The present invention is intended to provide a method for manufacturing a resin gear with a core metal by which there is no reduction in strength even with gates allowing decrease in material costs such as pin gates in the molding die for injection molding. The manufacturing method includes: gates at a primary molding step and gates at a secondary molding step are pin gates or the like. The number of the gates at the primary molding step and the number of the gates at the secondary molding step are plural and identical, and the gates are arranged circumferentially. Gate positions G21, . . . at the secondary molding step are circumferentially intermediate or nearly circumferentially intermediate between gate positions G11, . . . and weld positions W11, . . . adjacent to the gate positions G11, . . . in the primary molded article.

A resin gear includes a web with a side surface on which a first annular rib and a second annular rib are formed to be concentric with a boss. The web has an inner web portion coupling the first annular rib to the second annular rib, and an outer web portion coupling the second annular rib to a rim. The inner web portion is formed to have a thickness gradually reduced from one intersection point toward another intersection point, the intersection points being intersection points of a virtual radial direction line passing through a center of the boss with the second annular rib. The first annular rib has a side surface on which only one gate mark of an injection molding is formed at a position on a radially outer side with respect to a first tooth portion and a position biased to the other intersection point on the virtual radial direction line.

A drive wheel (10; 100) wherein the drive wheel (10; 100) is formed by an injection-molding process, and has a longitudinal axis (11; 108), having a hub region (12; 102) with a hub opening (13; 102), having an annular toothed-rim region (17; 106) with a radially outwardly projecting toothing (18; 105), having a substantially disk-like intermediate region (15; 112) which is arranged radially between the hub region (12; 102) and the toothed-rim region (17; 106), wherein the drive wheel (10; 100) has two bearing points (31, 32), arranged concentrically with the longitudinal axis (11; 108), for radial mounting and two bearing points (33, 34; 121, 122), for axial mounting, and wherein the hub region (12; 102) has an extension (14; 103) that protrudes from the plane of the intermediate region (15; 112) in the direction of the longitudinal axis (11; 108).

A multi-component gear wheel (10) for a gear assembly of a brake actuator, in particular of a motor vehicle includes a sleeve-shaped support body (100) made of a first plastic material and a gear wheel body (200) firmly integrally formed onto the support body and made of a second plastic material, which has a lower stiffness and higher elasticity than the first plastic material. The gear wheel body (200) has outer toothing (210) and inner spindle-nut toothing (230) for receiving a spindle (50). The spindle-nut toothing (230) is at least partially axially spaced apart from the outer toothing (210) in one direction. The support body protrudes axially at least partially into the region of the helical gear toothing and into the region of the spindle toothing (230). The support body (100) has a smaller outer diameter than the helical gear toothing

A manufacturing method of a resin molded member includes: an insert member molding step of building an insert member by stacking layers of a base resin containing continuous fibers by using a 3D printer; an aligning step of aligning the insert member in a cavity of an injection molding mold; and a resin portion molding step of molding a resin portion integrated with the insert member by filling an injection molding resin into the cavity, wherein the insert member is arranged on a surface of a weld portion by the resin portion molding step, and the continuous fibers in the insert member are oriented in direction crossing over the weld portion, the weld portion being formed in the resin portion.

A molded liner member for a fluid pump is disclosed. The liner member includes a generally annular ring, having an inner surface, an outer surface which is substantially concentric with the inner surface, and first and second end surfaces. The annular ring is molded from fiber reinforced polymer, and a majority of the fiber reinforcements in the polymer are oriented substantially parallel to an axis passing through the center of the annular ring. A method for making the liner member is also disclosed.

A light-weight gear including: an annular tooth portion made of metal; a shaft extending along a central axis of the tooth portion and made of metal; and a coupling element configured to couple the shaft to the tooth portion and made of a resin, in which a joining part between the shaft and the coupling element and a joining part between the tooth portion and the coupling element are provided with irregularities configured to be engaged with one another in a circumferential direction, and corners of the irregularities are rounded to release a stress. Also, provided is a manufacturing method of a light-weight gear including: disposing the tooth portion and the shaft in a mold and injecting a molten resin into a cavity of the mold, thereby simultaneously performing injection molding of the coupling element and joining the coupling element to the tooth portion and the shaft.

The present invention is intended to provide a manufacturing method of an insert molded article that makes it possible to manufacture efficiently the insert molded article including a metallic insert, an inside member made of a synthetic resin and covering a portion of the insert, and an outside member made of a synthetic resin different from the material of the inside member and covering a portion of the inside member using general molding machines, not a dedicated two-color molding machine. General molding machines are used to manufacture the insert molded article formed by injection molding of a resin part in twice. An insert core 7 is used in common in primary molding using a primary molding die C1 and in a secondary molding using a secondary molding die. A round shaft 7C of the insert core 7 is fitted into an internal hole 2C of an insert 2 to form a coupled body 10 in which the insert 2 and the insert core 7 are coupled together. The coupled body 10 is used in common at the primary molding step and the secondary molding step.

A gear includes a center portion and a peripheral portion. The center portion includes a rotation support portion and an inner web. The peripheral portion includes an annular rim having teeth and an outer web, and made of a material different from a material of the center portion. One portion of the outer web is configured to hold one portion of the inner web. An outer surface of the one portion of the outer web is sloped such that a thickness of the outer web increases as the outer web extends from the rotation support portion toward the rim.

A method of making a worm gear. The method includes forming a gear blank having a plurality of individual lugs formed about an outer circumferential edge of said blank to facilitate a uniform flow of a material around said plurality of individual lugs. The method also includes molding said material around said plurality of individual lugs to form a ring.