JPH07197948A - Synchronizer ring - Google Patents

Abstract

PURPOSE:To provide a synchronizer ring having specified frictional force stable with the lapse of time and performance resistant for wet frictional condition, efficiently manufacture the synchronizer ring and reduce a manufacturing cost. CONSTITUTION:A hole or groove 6 communicating an inner diameter surface 1a with an outer diameter surface 1b is formed on a synchronizer ring 1. A friction member 5 is formed continuously from the hole 6 so as to coat an outer surface of the ring 1. The friction member 5 is composed of a resin composition containing thermosetting resin having cork grains of grain diameters ranging between 0.1 to 2mm by 30 to 60wt.%, or a resin composition according to above further containing heat resistant rubber by 1 to 10wt.%.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a synchronizer ring used for a manual transmission of an automobile, and more particularly to a synchronizer ring having an improved friction material covering its tapered surface.

[0002]

2. Description of the Related Art Generally, in a manual transmission of an automobile, a synchronizing device is arranged on one side of a transmission gear so that the transmission gear can be smoothly changed. As such a synchronization mechanism, a key type,
Examples include pin-type and servo-type synchro devices.
In addition to the single cone sync, the key type has a multi cone sync mechanism such as a double cone sync and a triple cone sync.

FIG. 1 shows an example of a single cone type synchronizer, in which teeth 22 are provided on the outer circumference of a hub 21 which is prevented from rotating with respect to the output shaft 20 and which is slidably mounted on the outside of the hub 21. Teeth 24 that mesh with the teeth 22 are provided on the inner circumference of the sleeve 23. Further, a clutch gear 26 is arranged on one side of a transmission gear 25 rotatably provided outside the output shaft 20, a synchronizer cone 2 is attached to a side surface of the clutch gear 26, and a synchronizer provided outside the cone 2 is provided. A tapered surface 4 is formed on the inner diameter surface of the ring 1.

In this structure, the synchronizer ring 1 is moved toward the synchronizer cone 2 and the taper surface 4 of the ring 1 is brought into contact with the taper surface 3 provided on the outer diameter side of the synchronizer cone. 1 and the sleeve 23 are synchronously rotated with the transmission gear 25, and in that state, the teeth 24 of the sleeve 23 are replaced by the teeth 27 of the outer circumference of the synchronizer ring 1 and the teeth 28 of the clutch gear 26.
The rotation of the transmission gear 25 is transmitted to the output shaft 20 via the hub 21.

On the other hand, in the double cone type device having the double structure of the synchronizer cone so that the shift operation can be performed lightly and smoothly against the increase in the load applied to the transmission as the engine output increases,
A synchronizer ring 1 similar to the above is mounted.

The synchronizer ring 1 is made by forging high-strength brass as a material, and the tapered surface 4 of the inner diameter thereof has a dynamic friction coefficient μ = 0.12 or more in order to achieve a smooth synchronized state. Therefore, the function of exerting stable frictional force is required.

As a synchronizer ring in which the frictional force of the tapered surface 4 is stabilized, a technique of adhering a porous paper friction material to a metal base material is known.

[0008]

However, the above-mentioned conventional synchronizer rings have a problem that the water resistance is insufficient and they are easily peeled off, and the durability is poor, and the friction surface is carbonized to reduce the frictional force with time. There is.

Further, such a synchronizer ring has a problem that the manufacturing process required for adhering the friction material is complicated and the manufacturing cost cannot be reduced.

In view of the above, the present invention solves the above-mentioned problems, and makes the synchronizer ring stable so that the required frictional force is stable over time, and has the ability to withstand wet frictional conditions. It is an object to have a configuration that can reduce the

[0011]

In order to solve the above problems, according to the present invention, in a metal synchronizer ring having a tapered surface that frictionally engages with a synchronizer cone, a locking recess is provided near the tapered surface. To form
Cork particles with a particle size of 0.1 to 2 mm are added to the thermosetting resin 30 to 30
A friction material made of a resin composition mixed at 60% by weight is integrally formed by injection molding so as to be continuous with the surfaces of the locking recess and the tapered surface. If the cone angle of the tapered surface is about 5 ° to 20 °, smooth synchronization can be obtained.

Further, in the above-mentioned synchronizer ring, instead of the friction material made of the resin composition having the above-mentioned composition, 3 pieces of cork particles having a particle diameter of 0.1 to 2 mm are added to the thermosetting resin.
It is also possible to employ a friction material composed of a resin composition containing 0 to 60% by weight and 1 to 10% by weight of heat resistant rubber.

The details will be described below. The thermosetting resin used in the present invention is a general-purpose thermosetting resin having excellent mechanical strength and heat resistance, which is appropriately adopted according to the performance required for the transmission. Further, the reason why the thermosetting resin is used is that the thermosetting resin can be molded even if a large amount of the filler is blended in compared with the thermoplastic resin.
Examples of such thermosetting resins include phenol resins, unsaturated polyester resins, epoxy resins, diallyl phthalate resins, silicone resins, urea resins, polyimide resins and the like. The above-mentioned phenol resin and epoxy resin are natural ones and have a low water absorption rate of about 0.08 to 0.20%, are not easily attacked by many chemicals, and have little strength deterioration after long-term use. it is conceivable that.

The cork grain used in the present invention is a lightweight and heat-resistant cork structure produced from the bark of cork oak or Abemaki, and is crushed to a particle size of 0.1 to 2 mm. The particle size of such cork grains is
If the diameter is less than 0.1 mm, it is difficult to achieve the desired dynamic friction coefficient μ = 0.12 or more in the friction material, and it is 2 m.
If the diameter is larger than m, injection molding becomes difficult, which is not preferable.

The filling amount of the cork particles with respect to the thermosetting resin is 30 to 60% by weight, and more preferably 35 to 4%.
It is 5% by weight. This is because if it is less than this range, the dynamic friction coefficient tends to be low, and especially if it is less than 30% by weight, the condition that the dynamic friction coefficient μ = 0.12 or more cannot be satisfied. Also, if a large amount exceeding the above range is added, the molding material cannot be made uniform, and it becomes particularly difficult to compound the pellets.

The heat-resistant rubber used in the present invention is a well-known rubber material that can withstand the molding temperature when mixed with a thermosetting resin and can withstand the heat generation temperature of the friction material. In addition, it is, of course, preferable to employ rubber that is excellent not only in heat resistance but also in oil resistance and chemical resistance. Examples of such rubber include nitrile butadiene rubber, chloroprene rubber, butyl rubber, acrylic rubber, silicone rubber, ethylene propylene rubber, and fluororubber.

These heat-resistant rubbers have a heat-resistant temperature of at least about 130 ° C. or higher, and acrylic rubber and vulcanized butyl rubber have a heat resistance of about 160 ° C.

When the heat-resistant rubber is added to the resin composition, a suitable amount is 1 to 10% by weight. Because
This is because by adding 1 to 10% by weight of heat resistant rubber, the amount of decrease in the dynamic friction coefficient after 10,000 cycles by the dynamic friction coefficient test method described later can be reduced.
However, if the added amount is less than 1% by weight, the above-mentioned preferable effects do not appear, and if the added amount exceeds 10% by weight,
The dynamic friction coefficient of the friction material will rather decrease.

In addition to these, ceramic powder, wood powder, glass fiber, glass flakes, glass beads, carbons such as carbon fiber and graphite, fluorine-based resin, ceramic powder such as silicon carbide and silicon nitride, bronze,
About 3 to 33 parts by weight of metal powders such as copper, iron, etc., molybdenum disulfide, molybdenum powder, etc., one or more kinds of curing agents, lubricants, etc. may be added, and two or more kinds may be added. Further, about 3 to 15 parts by weight of the filler may be added and mixed. By adding such a filler, it is possible to provide a synchronizer ring which has excellent creep resistance and wear resistance and has a stable friction coefficient even if a motion such as compression or sliding is repeatedly applied to the synchronizer ring. It is considered possible.

It is considered that these fillers are appropriately held by the thermosetting resin and the heat resistant rubber in the above-mentioned blending amount to make it difficult to come off from the sliding surface. In addition, by adding these fillers, the heat resistance of the thermosetting resin can be raised to an instantaneous maximum temperature of about 260 ° C to about 300 ° C, which is sufficient for friction heat of the sliding surface. Can handle.

In order to injection-mold a resin composition made of such a material, for example, when a phenol resin is used, the raw material or low polymer is introduced into the cylinder at 60 to 100 ° C., and the temperature of the mold is set to this value. Phenolic resin can be cured 1
It may be set to 70 ° C or higher.

In this way, since the sliding portion of the ring is made of wear-resistant resin, the metal portion of the ring is not limited to high-strength brass, brass, etc., but carbon steel, nickel chrome steel, nickel chrome molybdenum steel. , Chrome steel, chrome molybdenum steel,
Manganese steel, manganese chrome steel, aluminum chrome molybdenum steel, tool steel, stainless steel with excellent corrosion resistance, free cutting steel with excellent machinability, clad steel and cast iron,
Castings such as copper-based material castings, aluminum-based material castings, and magnesium-based castings may be used as long as they are metal-based materials that can sufficiently cope with mechanical strength such as ring keys and teeth. Carbon steel, which is relatively inexpensive and hardened, is preferable. Further, in order to increase the mechanical strength of the key and the tooth portion, the ring may be carburized or induction hardened only on the tooth surface before molding the resin material into the ring. Induction hardening of the tooth surface only
Only the key part has the required quenching hardness, and the other parts are not easily affected by heat, so it has excellent dimensional stability and productivity.

In this way, it is possible to provide a synchronizer ring having a stable friction coefficient and wear resistance with a single cone synchronizing structure having only one friction surface between the synchronizer ring and the synchronized gear.

The 2WD-4WD switching device for a power distribution device of a four-wheel drive vehicle is not limited to a gear stage having a large load during a gear shifting operation of a vehicle equipped with a high-output, high-rotation engine. It could be used for

In addition, the two-wheel drive of the power distribution device of the four-wheel drive vehicle-
It is considered that the four-wheel drive switching device has a smaller number of repeated switchings than the number of shifts and switchings of a normal manual transmission, and can be used for a sufficiently long life.

Further, in order to increase the synchronizing capacity to about 2 to 3 times, a double cone synchronizing structure having a friction surface having two parts by providing a plurality of synchronizer rings or tapered cone parts of the synchronized gears and three parts. It can also be applied to a triple-cone sync structure that reduces the load during gear shifting, softens shocks during gear shifting, and provides a favorable gear shifting feeling. Small displacement vehicle (for example, displacement of about 1,300cc to 660cc or less, maximum output of about 1
For vehicles such as 0 to 64 horsepower or less) and for small / medium output vehicles such as forklifts, the double-cone sync structure and triple-cone structure, which have a complicated structure, increase the cost and increase the weight and space. It is considered that the present invention can also be used with a single-cone sync structure having a simple structure instead of the sync structure.

The key-type synchronizing mechanism is excellent in average in all points such as durability, assembling workability and operability, and is a widely used synchronizing mechanism in terms of cost. Yes, it is advantageous.

Of course, there is no problem even if it is applied to a pin type synchronizing mechanism for medium and large truck systems and a servo type synchronizing mechanism for sports vehicles.

The sliding portion can be used in a non-lubricated state depending on the specification conditions, but in general, it is lubricated with oil to improve friction and wear characteristics and to suppress heat generation on the sliding surface by cooling the oil. Is preferable.

[0030]

In the synchronizer ring according to the present invention, since the friction material made of a predetermined resin composition is integrally formed on the tapered surface by injection molding, it is possible to omit steps such as heat treatment, grinding and sticking of the friction material in manufacturing. Will be things.

Further, the friction material continuous to the locking recess is securely prevented from coming off, and peeling during use is prevented.

The thermosetting resin in the resin composition binds well even if the filling amount of cork particles and rubber is sufficiently increased. Cork particles having a predetermined particle size can be injection-molded and are exposed on the surface after molding to effectively increase the dynamic friction coefficient. The cork particles also have a function of stabilizing the frictional force of the rubber in the resin composition containing the heat resistant rubber for a long period of time.

[0033]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of an embodiment of the present invention will be described below with reference to the accompanying drawings. As shown in FIG. 2, in the embodiment, a synchronizer ring (hereinafter simply referred to as a ring) 1
A hole 6 that connects the inner diameter surface 1a and the outer diameter surface 1b is formed in the inner surface of the ring 1, and a friction material 5 is formed so as to continuously cover the outer surface of the ring 1 in the hole 6.

Since the hole 6 which connects the inner diameter surface 1a and the outer diameter surface 1b to each other is formed in the ring 1 as described above, for example, from about -40 ° C to about 13 ° C under severe usage conditions.
Even when used in a wide range of temperature such as 0 ° C., the sliding resin member and the ring of the metal-based member are always relatively strongly integrated with each other, and thus are unlikely to be affected by the difference in linear expansion coefficient between different materials. It is possible to provide an integrally formed ring having good strength. The communication hole 6 can be selected depending on the size of the ring,
It suffices if it is locked at about 1 to 15 places, and if this number is a multiple of 3 or a multiple of 5,
It is thought that the diagonal line becomes triangular and can be locked relatively firmly.

The member numbered 2 in the drawing is a synchronizer cone (hereinafter, referred to as
Abbreviated simply as cone. ), Flanges 7 and 8 are formed on the ring 1 and the cone 2, respectively, and teeth (not shown) are formed on the outer peripheral side of the ring 1.

In another embodiment shown in FIG. 3, annular grooves 14, 15 are formed in the end faces 1c, 1d of the synchronizer ring 1, respectively.
And a resin layer is formed continuously from the friction material 16 formed on the inner diameter surface 1a to the respective annular grooves 14 and 15. In this shape, the resin friction material 16 passes through the tapered surface 4 through a gentle curvature shape (for example, about R1 to R3) or a C chamfered portion (for example, about C0.3 to C3), and the end surfaces 1C and 1C.
Since it wraps around d and enters the annular grooves 14 and 15, the resin friction material and the metal-based member are relatively well bonded even under severe conditions such as a wide temperature difference as described above. Further, by making each corner relatively curved or C-chamfered, stress concentration may occur at the corner of the resin material even if the resin material expands or contracts due to a temperature difference. Can be prevented as much as possible, and a good coupling integral ring can be supplied. Thus, the annular grooves 14, 15
The friction material 16 can be held more firmly by continuing the resin layer. Further, the resin layer can be formed on either the ring 1 or the cone 2, but the ring 1 that can be easily attached to the injection mold is easier to insert-mold.

Now, Examples 1 and 2 and Comparative Examples 1 to 5 by distinguishing the resin composition constituting the friction material will be described below. Raw materials used in Examples and Comparative Examples are collectively shown below. All blending ratios are weight%
Indicated by.

(1) Phenolic resin Mitsui Toatsu Chemical Co., Ltd .: Milex RN-9510 (2) Cork grains (medium, average particle size 1 mm) (3) Glass fiber Asahi Fiber Glass Co., Ltd .: chopped strands, fiber diameter 13 μm , Fiber length 3 mm, aminosilane coupling treated product) (4) Wood powder (average particle size 1 mm) (5) Rubber powder Nihon Synthetic Rubber Co., Ltd .: Nitrile butadiene rubber, JSR-
P (6) Tetrafluoroethylene resin Kitamura Co., Ltd .: KTL 610 (7) Linter pulp Sanyo Kokusaku Pulp Co., Ltd .: KC Flock (8) Cashew dust Tohoku Kako Co., Ltd .: FF-1081 (9) Barium sulfate (general reagent) (10) Hardener Mitsui Toatsu Chemical Co., Ltd .: Hexamethylenetetramine, S-4 (11) Lubricant Dainichi Chemical Co., Ltd .: Calcium stearate, Daiwax IMN [Examples 1 to 6, Comparative Examples 1 to 6] Table 1 Alternatively, the raw materials were blended in the proportions shown in Table 2 and mixed together by a mixing roll (excluding rubber powder). In this case, front roll 1
The kneaded product was cooled to room temperature and then pulverized. Next, in Examples 4 to 7 and Comparative Examples 3, 6, and 7, rubber powder was mixed with the pulverized composition using a V-type blender.

The molding material for the friction material prepared as described above is supplied to an injection molding machine (IR-45P manufactured by Toshiba Corporation), and the front cylinder temperature is 100 ° C. and the rear cylinder temperature is 65.
℃, mold temperature 170 ℃, screw rotation speed 50 rpm,
Injection pressure 1100 to 1300 kg / cm ² , curing time 1
Under the condition of 20 seconds, the brass ring-shaped base material of the same shape shown in FIG. 1 was injection-molded to obtain a synchronizer ring.

The brass ring used as the base material is previously
Silane coupling agent (manufactured by Unicar Japan: A-110)
0 diluted with methanol 100 times) is applied,
It was left standing at room temperature and dried to improve the adhesiveness before use.

In order to improve the dimensional stability, about 1
Post heat treatment may be performed at 60 ° C. to about 200 ° C. for about 0.5 hours to 24 hours.

In this heat treatment temperature process, the temperature is gradually raised to about 100 ° C. to about 120 ° C., and the temperature is maintained for about 0.5 hours to 2 hours to evaporate the water in the molded body. After that, about 0.5 to 2 hours, gradually about 16
The temperature may be raised from 0 ° C. to about 200 ° C., the temperature may be maintained for about 0.5 hours to 2 hours, and then gradually cooled.
The series of heat treatment time from room temperature to high temperature to room temperature is about 8
It can be performed in about 10 hours to about 10 hours.

With respect to the obtained synchronizer ring, the dynamic friction coefficient at the beginning of the test and the dynamic friction coefficient after 10,000 cycles were measured by using a synchronizer unit tester manufactured by Automax. In other words, this tester is a device for testing the wear and friction characteristics due to the lubricating oil as a single piece of synchro, and as a function, it is a gear cone that rotates with inertial rotation force in an oil tank kept at a constant temperature. The test is performed by repeatedly pressing the synchronizer ring, and the synchro torque generated at that time is measured. Then, the test conditions in this case were as follows: the spindle speed was 500 rpm, the pressing load was 784 N, the inertia was 20 N · cm · s ² , and gear oil 75 W-85 W such as mineral oil was used as the lubricating oil.
The test was carried out at 0 ° C. in a mandrel oil bath, and the results are shown in Table 1 or Table 2.

[0044]

[Table 1]

[0045]

[Table 2]

As is clear from the results in Table 1, Examples 1 to 7 satisfying all the conditions satisfy the dynamic friction coefficient μ = 0.12 or more at the beginning of the test and after 10,000 cycles, and The injection moldability was good, and it was well integrated with the metal base material.

On the other hand, as is clear from the results of Table 2, in Comparative Example 1, since the cork particles were less than 30% by weight, the initial coefficient of dynamic friction was less than μ = 0.12. Further, in Comparative Example 2 in which the amount of cork particles was more than 60% by weight, granulation of pellets was impossible. In Comparative Example 3,
As a result of adding a large amount of rubber powder, the initial coefficient of dynamic friction was lowered, and the coefficient of dynamic friction was significantly reduced even after 10,000 cycles.

In Comparative Example 4, linter pulp, cashew dust, and barium sulfate, which are well-known as friction materials for brakes and the like, were used in place of cork particles, but the dynamic friction coefficient was as low as μ = 0.12 or less. In addition, Comparative Example 5
Then, a large amount of glass fiber was added, but after 10,000 cycles, the dynamic friction coefficient was extremely lowered, and the other material was greatly damaged.

In Comparative Example 6, wood powder used in the dry friction material was added, and the cork grains of Comparative Example 3 were replaced with wood powder. In this case, the dynamic friction coefficient was further reduced as compared with Comparative Example 3 in which cork particles of the same dry friction material were added.

[0050]

As described above, according to the present invention, a friction material made of a resin composition in which a predetermined amount of a predetermined amount of cork particles is mixed with a thermosetting resin is continuously formed on the surfaces of the locking recess and the tapered surface. Since the synchronizer ring is integrally formed by injection molding, this has a required frictional force, which is stable over time, can withstand wet friction conditions, and can reduce the manufacturing cost. There are advantages.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a single cone type synchronizing device.

FIG. 2 is a sectional view showing an example.

FIG. 3 is a sectional view showing another embodiment.

[Explanation of symbols]

 1 Synchronizer ring 2 Synchronizer cone 3, 4 Tapered surface 5, 16 Friction material 6 Hole 14, 15 Annular groove

Claims (2)

[Claims] 1. A metal synchronizer ring having a tapered surface that frictionally engages a synchronizer cone, wherein a locking recess is formed in the vicinity of the tapered surface, and a thermosetting resin having a particle diameter of 0.1 to 2 mm is used. 30-60% by weight of cork grains
A synchronizer ring, wherein a friction material made of the compounded resin composition is integrally formed by injection molding so as to be continuous with the surfaces of the locking recess and the tapered surface. 2. The synchronizer ring according to claim 1, wherein, instead of the friction material made of the resin composition having the above-mentioned composition, 30-60% by weight of cork particles having a particle diameter of 0.1-2 mm is added to the thermosetting resin. A synchronizer ring comprising a friction material composed of a resin composition containing 1 to 10% by weight of heat resistant rubber.