JP2625481B2 - Method for manufacturing switch wafer - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a wafer provided in a switch which is turned on / off by contacting and separating a movable contact and a fixed contact.

[Conventional technology]

As described in, for example, Japanese Utility Model Laid-Open Publication No. 61-103840, this type of switch includes a synthetic resin base called a wafer in which a pair of fixed contacts are insert-molded, and is incorporated in the base. It is roughly constituted by a movable contact which is always electrically connected to one of the fixed contacts, and an operating body which is rotatably or slidably mounted on the base and drives the movable contact. The base is formed in a box shape with an open upper surface, and both fixed contacts are disposed on the inner bottom surface of the base so as to be exposed, and a part of the base extends outside the base.

In the switch configured as above, when the operating body is rotated or slid, the movable contact is driven by the operating body, so that the movable contact and the opposite fixed contact on the other side are disconnected. It changes from being separated or from being separated to being connected, and is switched on and off.

[Problems to be solved by the invention]

By the way, in the conventional switch described above, the number of components is reduced to some extent by insert molding both fixed contacts on the base, but since the movable contacts and the base are separate components, the components are There is room for improvement in terms of further reducing the number of points and the resulting cost. In addition, since the movable contact and one of the fixed contacts must always be electrically connected, a means for pressing the movable contact to the fixed contact, for example, when a pressing portion is provided on the operating body, requires some contrivance. However, there is a problem that the structure of the switch becomes complicated and the assembling workability is poor. Furthermore, since the conduction between the movable contact and one of the fixed contacts is established by the pressing force of the pressing means, there is a problem in the reliability of connection between the two.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-described circumstances of the prior art, and has as its object to provide excellent assembling workability and connection reliability as well as low cost so that a movable contact and a fixed contact can be integrally formed on a base. The provision of such a switch.

[Means for solving the problem]

In order to achieve the above object, the present invention has a movable contact and a fixed side terminal which are opposed to a first flat plate portion having a movable side terminal through a folded portion by bending a metal plate. Forming a fixed contact standing upright on the second flat plate portion via the bent portion, and supplying the metal plate to an injection molding die, and thereafter, the injection molding die and the first flat plate portion. Filling the cavity with the molten resin, and cooling and solidifying the molten resin to form at least the first resin.
Forming a base made of a synthetic resin in which a part of the second flat plate is buried and a protrusion protruding near the bent base of the fixed contact is formed; Bending the end so as to face the movable contact on the basis of the projection as a bending reference.

[Action]

First, a hoop-shaped metal plate having a movable terminal
A movable contact that faces the flat plate portion via a folded portion, and a fixed contact that stands through the bent portion on a second flat plate portion having a fixed terminal are formed. Such bending can be performed using a press machine, so that the movable contact and the fixed contact are formed with high positional accuracy.

Next, the metal plate thus bent is supplied between the movable die and the fixed die of the injection molding die, and the die is clamped. Here, one of the movable mold and the fixed mold is provided with a first concave portion that allows the insertion of the movable contact at the time of mold clamping, and a second concave portion that allows the insertion of the fixed contact. The open end of the concave portion is closed by a first flat plate portion of the metal plate.

Next, a molten resin is filled in the cavity of the injection mold, and after cooling and solidifying, the mold is opened to form a synthetic resin base. In this case, since the open end of the first recess is closed by the first flat plate portion,
The movable contact is not buried in the base, and the resin is filled near the open end of the second recess, so that the protrusion is integrally formed near the bent base of the fixed contact.

Thereafter, by bending the free end of the fixed contact in the upright state so as to face the movable contact with the projection as a bending reference, a wafer having the fixed contact and the movable contact integrally formed on the base can be obtained.

Since the wafer obtained in this way can be insert-molded not only to fixed contacts but also to movable contacts that come into contact with and separate from the fixed contacts, the mounting of the movable contacts, which was conventionally required when assembling as a switch, is required. The step and the pressing means for pressing the movable contact against the fixed contact can be omitted, and the assembly cost is greatly reduced. Further, since the relative position between the movable contact and the fixed contact is determined by the mold accuracy when the hoop material is pressed and the bending accuracy of the fixed contact with respect to the projection, the accuracy is maintained, A switch with less contact failure can be provided.

〔Example〕

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a longitudinal sectional view of a switch according to one embodiment of the present invention. In FIG. 1, reference numeral 1 denotes a base made of a synthetic resin, which is formed in a box shape having an open upper end. A first flat plate portion 2 and a second flat plate portion 3 are arranged on the inner bottom surface of the base 1 at a predetermined interval.
It extends to the outside through the inside, and forms a movable side terminal 4 and a fixed side terminal 5, respectively. Reference numeral 6 denotes a movable contact.
Is formed by folding a part of the first flat plate portion 2 and further bending it in a crank shape.
Reference numeral 7 denotes a fixed contact. The fixed contact 7 is formed by bending a part of the second flat plate portion 3 upward, and further bending the fixed contact 7 so as to be in contact with the free end of the movable contact 6. . The bending of the fixed contact 7 in the horizontal direction is performed using the ridgeline of the upper surface of the projection 8 integrally formed on the inner bottom surface of the base 1 as a bending reference. ) Are embedded in the projection 8.

Reference numeral 9 denotes an operation lever made of a synthetic resin, and a drive unit 10 which comes into contact with the upper surface of the movable contact 6 is vertically provided on a top plate portion thereof. A hole 11 formed in the side surface of the operation lever 9 is rotatably supported by a support shaft 12 protruding from the outer surface of the base 1. A spring 1 is provided between the spring receiving portions 13 and 14 formed integrally with the inner bottom surface of the base 1.
The operation lever 9 is urged in the counterclockwise direction in FIG. 1 by the spring 15.

Note that two sets of the movable contact 6 and the fixed contact 7 including the terminals 4 and 5 described above are arranged side by side at a predetermined interval in a direction orthogonal to the first sheet of FIG. I'm sorry.

The operation of the switch thus configured is as follows.

FIG. 1 shows a state in which the operating lever 9 is not pressed. In this case, the movable contact 6 comes into contact with the fixed contact 7 by its own elasticity, and is in a switch-on state.

On the other hand, when the right end of the operation lever 9 in the figure is pressed in the direction of arrow A against the spring force of the spring 15, the operation lever 9 rotates clockwise around the support shaft 12. By this operation, the movable contact 6 is pressed by the drive unit 10 and bends away from the fixed contact 7 to be switched to the switch-off state.

Next, the manufacturing and assembling steps of the above switch will be described with reference to FIGS.

First, a supply member 16 having a movable contact 6 and a fixed contact 7 as shown in FIG. 2 is obtained by pressing a hoop-shaped metal plate. However, in this state, the fixed contact 7 is not bent in a hook shape as shown in FIG.
The movable contact 6 is formed by folding up a part of the first flat plate portion 2, and its free end is obliquely upward. It is in a tilted state. Further, the movable side and fixed side terminals 4 and 5 are not bent.

Next, the supply member 16 is supplied between the movable die 17 and the fixed die 18 of the injection molding die as shown in FIG. 3, and the die is clamped. The movable die 17 has a cavity 19 for allowing the rising portion of the movable contact 6 to be inserted and a slit 20 for allowing the upper portion of the fixed contact 7 to be inserted, in addition to the above-described cavity for molding the base 1. Is provided. Then, as shown in the figure, a molten resin 21 is injected into the cavity. In this case, the open surface of the concave portion 19 is the first flat plate portion 2.
As a result, the free end of the fixed contact 7 is regulated by the slit 20, so that the fixed contact 7 is pressed by the resin pressure. There is no deformation.

Next, after the molten resin 21 is cooled and solidified in a mold, the movable contact 6 is opened as shown in FIG.
A wafer is obtained in which the base 1 and the fixed contact 7 are insert-molded.

After the base 1 is formed in this manner, the upper part of the fixed contact 7 is bent at a right angle in the direction of arrow B in FIG. 5, and the lower surface of the fixed contact 7 is pressed against the movable contact 6 as shown in FIG. This bending step can be performed simply and reliably from the upper open end side of the base 1 by using, for example, an automatic machine since the projection 8 integrally formed on the inner bottom surface of the base 1 can be used as a bending reference. In addition, before and after the step of bending the fixed contact 7, the movable-side and fixed-side terminals 4, which protrude from the base 1,
Fold 5 downward at a right angle.

On the other hand, the operation lever 9 is formed separately from the base 1, and as shown in FIG. 7, the operation lever 9 and the spring 15 are respectively incorporated in the wafer formed as described above, and the hole 11 of the operation lever 9 is formed. Is fitted to the support shaft 12 of the base 1 to assemble the switch shown in FIG.

In the above embodiment, the switch can be constituted by the base 1, the operating lever 9, and the spring 15 in which not only the fixed contact 7 but also the movable contact 6 are insert-molded. Compared with this, the number of parts is reduced, and simplification of assembly and cost reduction can be achieved. Further, the positional relationship between the movable contact 6 and the movable contact 7 is set with high accuracy depending on the mold accuracy when the hoop material is pressed, and the fixed contact is determined by the resin pressure when the base 1 is formed. Since the movable contact 6 does not deform, the movable contact 6 can be brought into contact with the fixed contact 7 after bending with a stable pressure, and a switch with less contact failure can be provided.

〔The invention's effect〕

As described above, the present invention insert-molds a movable contact formed by folding a part of a metal plate and a fixed contact formed by cutting and raising a part of a metal plate into a base, The fixed contact in the upright state is bent toward the movable contact side using the projection integrally formed on the base as the bending reference, so that the movable contact, which has been considered difficult in the past, can be integrated into the base. Thus, it is possible to provide a low-cost switch having excellent assembling workability and connection reliability.

[Brief description of the drawings]

1 is a longitudinal sectional view of a switch, FIG. 2 is a perspective view of a supply member, FIG. 3 and FIG. 4 are sectional views of an injection mold, and FIG. 5 and 6 are perspective views showing a process of bending the fixed contact, and FIG. 7 is a perspective view showing an assembly process. DESCRIPTION OF SYMBOLS 1 ... Base, 2 ... 1st flat plate part, 3 ... 2nd flat plate part, 4 ... Movable terminal, 5 ... Fixed terminal, 6 ... Movable contact, 7 ... Fixed contact, 8 Projection, 9 Operation lever, 10 Drive unit, 11 Hole, 12 Support shaft, 13, 14
Spring receiving part, 15 Spring, 16 Supply member, 17
Movable type, 18: fixed type, 19: concave part, 20: slit,
21 ... Molten resin.

Claims (1)

(57) [Claims] A metal plate is bent to form a movable contact opposite to a first flat plate having a movable terminal via a folded portion and a second flat plate having a fixed terminal. Forming a fixed contact that rises through a curved portion, and supplying the metal plate to an injection molding die, and then melting the molten resin into a cavity formed by the injection molding die and the first flat plate portion. By filling and melting and solidifying the molten resin, thereby burying at least a part of the first and second flat plate portions and bulging the projections located near the bent base portion of the fixed contact. Forming a base made of synthetic resin; and bending a free end of the fixed contact in an upright state so as to face the movable contact with the projection as a bending reference. Production method.