Gear and manufacturing method thereof

Patent metadata

Field	Value
Publication number	US-2016016368-A1
Application number	US-201514794319-A
Country	US
Kind code	A1
Filing date	Jul 8, 2015
Priority date	Jul 16, 2014
Publication date	Jan 21, 2016
Grant date	—

Abstract

In a manufacturing method, an annular preform made of reinforcing fibers is set in a region of a mold which corresponds to a sleeve. In this state, this region of the mold and a region of the mold which corresponds to a tooth portion are filled with a resin. A gear is manufactured by this process.

First claim

What is claimed is:

1 . A method for manufacturing a gear, comprising:
setting an annular preform made of a reinforcing fiber in a region corresponding to a sleeve in a mold, the mold including an annular region corresponding to a tooth portion as a radial outermost region and a region located radially inward of the annular region so as to contact the annular region and corresponding to the sleeve; and impregnating the set annular preform with a resin and filling the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

2 . The method according to claim 1 , wherein
the annular preform is formed by stacking discs with a hole which are made of the reinforcing fiber.

3 . The method according to claim 1 , wherein
the annular preform is formed by connecting a braided cord made of the reinforcing fiber into an annular shape.

4 . The method according to claim 1 , wherein
the annular preform is formed as a three-dimensional fabric made of the reinforcing fiber.

5 . The method according to claim 1 , wherein
the annular preform is formed by winding up a cylinder made of the reinforcing fiber in a longitudinal direction.

6 . The method according to claim 1 , wherein
the resin is heated and melted, and the melted resin is injected into the mold by injection molding to impregnate the annular preform with the resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

7 . The method according to claim 2 , wherein
the resin is heated and melted, and the melted resin is injected into the mold by injection molding to impregnate the annular preform with the resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

8 . The method according to claim 3 , wherein
the resin is heated and melted, and the melted resin is injected into the mold by injection molding to impregnate the annular preform with the resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

9 . The method according to claim 4 , wherein
the resin is heated and melted, and the melted resin is injected into the mold by injection molding to impregnate the annular preform with the resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

10 . The method according to claim 5 wherein
the resin is heated and melted, and the melted resin is injected into the mold by injection molding to impregnate the annular preform with the resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

11 . The method according to claim 1 , wherein
a liquid precursor of the resin or a liquid resin is injected into the mold by resin injection molding to impregnate the annular preform with the liquid precursor or the liquid resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the liquid precursor or the liquid resin.

12 . The method according to claim 2 , wherein
a liquid precursor of the resin or a liquid resin is injected into the mold by resin injection molding to impregnate the annular preform with the liquid precursor or the liquid resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the liquid precursor or the liquid resin.

13 . The method according to claim 3 , wherein
a liquid precursor of the resin or a liquid resin is injected into the mold by resin injection molding to impregnate the annular preform with the liquid precursor or the liquid resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the liquid precursor or the liquid resin.

14 . The method according to claim 4 , wherein
a liquid precursor of the resin or a liquid resin is injected into the mold by resin injection molding to impregnate the annular preform with the liquid precursor or the liquid resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the liquid precursor or the liquid resin.

15 . The method according to claim 5 , wherein
a liquid precursor of the resin or a liquid resin is injected into the mold by resin injection molding to impregnate the annular preform with the liquid precursor or the liquid resin and to fill the entire regions of the mold which correspond to the tooth portion and the sleeve with the liquid precursor or the liquid resin.

16 . The method according to claim 1 , wherein
the tooth portion is formed to have a cylindrical outer periphery, and teeth are formed in the outer periphery by cutting after a molding is removed from the mold.

17 . The method according to claim 2 , wherein
the tooth portion is formed to have a cylindrical outer periphery, and teeth are formed in the outer periphery by cutting after a molding is removed from the mold.

18 . The method according to claim 3 , wherein
the tooth portion is formed to have a cylindrical outer periphery, and teeth are formed in the outer periphery by cutting after a molding is removed from the mold.

19 . The method according to claim 4 , wherein
the tooth portion is formed to have a cylindrical outer periphery, and teeth are formed in the outer periphery by cutting after a molding is removed from the mold.

20 . A gear that is manufactured by setting an annular preform made of a reinforcing fiber in a region corresponding to a sleeve in a mold, the mold including an annular region corresponding to a tooth portion as a radial outermost region and a region located radially inward of the annular region so as to contact the annular region and corresponding to the sleeve, and impregnating the annular preform with a resin and filling the entire regions of the mold which correspond to the tooth portion and the sleeve with the resin.

Assignees

• Jtekt Corp

Inventors

• Kunishima Takeshi

Classifications

• F16H2055/065

  Moulded gears, e.g. inserts therefor · CPC title

• B29L2015/003

  Gears · CPC title

• F16H55/17

  Toothed wheels (worm wheels F16H55/22; chain wheels F16H55/30) · CPC title

• B29C45/14819

  the inserts being completely encapsulated · CPC title

• B29B11/16

  comprising fillers or reinforcement {(non-woven fabrics per se D04H1/00, D04H3/00)} · CPC title