにベース部２と環状部３とが第３金型８および第６金型１１の内部に配置された状態となる。そして、第３金型８および第６金型１１の内部に樹脂を射出し、ベース部２と環状部３とを接合する接合部４を成形する。これにより、ベース部２と環状部３とを接合部４によって接合し、かつ、ベース部２に金属製シャフト２２が埋め込まれた樹脂製ギヤ３１が成形される。 Then, at the Z molding position of the injection molding device 20, the resin is injected into the inside of the third mold 8 and the sixth mold 11 by using the third injection device 14, and the base portion 2 and the annular portion 3 are joined. The joint portion 4 to be formed is formed between the base portion 2 and the annular portion 3. At this time, by turning the turntable 5 counterclockwise by 120 °, a third mold 8 accommodating the base portion 2 in which the metal shaft 22 is embedded as a lower mold is arranged at the Z forming position. In addition, a sixth mold 11 accommodating the annular portion 3 is arranged as an upper mold. Then, since the third mold 8 and the sixth mold 11 are mold-closed (mold-tightened), the base portion 2 and the annular portion 3 are third so that the base portion 2 is located inside the annular portion 3. It is in a state of being arranged inside the mold 8 and the sixth mold 11. Then, the resin is injected into the inside of the third mold 8 and the sixth mold 11 to form the joint portion 4 that joins the base portion 2 and the annular portion 3. As a result, a resin gear 31 is formed in which the base portion 2 and the annular portion 3 are joined by the joining portion 4 and the metal shaft 22 is embedded in the base portion 2.

成形完了後、各金型の型開きを行う。そして、第３金型８および第６金型１１から、例えば、図２に示す第３ロボット１７によって完成品である樹脂製ギヤ３１を取り出すとともに、梱包機１８に収容する。 After the molding is completed, each mold is opened. Then, the resin gear 31, which is a finished product, is taken out from the third mold 8 and the sixth mold 11 by, for example, the third robot 17 shown in FIG. 2, and is housed in the packing machine 18.

樹脂製ギヤ３１を梱包機１８に収容した後、ターンテーブル５を、例えば時計方向に１２０°旋回させ、Ｘ，Ｙ，Ｚの各成形位置で図６に示す処理を繰り返して実施する。 After the resin gear 31 is housed in the packing machine 18, the turntable 5 is swiveled by, for example, clockwise by 120 °, and the process shown in FIG. 6 is repeated at each of the X, Y, and Z molding positions.

以上のように、本実施の形態２の樹脂製ギヤ３１の製造方法においても、金属製シャフト２２が埋め込まれたベース部２を射出成形する工程、環状部３を射出成形する工程、ターンテーブル５を１２０°旋回させて環状部３の内側にベース部２を配置する工程、および接合部４を射出成形してベース部２と環状部３とを接合する工程を１サイクルとし、これらの工程が複数回繰り返して実施される。そして、複数回繰り返される１サイクルには、金属製シャフト２２を埋め込んでベース部２を射出成形する工程と環状部３を射出成形する工程とを同時に実施する１サイクルが含まれる。 As described above, also in the method for manufacturing the resin gear 31 of the second embodiment, the step of injection molding the base portion 2 in which the metal shaft 22 is embedded, the step of injection molding the annular portion 3, and the turntable 5 The step of arranging the base portion 2 inside the annular portion 3 by rotating 120 ° and the step of injection molding the joint portion 4 to join the base portion 2 and the annular portion 3 are defined as one cycle. It is repeated multiple times. The one cycle repeated a plurality of times includes one cycle in which the step of embedding the metal shaft 22 and injection molding the base portion 2 and the step of injection molding the annular portion 3 are simultaneously performed.

本実施の形態２では、金属製シャフト２２を埋め込んでベース部２を射出成形する工程と、環状部３を射出成形する工程と、接合部４を射出成形してベース部２と環状部３とを接合する工程と、を同時に実施する１サイクルが連続的に実施される場合を説明している。ただし、樹脂製ギヤ３１の組立てとしては、上述のように複数回繰り返される上記１サイクルにおいて、金属製シャフト２２を埋め込んでベース部２を射出成形する工程と、環状部３を射出成形する工程とを同時に実施する上記１サイクルを含んでいればよい。 In the second embodiment, a step of embedding a metal shaft 22 and injection molding the base portion 2, a step of injection molding the annular portion 3, and a step of injection molding the joint portion 4 to form the base portion 2 and the annular portion 3 The case where the step of joining and one cycle in which the steps are carried out at the same time is continuously carried out is described. However, as the assembly of the resin gear 31, in the above-mentioned one cycle repeated a plurality of times as described above, a step of embedding the metal shaft 22 and injection molding the base portion 2 and a step of injection molding the annular portion 3 are performed. It is sufficient to include the above-mentioned one cycle in which the above steps are carried out at the same time.

本実施の形態２の樹脂製ギヤ３１の組立てにおいても、樹脂製ギヤ３１を複数の部分に分けて該部分ごとに射出成形して製造する際に、金属製シャフト２２を埋め込んでベース部２を射出成形する工程と、環状部３を射出成形する工程とを同時に実施することにより、樹脂製ギヤ３１の生産性を高めることができる。 Also in the assembly of the resin gear 31 of the second embodiment, when the resin gear 31 is divided into a plurality of parts and injection molded for each part, the metal shaft 22 is embedded to form the base portion 2. By simultaneously performing the injection molding step and the injection molding step of the annular portion 3, the productivity of the resin gear 31 can be increased.

すなわち、ベース部２に金属製シャフト２２が埋め込まれた樹脂製ギヤ３１であっても、この樹脂製ギヤ３１の生産性を高めることができる。 That is, even if the resin gear 31 has the metal shaft 22 embedded in the base portion 2, the productivity of the resin gear 31 can be increased.

そして、本実施の形態２では、金属製シャフト２２を埋め込んでベース部２を射出成形する工程と、環状部３を射出成形する工程と、接合部４を射出成形してベース部２と環状部３とを接合する工程と、を同時に実施することにより、ベース部２に金属製シャフト２２が埋め込まれた樹脂製ギヤ３１の生産性をさらに高めることができる。 Then, in the second embodiment, the step of embedding the metal shaft 22 and injection molding the base portion 2, the step of injection molding the annular portion 3, and the step of injection molding the joint portion 4 to form the base portion 2 and the annular portion. By simultaneously performing the step of joining the 3 and the resin gear 31 in which the metal shaft 22 is embedded in the base portion 2, the productivity of the resin gear 31 can be further increased.

また、樹脂製ギヤ３１を、金属製シャフト２２が埋め込まれたベース部２と環状部３とに分けてそれぞれを樹脂成形して製造するため、金属製シャフト２２が埋め込まれたベース部２であっても、このベース部２および環状部３のそれぞれの形状の精度を高めることができる。これにより、環状部３の外周のギヤ部３ａの複数の歯の肉厚を均一に成形することができる。その結果、樹脂製ギヤ３１において高精度なギヤ形状を実現することが可能になる。これにより、ギヤ形状の精度を確保するためのトライ回数や金型改修費等の見極めまでの費用と時間を削減することができる。 Further, since the resin gear 31 is divided into a base portion 2 in which the metal shaft 22 is embedded and an annular portion 3 and each is manufactured by resin molding, the base portion 2 in which the metal shaft 22 is embedded is used. However, the accuracy of the shapes of the base portion 2 and the annular portion 3 can be improved. As a result, the wall thickness of the plurality of teeth of the gear portion 3a on the outer circumference of the annular portion 3 can be uniformly formed. As a result, it becomes possible to realize a highly accurate gear shape in the resin gear 31. As a result, it is possible to reduce the cost and time required to determine the number of trials and the mold repair cost for ensuring the accuracy of the gear shape.

なお、本実施の形態２の樹脂製ギヤ３１の組立ておよび樹脂製ギヤ３１によって得られるその他の効果については、実施の形態１の樹脂製ギヤ１の組立ておよび樹脂製ギヤ１によって得られるその他の効果と同様であるため、その重複説明は省略する。 Regarding the assembly of the resin gear 31 of the second embodiment and other effects obtained by the resin gear 31, other effects obtained by the assembly of the resin gear 1 of the first embodiment and the resin gear 1 can be obtained. Since it is the same as the above, the duplicate description will be omitted.

本発明は上記実施の形態に限定されるものではなく、その要旨を逸脱しない範囲で種々変更可能であることは言うまでもない。上記実施の形態においては、ターンテーブル５における第１回転位置と第２回転位置との成す角度、および第１金型６、第２金型７、第３金型８の配置間隔（回転中心Ｃの周上の角度）がそれぞれ１２０°の場合を説明したが、これらの角度は、１２０°に限らず１２０°以外の角度であってもよい。 It goes without saying that the present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the gist thereof. In the above embodiment, the angle formed by the first rotation position and the second rotation position on the turntable 5 and the arrangement interval of the first mold 6, the second mold 7, and the third mold 8 (rotation center C). The case where the angles on the circumference of each of the above is 120 ° has been described, but these angles are not limited to 120 ° and may be angles other than 120 °.

１ 樹脂製ギヤ、２ ベース部、２ａ 貫通孔、２ｂ 凹部、２ｃ リブ、２ｄ 溝、２ｅ 凹部、３ 環状部、３ａ ギヤ部（歯形部）、４ 接合部、４ａ 凸部、５ ターンテーブル、６ 第１金型（下型）、７ 第２金型（下型）、８ 第３金型（下型）、９ 第４金型（上型）、１０ 第５金型（上型）、１１ 第６金型（上型）、１２ 第１射出装置、１２ａ 射出筒、１２ｂ 射出口、１３ 第２射出装置、１３ａ 射出筒、１３ｂ 射出口、１４ 第３射出装置、１４ａ 射出筒、１４ｂ 射出口、１５ 第１ロボット、 １６ 第２ロボット、１７ 第３ロボット、１８ 梱包機、１９ 供給機、２０ 射出成形装置、２１ 射出成形システム、２２ 金属製シャフト、３１ 樹脂製ギヤ 1 Resin gear, 2 Base part, 2a through hole, 2b concave part, 2c rib, 2d groove, 2e concave part, 3 annular part, 3a gear part (dental part), 4 joint part, 4a convex part, 5 turntable, 6 1st mold (lower mold), 7 2nd mold (lower mold), 8 3rd mold (lower mold), 9 4th mold (upper mold), 10 5th mold (upper mold), 11 6th mold (upper mold), 12 1st injection device, 12a injection tube, 12b injection port, 13 2nd injection device, 13a injection tube, 13b injection port, 14 3rd injection device, 14a injection tube, 14b injection port , 15 1st robot, 16 2nd robot, 17 3rd robot, 18 packing machine, 19 feeder, 20 injection molding equipment, 21 injection molding system, 22 metal shaft, 31 resin gear

Claims (6)

（ａ）金型内に樹脂を射出して円板状のベース部を成形する工程と、
（ｂ）金型内に樹脂を射出して外周に歯形部を備え、かつ、前記ベース部の外径よりも大きな内径の環状部を成形する工程と、
（ｃ）前記環状部の内側に前記ベース部が位置するように前記ベース部と前記環状部とを金型内に配置する工程と、
（ｄ）金型内に樹脂を射出して前記ベース部と前記環状部とを接合する接合部を前記ベース部と前記環状部との間に成形する工程と、
を有し、
前記（ａ）工程〜前記（ｄ）工程を１サイクルとし、これを複数回繰り返す樹脂製ギヤの製造方法であって、
複数回繰り返される前記１サイクルには、前記（ａ）工程と前記（ｂ）工程とを同時に実施する前記１サイクルが含まれることを特徴とする樹脂製ギヤの製造方法。 (A) A process of injecting resin into a mold to form a disk-shaped base portion, and
(B) A step of injecting resin into a mold to form an annular portion having a tooth profile portion on the outer circumference and an inner diameter larger than the outer diameter of the base portion.
(C) A step of arranging the base portion and the annular portion in a mold so that the base portion is located inside the annular portion.
(D) A step of injecting resin into a mold to form a joint portion for joining the base portion and the annular portion between the base portion and the annular portion.
Have,
A method for manufacturing a resin gear, wherein the steps (a) to (d) are set as one cycle and this is repeated a plurality of times.
A method for manufacturing a resin gear, wherein the one cycle repeated a plurality of times includes the one cycle in which the step (a) and the step (b) are simultaneously performed. 前記（ａ）工程では、予め金属製シャフトを金型内に配置しておき、前記金属製シャフトをインサート部材として前記金属製シャフトの周りに前記ベース部を一体的に成形することを特徴とする請求項１に記載の樹脂製ギヤの製造方法。 The step (a) is characterized in that a metal shaft is arranged in a mold in advance, and the base portion is integrally formed around the metal shaft using the metal shaft as an insert member. The method for manufacturing a resin gear according to claim 1. 前記複数回繰り返される前記１サイクルには、前記（ａ）工程と前記（ｂ）工程と前記（ｄ）工程とを同時に実施する前記１サイクルが含まれることを特徴とする請求項１または請求項２に記載の樹脂製ギヤの製造方法。 Claim 1 or claim, wherein the one cycle repeated a plurality of times includes the one cycle in which the step (a), the step (b), and the step (d) are simultaneously performed. 2. The method for manufacturing a resin gear according to 2. 前記同時に実施する前記１サイクルは、回転自在に設けられたターンテーブル上に該ターンテーブルの回転中心に対して等間隔で配置された複数の金型において行われることを特徴とする請求項３に記載の樹脂製ギヤの製造方法。 According to claim 3, the one cycle to be carried out at the same time is carried out in a plurality of molds arranged on a rotatably provided turntable at equal intervals with respect to the rotation center of the turntable. The method for manufacturing a resin gear according to the description. 樹脂製の円板状のベース部と、
外周に歯形部を備え、かつ、前記ベース部の外径よりも大きな内径の樹脂製の環状部と、
前記ベース部と前記環状部とを接合する樹脂製の接合部と、
を有し、
前記ベース部は、前記環状部の内側に配置され、
前記接合部は、前記環状部と前記ベース部との間に配置されていることを特徴とする樹脂製ギヤ。 A disk-shaped base made of resin and
A resin annular portion having a tooth profile on the outer circumference and an inner diameter larger than the outer diameter of the base portion.
A resin joint that joins the base and the annular portion,
Have,
The base portion is arranged inside the annular portion and is arranged.
A resin gear characterized in that the joint portion is arranged between the annular portion and the base portion. 前記ベース部には、該ベース部の表面から厚さ方向に凹んだ複数の凹部が設けられていることを特徴とする請求項５に記載の樹脂製ギヤ。 The resin gear according to claim 5, wherein the base portion is provided with a plurality of recesses recessed in the thickness direction from the surface of the base portion.
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JP7403183B2 (en) 2022-04-07 2023-12-22 キング スチール マシネリー カンパニー リミテッド Assembly of polymer parts and injection molding method

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JPH074498A (en) * 1993-06-16 1995-01-10 Mitsubishi Chem Corp Resin gear and its manufacture
EP2353967A1 (en) * 2010-02-10 2011-08-10 Cie Automotive, S.A. Rack guide for a steering column of an automobile and method for manufacturing the same by injection moulding
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US11780129B2 (en) 2020-03-20 2023-10-10 King Steel Machinery Co., Ltd. Molding method for operating molding device
JP7403183B2 (en) 2022-04-07 2023-12-22 キング スチール マシネリー カンパニー リミテッド Assembly of polymer parts and injection molding method

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