JP4178642B2 - Air flow control device and manufacturing method thereof - Google Patents

Description

【０１１１】
【表２】

【０１１２】
【表３】

【０１１３】
表１に示したように、スロットルボディを成形する樹脂材料として、ポリエーテルエーテルエトン、スロットルバルブを成形する樹脂材料として、ポリアミド６６の組み合わせを採用することにより、スロットルバルブの成形収縮率がスロットルボディの成形収縮率よりも大きくなり、スロットルボディとスロットルバルブの干渉を阻止でき、スロットルバルブが可動になることがわかる。
【０１１４】
また、スロットルボディを成形する樹脂材料としてＴＰＩ、スロットルバルブを成形する樹脂材料としてＰＡ６の組み合わせを採用することにより、スロットルバルブの線膨張係数がスロットルボディに対し小さくなり、スロットルバルブの熱膨張によるスロットルボディとの干渉という弊害を生じることなく、高温でもスロットルバルブが可動になることがわかる。
【０１１５】
さらに、表３に示すように、スロットルボディ材料の融点（もしくは流動開始点）とスロットルバルブ材料の融点（もしくは流動開始点）が離れている場合はスロットルバルブの先端形状がＡ形状であっても良く（実施例５、６）、また、スロットルボディ材料の融点（もしくは流動開始点）とスロットルバルブ材料の融点（もしくは流動開始点）が近い場合はスロットルバルブの先端形状をＢ形状として両者の接点を少なくすることにより、両者が接着したとしても容易に剥離させることができる（実施例７、８）。
【図面の簡単な説明】
【図１】 本発明に係る空気流量制御装置の概略構成図である。
【図２】 本発明に係る空気流量制御装置の概略構成図である。
【図３】 本発明に係る空気流量制御装置の製造方法の第１の実施例を示す縦断面図である。
【図４】 本発明に係る空気流量制御装置の製造方法の第１の実施例を示す縦断面図である。
【図５】 本発明に係る空気流量制御装置の製造方法の第２の実施例を示すものであり、（ａ）は縦断面図、（ｂ）は（ａ）中のスロットルシャフトを横切る方向における部分断面図である。
【図６】 本発明に係る空気流量制御装置の製造方法の第２の実施例を示すものであり、（ａ）は縦断面図、（ｂ）は（ａ）中のスロットルシャフトを横切る方向における部分断面図である。
【図７】 スロットルシャフトに軸受を取り付けた状態を示すものであり、（ａ）は端面図、（ｂ）は縦断面図である。
【図８】 本発明に係る空気流量制御装置の製造方法の第３実施例を示すものであり、（ａ）は縦断面図、（ｂ）はシャフトを横切る方向における部分拡大断面図である。
【図９】 本発明に係る空気流量制御装置の製造方法の第３実施例を示すものであり、（ａ）は縦断面図、（ｂ）はシャフトを横切る方向における部分拡大断面図である。
【図１０】 本発明に係る空気流量制御装置の製造方法の第４の実施例を示す縦断面図である。
【図１１】 本発明に係る空気流量制御装置の製造方法の第４の実施例を示す縦断面図である。
【図１２】 本発明に係る空気流量制御装置の製造方法の第５の実施例を示すものであり、（ａ）は縦断面図、（ｂ）はシャフト型を横切る方向における部分断面図である。
【図１３】 本発明に係る空気流量制御装置の製造方法の第５の実施例を示すものであり、（ａ）は縦断面図、（ｂ）はシャフト型を横切る方向における部分断面図である。
【図１４】 樹脂注入口の他の実施例を示す成形型の縦断面図である。
【図１５】 スロットルシャフトに貫通孔を設けた実施例を示すものであり、（ａ）は端面図、（ｂ）は側面図である。
【図１６】 スロットルシャフトに貫通孔を設けた実施例を示すものであり、（ａ）は端面図、（ｂ）は側面図である。
【図１７】 スロットルシャフトに貫通孔を設けた実施例を示すものであり、（ａ）は端面図、（ｂ）は側面図である。
【図１８】 バルブ先端の断面形状例を示す部分拡大説明図である。
【符号の説明】
１０ 空気流量制御装置
１１ スロットルボディ
１１ａ 空気通路
１２ スロットルバルブ
１２ａ 面
１２ｂ 外周（輪郭）
１３ スロットルシャフト
１４ 軸受
２０ 上型（第１成形型）
２０ａ 端面
２０ｂ 第１樹脂注入口
２０ｃ 第２樹脂注入口
２１ 上型
３０ 下型（第２成形型）
３０ａ 端面
３１ 下型
４０，４１ 側面型
５０ 上型（第１成形型）
５０ａ 端面
５０ｂ 第１樹脂注入口
５０ｃ 第２樹脂注入口
５０ｄ 凹部
６０ 下型（第２成形型）
６０ａ 端面
６０ｄ 凹部
６１ 下型
７０，７１ 側面型
８０ 上型（第１成形型）
８０ａ 端面
８０ｂ 第１樹脂注入口
８０ｃ 第２樹脂注入口
８０ｄ 凹部
８１ 上型
９０ 下型（第２成形型）
９０ａ 端面
９０ｄ 凹部
９１ 下型
１００，１０１ 側面型
１１０，１１１ 軸受型（第３成形型）
１２０ 上型（第１成形型）
１２０ａ 端面
１２０ｂ 第１樹脂注入口
１２０ｃ 第２樹脂注入口
１２０ｄ 凹部
１２１ 上型
１３０ 下型（第２成形型）
１３０ａ 端面
１３０ｄ 凹部
１４０，１４１ 側面型
１５０，１５１ シャフト型（第４成形型）
１６０ 上型（第１成形型）
１６０ｂ 第１樹脂注入口
１６０ｃ 第２樹脂注入口
１７０ 下型（第２成形型）
１８０，１８１ 側面型[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an air flow rate control device that forms a part of an intake passage of an internal combustion engine (engine) or the like and controls an intake air flow rate, and a manufacturing method thereof, and more particularly, an air flow rate formed by injection molding of a resin material. The present invention relates to a control device and a manufacturing method thereof.
[0002]
[Prior art]
In recent years, for the purpose of improving fuel economy and reducing weight, etc., the use of resin for parts around an internal combustion engine (engine) has been studied. As part of the air flow control device (throttle chamber) that forms a part of the intake passage of the internal combustion engine, resinization is being studied.
[0003]
By the way, when the throttle body and the throttle valve constituting the air flow control device are injection-molded using a composite material having a synthetic resin as a base material (matrix), deformation (molding distortion) due to shrinkage after molding occurs. .
[0004]
Due to this molding distortion, the inner circumference of the throttle body (air passage with a circular cross section) or a circular outline formed using a metal material such as aluminum alloy, zinc alloy, brass, etc., which are currently mainstream. When compared with the outer periphery of the throttle valve, the inner periphery of the throttle body made of a resin material and the outer periphery of the throttle valve are less rounded.
[0005]
When the roundness decreases as described above, the gap between the inner periphery of the throttle body and the outer periphery of the throttle valve increases, and the amount of air leakage increases when the throttle valve is fully closed. Thus, if the amount of fuel (for example, gasoline) used in the internal combustion engine is controlled by the flow rate of air, the increase in the amount of air leakage will lead to deterioration in fuel consumption.
[0006]
Therefore, in order to bring both the inner circumference of the throttle body and the outer circumference of the throttle valve close to a perfect circle and to reduce the gap between them, the throttle body and the throttle valve are injection-molded with respective molds, and each molded product is molded. Manufacturing, measuring the dimensions of those molded products, calculating the amount of distortion with respect to the desired perfect circle, correcting the mold based on this calculation result, and molding again with the corrected mold A method to reduce the amount of air leakage by manufacturing the product, repeatedly measuring the dimensions of the molded product, and correcting the mold again to bring the inner circumference of the throttle body and the outer circumference of the throttle valve closer to the desired perfect circle. It is being considered.
[0007]
[Problems to be solved by the invention]
However, in the above-described method, it is necessary to first design the throttle body and the throttle valve and to manufacture a mold, and then to manufacture a molded product using those molds, and then to obtain the molding obtained. It is necessary to go through the process of measuring the product and correcting the mold. In addition, even though these steps are performed, a shape close to a desired perfect circle cannot be formed at one time, and it is necessary to repeat these steps several times. Therefore, there has been a problem that it takes a long time to develop a resin air flow control device.
[0008]
The present invention has been made in view of the above problems, and the object of the present invention is to develop a resin air flow rate control device in a short time, reduce the amount of air leakage, and reduce the weight. It is an object of the present invention to provide an air flow rate control device and a manufacturing method thereof that can improve the degree of freedom of design.
[0009]
The invention described in claim 1 includes a throttle body having an air passage, a throttle valve for opening and closing the air passage, and a throttle shaft for supporting the throttle valve so as to be positioned in the air passage of the throttle body. And defining the inner wall surface of the air passage of the throttle body, and relatively movable so that the end faces facing each other in the extending direction of the air passage are joined and detached, and the end faces are joined. An air flow rate control device in which the throttle body and the throttle valve are formed by injection molding using a first mold, a second mold, and a side mold that have a recess that sandwiches the throttle shaft in a state where the throttle shaft is sandwiched. The body is inserted into the recesses in the end surfaces of the first and second molds joined to each other. The throttle valve is molded by injecting a composite material having a synthetic resin as a base material into a cavity defined by the first and second molding dies and the side surface mold with the rubber shaft sandwiched therebetween. By relatively moving the first mold and the second mold so that the end face of the first mold, the end face of the second mold, and the throttle shaft are separated from each other, each end face of the throttle shaft is surrounded. In a direction transverse to the air passage of the throttle body, a cavity defined by each end face and the air passage inner wall surface of the injection-molded throttle body is encased by the composite material. The composite shrinkage ratio of the synthetic resin as the base material is higher than the molding shrinkage rate in the spreading direction of the flat surface of the throttle valve. It is characterized by being molded by injecting material.
[0010]
According to a second aspect of the present invention, there is provided a throttle plate having a composite material whose base material is the synthetic resin forming the throttle valve according to the first aspect of the present invention, rather than the linear expansion coefficient in the direction across the air passage of the throttle body. The linear expansion coefficient in the spreading direction of the surface is small.
[0011]
Invention of Claim 3 is a manufacturing method of the air flow rate control apparatus of Claim 1 or 2, Comprising: A 1st and 2nd shaping | molding die inserts a throttle shaft in the state which each end surface joined. The first and second molds and the side molds are defined in such a state that the end surfaces of the first mold and the second mold are joined and the throttle shaft is sandwiched in the recesses. A first step of molding the throttle body by injecting the composite material into the cavity, and the first mold and the end face of the first mold, the end face of the second mold and the throttle shaft are separated from each other After relatively moving the second mold, molding is performed on each end face and the first step so that the portion of the throttle shaft surrounded by each end face is encapsulated by the composite material. Slot It is characterized in that it comprises a second step of molding the throttle valve is injected the composite material into a cavity defined by an air passage wall surface of the body.
[0012]
According to a fourth aspect of the present invention, there is provided a method for manufacturing the air flow rate control device according to the first or second aspect, wherein the first and second molding dies sandwich the throttle shaft with their end faces joined. The first and second molds and the side molds are defined in such a state that the end surfaces of the first mold and the second mold are joined and the throttle shaft is sandwiched in the recesses. A first step of injecting the composite material into a cavity to be molded to form a throttle body; and after moving the second mold so that the second mold and the throttle shaft are separated, each of the throttle shafts The cavity is defined by a cavity defined by each end face and the inner wall surface of the air passage of the throttle body formed by the first step so that a portion of the region surrounded by the end face is encapsulated by the composite material. A slip material is injected is characterized in that it comprises a second step of molding the throttle valve.
[0013]
According to a fifth aspect of the present invention, there is provided a bearing that rotatably supports the throttle shaft with respect to the throttle body according to the third or fourth aspect, and the second is in a state in which the throttle shaft is previously supported by the bearing. It is characterized by performing the process.
[0014]
A sixth aspect of the present invention is a method of manufacturing an air flow rate control device including a bearing that rotatably supports a throttle shaft with respect to the throttle body according to the first or second aspect. The two molds have a recess for sandwiching the throttle shaft in a state in which the end faces are joined, define a region where the throttle shaft is supported and a bearing is disposed, and can advance and retreat in the axial direction of the throttle shaft. Using the third mold, the end face of the first mold and the end face of the second mold are joined to sandwich the throttle shaft in the recess, and the third mold is positioned in the region where the bearing is disposed. A first step of molding a throttle body by injecting a composite material into a cavity defined by the first and second molds and the side mold, and an end face of the first mold, The first mold and the second mold are relatively moved so that the end face of the mold and the throttle shaft are separated from each other, and the third mold is retracted so as to be out of the region where the bearing is disposed. Thereafter, the air passage inner wall surface of the throttle body formed by the first step and the bearings and the bearings are formed so that a portion of the throttle shaft surrounded by each end surface is encapsulated by the composite material. And a second step of integrally molding the throttle valve and the bearing so as to encapsulate the throttle shaft by injecting the composite material into a cavity defined by the region to be disposed.
[0015]
A seventh aspect of the present invention is a method of manufacturing an air flow rate control device including a bearing that rotatably supports a throttle shaft with respect to the throttle body according to the first or second aspect. The second mold has a recess that sandwiches the throttle shaft in a state in which the end faces are joined, and is positioned in the recess and in the region where the bearing is disposed, and is movable in the axial direction of the throttle shaft. In the state where the end face of the first mold and the end face of the second mold are joined and the fourth mold is positioned in the recess and in the region where the bearing is disposed, using the mold. The first step of molding the throttle body by injecting the composite material into the cavity defined by the second mold and the side mold, and the end face of the first mold and the end face of the second mold are separated from each other. 1 mold and 2nd After the mold is relatively moved and the fourth mold is moved so as to be out of the recess and the area where the bearing is disposed, the portion of the throttle shaft surrounded by each end face is the composite The composite material is injected into a cavity defined by each of the end surfaces and the air passage inner wall surface of the throttle body and the region where the bearing is disposed so as to be encapsulated by the material, and the throttle And a second step of integrally forming a throttle valve, a throttle shaft, and a bearing so as to encapsulate the shaft.
[0016]
The invention according to claim 8 is a film for injecting the composite material from the entire circumferential direction of the space in which the air passage of the throttle body is formed in the first step according to any one of claims 3 to 7. A gate is employed, and in the second step, a one-point gate for injecting the composite material from a substantially central portion of a space in which the throttle valve is molded is employed.
[0023]
【The invention's effect】
According to the first aspect of the present invention, the mold is formed so that the gap between the two is as small as possible so that the outer periphery of the throttle valve is adapted to the air passage formed in the throttle body, that is, the inner periphery of the throttle body. Since the molding shrinkage in the surface direction (diameter direction) of the throttle valve is larger than the molding shrinkage in the direction crossing the air passage of the throttle body (diameter direction of the passage cross section) even after The throttle valve does not become inoperable by biting into the inner periphery of the throttle body or engaging tightly, and an appropriate clearance is always maintained to ensure the rotation of the throttle valve. As a result, functional reliability can be ensured and weight reduction of the apparatus can be achieved.
Further, when the throttle valve is molded, the inner periphery of the throttle body (the inner wall surface of the air passage) is used as a part of the mold, so that the shape of the inner periphery of the throttle body is transferred to the outer periphery of the throttle valve. For this reason, the outer circumference of the throttle valve and the inner circumference of the throttle body do not necessarily need to be exactly circular, and the gap between the two can be set as small as possible. Therefore, the amount of air leakage when the throttle valve is fully closed is reduced. It becomes possible to reduce. In addition, it is not only necessary to modify the throttle body mold, but also to a throttle valve mold that has been manufactured separately.
As a result, it is possible to improve the fuel consumption when the throttle valve is fully closed, shorten the manufacturing time, and reduce the manufacturing cost by eliminating the need for a separate mold for the throttle valve.
Further, as compared with the case where the throttle valve and the throttle shaft are formed as separate bodies, the assembling man-hours of both can be omitted, and the manufacturing process can be simplified and the number of parts can be reduced.
[0024]
According to the air flow rate control device according to claim 2 of the present invention, even when the resin throttle valve and the throttle body are thermally expanded due to external heat received in the environment where the air flow rate control device is placed, etc. Since the linear expansion coefficient in the surface direction (diameter direction) of the throttle valve is smaller than the linear expansion coefficient in the direction crossing the air passage of the throttle body (diameter direction of the passage cross section), the outer periphery of the throttle valve is inside the throttle body. The throttle valve does not become inoperable by biting into the circumference or engaging in a tight fit, and a proper clearance is always maintained to ensure the rotation of the throttle valve. The above reliability can be ensured and the weight of the apparatus can be reduced.
[0031]
According to invention of Claim 3, the following effect can be acquired.
When forming the throttle valve, the inner periphery of the throttle body (the inner wall surface of the air passage) is used as a part of the molding die, so that the shape of the inner periphery of the throttle body is transferred to the outer periphery of the throttle valve. For this reason, the outer circumference of the throttle valve and the inner circumference of the throttle body do not necessarily need to be exactly circular, and the gap between the two can be set as small as possible. Therefore, the amount of air leakage when the throttle valve is fully closed is reduced. It becomes possible to reduce.
In addition, it is not only necessary to modify the throttle body mold, but also to a throttle valve mold that has been manufactured separately.
As a result, it is possible to improve the fuel consumption when the throttle valve is fully closed, shorten the manufacturing time, and reduce the manufacturing cost by eliminating the need for a separate mold for the throttle valve.
In addition, the throttle shaft is placed in the mold, and a composite material is injected so as to encapsulate the throttle shaft to mold the throttle valve. On the other hand, it can be firmly bonded.
Thereby, the assembly man-hour of a throttle shaft can be saved and the manufacturing process can be simplified.
[0033]
According to the invention described in claim 4, in addition to the effect obtained by the invention described in claim 3, the molding space for the throttle valve can be formed by moving the second mold slightly during molding. Production with shorter cycle time becomes possible.
[0034]
According to the invention described in claim 5, in addition to the effects obtained by the invention described in claims 3 and 4, the injection of the throttle valve is performed in a state where the bearing is previously attached to the throttle shaft. The alignment between the throttle body and the throttle valve at the time of injection molding is maintained as it is, and the alignment between the inner periphery of the throttle body and the outer periphery of the throttle valve can be made more accurate than when a bearing is attached in a later process.
[0035]
According to the invention described in claim 6, in addition to the effect obtained by the invention described in claim 3, the composite material is injection-molded so as to encapsulate the throttle shaft arranged in advance in the mold. Since the throttle valve and the bearing are integrally formed, the throttle valve, the bearing, and the throttle shaft are formed as a single unit that is firmly coupled.
[0036]
As a result, the assembly work of the throttle shaft and the bearing can be saved, the manufacturing process can be simplified, and the inner periphery of the throttle body and the throttle can be achieved through the bearing that is integrally formed at the time of injection molding. The alignment with the outer periphery of the valve can be made highly accurate.
[0037]
According to the invention described in claim 7, since the throttle valve, the throttle shaft, and the bearing are integrally formed by injection molding of the composite material in addition to the effects obtained by the invention of claim 3, As a result, it is possible to eliminate the man-hours for assembling the parts and to simplify the manufacturing process.
[0038]
According to the invention described in claim 8, when molding the throttle body, it is possible to reduce the bias of molding distortion by injecting and molding the composite material from the entire inner periphery. The inner circumference of can be brought close to a perfect circle. Also, when molding the throttle valve, it is possible to reduce the bias of molding distortion by injecting and molding the composite material from the substantially central portion, and the outer circumference of the molded throttle valve is made close to a perfect circle. be able to.
[0039]
As a result, the gap between the inner periphery of the throttle body and the outer periphery of the throttle valve can be made as small as possible, and an improvement in fuel consumption when the throttle valve is fully closed can be achieved.
[0040]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the accompanying drawings.
[0041]
1 and 2 are a front view and a side view showing a schematic configuration of an air flow control device according to the present invention. As shown in FIGS. 1 and 2, the air flow rate control device 10 includes a throttle body 11 formed so as to define an air passage 11a using a composite material having a synthetic resin as a base material. And a throttle valve 12 having a flat surface 12a and having a contour 12b fitted to the air passage 11a, and a throttle for supporting the throttle valve 12 so as to be positioned in the air passage 11a of the throttle body 11. A shaft 13 and a bearing 14 that rotatably supports the throttle shaft 13 with respect to the throttle body 11 are provided so that the throttle valve 12 opens and closes the air passage 11a of the throttle body 11.
[0042]
Here, as a base material (matrix) of the composite material used for molding the throttle body 11 and the throttle valve 12, for example, polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyamide 6, polyamide 66, polyamide resin such as aromatic polyamide, general-purpose resin such as ABS, polycarbonate, polyacetal, super engineering plastic such as polyphenylene sulfide, polyether sulfone, polyether ether ketone, polyether nitrile, polyether imide, Thermosetting resins such as phenol resin, epoxy resin, and unsaturated polyester resin, and synthetic resins such as silicone resin and Teflon resin can be employed.
[0043]
The fiber material and the filling material included in the composite material used for forming the throttle body 11 and the throttle valve 12 are fibers such as glass fiber, carbon fiber, ceramic fiber, cellulose fiber, vinylon fiber, brass fiber, and aramid fiber. , Calcium carbonate, zinc oxide, titanium oxide, alumina, silica, magnesium hydroxide, talc, calcium silicate, mica, glass, carbon, graphite, thermosetting resin powder, cashew dust, etc. are effective, and in some cases flame retardant Further, an ultraviolet ray inhibitor, an antioxidant, a lubricant and the like may be appropriately blended.
[0044]
By the way, regarding the molding shrinkage ratio of the composite material forming the throttle valve 12 and the composite material forming the throttle body 11, the molding shrinkage ratio in the spreading direction (straight direction) of the flat surface 12a of the throttle valve 12 is the throttle shrinkage. It is larger than the molding shrinkage rate in the direction crossing the air passage 11a of the body 11 (diameter direction of the passage cross section).
[0045]
With this configuration, even if the throttle valve 12 and the throttle body 11 are contracted and deformed after molding, interference between the outer periphery 12b of the throttle valve 12 and the inner periphery of the throttle body 11 (the inner wall surface of the air passage 11a) is prevented. The throttle valve 12 can be rotated in the air passage 11a of the throttle body 11 so as to be opened and closed.
[0046]
Since the molding shrinkage rate of the composite material can be changed by adding fibers or fillers, various combinations can be employed. For example, as a composite material for forming the throttle body 11, polyether ether ketone, a combination of Teflon resin as a material for forming the throttle valve 12, or as a composite material for forming the throttle body 11, glass fiber and carbonate Examples of the material for forming the polyphenylene sulfide reinforced with the calcium filler and the throttle valve 12 include a combination of ABS resin.
[0047]
As for the linear expansion coefficient between the composite material forming the throttle valve 12 and the composite material forming the throttle body 11, the linear expansion coefficient in the spreading direction (linear direction) of the flat surface 12 a of the throttle valve 12 is It is smaller than the linear expansion coefficient in the direction crossing the air passage 11a of the body 11 (diameter direction of the passage cross section).
[0048]
With this configuration, even if the throttle valve 12 and the throttle body 11 are thermally deformed due to the influence of the heat of the atmosphere, the outer periphery 12b of the throttle valve 12 and the inner periphery of the throttle body 11 (inside the air passage 11a) The throttle valve 12 can be rotated in the air passage 11a of the throttle body 11 so as to be openable and closable.
[0049]
As the composite material for obtaining the linear expansion coefficient as described above, for example, polyetherimide can be used as the composite material forming the throttle body 11, and polyamide 6 or the like can be used as the material forming the throttle valve 12.
[0050]
Next, a first embodiment of the manufacturing method of the air flow rate control device according to the present invention will be described. 3 and 4 are cross-sectional views showing the structure of a mold (mold) in the present invention. As shown in FIG. 3, this mold has a cavity V for molding the throttle body 11. ₁ Are provided with upper molds 20 and 21, lower molds 30 and 31, and side molds 40 and 41.
[0051]
The upper mold 20 and the lower mold 30 define an inner wall surface of the air passage 11a of the throttle body 11, and end surfaces 20a and 40a facing each other in the extending direction of the air passage 11a are joined and detached. A first mold and a second mold that are movable relative to each other are formed. Further, a part of the side surface molds 40 and 41 forms a cavity when molding a bearing boss portion 11d for attaching the bearing 14 and a flange portion 11b for attaching the throttle body 11 to other intake passage parts. The upper mold 20 is provided with a first resin injection port 20b that opens on the outer peripheral surface thereof, and a second resin injection port 20c that opens at a substantially central portion of the end surface 20a region.
[0052]
When injection molding is performed using a mold having the above-described configuration, first, as shown in FIG. 3, a metal bearing 14 is attached to a part of the side molds 40 and 41, and the end face 20 a and the lower mold 20 of the upper mold 20 are attached. In a state where the end face 30a of the mold 30 is joined, a predetermined space that is defined, that is, the cavity V ₁ Inwardly, a resin material is injected from the first resin inlet 20b to mold the throttle body 11 (first step).
[0053]
Next, as shown in FIG. 4, the upper mold 20 and the lower mold 30 are relatively moved so that the end face 20a of the upper mold 20 and the end face 30a of the lower mold 30 are separated from each other. Here, the lower mold 40 is moved downward. Slide to (arrow L). A space defined by each end face 20a, 30a and the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, that is, a cavity V for forming the throttle valve 12. ₂ Inwardly, a resin material is injected from the second resin inlet 20c to mold the throttle valve 12 (second step).
[0054]
Thus, the throttle body 11 and the throttle valve 12 can be manufactured by performing two shots with one mold.
[0055]
Thereafter, for example, a metal throttle shaft 13 is passed through a bearing 14 fixed to the throttle body 11, and the throttle valve 12 is fixed to the throttle shaft 13 to form an air flow control device.
[0056]
The outer periphery 12b of the throttle valve 12 formed here may not necessarily be a perfect circle, but is a trace of the shape of the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step. Therefore, the gap between the inner periphery of the throttle body 11 and the outer periphery 12b of the throttle valve 12 is minimized, and the amount of air leakage when fully closed can be reduced. By using such a technique, it is not necessary to modify the throttle body mold.
[0057]
In addition, since a separate mold for a throttle valve that has been manufactured separately is not necessary, a series of conventionally designed and manufactured throttle valve molds and mold modifications after molding are all unnecessary.
[0058]
Next, a second embodiment of the method for manufacturing the air flow rate control device according to the present invention will be described. 5 and 6 are cross-sectional views showing the structure of a mold (mold) in the present invention. As shown in FIG. 5, this mold has a cavity V for molding the throttle body 11. ₁ Are provided with upper molds 50 and 51, lower molds 60 and 61, and side molds 70 and 71.
[0059]
The upper mold 50 and the lower mold 60 define the inner wall surface of the air passage 11a of the throttle body 11, and the end faces 50a and 60a facing each other in the extending direction of the air passage 11a are joined and detached. The first molding die and the second molding die having recesses 50d and 60d that sandwich the throttle shaft 13 in a state where the end surfaces 50a and 60a are joined to each other are formed.
[0060]
Also, a part of the side surface molds 70 and 71 forms a cavity when molding a bearing boss portion 11d for attaching the bearing 14, a flange portion 11b for attaching the throttle body 11 to other intake passage parts, and the like. The upper mold 50 is provided with a first resin injection port 50b that opens on the outer peripheral surface thereof, and a second resin injection port 50c that opens at a substantially central portion of the recess 50d formed on the end surface 50a. ing.
[0061]
When injection molding is performed using a mold having the above-described configuration, first, as shown in FIG. 5, the throttle shaft 13 (see FIG. 7) to which the bearing 14 is attached is sandwiched between the recesses 50d and 60d, In a state where the end face 50a of the upper die 50 and the end face 60a of the lower die 60 are joined, a predetermined space, that is, a cavity V defined ₁ Inwardly, a resin material is injected from the first resin inlet 50b to mold the throttle body 11 (first step).
[0062]
Next, as shown in FIG. 6, the upper mold 50 and the lower mold 60 are relatively moved so that the end surface 50a of the upper mold 50, the end surface 60a of the lower mold 60, and the throttle shaft 13 are separated from each other. A mold other than the upper mold 50 is slid downward (arrow L), and the lower mold 60 is further slid downward. A space defined by each end face 50a, 60a and the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, that is, a cavity V for forming the throttle valve 12. ₂ Inwardly, the resin material is injected from the second resin injection port 50c so that the portion of the throttle shaft 13 surrounded by the respective end faces 50a, 60a is encapsulated by the resin material. Molding (second step).
[0063]
Thus, by performing two shots with one mold, it is possible to manufacture an air flow rate control device in which the throttle valve 12 integrally coupled to the throttle shaft 13 is assembled to the throttle body 11.
[0064]
Since the outer periphery 12b of the throttle valve 12 formed here is a trace of the shape of the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, as described above, The amount of air leakage can be reduced.
[0065]
In addition, the use of such a technique eliminates the need for modification of the throttle body mold, and further eliminates the need for a throttle valve mold that has been manufactured separately. The design, production, and mold modification after molding are all unnecessary.
[0066]
Further, the step of assembling the throttle shaft 13 to the throttle valve 12 can be omitted.
[0067]
Next, a description will be given of a third embodiment of the manufacturing method of the air flow rate control apparatus according to the present invention. 8 and 9 are cross-sectional views showing the structure of a mold (mold) in the present invention. As shown in FIG. 8, this mold has a cavity V for molding the throttle body 11. ₁ Are provided with upper molds 50 and 51, lower molds 60 and 61, and side molds 70 and 71.
[0068]
The upper mold 50 and the lower mold 60 define the inner wall surface of the air passage 11a of the throttle body 11, and the lower mold 60 is joined and detached from the respective end faces 50a, 60a facing each other in the extending direction of the air passage 11a. The first mold and the second mold having the recesses 50d and 60d that sandwich the throttle shaft 13 with the end faces 50a and 60a being joined are formed.
[0069]
Also, a part of the side surface molds 70 and 71 forms a cavity when molding a bearing boss portion 11d for attaching the bearing 14, a flange portion 11b for attaching the throttle body 11 to other intake passage parts, and the like. The upper mold 50 is provided with a first resin injection port 50b that opens on the outer peripheral surface thereof, and a second resin injection port 50c that opens at a substantially central portion of the recess 50d formed on the end surface 50a. ing.
[0070]
When performing injection molding using a mold having the above structure, first, as shown in FIG. 8, the throttle shaft 13 (see FIG. 7) to which the bearing 14 is attached is sandwiched between the recesses 50d and 60d, In a state where the end face 50a of the upper die 50 and the end face 60a of the lower die 60 are joined, a predetermined space, that is, a cavity V defined ₁ Inwardly, a resin material is injected from the first resin inlet 50b to mold the throttle body 11 (first step).
[0071]
Next, as shown in FIG. 9, the lower die 60 is slid downward (arrow L) so that the end surface 50a of the upper die 50, the end surface 60a of the lower die 60, and the throttle shaft 13 are separated from each other. A space defined by each end face 50a, 60a and the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, that is, a cavity V for forming the throttle valve 12. ₂ Inside, the resin material is injected from the second resin injection port 50c, and the throttle valve 12 integrated with the throttle shaft 13 is formed through the through hole 13a of the throttle shaft 13 (second step).
[0072]
Thus, by performing two shots with one mold, it is possible to manufacture an air flow rate control device in which the throttle valve 12 integrally coupled to the throttle shaft 13 is assembled to the throttle body 11.
[0073]
Since the outer periphery 12b of the throttle valve 12 formed here is a trace of the shape of the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, as described above, The amount of air leakage can be reduced.
[0074]
In addition, the use of such a technique eliminates the need for modification of the throttle body mold, and further eliminates the need for a throttle valve mold that has been manufactured separately. The design, production, and mold modification after molding are all unnecessary.
[0075]
Furthermore, the process of assembling the throttle shaft 13 to the throttle valve 12 can be omitted.
[0076]
Furthermore, since only one mold is slid at the time of molding and the amount of movement is small, production with shorter cycle time becomes possible.
[0077]
Next, a description will be given of a fourth embodiment of the method for manufacturing the air flow control device according to the present invention. 10 and 11 are cross-sectional views showing the structure of a mold (mold) in the present invention. As shown in FIG. 10, this mold has a cavity V for molding the throttle body 11. ₁ Are formed with upper molds 80 and 81, lower molds 90 and 91, side molds 100 and 101, and bearing molds 110 and 111 positioned on the side surfaces.
[0078]
The upper mold 80 and the lower mold 90 define the inner wall surface of the air passage 11a of the throttle body 11, and the end faces 80a and 90a that oppose each other in the extending direction of the air passage 11a are joined and detached. The first molding die and the second molding die having recesses 80d and 90d that sandwich the throttle shaft 13 with the end faces 80a and 90a being joined to each other are formed.
[0079]
The bearing molds 110 and 111 form a third mold that supports the throttle shaft 13 and demarcates a region where the bearing is disposed, and that can advance and retreat in the axial direction of the throttle shaft 13 (arrow H).
[0080]
Further, a part of the side molds 100 and 101 forms a cavity for molding a bearing boss portion 11d for positioning the bearing 14, a flange portion 11b for attaching the throttle body 11 to other intake passage parts, and the like. The upper mold 80 is provided with a first resin injection port 80b that opens on the outer peripheral surface thereof and a second resin injection port 80c that opens at a substantially central portion of the recess 80d formed on the end surface 80a. ing.
[0081]
When injection molding is performed using a mold having the above-described configuration, first, as shown in FIG. 10, the throttle shaft 13 is sandwiched between the recesses 80d and 90d so that the end surface 80a of the upper mold 80 and the lower mold 90 are sandwiched. The bearing molds 110 and 111 are fitted on both ends of the throttle shaft 13, and the bearing molds 110 and 111 are advanced to a region where the bearing is to be disposed (molded). A predetermined space or cavity V defined ₁ Inwardly, a resin material is injected from the first resin inlet 80b to mold the throttle body 11 (first step).
[0082]
Next, as shown in FIG. 11, the upper mold 80 and the lower mold 90 are relatively moved so that the end surface 80a of the upper mold 80, the end surface 90a of the lower mold 90, and the throttle shaft 13 are separated from each other. The molds other than the lower mold 80 are slid downward (arrow L), the lower mold 90 is further slid downward, and the bearing molds 110 and 111 are retracted toward both outer sides so as to be out of the region where the bearing is formed. Let Then, a space defined by each end face 80a, 90a, the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step and the region for forming the bearing, that is, the throttle valve 12 and the bearing are formed. Cavity V to do ₂ The resin material is injected from the second resin inlet 80c so as to enclose the throttle shaft 13 inward, and the throttle valve 12 and the bearing are integrally molded simultaneously (second step).
[0083]
Thus, by performing two shots with one mold, an air flow rate control device in which the throttle valve 12 and the bearing are integrally formed so as to be integrally coupled with the throttle shaft 13 can be manufactured. it can.
[0084]
Since the outer periphery 12b of the throttle valve 12 formed here is a trace of the shape of the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, as described above, The amount of air leakage can be reduced.
[0085]
In addition, the use of such a technique eliminates the need for modification of the throttle body mold, and further eliminates the need for a throttle valve mold that has been manufactured separately. The design, production, and mold modification after molding are all unnecessary.
[0086]
Further, the process of assembling the throttle shaft 13 with respect to the throttle valve 12 can be omitted, and a separate bearing is not required, which contributes to a reduction in the number of parts, a reduction in parts management costs, and the like.
[0087]
Next, a fifth embodiment of the method for manufacturing the air flow rate control device according to the present invention will be described. 12 and 13 are cross-sectional views showing the structure of a mold (mold) in the present invention. As shown in FIG. 12, this mold has a cavity V for molding the throttle body 11. ₁ The upper molds 120 and 121, the lower molds 130 and 131, the side molds 140 and 141, and the shaft molds 150 and 151 positioned on the side surfaces are provided.
[0088]
The upper mold 120 and the lower mold 130 define the inner wall surface of the air passage 11a of the throttle body 11, and the end faces 120a and 130a facing each other in the extending direction of the air passage 11 are joined and detached. The first molding die and the second molding die having recesses 120d and 130d that define the throttle shaft are formed in a state where the end surfaces 120a and 130a are joined to each other.
[0089]
The shaft molds 150 and 151 form a fourth mold that is positioned in the recesses 120d and 130d and in the region where the bearings are arranged and is movable in the axial direction of the throttle shaft.
[0090]
Further, a part of the side surface molds 140 and 141 forms a cavity when molding a bearing boss portion 11d for positioning the bearing, a flange portion 11b for attaching the throttle body 11 to other intake passage components, and the like. The upper mold 120 is provided with a first resin injection port 120b that opens on the outer peripheral surface thereof, and a second resin injection port 120c that opens at a substantially central portion of the recess 120d formed on the end surface 120a. Yes.
[0091]
When injection molding is performed using a mold having the above structure, first, as shown in FIG. 12, the shaft molds 150 and 151 are sandwiched between the recesses 120d and 130d, that is, in the recesses 120d and 130d and in the bearings. The shaft molds 150 and 151 are positioned in a region where the upper mold 120 and the end surface 120a of the upper mold 120 and the end surface 130a of the lower mold 130 are joined to each other. ₁ Inwardly, a resin material is injected from the first resin inlet 120b to mold the throttle body 11 (first step).
[0092]
Next, as shown in FIG. 13, the upper mold 120 and the lower mold 130 are relatively moved so that the end face 120a of the upper mold 120 and the end face 130 of the lower mold 130 are separated from each other. The other molds are slid downward (arrow L), and the lower mold 130 is further slid downward. Further, the shaft molds 150 and 151 are retracted toward both outer sides so as to be out of the recesses 120d and 130d and the region where the bearing is disposed.
[0093]
A space defined by each end face 120a, 130a and the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step and the region where the bearing is disposed, that is, the throttle valve 12, the throttle shaft, and Cavity V for molding bearings ₂ Inwardly, a resin material is injected from the second resin inlet 120c to integrally mold the throttle valve 12, the throttle shaft, and the bearing (second step). Here, the both ends of the molded throttle shaft also serve as a bearing.
[0094]
In this way, by performing two shots with one mold, an air flow rate control device having a throttle body, an integrally formed throttle shaft, a bearing, and a throttle valve can be manufactured.
[0095]
Since the outer periphery 12b of the throttle valve 12 formed here is a trace of the shape of the inner wall surface of the air passage 11a of the throttle body 11 formed by the first step, as described above, The amount of air leakage can be reduced.
[0096]
In addition, the use of such a technique eliminates the need for modification of the throttle body mold, and further eliminates the need for a throttle valve mold that has been manufactured separately. The design, production, and mold modification after molding are all unnecessary.
[0097]
Further, the process of assembling the throttle shaft and the bearing to the throttle valve can be omitted, which contributes to simplification of the manufacturing process, reduction of the number of parts, reduction of parts management cost, and the like.
[0098]
For the upper molds 20, 50, 80, 120 applied in the first step of the embodiment described above, the upper mold 160 as shown in FIG. 14, that is, the cavity in which the air passage 11a of the throttle body 11 is molded. V ₁ As a first resin injection port for injecting a resin material into the cavity V ₁ A film gate that injects a resin material from the entire circumferential direction can be employed.
[0099]
In this case, the molded throttle body is less biased in molding distortion, and the air passage 11a can be brought close to a perfect circle.
[0100]
Further, as the second resin injection port 160c, a space in which the throttle valve 12 is molded (cavity V ₂ By adopting a one-point gate for injecting a resin material from the substantially central portion of the), the molding distortion in the molded throttle valve is reduced, and the outer circumference of the throttle valve can be brought close to a perfect circle.
[0101]
Further, as shown in FIGS. 15 to 17, if the throttle shaft 13 in the above-described embodiment is provided with at least one through hole 13a, 13b, the injected resin material can be used as the through hole 13a. , 13b and solidifies so that the throttle valve 12 and the throttle valve 13 can be firmly coupled to each other.
[0102]
Next, in the configuration of the molded throttle valve and throttle body, the results of evaluating the operating conditions of the throttle valves according to the specifications of Examples 1 to 8 and Comparative Examples 1 and 2 in Tables 1 to 3 shown below will be described. To do.
[0103]
The resin materials in Examples 1 to 8 and Comparative Examples 1 and 2 were selected from polyethersulfone, polyetheretherketone, thermoplastic polyimide, polyetherimide, polyamide 6, polyamide 66, ABS, and polypropylene. Using a composite material with a synthetic resin matrix, a throttle body and a throttle valve were manufactured, and the presence of interference with the throttle body due to poor throttle valve opening and thermal expansion of the throttle valve was investigated.
[0104]
Here, the manufacturers and trade names / grades of the synthetic resin used as the matrix are as follows.
[0105]
Polyethersulfone [PES] (Mitsui Toatsu Chemical Co., Ltd., trade name “Victorex PES3600G”), Polyetheretherketone [PEEK] (Mitsui Toatsu Chemical Co., Ltd., trade name “Victorex PEEK450G” ), Thermoplastic polyimide [TPI] (Mitsui Toatsu Chemical Co., Ltd., trade name “Aurum 500PL”), polyetherimide [PEI] (US GE Co., Ltd., trade name “Ultem 1000”), polyamide 6 [PA6] (manufactured by Toray Industries, Inc., trade name “Amilan CM1017”), polyamide 66 [PA66] (manufactured by Asahi Kasei Corporation, trade name “Leona 1402S”), [ABS] (manufactured by Kaneka Chemical Co., Ltd.) , Trade name “MUH E7301”), polypropylene [PP] (made by Idemitsu Petrochemical Co., Ltd., trade name “Polypro J700G”).
[0106]
Further, in order to clarify the difference between the linear expansion coefficients of the throttle valve and the throttle body, glass beads (manufactured by Toshiba Barotini Co., Ltd., trade name “Rynite 500”) were blended in the composite material to be formed. The mixing ratio of the glass beads was appropriately set according to the combination of the throttle valve and the throttle body.
[0107]
In addition, the throttle valve opening failure was evaluated by measuring the torque at the beginning of the throttle valve opening after integrating the throttle valve and throttle body and using an air flow control device with a return spring, accelerator drum, etc. .
[0108]
Furthermore, to evaluate the interference with the throttle body due to the thermal expansion of the throttle valve, leave it in an oven at 120 ° C for 30 minutes, measure the torque at the beginning of the throttle valve opening, and check whether there is a return failure of the throttle valve. It was.
[0109]
Here, when the torque at which the throttle valve begins to open is smaller than the throttle valve's fully opened torque, a circle is marked in the result column of the table, and the throttle valve's opening torque exceeds the throttle valve's fully opened torque. The air flow rate control device is marked as x in the result column of the table, assuming that it is not practical.
[0110]
[Table 1]

[0111]
[Table 2]

[0112]
[Table 3]

[0113]
As shown in Table 1, by adopting a combination of polyether ether etone as the resin material for molding the throttle body and polyamide 66 as the resin material for molding the throttle valve, the molding contraction rate of the throttle valve can be reduced. It can be seen that the molding shrinkage ratio of the throttle valve becomes larger, the interference between the throttle body and the throttle valve can be prevented, and the throttle valve becomes movable.
[0114]
Further, by adopting a combination of TPI as a resin material for molding the throttle body and PA6 as a resin material for molding the throttle valve, the linear expansion coefficient of the throttle valve becomes smaller than that of the throttle body, and the throttle due to the thermal expansion of the throttle valve. It can be seen that the throttle valve can be moved even at high temperatures without causing the harmful effect of interference with the body.
[0115]
Further, as shown in Table 3, when the melting point (or flow starting point) of the throttle body material and the melting point (or flow starting point) of the throttle valve material are separated, the tip shape of the throttle valve is A-shaped. If the melting point (or flow starting point) of the throttle body material is close to the melting point (or flow starting point) of the throttle valve material, the tip shape of the throttle valve is set to the B shape and the two contacts Can be easily peeled even if they are bonded together (Examples 7 and 8).
[Brief description of the drawings]
FIG. 1 is a schematic configuration diagram of an air flow rate control device according to the present invention.
FIG. 2 is a schematic configuration diagram of an air flow control device according to the present invention.
FIG. 3 is a longitudinal sectional view showing a first embodiment of a method of manufacturing an air flow rate control device according to the present invention.
FIG. 4 is a longitudinal sectional view showing a first embodiment of a method of manufacturing an air flow rate control device according to the present invention.
FIGS. 5A and 5B show a second embodiment of the manufacturing method of the air flow control device according to the present invention, wherein FIG. 5A is a longitudinal sectional view, and FIG. 5B is a cross-sectional view across the throttle shaft in FIG. It is a fragmentary sectional view.
6A and 6B show a second embodiment of a method for manufacturing an air flow rate control device according to the present invention, wherein FIG. 6A is a longitudinal sectional view, and FIG. 6B is a cross-sectional view across a throttle shaft in FIG. It is a fragmentary sectional view.
7A and 7B show a state in which a bearing is attached to a throttle shaft, where FIG. 7A is an end view, and FIG. 7B is a longitudinal sectional view.
FIGS. 8A and 8B show a third embodiment of the manufacturing method of the air flow control device according to the present invention, wherein FIG. 8A is a longitudinal sectional view, and FIG. 8B is a partially enlarged sectional view in a direction crossing the shaft.
FIGS. 9A and 9B show a third embodiment of a method for manufacturing an air flow rate control device according to the present invention, wherein FIG. 9A is a longitudinal sectional view and FIG. 9B is a partially enlarged sectional view in a direction crossing a shaft.
FIG. 10 is a longitudinal sectional view showing a fourth embodiment of the manufacturing method of the air flow rate control apparatus according to the present invention.
FIG. 11 is a longitudinal sectional view showing a fourth embodiment of the manufacturing method of the air flow control device according to the present invention.
FIGS. 12A and 12B show a fifth embodiment of the manufacturing method of the air flow rate control device according to the present invention, wherein FIG. 12A is a longitudinal sectional view, and FIG. 12B is a partial sectional view in a direction crossing the shaft mold. .
FIGS. 13A and 13B show a fifth embodiment of the manufacturing method of the air flow rate control device according to the present invention, wherein FIG. 13A is a longitudinal sectional view, and FIG. 13B is a partial sectional view in a direction crossing the shaft mold. .
FIG. 14 is a longitudinal sectional view of a molding die showing another embodiment of a resin injection port.
FIGS. 15A and 15B show an embodiment in which a through hole is provided in a throttle shaft, where FIG. 15A is an end view and FIG. 15B is a side view.
FIGS. 16A and 16B show an embodiment in which a through hole is provided in a throttle shaft, where FIG. 16A is an end view and FIG. 16B is a side view.
FIGS. 17A and 17B show an embodiment in which a through hole is provided in a throttle shaft, where FIG. 17A is an end view and FIG. 17B is a side view.
FIG. 18 is a partially enlarged explanatory view showing an example of a cross-sectional shape of a valve tip.
[Explanation of symbols]
10 Air flow control device
11 Throttle body
11a Air passage
12 Throttle valve
12a side
12b Outer circumference (contour)
13 Throttle shaft
14 Bearing
20 Upper mold (first mold)
20a end face
20b First resin inlet
20c Second resin inlet
21 Upper mold
30 Lower mold (second mold)
30a end face
31 Lower mold
40, 41 Side type
50 Upper mold (first mold)
50a end face
50b First resin inlet
50c Second resin inlet
50d recess
60 Lower mold (second mold)
60a end face
60d recess
61 Lower mold
70, 71 Side type
80 Upper mold (first mold)
80a end face
80b First resin inlet
80c Second resin inlet
80d recess
81 Upper mold
90 Lower mold (second mold)
90a end face
90d recess
91 Lower mold
100, 101 Side type
110, 111 Bearing mold (third mold)
120 Upper mold (first mold)
120a end face
120b First resin inlet
120c Second resin inlet
120d recess
121 Upper mold
130 Lower mold (second mold)
130a end face
130d recess
140,141 Side type
150,151 Shaft mold (4th mold)
160 Upper mold (first mold)
160b First resin inlet
160c Second resin inlet
170 Lower mold (second mold)
180,181 side type

Claims (8)

A throttle body having an air passage, a throttle valve for opening and closing the air passage, and a throttle shaft for supporting the throttle valve so as to be positioned in the air passage of the throttle body,
While defining the inner wall surface of the air passage of the throttle body, the end faces facing each other in the extending direction of the air passage are relatively movable so as to be joined and detached , and the respective end faces are joined. An air flow rate control device in which the throttle body and the throttle valve are formed by injection molding using a first mold and a second mold having a recess that sandwiches the throttle shaft , and a side mold ,
The throttle body has a cavity defined by the first and second molds and the side mold in a state where the throttle shaft is sandwiched in the recesses of the end surfaces of the first and second molds joined to each other. In addition to being molded by injecting a composite material based on synthetic resin,
The throttle valve, the end face of the first mold, by the end face and the throttle shaft of the second mold are relatively moved first mold and the second mold so as to leave each other, of the throttle shaft In the cavity defined by each end face and the inner wall surface of the air passage of the injection molded throttle body, a portion of the area surrounded by each end face is encapsulated by the composite material . The molding shrinkage rate in the spreading direction of the flat plate surface of the throttle valve is larger than the molding shrinkage rate in the direction crossing the air passage. A featured air flow rate control device.   The composite material based on the synthetic resin forming the throttle valve has a smaller linear expansion coefficient in the spreading direction of the flat surface of the throttle valve than the linear expansion coefficient in the direction crossing the air passage of the throttle body. The air flow rate control device according to claim 1. It is a manufacturing method of the air flow control device according to claim 1 or 2,
  The first and second molds have a recess that sandwiches the throttle shaft in a state in which the respective end surfaces are joined,
  In a state where the end face of the first mold and the end face of the second mold are joined and the throttle shaft is sandwiched in the recess, the composite material is put into the cavity defined by the first and second molds and the side mold. A first step of injecting and forming a throttle body;
  After the first mold and the second mold are relatively moved so that the end face of the first mold, the end face of the second mold and the throttle shaft are separated from each other, the end faces of the throttle shaft are surrounded by the respective end faces. The composite material is injected into a cavity defined by each end face and the inner wall surface of the air passage of the throttle body formed by the first step so that a portion of the region to be encapsulated is covered with the composite material. And a second step of forming the throttle valve. It is a manufacturing method of the air flow control device according to claim 1 or 2,
The first and second molds have a recess that sandwiches the throttle shaft in a state in which the respective end surfaces are joined,
In a state where the end face of the first mold and the end face of the second mold are joined and the throttle shaft is sandwiched in the recess, the composite material is put into the cavity defined by the first and second molds and the side mold. A first step of injecting and forming a throttle body;
After moving the second mold so that the second mold and the throttle shaft are separated, the respective portions of the throttle shaft surrounded by the respective end faces are encapsulated by the composite material. A second step of forming a throttle valve by injecting the composite material into a cavity defined by an end surface and an air passage inner wall surface of the throttle body formed by the first step. Manufacturing method of flow control device. It has a bearing that rotatably supports the throttle shaft with respect to the throttle body.
The method of manufacturing an air flow rate control device according to claim 3 or 4, wherein the second step is performed in a state where the throttle shaft is previously supported by a bearing . A method of manufacturing an air flow rate control device including a bearing that rotatably supports a throttle shaft with respect to the throttle body according to claim 1 or 2,
The first and second molds have a recess for sandwiching the throttle shaft in a state where the end faces are joined, define a region where the throttle shaft is supported and a bearing is disposed, and the axial direction of the throttle shaft In the third mold that can advance and retreat in
In a state where the end surface of the first mold and the end surface of the second mold are joined, the throttle shaft is sandwiched in the recess, and the third mold is positioned in the region where the bearing is disposed. A first step of molding a throttle body by injecting a composite material into a cavity defined by two molds and a side mold;
The first mold and the second mold are moved relative to each other so that the end face of the first mold, the end face of the second mold and the throttle shaft are separated from each other, and the first mold and the second mold are separated from the region where the bearing is disposed. After the third mold is moved backward, the throttle formed by the first step and each end face so that the portion of the throttle shaft surrounded by each end face is encapsulated by the composite material. A second step of integrally molding the throttle valve and the bearing so as to encapsulate the throttle shaft by injecting a composite material into a cavity defined by an inner wall surface of the air passage and a region where the bearing is disposed ; The manufacturing method of the air flow rate control apparatus characterized by the above-mentioned. A method of manufacturing an air flow rate control device including a bearing that rotatably supports a throttle shaft with respect to the throttle body according to claim 1 or 2,
The first and second molds have recesses that sandwich the throttle shaft with their end faces joined, and are positioned in the recesses and in the region where the bearings are arranged and move in the axial direction of the throttle shaft. Using a possible fourth mold,
In a state where the end surface of the first mold and the end surface of the second mold are joined and the fourth mold is positioned in the recess and the region where the bearing is disposed, A first step of injecting a composite material into a cavity defined by a side mold to mold a throttle body;
The first mold and the second mold are moved relative to each other so that the end face of the first mold and the end face of the second mold are separated from each other, and are separated from the inside of the recess and the region where the bearing is disposed. After the fourth mold is moved, the throttle body molded by the first step and the end surfaces so that the portion of the throttle shaft surrounded by the end surfaces is encapsulated by the composite material. The throttle valve, the throttle shaft, and the bearing are integrally molded so as to encapsulate the throttle shaft by injecting the composite material into a cavity defined by the inner wall surface of the air passage and the region where the bearing is disposed. A method for manufacturing an air flow rate control device. In the first step, a film gate for injecting the composite material from the entire circumferential direction of the space in which the air passage of the throttle body is formed is adopted, and in the second step, a substantially central portion of the space in which the throttle valve is formed The method for manufacturing an air flow rate control device according to claim 3, wherein a single-point gate for injecting the composite material is used.

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