One-piece resin component for dynamoelectric machine and manufacturing method using the same

1. A one-piece resin component for a dynamoelectric machine, comprising:

a resin housing, which is configured to form at least a part of a housing of the dynamoelectric machine; and

a plurality of stackable resin portions, which are formed integrally with the resin housing and radially outwardly project from the resin housing, wherein each of the plurality of stackable resin portions is adapted to be stacked in a stacking direction against a corresponding one of a plurality of stackable resin portions of another one-piece resin component that is generally identical to the one-piece resin component, wherein

the resin housing is a gear housing that includes a wheel receiving portion, which is adapted to receive a worm wheel of the dynamoelectric machine at a location radially inward of a cylindrical peripheral wall of the wheel receiving portion,

a first engaging part and a second engaging part are formed in one end part and the other end part, respectively, of each of the plurality of stackable resin portions of the one-piece resin component, and

one of the first engaging part and the second engaging part of each of the plurality of stackable resin portions of the one-piece resin component is adapted to be axially engaged with a corresponding one of a first engaging part and a second engaging part, which are formed in one end part and the other end part, respectively, of a corresponding one of the plurality of stackable resin portions of the another one-piece resin component, to limit disengagement therebetween in a direction perpendicular to the stacking direction that is parallel to an axial direction of the wheel receiving portion of the one-piece resin component.

2. The one-piece resin component according to claim 1 , wherein:

one of the first engaging part and the second engaging part of each of the plurality of stackable resin portions of the one-piece resin component is an axial recess; and

the other one of the first engaging part and the second engaging part of each of the plurality of stackable resin portions of the one-piece resin component is an axial protrusion.

3. The one-piece resin component according to claim 1 , wherein the first engaging part and the second engaging part of each of the plurality of stackable resin portions of the one-piece resin component are axially placed outside of an axial extent of the cylindrical peripheral wall of the wheel receiving portion.

4. A manufacturing method, comprising:

molding a plurality of one-piece resin components from a resin material, wherein each of the plurality of one-piece resin components includes:

a resin housing, which is configured to form at least a part of a housing of a dynamoelectric machine; and

a plurality of stackable resin portions, which are formed integrally with the resin housing and radially outwardly project from the resin housing; and

transferring the plurality of one-piece resin components after the molding thereof in a stacked state, in which the plurality of one-piece resin components is stacked in a stacking direction by stacking each of the plurality of stackable resin portions of each of the plurality of one-piece resin components against a corresponding one of the plurality of stackable resin portions of an adjacent one of the plurality of one-piece resin components, wherein

the molding of the plurality of one-piece resin components includes molding a first engaging part and a second engaging part in one end part and the other end part, respectively, of each of the plurality of stackable resin portions of each of the plurality of one-piece resin components, and

the transferring of the plurality of one-piece resin components includes stacking the plurality of one-piece resin components such that each adjacent two of the plurality of one-piece resin components are stacked one after another such that the first engaging parts of the plurality of stackable resin portions of one of the adjacent two of the plurality of one-piece resin components are engaged with the second engaging parts of the plurality of stackable resin portions of the other one of the adjacent two of the plurality of one-piece resin components in the stacking direction to limit disengagement therebetween in a direction perpendicular to the stacking direction.

5. The manufacturing method according to claim 4 , wherein the resin housing of each of the plurality of one-piece resin components is a gear housing that is adapted to receive a gear of the dynamoelectric machine therein.

6. The manufacturing method according to claim 5 , wherein:

the gear housing of each of the plurality of one-piece resin components has a wheel receiving portion that is adapted to receive a worm wheel as the gear of the dynamoelectric machine and includes a cylindrical peripheral wall, which axially extends from a bottom wall of the wheel receiving portion to receive the worm wheel therein; and

the plurality of stackable resin portions of each of the plurality of one-piece resin components includes at least three stackable resin portions, which radially outwardly project relative to the cylindrical peripheral wall and are circumferentially arranged one after another.

7. The manufacturing method according to claim 4 , further comprising assembling another component of the dynamoelectric machine to the resin housing of each of the plurality of one-piece resin components while using the plurality of stackable resin portions of the one-piece resin component as a positional reference.

8. The manufacturing method according to claim 4 , wherein the plurality of stackable resin portions of each of the plurality of one-piece resin components is configured to enable standing of the one-piece resin component in a direction generally perpendicular to the stacking direction.

9. The manufacturing method according to claim 4 , further comprising cutting off the plurality of stackable resin portions from the rest of each of the plurality of one-piece resin components after the transferring of the plurality of one-piece resin components.

10. The manufacturing method according to claim 4 , wherein the molding of the plurality of one-piece resin components includes molding each of the plurality of one-piece resin components in a corresponding cavity of a molding die that includes a resin housing molding part, in which the resin housing is molded, and a plurality of stackable resin portion molding parts, in which the plurality of stackable resin portions is molded, by injecting a molten resin material into the cavity through a gate of the molding die, which is located adjacent to the cavity, while at least one of the plurality of stackable resin portion molding parts is placed furthermost from the gate in the cavity.