JP3018853B2 - Fiber reinforced resin impeller molding and molding die for fiber reinforced resin impeller molding - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber reinforced resin impeller used in a centrifugal compressor, and more particularly to a molded article shape of a fiber reinforced resin impeller of a turbocharger for an internal combustion engine and a molding die used for producing the impeller. It is.

[0002]

2. Description of the Related Art Turbochargers (turbine-type superchargers) for passenger cars in Japan have been installed in earnest.
It was 1979, and since then, the improvement of the engine's power performance has been favored, and the number has continued to increase steadily.However, in order to realize further performance improvement, the acceleration performance in the low speed range, It has been desired to reduce the so-called turbo lag peculiar to turbo cars.

Various methods can be considered to reduce the turbo lag. However, it is effective to reduce the inertia moment by reducing the weight of the rotor of the turbocharger, and it is more effective than the conventional nickel-based metal material having a high specific gravity. Considering the application of ceramic materials that can greatly reduce weight,
In October 1985, the world's first passenger car equipped with a ceramic turbocharger rotor was released (“Service Shouho No. 542 NISSAN Fairlady Z” published in October 1985).

[0004] In addition, in order to improve the turbo lag, a means for changing the A / R of the turbine housing (A: cross-sectional area of the narrowest part of the scroll of the turbine housing, R: distance from the center of the shaft) is provided. It has been commercialized one after another, such as the one provided, the change from the plain bearing of the bearing part to the ball bearing type, and the combined use with the supercharger. Further, in order to further reduce the moment of inertia, studies have been made to use a fiber reinforced resin for the compressor impeller.

A method for producing a fiber reinforced resin impeller is disclosed in JP-B-52-48326 and JP-A-59-18.
296, JP 1-78287, JP 1
As disclosed in JP-A-76525, JP-A-2-132820, etc., a fiber-reinforced resin impeller has a divided structure, and each part is manufactured by injection molding, and then bonded, screwed, welded, or the like. Bonding / joining method and Japanese Utility Model Application Laid-Open No. 1-36120, 1-11539
17, JP-A-3-207724, JP-A-3-207724
As disclosed in JP-A-267599, two methods for manufacturing an impeller molded body made of a fiber-reinforced resin including an end product shape by injection molding or extrusion molding without dividing the impeller, and cutting out unnecessary portions. Are roughly divided into

In the latter case, in the case of the current aluminum alloy impeller, almost all parts of the outer periphery of the impeller, including the shaft hole, must be machined. Therefore, there is a possibility that an impeller with a low cost can be provided rather than using an aluminum alloy which is much cheaper in raw material price.

[0007]

SUMMARY OF THE INVENTION Incidentally, Japanese Patent Laid-Open No.
Although the durability reliability of the fiber reinforced resin impeller has been greatly improved by using a high-performance material as disclosed in Japanese Patent No. 175972, there are some problems that must be solved for practical use. there were.

[0008] As one of them, there is "abnormal sound (hune sound)" at the time of turbocharger supercharging. This unique noise unique to turbocharged vehicles was rather favored as a discrimination point between turbocharged vehicles and non-equipped vehicles immediately after the turbocharged vehicles became commercially available, but in recent years the importance of quietness of vehicles has been emphasized. As it has become more common, it has become necessary to reduce this noise.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of such conventional circumstances, and an object of the present invention is to provide an inexpensive fiber-reinforced resin which does not generate the "unusual noise" peculiar to a turbocharged vehicle. An object of the present invention is to provide an impeller molded body suitable as an impeller and a molding die thereof.

[0010]

The abnormal noise of the turbocharger is generated by a mechanism as shown in FIGS. That is, in the impeller 1 having the shaft hole 1a, in a state where the shaft 2 is inserted into the shaft hole 1a and fixed by the nut 3, as shown in FIG. 12, the diameter of the shaft hole 1a of the impeller 1 and the diameter of the shaft 2 are different. When the dimensional difference is small, the noise is small and there is no practical problem.

On the other hand, as shown in FIG. 13, when the difference between the diameter of the shaft hole 1a of the impeller 1 and the diameter of the shaft 2 is large, the impeller 1 rotates eccentrically. For this reason, at the time of supercharging, when the rotation speed of the impeller 1 increases, the eccentric rotation increases and abnormal noise occurs. When the difference between the diameter of the shaft hole 1a of the impeller 1 and the diameter of the shaft 2 is further increased, the nut 3 is loosened by the eccentric rotation, and the noise is further increased.
Therefore, in the case of the aluminum alloy impeller 1,
By preparing shafts 2 having different diameters and performing selective fitting, abnormal noise is reduced.

FIG. 14 shows a cross section of the impeller molded body 11 made of fiber reinforced resin. As shown in FIG. 14, the impeller molded body 11 has a shaft hole 1a, a boss 1b, a wing 1c, and a back plate 1d. In FIG. 14, the injection molding is performed from the boss 1b side of the impeller 1, so that the sprue 4 remains at the tip of the boss 1b. Since the impeller itself is a considerably thick part, it is not easy to achieve dimensional accuracy. In particular, the site shown in FIG.
The "sink" generated during cooling is remarkable, and if the pin diameter of the mold is made to be the same as the dimension indicated in the drawing, a dimensional difference as large as about 300 .mu.m occurs at the maximum "sink" generation site shown in FIG.

By the way, in the case of an aluminum alloy impeller, since the shaft hole is finished by a reamer, the diameter of the shaft hole of the impeller is almost constant over the entire region. It is. On the other hand, in the case of the impeller 1 made of fiber reinforced resin, since the shaft hole 1a is inexpensively formed by a pin protruding from a molding die, the inventor has mainly considered eliminating the machining of the shaft hole 1a. .

However, the shaping of the shaft hole 1a by the pin causes variations in the shaft hole diameter due to fluctuations in the mold, resin temperature, and the like. This is a very disadvantageous method for prevention.

In the case of a composite material reinforced with a fiber reinforced resin, particularly a carbon fiber, tool wear is severe, and durability is insufficient with a soft or carbide tool used for processing an aluminum alloy impeller. . CFRP, GFRP
In machining, diamond tools are often used, but are expensive and the tool life is not long in any case. Further, since it is not possible to increase the feed speed of the tool, it takes more time to process the aluminum alloy impeller than when machining it. Therefore, if the shaft hole is machined, it is difficult to provide an inexpensive fiber reinforced resin impeller.

The present invention has been made in view of such conventional problems, and the present inventor has clarified a shaft hole accuracy management portion required at a minimum in order to prevent the generation of abnormal noise. Regarding the shaft hole diameter of the part not involved in the generation of sound,
Dimensional accuracy is not required.

As shown in FIG. 16, when the diameter of the shaft hole 1a near both end surfaces of the impeller 1 is larger than the diameter of the shaft 2, the impeller 1 rotates eccentrically, and abnormal noise is generated. As shown in FIG. 17, it was found that if the difference between the shaft hole diameter near the both end surfaces of the impeller and the shaft diameter was small, no abnormal noise was generated even if the shaft hole diameter at the center was large.

FIG. 18 shows a fitting state of the shaft 2 and the impeller 1 made of fiber reinforced resin. Strictly speaking, the shaft tip 1a does not contact the shaft hole 1a near the boss 1b of the impeller 1 and the shaft 2 because the tip of the shaft has the structure of the screw portion 2a. Therefore, if the concept of abnormal noise prevention shown in FIG. 16 is not wrong, as shown in FIG.
The diameter of the shaft hole near the back plate side end face of the impeller 1 and the diameter of the shaft hole near the terminal end on the boss portion where the shaft and the shaft hole come into contact should not be excessively large with respect to the shaft diameter. become.

When the diameter of the shaft hole is smaller than the diameter of the shaft, no noise is generated as long as the fitting can be performed. However, it is important that the difference between the shaft hole diameter and the shaft diameter does not become too large for fitting.

FIG. 19 shows the results of a study on the temperature of the resin impeller and the possibility of assembly. Resin impellers having different shaft hole diameters were heated in an oven and examined for assemblability with a standard diameter shaft (left at room temperature).

In experiments, the diameter of the shaft hole was set to be 40 times smaller than the diameter of the shaft.
Even if it was smaller than μm, it was possible to assemble it by heating it to 200 ° C. or more. However, the shaft hole shrinks due to air cooling as soon as it is removed from the oven. For this reason, it is not realistic to perform such an assembly operation in a mass production process. Further, there is a concern that the residual stress generated due to a difference in thermal expansion coefficient between the resin impeller and the shaft may affect the durability reliability.

When the difference between the diameter of the shaft hole and the diameter of the shaft is 15 μm or less, the assembly can be easily performed by simple heating. All you have to do is place the impeller on a hot plate and heat it. The work is very simple and suitable for mass production.

Thus, as described above, the present invention has been made by clarifying the minimum required shaft hole accuracy management part in order to prevent the generation of abnormal noise. Fiber-reinforced resin impeller moldings are
In the impeller molded body made of fiber reinforced resin used as a product without performing machining of the shaft hole, as shown in FIG. 20, provided at both ends of a portion where the inner surface of the shaft hole of the impeller and the shaft are in contact, The shaft hole diameter of the back plate side shaft hole diameter management region A of 3 mm or more on the back plate side and the boss side shaft hole diameter management region B of 2 mm or more on the boss side is set to-
It is characterized by being set to 0.015 mm to +0.020 mm.

Further, in the embodiment, in the impeller molded body made of fiber reinforced resin which is molded by performing injection from the boss side of the impeller, the impeller has a back plate side end surface and a sprue which is a boss side cutout portion. It is characterized in that a back plate side cutout portion is provided at the upper position, and in the same embodiment, the back plate side provided at a position on the back plate side end surface of the impeller and coaxially with the sprue which is the boss side cutout portion The size of the resection site is 2 mm or less or 8 mm or more.

Further, the molding die for molding an impeller molded body made of a fiber-reinforced resin according to the present invention comprises a cavity portion corresponding to the shape of the impeller molded body made of a fiber-reinforced resin, a pin forming a shaft hole of the impeller, and a fiber-reinforced resin. It is characterized by having a spacer capable of changing the width dimension of the back plate side cut portion provided in the impeller molded body, and in the embodiment, without removing the molding die to the injection molding machine, the spacer Is characterized in that the size of the cut-out portion on the back plate side provided in the impeller molded body made of fiber reinforced resin can be changed.

By showing the experimental results below the maximum difference between the shaft hole diameter and the shaft diameter, the validity of the concept shown in FIG. 18 is shown, and the shaft hole diameter (FIGS. Shaft bore diameter management sites A and B shown
) And the maximum difference between the shaft diameter.

[0027]

EXAMPLE 1 The difference between the shaft hole diameter of the shaft hole diameter management region A and the shaft hole diameter of the shaft hole diameter management region B shown in FIG. 20 was +0.001.
10 impellers made of fiber-reinforced resin between mm and +0.005 mm (shaft hole diameter> shaft diameter is indicated by + and shaft hole diameter <shaft diameter is indicated by −) are prepared and incorporated into the turbocharger. After that, 80,000rpm,
100,000 rpm. The vibration G at the time was measured.

The diameter of the shaft used here is 7.503.
mm, the nut bearing surface diameter was 14.6 mm, and the nut tightening torque was 1.8 kg · m. The pass / fail judgment regarding abnormal noise generation is 80,000 rpm. 0.5G or less at time 10
0,000 rpm. In some cases, 1.0 G or less was determined as a criterion.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.001 mm to +0.005 mm at least 5 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B was used. Table 1 shows the test results.

Embodiment 2 The difference between the shaft hole diameter of the shaft hole diameter management area A and the shaft hole diameter of the shaft hole diameter management area B and the shaft diameter is +0.005 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 010 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 1.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.005 mm to +0.010 mm was at least 5 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B. The test results are also shown in Table 1.

Embodiment 3 The difference between the shaft hole diameter of the shaft hole diameter management part A and the shaft hole diameter of the shaft hole diameter management part B is +0.010 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 015 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 1.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having an area having a shaft hole diameter of 0.010 mm to +0.015 mm was at least 5 mm or more in both the shaft hole diameter management area A and the shaft hole diameter management area B. The test results are also shown in Table 1.

Embodiment 4 The difference between the shaft hole diameter of the shaft hole diameter management region A and the shaft hole diameter of the shaft hole diameter management region B is +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 1.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.015 mm to +0.020 mm at least 5 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B was used. The test results are also shown in Table 1.

COMPARATIVE EXAMPLE 1 The difference between the shaft hole diameter of the shaft hole diameter management area A and the shaft hole diameter of the shaft hole diameter management area B and the shaft diameter was +0.020 mm to +0.02 mm.
Ten impellers made of fiber-reinforced resin having a distance between 025 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 1.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.020 mm to +0.025 mm was at least 5 mm in both the shaft hole diameter management region A and the shaft hole diameter management region B. The test results are also shown in Table 1.

Comparative Example 2 The difference between the shaft hole diameter of the shaft hole diameter management area A and the shaft hole diameter of the shaft hole diameter management area B was +0.025 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 030 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 1.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.025 mm to +0.030 mm at least 5 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B was used. The test results are also shown in Table 1.

[0040]

[Table 1]

Maximum difference between shaft hole diameter and shaft diameter and generation of abnormal noise
Relationship table results As is clear from that shown in 1 of the shaft hole diameter of the shaft hole diameter and Shaft Diameter management site B of Shaft Diameter management site A, the difference between the shaft diameter exceeds + 0.020 mm Abnormal noise is generated in the turbocharger.

(Shaft direction) Length of Shaft Hole Diameter Management Portion Next, the shaft hole diameter of the shaft hole diameter management portion A and the shaft hole diameter of the shaft hole diameter management portion B shown in FIG. The difference is +
An impeller of 0.015 mm to +0.020 mm was prepared, and the relationship between the (shaft direction) length of the shaft hole diameter management site and the frequency of abnormal noise generation products was clarified. If the length of the shaft hole diameter management portion can be reduced, the proportion of impellers that do not need to be machined will increase.

Embodiment 5 The difference between the shaft hole diameter of the shaft hole diameter management part A and the shaft hole diameter of the shaft hole diameter management part B shown in FIG.
Prepare 10 fiber reinforced resin impellers between mm and +0.020 mm (shaft hole diameter> shaft diameter is indicated by +, shaft hole diameter <shaft diameter is indicated by −), and incorporated into the turbocharger. After that, 80,000rpm,
100,000 rpm. The vibration G at the time was measured.

The diameter of the shaft used was 7.503 mm,
The nut seat diameter was 14.6 mm, and the nut tightening torque was 1.8 kg · m. The pass / fail judgment regarding abnormal noise generation is 80,000 rpm. 0.5G or less at time, 100,
000 rpm. In some cases, 1.0 G or less was determined as a criterion.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.015 mm to +0.020 mm was at least 8 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B. Table 2 shows the test results.

Embodiment 6 The difference between the shaft hole diameter of the shaft hole diameter management area A and the shaft hole diameter of the shaft hole diameter management area B and the shaft diameter is +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, in the experiment, the difference from the shaft diameter was +
An impeller having a region having a shaft hole diameter of 0.015 mm to +0.020 mm at least 4 mm or more in both the shaft hole diameter management region A and the shaft hole diameter management region B was used. The test results are also shown in Table 2.

Embodiment 7 The difference between the shaft hole diameter of the shaft hole diameter management section A and the shaft hole diameter of the shaft hole diameter management section B and the shaft diameter is +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, in the experiment, the difference from the shaft diameter was +
In a region having a shaft hole diameter of 0.015 mm to +0.020 mm, an impeller of at least 3 mm to 4 mm or more was used in both the shaft hole diameter management region A and the shaft hole diameter management region B. The test results are also shown in Table 2.

Comparative Example 3 The difference between the shaft hole diameter of the shaft hole diameter management area A and the shaft hole diameter of the shaft hole diameter management area B and the shaft diameter was +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, in the experiment, the difference from the shaft diameter was +
In the region having a shaft hole diameter of 0.015 mm to +0.020 mm, the impellers of 2 mm to 3 mm were used in both the shaft hole diameter management region A and the shaft hole diameter management region B. The test results are also shown in Table 2.

COMPARATIVE EXAMPLE 4 The difference between the shaft hole diameter of the shaft hole diameter management part A and the shaft hole diameter of the shaft hole diameter management part B and the shaft diameter was +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, in the experiment, the difference from the shaft diameter was +
The impeller having a shaft hole diameter of 0.015 mm to +0.020 mm is 2 mm or less in both the shaft hole diameter management region A and the shaft hole diameter management region B. The test results are also shown in Table 2.

Embodiment 8 The difference between the shaft hole diameter of the shaft hole diameter management part A and the shaft hole diameter of the shaft hole diameter management part B and the shaft diameter is +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, in the experiment, the difference from the shaft diameter was +
For the region having a shaft hole diameter of 0.015 mm to +0.020 mm, an impeller having a shaft hole diameter management site A of 3 mm to 4 mm and a shaft hole diameter management site B of 2 mm to 3 mm was used. The test results are also shown in Table 2.

COMPARATIVE EXAMPLE 5 The difference between the shaft hole diameter of the shaft hole diameter management part A and the shaft hole diameter of the shaft hole diameter management part B and the shaft diameter was +0.015 mm to +0.05 mm.
Ten impellers made of fiber-reinforced resin having a distance of 020 mm were prepared, assembled into a turbocharger, and the vibration G was measured in the same manner as in Example 5.

In this case, the difference from the shaft diameter was +
For the region having a shaft hole diameter of 0.015 mm to +0.020 mm, an impeller having a shaft hole diameter management site A of 2 mm to 3 mm and a shaft hole diameter management site B of 3 mm to 4 mm was used. The test results are also shown in Table 2.

[0058]

[Table 2]

The (shaft direction) length of the shaft hole diameter management part
As is clear from the results shown in the relationship table 2 and abnormal noise generation, more than 3mm in shaft hole diameter administration site A, 2 mm or more regions in the shaft hole diameter managing site B, the difference between the shaft hole diameter and the shaft diameter Can be reduced to +0.020 mm or less, no abnormal noise occurs. Moreover, it can be seen that a fiber reinforced resin impeller which does not require machining of the shaft hole can be provided. In addition, the shaft hole diameter management part B has a smaller shaft hole diameter management part length necessary for preventing abnormal noise.
On the boss 1b side, there is little variation in the shaft hole diameter in the shaft direction because "sink" is unlikely to occur, and because the boss 1b has a smaller volume than the back plate 1d, the difference between the shaft hole diameter and the shaft diameter is small. It is considered that the imbalance caused by the difference is small.

Therefore, based on the results shown in FIG. 19 and the results shown in the above Examples and Comparative Examples, the back-side shaft hole diameter management region A shown in FIG. In a region having a length of 2 mm or more in the diameter management region B, the shaft hole diameter is set to −0.015 mm to +0.02 with respect to the shaft diameter.
If an impeller made of fiber-reinforced resin having a thickness of 0 mm is manufactured, an inexpensive impeller that does not generate abnormal noise can be provided.

Abolishment of Shaft Hole Machining If the above impeller can be manufactured, a fiber reinforced resin impeller can be provided as a product without machining the shaft hole. However, in order to achieve the purpose of providing an inexpensive impeller by eliminating machining of the shaft hole, it is necessary to further solve the following two problems.

(1) Even if the same pin is used, if the material lot changes, the average shaft hole diameter of the molded product changes. Since there is a limit in preparing shafts having different diameters, it is highly possible that a large number of fiber-reinforced resin impellers that are difficult to fit when a material lot is changed.

(2) It is not easy to suppress the variation of the shaft hole diameter of the impeller belonging to a thick part in which the dimensional variation is liable to occur in the range of −0.015 mm to +0.020 mm with respect to the shaft diameter.

Each time the material lot changes, the average shaft hole diameter changes or the diameter difference (+0.015 mm to +0.02
If the impeller which deviates from 0 mm) is generated by many percent, machining of the shaft hole cannot be abolished in the mass production process. Therefore, the solution of these two problems is an absolute condition for providing an inexpensive fiber reinforced resin impeller.

Factors affecting the essential variation of the shaft hole diameter described in (2) include not only the variation between the lots of the material but also the molding conditions such as the mold temperature and the cylinder temperature. Various factors, such as variations in the temperature of the molding site and variations in the temperature of the molding site, can be considered. By the way, when attention is paid to the impeller molded body itself, the portion where the shaft hole diameter defect is likely to occur as shown in FIG. 15 is the thickest portion of the impeller, and is a portion where it is essentially difficult to ensure dimensional accuracy. However, regarding the variation in the diameter of the shaft hole, it was considered appropriate to consider that the cooling state of the portion where the shaft hole diameter was significantly defective shown in FIG. 15 was unstable. Since the portion where the shaft hole diameter defect is remarkable shown in FIG. 15 is located at a position relatively short from the end face of the impeller back plate side, the temperature variation of the die causes the cooling temperature variation of the portion where the shaft hole diameter defect is remarkable. It was considered that the variation of the shaft hole diameter was increased as a result.

Therefore, as shown in FIG. 1, the inventor of the present invention has proposed a method of injection molding from a boss side through a sprue to provide a cut-out portion on the back plate side in the same manner as a cut-off portion on the boss side. A method for stabilizing the cooling rate by providing a cooling medium was studied. That is, in FIG. 1, if the size of the back plate side resection portion is set small, the distance between the portion where the shaft hole diameter defect is likely to occur and the mold surface shown in FIG. For this reason, variation in the diameter of the shaft hole is reduced. However, since a relatively large molding strain may be frozen by quenching, if a material that requires annealing treatment after molding is used, the variation in the shaft hole diameter may be slightly increased due to the annealing treatment. . In addition, cold slug (cooled resin remaining at the tip of the nozzle of the injection molding machine. If left in the molded article, it may cause cracks) in the molded article, the quality and quality are reduced.
If reliability is significantly impaired, it may be desirable to increase the backplate resection to some extent. When the size of the back plate side resection site is further increased, the transition from rapid cooling to slow cooling occurs. In this region, the variation of the shaft hole diameter is maximized because it is slightly affected by the mold temperature. further,
When the size is increased, the influence of the variation in the mold temperature is reduced and the temperature is gradually decreased, so that the variation in the diameter of the shaft hole is reduced again. That is, there is an optimum dimension for minimizing the variation of the shaft hole diameter.

FIG. 2 shows the relationship between the diameter of the shaft hole and its variation and the size of the cutout on the backboard side. As shown in FIG. When the size of the hole is small ・ The dispersion of the shaft hole diameter is small due to rapid cooling ・ The difference between the pin diameter and the shaft hole diameter is relatively small ・ The annealing hole treatment may cause the dispersion of the shaft hole diameter to be slightly larger As shown in FIG. 2 (b), (b) when the size of the cut portion on the back plate side is medium ・ The cooling speed is unstable, so the variation of the shaft hole diameter is large ・ The pin diameter and the shaft The difference from the hole diameter is moderate, and as shown in Fig. 2 (c), (c) When the size of the cutout on the back side is large. The difference between the pin diameter and the shaft hole diameter is relatively large. This means that the possibility of the increase is small.

There is a close relationship between the size of the back plate side resection site and the average shaft hole diameter. Increasing the size of the back plate side resection portion increases the distance between the portion where the shaft hole diameter variation is largest and the back plate side end surface of the molded body, so that the degree of “sink” increases, and the molding die The difference between the diameter of the pin and the diameter of the shaft hole of the molded body increases. This phenomenon is very convenient for coping with the fluctuation of the average shaft hole diameter caused by the material variation. As described above, the pin diameter of the molding die does not equal the shaft hole diameter. Therefore, it is necessary to design the pin diameter smaller than a desired shaft hole diameter in consideration of the expansion of the shaft hole diameter.

However, since the degree of expansion of the shaft hole diameter depends on the material lot and the molding conditions, a desired shaft hole diameter cannot be obtained if the material lot changes even if the molding conditions are fixed. For this reason, it is necessary to correct the pin diameter or to redesign the pin every time the material lot changes. However, as shown in FIG. 3, the need for pin correction is greatly reduced if a mold structure is used that allows adjustment of the size of the back plate side resection site. For example, when the shaft hole diameter becomes smaller than a desired diameter due to the change of the material lot, it may be adjusted so that the size of the back plate side resection portion becomes larger. In addition, when the diameter has become large, it may be adjusted so that the size of the back plate side resection part becomes small.

FIG. 3 shows a molding die for injection molding of a resin impeller according to an embodiment of the present invention. The molding die 10 has a cavity shape corresponding to a boss side cut-out portion and a sprue shape. A mold C having a cavity shape corresponding to the shape of the final product, a mold B composed of a total of 12 medium tops, 6 large and small pieces each forming an impeller blade portion and an impeller shaft portion, and a back plate. A mold A having a cavity shape including a side excision site, and a pin 5 projecting into each cavity from the mold A to form an impeller shaft hole are provided, and the mold A is provided on the back plate side of the impeller. It has a spacer 6 which forms the end face of the resection site and allows the depth of the back side resection site to be adjusted. The spacer 6 can be moved up and down by a driving mechanism (not shown) by a spacer position adjusting rod 8. It has been, the dimension H of the back plate side excision site can be changed.

As shown in FIG. 4, when there is a back plate side cut portion 9, the fiber orientation is random at the back plate side cut portion 9 and the fiber orientation is circular on the back plate side of the impeller. In the direction strengthened in the circumferential direction, the strength is remarkably excellent. On the other hand, as shown in FIG. Since the orientation is random, the strength is inferior.

In order to increase the resection depth of the back plate side resection site 9, as shown in FIG. 6, the position of the spacer 6 is made lower than that in FIG.

The relationship between the size of the back plate side resection site and the average shaft hole diameter
In the following, the average shaft hole diameter can be changed without changing the pin diameter of the mold by adding a mechanism for adjusting the size of the back plate side resection site according to the embodiment. Indicates that

Embodiment 9 As shown in FIGS. 3 and 6, a mold C having a cavity shape corresponding to the cut portion on the boss side, and six large and small molds forming a cavity shape corresponding to the final product shape, a total of 12 Fiber reinforcement using a mold B composed of a middle piece, a mold A having a cavity shape including a cutout on the back side, and an injection mold 10 having a pin 5 and a spacer 6 for adjusting a resin reservoir depth. A resin impeller was molded.

For molding, "Victre" manufactured by ICI of the United Kingdom was used.
x PEK 220P "polyetherketone resin" and "Ultem 1000" polyetherimide resin manufactured by GE, USA at a ratio of 80:20 by weight, and "VictrexPES 5003P" polyethersulfone resin manufactured by ICI, UK. After convergence, 1 at 370 ° C
Heat treatment was performed for 0 hours. Next, carbon fiber (Toho Rayon Co., Ltd. Beslight HTA) was blended so that the fiber weight was 30 wt% with respect to the total weight of the resin weight and the fiber weight, and then melted and kneaded using an extruder. Thereafter, 30 wt% carbon fiber reinforced resin pellets produced by an extruding operation were used. MI used in the experiment (melt flow index, temperature 400 ° C, load 2.16kgf)
(Details regarding the present molding material are disclosed in JP-A-2-175972).

The injection molding machine was manufactured by Japan Steel Works, Ltd.
Using a J-75SSIIA injection molding machine, cylinder temperature 400 ° C / 400 ° C / 390 ° C / 370 ° C (temperature setting was shown in order from the nozzle side to the hopper side), injection pressure:
Primary: 50%, Secondary: 90%, Tertiary: 60%, Packing time: Primary: 4.0 seconds, Secondary: 5.0 seconds, Tertiary: 30.0
FIG. 3 and FIG. 6 under molding conditions of second: and mold temperature: 220 ° C.
The impeller made of fiber reinforced resin was molded using the mold shown in FIG.

In this case, the diameter of the pin 5 used for molding is about 6.35 mm at room temperature, and the size of the cutout on the backboard side is 0 mm.
mm.

Example 10 An impeller made of fiber-reinforced resin was molded using the same injection molding mold 10 as in Example 9. For the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. And in this case, the diameter of the pin 5 used for molding is about 6.35 mm at room temperature,
The size of the back plate side resection site was 3 mm.

Example 11 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm.

Example 12 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm.

Example 13 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm.

Example 14 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm.

The relationship between the size of the back plate side resection site and the average shaft hole diameter
In the following, according to the embodiment in which the annealing process is performed at 230 ° C. for 5 hours, the change of the average shaft hole diameter by changing the size of the back plate side resection site requires the annealing process. Shows that it is also effective for materials.

Example 15 An impeller made of fiber-reinforced resin was molded using the same injection molding mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the back plate side resection site was 0 mm.

Example 16 Using the same injection mold 10 as in Example 9, an impeller made of fiber-reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm.

Example 17 Using the same injection molding mold 10 as in Example 9, an impeller made of fiber-reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm.

Example 18 Using the same injection mold 10 as in Example 9, an impeller made of fiber-reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm.

Example 19 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm.

Example 20 Using the same injection molding mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm.

Different melt flow index (MI)
Material Next, a material having an MI different from that of the above example (Note: In the above example, the MI is 2.4 or less, and in the comparative example, the MI is 4.0.
9) The impeller made of fiber reinforced resin is molded using
It is shown that, even when a material having a different I is used, a desired average shaft hole diameter can be obtained without changing the pin diameter by changing the size of the back plate side resection site. In this case, the average criterion for judging whether or not the average shaft hole diameter is 6.400 to 6.410 mm is good or bad. The unit of MI is g / 1.
0 min.

Comparative Example 6 A fiber-reinforced resin impeller was molded using the same injection molding mold 10 as in Example 9. For molding, the same carbon fiber reinforced resin pellets as those of Example 9 (material having MI (melt flow index, temperature of 400 ° C., load 2.16 kgf) of 4.9) except for the melt flow index of the material, and Example 9 A fiber reinforced resin impeller was molded under the same injection molding conditions. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm.

Example 21 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. For molding, the same carbon fiber reinforced resin pellets as those of Example 9 (material having MI (melt flow index, temperature of 400 ° C., load 2.16 kgf) of 4.9) except for the melt flow index of the material, and Example 9 A fiber reinforced resin impeller was molded under the same injection molding conditions. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm.

Comparative Example 7 An impeller made of fiber-reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, the same carbon fiber reinforced resin pellets as those of Example 9 (material having MI (melt flow index, temperature of 400 ° C., load 2.16 kgf) of 4.9) except for the melt flow index of the material, and Example 9 After molding a fiber reinforced resin impeller under the same injection molding conditions, annealing was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding is about 6.35 mm at room temperature, and the size of the cutout on the back side is 8 mm.
mm.

Comparative Example 8 An impeller made of fiber-reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, the same carbon fiber reinforced resin pellets as those of Example 9 (material having MI (melt flow index, temperature of 400 ° C., load 2.16 kgf) of 4.9) except for the melt flow index of the material, and Example 9 A fiber reinforced resin impeller was molded under the same injection molding conditions. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm.

Example Results The results of Examples 9 to 14 are shown in FIG. 7, the results of Examples 15 to 20 are shown in FIG. 8, and the results of Example 21 and Comparative Examples 6 to 8 are shown in FIG. Indicated. As shown in FIG. 7, in order to set the average shaft hole diameter to 6.400 mm to 6.410 mm, in this case, the size of the back plate side resection site may be set to a to b. Further, in the case of FIG. 9, the size of the back plate side resection site may be set to c to d. In any case, it can be understood that the diameter of the shaft hole can be changed by changing the size of the back plate side resection site.

Variations in the size of the resected part on the back side and the diameter of the shaft hole
(Without annealing treatment) Next, the effect of reducing the variation in the size of the back plate side cut portion and the diameter of the shaft hole will be described with reference to examples and comparative examples.

First, the relationship between the size of the back plate side resection site and the variation in the diameter of the shaft hole will be described with reference to examples and comparative examples. In this case, the determination of the quality of the variation is made by 50
Each impeller is formed, and the difference between the shaft hole diameter of the impeller having the largest diameter and the shaft hole diameter of the impeller having the smallest diameter is 0.040 m.
m or less was used as a criterion. However, as shown in the first half, since the generation of abnormal noise is related to the location where the accuracy of the shaft hole diameter is poor, etc. The example and the comparative example show that there is an optimum size of the back plate resection site.

Example 22 An impeller made of a fiber-reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the back plate side resection site was 0 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Comparative Example 9 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Comparative Example 10 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Example 23 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Example 24 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Example 25 A fiber-reinforced resin impeller was molded using the same injection molding mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm. FIG. 10 shows the measurement results of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for 50 impellers.

Variations in the size of the back plate side resection site and the diameter of the shaft hole
In the following, according to the embodiment in which the annealing process is performed at 230 ° C. for 5 hours, the variation in the diameter of the shaft hole by changing the size of the back plate side excision portion is reduced by the annealing process. It is also effective for materials that require

Example 26 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the back plate side resection site was 0 mm. FIG. 11 shows the impeller 50.
The measurement result of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for each piece is shown.

Comparative Example 11 An impeller made of fiber reinforced resin was molded using the same injection molding mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm. FIG. 11 shows the impeller 50.
The measurement result of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for each piece is shown.

Comparative Example 12 An impeller made of fiber reinforced resin was molded using the same injection molding mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm. FIG. 11 shows the impeller 50.
The measurement result of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for each piece is shown.

Example 27 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm. FIG. 11 shows the impeller 50.
The measurement result of the variation of the shaft hole diameter (measured at the shaft hole diameter management site A) for each piece is shown.

Example 28 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm. FIG. 11 shows the impeller 5
The measurement result of the variation of the shaft hole diameter for 0 pieces (measured at the shaft hole diameter management part A) is shown.

Example 29 Using the same molding die 10 for injection molding as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm. FIG. 11 shows the impeller 5
The measurement result of the variation of the shaft hole diameter for 0 pieces (measured at the shaft hole diameter management part A) is shown.

As shown in FIGS. 10 and 11, when the size of the back plate side resection is 0 mm or more than 8 mm, the variation in the diameter of the shaft hole can be made 0.040 mm or less. .

The size of the resected part on the back side and the generation of abnormal noise (animation)
In the following Examples and Comparative Examples, the occurrence of abnormal noise was determined by vibration G measurement, and a new case where the size of the back side resection site was 2 mm was examined. Clarify the dimensional range in which the effect of reducing the amount can be expected.

Example 30 A fiber-reinforced resin impeller was molded using the same injection molding mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the back plate side resection site was 0 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.355 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Example 31 A fiber-reinforced resin impeller was molded using the same injection molding mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 2 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.362 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Comparative Example 13 A fiber-reinforced resin impeller was molded using the same injection mold 10 as in Example 9. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.380 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Comparative Example 14 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.392 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Example 32 Using the same injection mold 10 as in Example 9, an impeller made of fiber reinforced resin was molded. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.403 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Example 33 Using the same injection molding mold 10 as in Example 9, a fiber reinforced resin impeller was molded. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.460 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Example 34 Using the same injection molding mold 10 as in Example 9, a fiber reinforced resin impeller was molded. For molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.489 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

The size of the resected part on the back side and the generation of abnormal noise (animation)
In the following, description will be made based on an example and a comparative example in which an annealing process is performed at 230 ° C. for 5 hours.

Example 35 Using the same injection mold 10 as in Example 9, a fiber reinforced resin impeller was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the back plate side resection site was 0 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.353 mm. In addition,
The imperfection criterion for the impeller is the same as in Tables 1 and 2.
Table 3 shows the test results.

Example 36 An impeller made of fiber reinforced resin was molded using the same injection mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 2 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.359 mm. In addition,
The imperfection criterion for the impeller is the same as in Tables 1 and 2.
Table 3 shows the test results.

Comparative Example 15 An impeller made of fiber-reinforced resin was molded using the same injection mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used in the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 3 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.370 mm. In addition,
The imperfection criterion for the impeller is the same as in Tables 1 and 2.
Table 3 shows the test results.

COMPARATIVE EXAMPLE 16 A fiber-reinforced resin impeller was molded using the same injection mold 10 as in Example 9. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the backboard side was 5 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.379 mm. In addition,
The imperfection criterion for the impeller is the same as in Tables 1 and 2.
Table 3 shows the test results.

Example 37 Using the same injection mold 10 as in Example 9, a fiber reinforced resin impeller was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cut portion on the back side was 8 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.396 mm. In addition,
The imperfection criterion for the impeller is the same as in Tables 1 and 2.
Table 3 shows the test results.

Example 38 Using the same mold 10 for injection molding as in Example 9, an impeller made of fiber reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for molding was about 6.35 mm at room temperature, and the size of the cut-out portion on the back side was 10 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.450 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

Example 39 Using the same injection mold 10 as in Example 9, an impeller made of fiber-reinforced resin was molded. In the molding, a fiber reinforced resin impeller was molded under the same carbon fiber reinforced resin pellets and injection molding conditions as in Example 9, and then an annealing treatment was performed at 230 ° C. for 5 hours. In this case, the diameter of the pin 5 used for the molding was about 6.35 mm at room temperature, and the size of the cutout on the back side was 15 mm. Ten impellers thus obtained were subjected to a vibration G measurement test. The diameter of the shaft used for fitting was 6.485 mm. It should be noted that the impulse acceptance criteria for impellers are the same as in Tables 1 and 2. Table 3 shows the test results.

[0128]

[Table 3]

Results As is clear from the examples and comparative examples, it is possible to provide a fiber reinforced resin impeller that does not generate abnormal noise when the size of the back plate side cutout is 2 mm or less and 8 mm or more. It can be seen that it is.

Summary As described above, in the present invention, in order to provide a fiber reinforced resin impeller that does not generate abnormal noise without first performing machining of a shaft hole, the requirements that the impeller must have Revealed.

Next, a method was found to cope with the fluctuation of the shaft hole diameter caused by the lot-to-lot variation in the material characteristics, which cannot be avoided in the mass production process, without correcting the pin diameter of the mold.

Further, as a method of reducing the variation in the diameter of the shaft hole, which is the most problematic in consideration of the production cost, a new cut portion is provided on the end face of the impeller on the back plate side, and the size of the cut portion is optimized. It has been found that it is possible to minimize the variation in the diameter of the shaft hole by using the method.

According to the invention as described above, it is possible to provide a high-quality fiber-reinforced resin impeller which does not require machining of a shaft hole and which is inexpensive and does not generate abnormal noise at a mass production level.

Finally, points to be noted when applying the present invention will be briefly described.

When the present invention is applied, if the purpose is only to reduce the variation in the diameter of the shaft hole, the size of the cutout portion on the back side should satisfy the condition of 2 mm or less or 8 mm or more. However, if it is also expected that the fluctuation of the shaft hole diameter itself caused by the difference of the material lot or the change of the molding conditions can be improved by adjusting the dimensions of the back plate side resection site without correcting the pin diameter. The size of the resection site on the back side is 8 mm or more, preferably 12 mm to 13 m.
m or more. FIG. 10 and FIG.
As is clear from FIG. 1, when the back plate side resection part becomes large to a certain extent, the cooling rate becomes stable, so that the variation in the diameter of the shaft hole becomes stable at 0.020 mm to 0.030 mm. On the other hand, as is clear from FIGS. 7 to 9, the diameter of the shaft hole itself increases as the size of the back plate side resection portion increases. For this reason, if the initial adjustment of the mold pin diameter is performed in a state where the size of the back plate-side cut portion is relatively large, a slight adjustment of the size of the back plate-side cut portion causes a change in the material lot or the like. It can cope with fluctuations in the shaft hole diameter. At this time, if the upper limit of the size of the back plate side resection part is small, when the size of the back plate side resection part is adjusted for the purpose of changing the shaft hole diameter, it is set to a dimension having a large variation of the shaft hole diameter of 2 mm to 8 mm. This is because an inevitable case occurs. For this reason, the initial adjustment of the pin diameter is performed by weight after confirming that the variation does not increase due to the change in the size of the back plate side resection site in the size region of the back plate side resection site where the variation in the shaft hole diameter is small. is there. In addition, as shown in FIG. 4 and FIG. 5, the present invention can control the orientation of the fibers inside the impeller by changing the size of the cut-out portion on the backboard side. It can also be used as a means for improving the strength characteristics of the steel.

[0136]

As described above, according to the present invention, there is provided an impeller molded body suitable for an inexpensive fiber-reinforced resin impeller, which does not generate "unusual noise" peculiar to a turbocharged vehicle, and a molding die thereof. A remarkably excellent effect is obtained that it can be obtained.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of an improved fiber-reinforced resin impeller molded article according to one embodiment of the present invention.

FIG. 2 Shaft hole diameter of a fiber-reinforced resin impeller molded body, its variation, and dimensions of the cutout on the back side (three types of large, medium and small)
FIG. 4 is an explanatory diagram showing a relationship with the above.

FIG. 3 is an explanatory cross-sectional view showing a structure of a molding die capable of changing a depth of a back plate side resection site.

FIG. 4 is an explanatory view showing the orientation of fibers when the impeller has a back plate side resection site.

FIG. 5 is an explanatory view showing the orientation of fibers when the impeller has no back plate side resection site.

FIG. 6 is an explanatory sectional view showing a state in which a spacer is lowered in a molding die capable of changing the depth of a back plate side resection site.

FIG. 7 is a graph showing the relationship between the size of the back plate side resection site and the average shaft hole diameter of the shaft hole diameter management site A.

FIG. 8 is a graph showing the relationship between the size of the back plate side resection site and the average shaft hole diameter of the shaft hole diameter management site A.

FIG. 9 is a graph showing the relationship between the size of the back plate side resection site and the average shaft hole diameter of the shaft hole diameter management site A.

FIG. 10 is a graph showing the relationship between the size of the back plate side resection site and the variation in shaft hole diameter.

FIG. 11 is a graph showing the relationship between the size of the back plate side resection site and the variation of the shaft hole diameter.

FIG. 12 is an explanatory diagram showing that abnormal noise generation is small when the difference between the shaft hole diameter of the impeller and the shaft diameter is small.

FIG. 13 is an explanatory diagram showing an abnormal noise generation mechanism of the turbocharger when the shaft hole diameter of the impeller is considerably larger than the shaft diameter.

FIG. 14 is an explanatory view of a conventional fiber reinforced resin impeller molded body.

FIG. 15 is an explanatory diagram showing an area where a shaft hole dimensional defect is likely to occur due to “sink” occurring during molding.

FIG. 16 is an explanatory diagram showing a case where abnormal noise is generated depending on a portion with poor shaft hole accuracy.

FIG. 17 is an explanatory diagram showing a case where abnormal noise does not occur depending on a portion with a poor shaft hole accuracy.

FIG. 18 is an explanatory view showing a portion requiring shaft hole accuracy and a portion not requiring the accuracy.

FIG. 19 is a graph showing a minus tolerance of a shaft hole that can be assembled.

FIG. 20 is an explanatory view showing shaft hole diameter management parts A and B provided at both ends of a shaft hole / shaft contact part.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber-reinforced resin impeller 1a Shaft hole 1b Boss 1c Wing 1d Back plate 2 Shaft 3 Nut 4 Sprue 5 Pin 6 Depth adjusting spacer 8 Depth adjusting rod 10 Mold for forming fiber-reinforced resin impeller 11 Fiber impregnated resin impeller molded body A Back side shaft hole diameter management area B Boss shaft hole diameter management area

Continuation of the front page (51) Int.Cl. ⁷ identification code FI // B29K 105: 06 B29L 31:08 (58) Investigated field (Int.Cl. ⁷ , DB name) F01D 5/04 B29C 45/26 F01D 5/28 F02B 39/00 B29K 105: 06 B29L 31:08

Claims (5)

(57) [Claims] 1. A boss side provided at both ends of a portion where an inner surface of a shaft hole of the impeller and a shaft come into contact with each other in a fiber reinforced resin impeller molded body used as a product without machining the shaft hole. The shaft hole diameter of the shaft hole diameter management portion of 2 mm or more and the back plate side of 3 mm or more is set to −0.015 mm to +0.020 mm with respect to the shaft diameter to be fitted. An impeller molded product made of fiber reinforced resin to be used as a product without using it. 2. A fiber-reinforced resin impeller molded body formed by performing injection from the boss side of an impeller, wherein the back is located at an end face of the back plate side of the impeller and coaxially with a sprue which is a cutout portion on the boss side. An impeller molded body made of fiber reinforced resin, wherein a plate side cut portion is provided. 3. The size of a back plate side cutout portion provided at the back plate side end surface of the impeller and at a position coaxial with a sprue which is a boss side cutout portion is 2 mm or less or 8 mm or more. An impeller molded body made of the fiber-reinforced resin according to claim 2. 4. A width direction of a cavity portion corresponding to the shape of a fiber reinforced resin impeller molded body, a pin forming a shaft hole of the impeller, and a back plate side cutout portion provided in the fiber reinforced resin impeller molded body can be changed. A molding die for molding an impeller made of fiber reinforced resin, comprising a spacer having the following configuration. 5. A mechanism for changing a position of the spacer without detaching a mold from an injection molding machine,
5. The molding die for molding a fiber reinforced resin impeller according to claim 4, wherein the size of the back plate side cutout portion provided in the fiber reinforced resin impeller molding can be changed.