Manufacturing method of bar component and bar component

Patent metadata

Field	Value
Publication number	US-9956987-B2
Application number	US-201414539283-A
Country	US
Kind code	B2
Filing date	Nov 12, 2014
Priority date	Nov 22, 2013
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

A manufacturing method of a bar component including a pipe made of a carbon fiber reinforced resin and an internal metal member having an outer peripheral surface in contact with an inner peripheral surface of an end portion of the pipe in an axial direction is provided. The method includes: preparing a core including a metal mandrel extending in the axial direction and the internal metal member having the outer peripheral surface subjected to surface roughening process; winding a prepreg sheet obtained by impregnating carbon fibers with resin around an outer peripheral surface of the core; forming the pipe having the end portion fitted onto and fixed to the outer peripheral surface of the internal metal member by baking and curing the prepreg sheet wound around the outer peripheral surface of the core; and removing the mandrel from the pipe.

First claim

What is claimed is:

1. A manufacturing method of a bar component including a pipe made of a carbon fiber reinforced resin and an internal metal member having an outer peripheral surface in contact with an inner peripheral surface of an end portion of the pipe in an axial direction, the method comprising:
preparing a core including a metal mandrel extending in the axial direction and the internal metal member having the outer peripheral surface subjected to surface roughening process;
winding a prepreg sheet obtained by impregnating carbon fibers with resin around an outer peripheral surface of the core;
forming the pipe having the end portion fitted onto and fixed to the outer peripheral surface of the internal metal member by baking and curing the prepreg sheet wound around the outer peripheral surface of the core; and
removing the mandrel from the pipe,
wherein the prepreg sheet is wound around the outer peripheral surface of the core with a heat-adhesive film interposed between the prepreg sheet and an outer peripheral surface of the internal metal member.

2. The manufacturing method of a bar component according to claim 1 , wherein:
the internal metal member is a metal annular ring; and
the core is prepared by fitting the metal annular ring onto the mandrel.

3. The manufacturing method of a bar component according to claim 2 , further comprising
screw-fastening a metal component to an inner peripheral surface of the metal annular ring to fasten the metal component to the end portion of the pipe.

4. The manufacturing method of a bar component according to claim 3 , further comprising
forming, in the inner peripheral surface of the metal annular ring, a female threaded portion to be screw-fastened to a male threaded portion provided in the metal component.

5. The manufacturing method of a bar component according to claim 1 , wherein:
the bar component includes the pipe, and a metal component having a main body portion and an extended portion smaller in diameter than the main body portion, the main body portion and the extended portion being arranged in the axial direction of the pipe;
the internal metal member is the extended portion; and
the core is prepared by connecting the mandrel and the extended portion to each other in the axial direction.

6. The manufacturing method of a bar component according to claim 5 , wherein the extended portion has a tapered shape in which a diameter is increased with distance from the main body portion in the axial direction.

7. The manufacturing method of a bar component according to claim 5 , wherein the extended portion includes a protruded portion that is protruded from an outer peripheral surface of the extended, portion, and positions the pipe in the axial direction.

8. A bar component manufactured by the manufacturing method according to claim 1 .

9. A bar component manufactured by the manufacturing method according to claim 2 .

10. The bar component according to claim 9 , wherein a part of the metal annular ring is protruded from the pipe to an outside in the axial direction.

11. The bar component according to claim 10 , wherein the bar component constitutes a rack bar included in a rack and pinion type steering device.

12. A bar component manufactured by the manufacturing method according to claim 5 .

13. The bar component according to claim 12 , wherein the bar component constitutes a rack bar included m a rack and pinion type steering device.

Assignees

• Jtekt Corp

Inventors

• Kunishima Takeshi

Classifications

• Y10T428/1355

  Elemental metal containing [e.g., substrate, foil, film, coating, etc.] · CPC title

• B32B38/00

  Ancillary operations in connection with laminating processes · CPC title

• B32B37/142

  Laminating of sheets, panels or inserts, e.g. stiffeners, by wrapping in at least one outer layer, or inserting into a preformed pocket · CPC title

• B29C70/32 Primary

  on a rotating mould, former or core · CPC title

• B32B2038/0052

  Other operations not otherwise provided for · CPC title