CN1066388C - Sythetic resin unit formed integrally with metallic unit and making of same - Google Patents

Abstract

A process for prodn. of a plastic prod. with integrally moulded metal parts involves: (i) locating a set of metal components (3,4,5) comprising different types connected by bridging pieces, in the tool cavity; (ii) injecting plastic into the tool cavity to form the prod. body (2); (iii) removing the bridging pieces (59) to leave separate metal components (3,4,5) integrated in the plastic body (2). The plastic prod. (2) including metal parts (3,4,5) is claimed. Holes (8) in the plastic body (2) allow removal of the bridging pieces (59). A complete lamp assembly is also claimed, in which the bulb is held by metal parts (22,23) conducting the current and a lens covers the front side of the lamp body.

Description

Form the manufacture method of the synthetic resin members of one with hard ware

The present invention relates to later-model synthetic resin members and reach the manufacture method that forms the synthetic resin members of one with hard ware with hard ware formation one.Specifically, to provide a kind of later-model synthetic resin members to reach the manufacture method that forms the synthetic resin members of one with hard ware exactly with hard ware formation one, purpose is to improve the assembly precision of hard ware in synthetic resin members, and avoid the unnecessary contact between hard ware, work capacity when saving the hard ware assembling simultaneously, cost-cutting.

About the illuminating lamp on traditional vanity mirror of being located in the automobile bodies, their shell have shown in Figure 64 and Figure 65 that the back will be addressed.

A becomes to erect long box-type illuminating lamp shell, is installed on the adjacent peristome of mirror installation portion with mirror shell not shown in the figures.

Be fixed with bulb clamping accessory b, c in the inside of illuminating lamp shell a, use holding piece d, the e of the leading flank of being located at this bulb clamping accessory b, c to fix bulb f.

G is a switch, from the protruding terminal plate h that is provided with of this switch g.The contact part i that is located at described bulb clamping accessory b contacts with the terminal (not shown) that expose the bottom surface of the casing j of switch g, in case the operating knob k of switch g is pressed, in the casing j of switch g, the described not shown terminal that described contact part j is contacted promptly becomes contact condition with described terminal plate h.

And, be formed in the hole m of terminal plate h on being formed at described illuminating lamp shell a of terminal plate l on the bulb clamping accessory c and switch g outstandingly, here, this hole m and 2 terminal plate h, l form adaptor union n.

When not shown vanity mirror was loaded on not shown anti-dazzle device, the set adaptor union of wirning harness front end that extends from anti-dazzle device just was connected with described adaptor union n, and bulb f connects through the power supply unit of switch g and car body.

Use on the illuminating lamp shell a at described traditional vanity mirror, tube clamping accessory b, the c of each self-forming and switch g must assemble with housing main body a respectively, waste time and energy, and become the reason that cost rises.

In addition, each tube clamping accessory b, c and switch g be one by one with housing main body a stack-mounted, so each tube clamping accessory b, c and the assembly precision that closes between g are difficult to guarantee to also have risk of short-circuits sometimes.

And synthetic resin members of the present invention and hard ware formation one reaches and the manufacture method of the synthetic resin members of hard ware formation one is exactly in order to solve the problem of described orthodox method, should be by forming a plurality of punching hole through the integrated hard ware group that connecting bridge is linked to be through inserting on the integrated synthetic resin system main body that forms with the synthetic resin members of hard ware formation one by multiple hard ware, and at this punching hole place described connecting bridge is cut off, described multiple hard ware is independently formed separately.

The manufacture method that of the present invention and hard ware forms the synthetic resin members of one then is the integrated hard ware group that is linked to be through connecting bridge by multiple hard ware to be inserted the shaping of a synthetic resin system main body use in the forming die, be shaped with injecting synthetic resin system main body resin in the forming die to this synthetic resin system main body, after forming the synthetic resin members intermediate of synthetic resin system main body and hard ware group formation one, described connecting bridge is cut off, make described multiple hard ware independent separately, produce the synthetic resin members that forms one with hard ware thus.

Thereby, because it is to make the hard ware group and the synthetic resin system main body that form one by multiple hard ware be configured as one by inserting to be shaped that of the present invention and hard ware form the synthetic resin members of one, so need not multiple hard ware is respectively charged in the synthetic resin system main body, time saving and energy saving, but cost-cutting.And owing to each hard ware is packed into by inserting to be shaped, so can improve the assembly precision between each hard ware, the nonuseable part of each hard ware is topped by resin institute in addition, so avoided the unexpected danger that contacts between the hard ware.

In addition, the manufacture method that of the present invention and hard ware form the synthetic resin members of one is the integrated hard ware group that is linked to be through connecting bridge by multiple hard ware to be inserted the shaping of synthetic resin system main body carry out in forming die forming the synthetic resin members intermediate after the shaping of synthetic resin system main body, then connecting bridge is cut off, make each hard ware each self-separation on electric, produce the synthetic resin members that forms one with hard ware thus, so can efficient produce the synthetic resin members that forms one with hard ware highly, not only can cost-cutting, also can improve the assembly precision between each hard ware.

Below accompanying drawing is made brief description.

Fig. 1 is used for 1st embodiment of vanity mirror with the illuminating lamp shell to the synthetic resin members with hard ware formation one of the present invention, is the partial front elevation view of the equipped state of bonded assembly vanity mirror on expression and the anti-dazzle device.

Fig. 2 is the amplification view along the 2-2 line of Fig. 1.

Fig. 3 is the amplification view along the 3-3 line of Fig. 1.

Fig. 4 is a block diagram.

Fig. 5 is a front view.

Fig. 6 is a back view.

Fig. 7 is the amplification view along the 7-7 line of Fig. 5.

Fig. 8 is the amplification view along the 8-8 line of Fig. 5.

Fig. 9 is the amplification view along the 9-9 line of Fig. 6.

Figure 10 is the amplification view along the 10-10 line of Fig. 5.

Figure 11 is the amplification view along the 11-11 line of Fig. 5.

Figure 12 is an amplification stereogram of wanting portion.

Figure 13 is a block diagram of making contact element group material therefor, the skeleton diagram of the embodiment that Figure 14 to Figure 17 synthetic resin members manufacture method that all to be expressions form one to of the present invention and hard ware applies to vanity mirror when using the manufacture method of illuminating lamp shell.

Figure 14 is the block diagram of the original shape contact element group of the material punch process postforming of Figure 13.

Figure 15 is the block diagram that original shape contact element group is carried out the contact element group of bending machining postforming.

Figure 16 is the front view of contact element group.

Figure 17 is the block diagram that the contact element group is inserted the illuminating lamp shell intermediate of postforming.

Figure 18 is the amplification stereogram of the illuminating lamp shell used of vanity mirror, and Figure 19 to Figure 42 is synthetic resin members and manufacture method thereof that of the present invention and hard ware are formed one and is used for 2nd embodiment of vanity mirror with illuminating lamp shell and manufacture method thereof.

Figure 19 opens and takes off front view behind the lens of illuminating lamp to the lid of vanity mirror.

Figure 20 is the back view of vanity mirror.

Figure 21 is the back view of lid.

Figure 22 is the amplification view when the 22-22 line of Figure 19 cuts off and lid closed.

Figure 23 is the amplification view when the 23-23 line of Figure 19 cuts off and lid closed.

Figure 24 is the cutaway view when the 24-24 line of Figure 19 cuts off and lid closed.

Figure 25 is the front view of vanity mirror shell.

Figure 26 be male want portion's amplification stereogram.

Figure 27 be the male variation want portion's amplification stereogram.

Figure 28 be another variation of male want portion's amplification stereogram.

Figure 29 is the amplification view when the 29-29 line of Figure 19 cuts off and lid closed.

Figure 30 is the amplification view when the 30-30 line of Figure 19 cuts off and lid closed.

Figure 31 is the amplification stereogram of mirror engagement section.

Figure 32 is the end of expression mirror and the amplification stereogram of mirror engagement section fastening state.

Figure 33 is the amplification stereogram of cloudy terminal.

Figure 34 is the amplification view along the 34-34 line of Figure 33.

Figure 35 is the enlarged front view of cloudy terminal.

Figure 36 is the enlarged drawing after cloudy terminal is launched.

Figure 37 be the expression male when engaging with cloudy terminal state want portion's amplification view.

Figure 38 be the expression lid when opening the switch portion state want portion's amplification view.

Figure 39 be the expression lid when closing the switch portion state want portion's amplification view.

Figure 40 be the expression lid when closing lid remain on this closed condition holding device want portion's amplification view.

Figure 41 be the expression lid when opening lid remain on this open mode holding device want portion's amplification view.

Figure 42 is the amplification stereogram of contact element group continuum.

Figure 43 is the amplification stereogram of the vanity mirror of the 2nd embodiment with illuminating lamp casing deformation example.

Figure 44 is the cutaway view along the 44-44 line of Figure 43.

Figure 45 is the cutaway view along the 45-45 line of Figure 43.

Figure 46 is the enlarged front view behind the indoor illumination cut-out lens, and Figure 47 to Figure 62 all represents of the present invention and hard ware are formed the synthetic resin members of one and apply to the illuminating lamp shell of indoor illumination and the 3rd embodiment of manufacture method thereof with manufacture method that hard ware forms the synthetic resin members of one.

Figure 47 is the amplification rearview of indoor illumination.

Figure 48 is the cutaway view along the 48-48 line of Figure 47.

Figure 49 is the cutaway view along the 49-49 line of Figure 47.

Figure 50 is the cutaway view along the 50-50 line of Figure 47.

Figure 51 is the amplification view of fluorescent tube maintaining part.

Figure 52 is the amplification view of the engagement section between lens bottom and housing main body.

Figure 53 is the amplification view of the engagement section between lens upper end and housing main body.

Figure 54 is the amplification stereogram of switch knob.

Figure 55 is the enlarged front view of make and break contact portion.

Figure 56 is the amplification stereogram of the adaptor union portion of illuminating lamp shell back side formation.

Figure 57 is the amplification stereogram of contact element group continuum.

Figure 58 be switch knob and assembling thereof variation want portion's amplification view.

Figure 59 be switch knob and assembling thereof another variation want portion's amplification view.

Figure 60 be switch knob and assembling thereof another variation want portion's amplification view.

Figure 61 be switch knob and assembling thereof a variation again want portion's amplification view.

Figure 62 be switch knob and assembling thereof a variation again want portion's amplification view.

Figure 63 be switch knob and assembling thereof a variation again want portion's amplification view.

Figure 64 and Figure 65 are the example of traditional vanity mirror with the illuminating lamp shell, and Figure 64 is its block diagram of wanting portion.

Figure 65 is an exploded perspective view.

Describe the synthetic resin members with hard ware formation one of the present invention in detail below in conjunction with embodiment shown in the drawings and reach the manufacture method that forms the synthetic resin members of one with hard ware.

Fig. 1 to Figure 17 represents the present invention is used for 1st embodiment of vanity mirror with illuminating lamp shell and manufacture method thereof.

The illuminating lamp shell that vanity mirror of the present invention is used at first is described, its manufacture method is described then.

1 is vanity mirror illuminating lamp shell among the figure, is made up of plastic housing main body 2 and 3 contact elements 3,4,5 of this housing main body 2 of packing into by what is called insertion shaping.

Housing main body 2 is used synthetic resin, such as formation such as ABS resin, and front openings sees that from the front being one slightly becomes to erect the more shallow flat box-shaped of long shape oblong and depth.

Form at the both ends up and down of the inner bottom surface of housing main body 2 platform 6,6 that slightly forwards protrudes ', this platform 6,6 ' substantial middle portion form openings 7,7 ', the side position of taking back at the platform 6 of upside forms 2 punching hole arranged side by side up and down in addition, near the both sides, bottom of through hole 7, respectively form 1 punching hole, amount to 4 punching hole 8.

At the upper side of housing main body 2, be provided with the projection of protruding upward 9,10 at left end and the central position that takes over slightly.Form the otch 11 of L font in the upper end of the right flank of the projection 9 in left side, form the downward blocking surface 12 that bends to the L font in the upper end of the projection 10 on right side.

Upper end from described protruding 9 base portion to surrounding wall portion forms inspection door 13.

14, the 14th, at the positioning rib that the mediad fore-and-aft direction of the above-below direction of side walls 15,15 inner faces stretches out, leading section 14a, the 14a of its inner face is to the dip plane of side walls 15,15 lopsidedness along with the extension of forward end.

The 16th, from the inner face of the side walls 15 in left side than described positioning rib 14 slightly the rearward end of the position of top to right-hand tongue-shaped compressed part of stretching out.

The 17th, the knock hole that on the backplate 18 of the slightly top position of described compressed part 16, forms.

Overleaf on the plate 18 except described platform 6,6 ' part, that is, and with the back side of middle body 19 cooresponding parts form a plurality of apertures 20,20 ...

The 21st, with the fender that housing main body 2 fuses, it is in addition topped with the part except right-hand member between the projection 9,10 from the back side.

Contact element 3,4,5 usefulness have electric conductivity and elastomeric metallic material such as corrosion-resistant steel (for example SUS304) to be made, and in order to improve conductivity water temperature and depth and durability, also available brass, phosphor bronze etc. are made.

Contact element 3 is by bulb socket 22, terminal plate 23, and a integral body that 22 and 23 junction surfaces that linked 24 are formed.Bulb socket 22 is made up of base portion 25 and the holding piece 26,26 that forwards erects from the two edges up and down of this base portion 25, has formed the card- tight part 27,27 that makes 2 bendings near each other at holding piece 26,26 by tip location.In addition, stretch out at the right-hand member edge of base portion 25 and to imbed sheet 25a, this imbeds the bending of sheet 25a tilted rearward.

And the interval between the tip of holding piece 26,26 is less than the width up and down of base portion 25, the rising portions 26 that erects from base portion 25 of holding piece 26,26 ', 26 ' not be the right angle, but it is planar to form the crooked so-called R of band.

The junction surface 24 of contact element 3 roughly becomes the band shape of direction extension up and down, and portion forms ladder 24a therebetween, is that the boundary is divided into first half 24b and lower part 24c with this ladder 24a, and first half 24b slightly forwards protrudes than lower part 24c.And first half 24b imbeds in the leading section of the left part of upside platform 6 of housing main body 2 and left lateral sides wall 15.The right hand edge of the roughly centre portion of lower part 24c stretches out to the right, makes this a part of amplitude broad, and has formed knock hole 28 on the position that takes over of this part.And roughly half the part in the left side of this lower part 24c is embedded in the rear end sidepiece of left lateral sides wall 15 of housing main body 2, and 22 of remainder and bulb sockets are located in the shallow recess 29 that the left part of middle body 19 of the inner bottom surface of housing main body 2 forms.

What form on the base portion 25 of bulb socket 22 in addition, imbeds in the backplate 18 that sheet 25a is embedded in housing main body 2.And the knock hole 17 of formation is consistent on the knock hole 28 that the lower part 24c at junction surface 24 go up to form and the backplate 18 of housing main body 2.In addition, the compressed part 16 of stretching out from the left lateral sides wall 15 of housing main body 2 becomes contact condition with the front side of the end parts on the lower side of the lower part 24c at junction surface 24, and this part that prevents junction surface 24 thus is projection forwards.

In addition, terminal plate 23 towards above-below direction, stretch out to right-hand from the right flank of the otch 11 of the described left hand projection 9 of housing main body 2.And its right-hand member is near the upper end left surface of described right side projection 10.

Also have, compare with the base end part 23a and the point 23b of terminal plate 23, intermediate portion 23c is thinner.

24 the upper end at the junction surface, promptly the part near terminal plate 23 has formed the curve 30 that bends to concavity.The position of terminal plate 23 is shifted slightly downwards.

Contact element 4 is by junction surface 34 principal part 32 that is formed by conjugate foramen 31 to be fused with terminal plate 33 to form.Stretch out snap fit tabs 31a, 31a from 2 relative positions of edge of opening of conjugate foramen 31.And, see junction surface 34 from the front, form the crank-like that 2 L words are linked up, it links up the left end of upper end, the left end edge of principal part 32 and terminal plate 33.In addition, terminal plate 33 bends for junction surface 34 upward at its base end part, makes it face above-below direction.Point at terminal plate 33 has formed the protruding 33a that forges upward.

The principal part 32 of this contact element 4 all is embedded in except that the peripheral part of conjugate foramen 31 in the platform 6 of housing main body 2 tops, and conjugate foramen 31 is positioned at the front side of through hole 7.Also have, the bore of conjugate foramen 31 is slightly less than the bore of through hole 7, and from fore-and-aft direction, the edge of opening of conjugate foramen 31 is positioned at the inboard of the edge of opening of through hole 7.

Junction surface 34 is embedded in the platform 6 of top, and stretch out to right-hand terminal plate 33 position under the otch 11 of the left hand projection 9 of housing main body 2, and is in parallel below the terminal plate 23 of described contact element 3, constitutes the switching contact portion of switch at this.

As mentioned above,, the switch block g that establishes in addition in the conventional case can be saved, thereby the required artificial and time of assembling of this switch block can be saved by constitute the switching contact portion of switches with contact element 3,4 terminal plate 23,33 separately, but cost-cutting also.

Because the rear side of these terminal plates 23,33 is fenders 21, so during the vanity mirror that after illuminating lamp shell 1 is loaded on, will address in the back, can avoid terminal plate 23,33 direct contact vanity mirrors, thereby can avoid the distortion or the damage of terminal plate 23,33.

In addition, the point 33b of terminal plate 33 is positioned at the downside of blocking surface 12 of the projection 10 on housing main body 2 right sides, can not be moved upward from blocking surface 12.

Keeping predetermined gap terminal plate 33 and 23 therefrom, terminal plate 33 too is short-circuited near terminal plate 23.In addition, near the part the upper end right hand edge near the part the upper end left hand edge at the junction surface 34 of contact element 4 and the junction surface 24 of contact element 3 is exposed from the described inspection door 13 of housing main body 2.

The bulb socket 36 that contact element 5 stretches out to the right by principal part 35, from the substantial middle portion of the right side edge of this principal part 35, and and the lower edge of principal part 35 is connected with and an integral body being made up of the joint fastener portion 38 of conjugate foramen 37 of portion in the central.

Joint fastener portion 38 is connected with principal part 35 through the portion of being connected with 39, and this is connected with portion 39 and extends up and down, and forms the ladder 39a that extends forwards, backwards halfway, and like this, joint fastener portion 38 just is positioned at than principal part 35 position on the front.

Principal part 35 is seen the word shape that roughly become from the front, at the edge, the left and right sides of its bottom and the left and right sides edges at two ends of upper end lower part amount to 4 positions stretch out respectively be provided with imbed sheet 35a, 35a ..., these imbed sheet 35a, 35a ... bending is rearward tilted.

Bulb socket 36 is made up of base portion 40 and the holding piece 41,41 that forwards erects from two edges up and down of this base portion 40, forms the card- tight part 42,42 of a pair of bending near each other in the inclined to one side tip location of holding piece 41,41.

And the interval between the tip of holding piece 41,41 is less than the width up and down of base portion 42, the rising portions 41 that erects from base portion 40 of holding piece 41,41 ', 41 ' not be the right angle, but it is planar to form the crooked so-called R of band.

Stretch out snap fit tabs 37a, 37a from 2 relative positions of edge of opening of the conjugate foramen 37 of joint fastener portion 38.

The principal part 35 of this contact element 5 and bulb socket 36 are positioned at the shallow recess 43 of the inner bottom surface formation of housing main body 2, and joint fastener portion 38 is except that the peripheral part of conjugate foramen 37, all be embedded in the platform part 6 of the downside of housing main body 2 ' in, conjugate foramen 37 be positioned at through hole 7 ' the front side.In addition, the relative aperture through hole 7 of conjugate foramen 37 ' bore smaller, from fore-and-aft direction, the edge of opening of connecting bore 37 be positioned at through hole 7 ' the inboard of edge of opening.In addition, the central portion of the right part of bulb socket 36 contacts with the aft end face of the positioning rib 14 on right side.

In addition, form on the principal part 35 4 imbed sheet 35a, 35a ... imbed in the backplate 18 of housing main body 2.

And, be positioned at housing main body 2 described aperture 20,20 ... the depths be the junction surface 24 of contact element 3 and the base portion 25 of bulb socket 22, the principal part 35 of contact element 5 and the base portion 40 of bulb socket 36.

The 44th, vanity mirror, the 45th, its shell, the 46th, be loaded on the mirror on the shell 45, the 47th, the recess that forms in mirror 46 sides.

And described vanity mirror is fixed in the described recess 47 with 1 cooperation of illuminating lamp shell.In addition, there is the fluorescent tube 49 of lamp holder 48,48 at two ends, its lamp holder 48,48 is clamped in the illuminating lamp shell 1 by the holding piece 41,41 of the holding piece 26,26 of bulb socket 22 and bulb socket 36 respectively, and the front openings place of this illuminating lamp shell 1 is topped by lens institute not shown in the figures, constitutes illuminating lamp 50.

In addition, the interval between the face is identical or more bigger with the length of described fluorescent tube 49 opposite one another for 2 of described positioning rib 14,14, as mentioned above, when fluorescent tube 49 being contained on the bulb socket 22,36, even the position of fluorescent tube 49 is shifted slightly to the left and right, as long as the end of a lamp holder 48 is contacted with the dip plane 14a of a positioning rib 14, and along the contact dip plane 14a move to the side, can make it be in the tram.And this positioning rib 14,14 can stop the bulb unnecessary movement, prevents accidents such as short circuit.

The 51st, supported, rotate lid freely by vanity mirror shell 45, can open and close the front of mirror 46 and illuminating lamp 50, in case this lid 51 is opened, the effect projection 52 of being located at this lid 51 just pushes the inclined to one side tip location of the terminal plate 23 of described contact element 3 from the top, make terminal plate 23 bendings, its point 23b is moved downwards, terminal plate 23 is contacted with 33, make described fluorescent tube 49 be energized (see figure 2).

In addition, the pars intermedia 23c of terminal plate 23 is narrower than its base end part 23a and point 23b, so when terminal plate 23 is bent by described effect projection 52, can avoid stress concentration at the part, thereby increase the durability of terminal plate 23.

In addition, owing to formed the protruding 33a that protrudes to the direction of terminal plate 23 at the point 33b of terminal plate 33, so when terminal plate 23 when terminal plate 33 1 lateral bendings are bent, contact the bad contact that the error in the time of can avoiding because of shaping etc. causes reliably between terminal plate 23 and 33 point.

The 53rd, be located at the anti-dazzle device in the automobile bodies, on this anti-dazzle device 53, imbedded described vanity mirror 44 in the formed recess 54.

And, in the recess 54 of anti-dazzle device 53, disposing the structure member with electric conductivity 55,56 that engages with each terminal of automobile power source respectively, the screw 57 that runs through conjugate foramen 31 and through hole 7 from the front side combines with structure member 55 screw threads, run through from the front side conjugate foramen 37 and through hole 7 ' screw 57 ' then combine with structure member 56 screw threads.Screw 57,57 ' usefulness has the material of electric conductivity to be made, thereby, contact element 4 through screws 57 and with 55 one-tenths electrical engagement of structure member, 5 of contact elements pass through screw 57 ' and with 56 one-tenth electrical engagement of structure member.Thereby, in case described terminal plate 33 contacts with 23, just constituted the C/LOOP of another lamp holder 48-contact element 5-structure member 56-power supply of a lamp holder 48-fluorescent tube 49 of power supply-structure member 55-contact element 4-contact element 3-fluorescent tube 49, fluorescent tube 49 bright lamps.

Also have, snap fit tabs 31a, the 31a that forms on the described conjugate foramen 31,37,37a, 37a incision screw 57,57 ' groove in, make contact element 4,5 and screw 57,57 ' reliably contact, again because the through hole 7,7 of housing main body 2 ' bore greater than the bore of conjugate foramen 31,37, when so even housing main body 2 is shaped through hole 7,7 ' edge of opening produce burr etc., screw 57,57 ' also can contact with the edge of opening of conjugate foramen 31,37 reliably.

The following describes the manufacture method of described vanity mirror with illuminating lamp shell 1.

At first, form the integrated contact element group that is linked to be through connecting bridge by described contact element 3,4,5.

The 58th, the contact element group, contact element 3,4,5 process connecting bridges 59,59 ... and fuse.Promptly, the lower end of the left side edge of 2 positions that separate up and down of the right side edge of the end parts on the upper side at the junction surface 24 of contact element 3 and the principal part 32 of contact element 4 and linking with connecting bridge 59,59 respectively between 2 positions of end on the upper side, in addition, respectively with connecting bridge 59,59 bindings, form the contact element group 58 that fuses by contact element 3,4,5 thus between 2 positions of the right-hand member of the lower edge of the principal part 32 of contact element 4 and the end of taking back and 2 positions at the two ends, the upper limb left and right sides of the principal part 35 of contact element 5.

The 60th, the material of contact element group 58, the thin plate of available SUS, brass, phosphor bronze etc., its thickness is about 0.25mm.

These material 60 drawings, form by the plasmodium 3 of each contact element 3,4,5 of contact element group ', 4 ', the 5 ' original shape contact element group 61 that constituted.

Then, to the plasmodium 3 of above original shape contact element group 61 ', 4 ', 5 ' carry out bending process, form the contact element group 58 that is formed by connecting by 3 contact elements.

Promptly, about contact element plasmodium 3 ', be that the suitable portion 22 of bulb socket ' bending back is formed bulb socket 22, the suitable portion 23 of terminal plate ' base portion bend the back upward and form terminal plate 23, in addition, the suitable portion 24 at the junction surface ' near the suitable portion 23 of terminal plate ' part set up kink 30, form junction surface 24.And be bent to form and imbed sheet 25a.

About contact element plasmodium 4 ', be the suitable portion 33 of terminal plate ' base portion bend upward, form terminal plate 33.

When terminal plate 23 and 33 was packed in the housing main body 2, its plane should be relative each other, and the position should be approaching.Yet, because in the stage that forms original shape contact element group 60, the suitable portion 33 of terminal plate ' suitable portion 23 with terminal plate ' between separate certain width, so both can not be too near to.Thereby, as intactly 23 ' and 33 ' respectively in separately base portion bending, terminal plate 23 will be too far away apart with 33.At this moment, on junction surface 24, form kink 30, just can be transferred to suitable scope to the interval of 23,33 of terminal plates.

About contact element plasmodium 5 ', be that the suitable portion 36 of bulb socket ' bending back is formed bulb socket 36, and the suitable portion 39 of connecting portion ' respectively by the suitable portion 36 of bulb socket ' a side and by the suitable portion 38 of joint fastener ' a lateral buckling, make at the suitable portion 36 of bulb socket ' suitable portion a 38 ' formation ladder with joint fastener.

Described contact element group 58 insertions are had the housing main body shaping to be used in the forming die with the housing main body shaping of the shaping machine of forming die, and in this housing main body is shaped with forming die, inject the resin that housing main body is used, form the illuminating lamp housing main body intermediate that resinous housing main body 2 and contact element group 58 become one.

62,62 ... it is the pushing pin, it be passed in the through holes 64,64 that form in the forming die 63 ... and in die cavity 66, stretch out, and the back side of the roughly centre portion at the junction surface 24 of pushing contact element 3, and the back side of the central portion of the base portion 40 of the back side of the right side edge portion of the back side at the both ends, the left and right sides of the back side at the both ends, the left and right sides of the upper end of the principal part 35 of the back side of the central portion of the base portion 25 of bulb socket 22, contact element 5, bottom, substantial middle portion and bulb socket 36, their surface is urged to the cavity surface of another shaping die 65.Thus, the surface of the junction surface 24 of contact element 3 and the base portion 25 of bulb socket 22, the surface of the principal part 35 of contact element 5 and the base portion 40 of bulb socket 36 is pushed into the cavity surface of another shaping die 65, thereby prevented that reliably resin flow that housing main body uses is to these parts, promptly 24,25,35,40 surface, and these parts, promptly 24,25,35,40 inner bottom surfaces from shell 1 expose, function with reflecting surface, in addition, because these parts, promptly 24,25,35,40 inner bottom surfaces from shell 1 expose, the heat of fluorescent tube 49 has improved the resistance to effect of heat of illuminating lamp shell 1 to the radiation of housing main body 2 when just having blocked bright lamp.

And because contact element 3 and 5 is urged to the cavity surface of another shaping die 65 tightly, this contact element 3 and 5 position stability can prevent that the position of the contact element 3,5 that the injection pressure when being shaped causes from moving.

Also have, form on these contact elements 3,5 imbed sheet 25a, 35a, 35a ... be to imbed in the backplate 18 of housing main body 2.Thereby, when changing fluorescent tube 49 and take off old fluorescent tube 49, though can produce the application force that its base portion 25,40 is peeled off from backplate 18 to bulb socket 22 or 36, but since described imbed sheet 25a, 35a, 35a ... imbed backplate 18, so can prevent from the base portion 25,40 of bulb socket 22 or 36 is peeled off from backplate 18.Also have, the compressed part 16 that one of the junction surface 24 of contact element 3 portion is in addition topped from the place ahead also helps preventing this class and peels off.

In addition, these pushing pins 62,62 during shaping ... the part that is positioned at die cavity 66 after shaping promptly as aperture 20,20 ... and stay on the housing main body 2.

The 67th, stretch out the locating dowel pin of setting from another forming die 65, it runs through the knock hole 28 of contact element 3, extends in the middle of the die cavity 66.Make the stationkeeping of contact element 3 therefrom, move the position of the contact element 3 that the injection pressure when preventing because of shaping causes.

In addition, the part that this locating dowel pin 67 is positioned at die cavity 66 during shaping is being stayed on the housing main body 2 as knock hole 17 after the shaping.

The 68th, stretch out the pushing pin of setting from a forming die 63, the 69th, sell the pushing pin that stretch out 68 cooresponding positions from another forming die 65 with above-mentioned pushing.In case 2 forming dies, 63,65 matched moulds, then between the tip of described pushing pin 68,69 clamping contact element 3 junction surface 24 end parts on the upper side and with the upper end at the junction surface 34 of the approaching contact element 4 of this part, these parts can the injection pressure when being shaped not moved, contact.In addition,,, also can make the position between terminal plate 23 and 33 not normal if departed from assigned position even these parts do not contact each other, and because the clamping of described pushing 68,69, just prevented the generation of this class problem.

Also have, these pushing pin 68,69 parts that are positioned at die cavity 66 are being stayed on the housing main body 2 as inspection door 13 after the shaping during shaping.After shaping, can confirm the state at the junction surface 24,34 of contact element 3,4 by this inspection door 13.

To make 12 one-tenth surface contact states of blocking surface of point 33b and housing main body 2 of the terminal plate 33 of contact element 4 during shaping.Thereby, when being shaped end, this point 33b becomes the state that is attached on the blocking surface 12, but in case illuminating lamp shell 1 is assembled on the vanity mirror 44, and when making terminal plate 33 deflections with the effect projection 52 process terminal plates 23 of lid 51, the point 33b of this terminal plate 33 promptly peels off from blocking surface 12.

When the injection in die cavity 66 finishes, when carrying out the demoulding, because between the tip of the holding piece 26,26 of bulb socket 22, the 36 and interval between the tip of holding piece 41,41 is less than the width up and down of base portion 25,40, so need not to use slide core just can successfully carry out the demoulding.Promptly, as long as on another one forming die 65, be pre-formed the concave part 70,70 (one of them only is shown among Fig. 8) that holds bulb socket 22,36, the holding piece 26,26 and 41,41 of bulb socket 22,36 just can be extracted from this concave part 70,70, and can not meet the inner face of this concave part 70,70.

In addition, the rising portions 26 that erects from the base portion 25,40 of the holding piece 26,26,41,41 of bulb socket 22,36 ', 26 ', 41 ', 41 ' not be the right angle, but it is planar to form the crooked so-called R of band, so improved formability.That is, as this part 26 ', 26 ', 41 ', 41 ' square up, then when carrying out the loading and unloading of operation such as injection molding or fluorescent tube, make these part generation crackles easily, these parts are made the planar crackle that then can prevent of R take place, improve formability.

Then, after the shaping of having finished described housing main body 2, i.e. punching press formation punching hole 8,8 ..., form illuminating lamp shell 1.Because these punching hole 8,8 ... formation, link contact element 3,4,5 connecting bridge 59,59 ... this punching hole 8,8 ... the position be cut off, make contact element 3,4,5 independent separately on electric.

Use in illuminating lamp shell and the manufacture method thereof at described vanity mirror, the contact element 3,4,5 of housing main body 2 of packing into forms an integral body, and by inserting the housing main body 2 of integrally packing into that is shaped, so the assembly precision of each contact element 3,4,5 in housing main body 2 improved, and because the nonuseable part of each contact element 3,4,5 is topped by the resin of housing main body 2 institute, so reduced risk of short-circuits.Save the manpower and the time of assembling simultaneously, reduce assembly cost.

Figure 18 to Figure 42 is of the present invention and the synthetic resin members of hard ware formation one reaches and the 2nd embodiment of the manufacture method of the synthetic resin members of hard ware formation one.

The 2nd embodiment also is illuminating lamp shell and the manufacture method thereof that the present invention is applied to vanity mirror.

The 73rd, vanity mirror illuminating lamp shell, by plastic housing main body 74 be shaped and form by inserting with 75,76,77 and 2 enhancings of 3 contact elements sheet 78,79 that this housing main body 74 forms one.

Housing main body 74 is used synthetic resin, such as ABS resin etc. makes, and front openings sees it is the slightly perpendicular long flat box-shaped of oblong from the front.

The platform 80,80 that the formation of both ends up and down of housing main body 74 inner bottom surfaces is slightly forwards protruded ', this platform 80,80 ' substantial middle portion form through hole 81,81 ', and between the through hole 81 of the platform 80 of upside and two ends, the left and right sides and the platform 80 of downside ' through hole 81 ' and right-hand member between formation punching hole 82,82,82.

Platform 80 and 80 ' between part become recess 83, the part 83a of the summary 1/3rd of the central authorities of these recess 83 above-below directions is minimum tabular surfaces, and up and down bonded assembly part 83b, 83b ' are dip plane from this tabular surface 83a to described platform 80,80 ' gradually displacements forwards with this tabular surface 83a.

In housing main body 74 sides near 4 positions of upper and lower side position, promptly with described platform 80,80 ' cooresponding position, both sides form recess 84,84 ...These recesses 84,84 ... the front end of the lateral opening portion forward slightly place of front edge that extends to side walls 85 stop, its rear end then arrives the back of housing main body 74.In addition, these recesses 84,84 ... platform 80,80 ' on front end arrive platform 80,80 ' the front, the rear end then arrives the back of housing main body 74.

Housing main body 74 left and right sides lateral surfaces near the position at two ends up and down form the concave part 86,86 that arrives the rear and front end ...

Contact element 75 is by forming an integral body with the lower part, promptly reflecting part 87, from the central portion of the above-below direction of these reflecting part 87 left side edge to left stretch out the bulb socket 88 of setting, the connecting strap 89,89 that extends downwards by left and right sides edge from described reflecting part 87 ' the lower end to left or right-hand male of stretching out 90,90 ', and by become anti-character cut in bas-relief shape and forwards, backwards the direction link piece in a narrow margin 91,91 of extending and with male 90,90 ' the enhancing portion 92 that links of base end part lower edge.

Reflecting part 87 is by the grow crosswise tabular central portion 93 of rectangle and extend with the below upward from the two edges up and down of this central portion 93 and along with the rake 94,94 of the displacement of forwards tilting away from central portion 93 gradually ' and form an integral body of face forward and one-tenth, described link piece 89,89 ' extend downwards from the left and right sides of the central portion 93 of reflecting part 87.

Bulb socket 88 is made up of base portion 95 and the holding piece 96,96 that erects from the both sides up and down of this base portion 95, forms crooked card-tight part near each other 97,97 in the inclined to one side front position of holding piece 96,96.In addition, bury sheet 98 from base portion 95 underground with stretching out to be provided with by the opposite another side in one side of reflecting part 87.

The left-right symmetric of male 90 and 90 ' not only and construct identically so only a side is wherein described, then is marked with same symbol at same section to the opposing party, and the omission explanation.

Male 90 is formed by conductive part 99 and with injection moulding portion 100 that this conductive part 99 forms one.Conductive part 99 forms one by the plate-like portion 99a of the rectangle of growing crosswise that links with described link piece 89 and side band part 99b, the 99b that forwards stretches out from the both sides up and down of this plate-like portion 99a.In addition, the substantial middle portion at plate-like portion 99a point forms aperture 99c.

The synthetic resin that injection moulding portion 100 usefulness are identical with the material resin of described housing main body 74 is made, and forms one beyond side band part 99b, the 99b with stretching out on the plate-like portion 99a of conductive part 99 to be provided with, and its thickness roughly width with side band part 99b, 99b is identical.And this injection moulding portion 100 is provided with the point 100a that more stretches out than the tip of plate-like portion 99a, the front and back of this point 100a and up and down 4 faces are bevelleds, along with to the stretching out of tip, width and thickness diminish gradually up and down.And, on injection moulding portion 100 and the cooresponding position of described aperture 99c, form than the big slightly aperture 100b of this aperture 99c bore.In addition, such injection moulding portion 100 is shaped by inserting shaping with in the housing main body 74 formation one at contact element 75.

Then, this contact element 75 is shaped by so-called insertion and forms one with described housing main body 74, its reflecting part 87 exposes from the front of the substantial middle portion of housing main body 74, promptly, central portion 93 is positioned at the front of central portion of tabular surface 83a left and right directions of the recess 83 of housing main body 74, the front of the rake 83b of rake 94,94 ' be positioned at recess 83, the central portion of 83b ' left and right directions, bulb socket 88 is positioned at the left part of the tabular surface 83a of recess 83, faces the wall and meditates in 85 in the left side that the point of burying sheet 98 underground is embedded in housing main body 74.In addition, male 90,90 ' be positioned at recess 84,84 with the state that stretches out from the inner end of the recess 84,84 of housing main body 74 downsides.Also has link piece 89,89 ' the become state that is embedded in the housing main body 74.And in the front of housing main body 74 formation shallow recess 101, the reflecting part 87 of contact element 75 and the base portion 95 of bulb socket 88 are positioned at this shallow recess 101.

Contact element 76 forms one by bulb socket 102, terminal plate 103 and joint fastener 104 that this bulb socket 102 is engaged with terminal plate 103.

Bulb socket 102 is made up of the holding piece 106,106 that base portion 105 and both sides up and down from this base portion 105 erect, and forms the card-tight part 107,107 of bending near each other in the position of the close front end of holding piece 106,106.In addition, stretch out to be provided with in the left side edge of base portion 105 and bury sheet 108 underground.

Joint fastener 104 is banded in a narrow margin sheets of extending of direction up and down, and the base portion right side edge of its bottom and bulb socket 102 connects as one.And about 1/3rd part 104a of joint fastener 104 lower ends are rakes of displacement backward along with extending downwards.

Terminal plate 103 is banded sheets of direction extension to the left and right, and its Width is along fore-and-aft direction, and the upper limb of the lagging dege of its right part and described joint fastener 104 connects as one.

Such contact element 76, its bulb socket 102 is positioned at the front, right part of the tabular surface 83a of housing main body 74, and its base portion 105 is positioned at the shallow recess 109 of 83a right part, par.And, to bury sheet 108 underground and be embedded in the 83a of par, joint fastener 104 is embedded in the right side and faces the wall and meditates in 85.In addition, terminal plate 103 stretches out to left from the end position on the upper side of the projection 110 that is connected as a single entity with right part above the housing main body 74 and stretches out upward.The position that left and right directions central authorities on housing main body 74 take back is provided with the projection of protruding upward 111, the upper end of this projection 111 is to the right-hand crank-like of stretching out into, and forming 2 cascaded surface 112a, 112b towards the below, the cascaded surface 112a of the left part of described terminal plate 103 and upside makes Elastic Contact.

Contact element 77 is by an integral body that forms with the lower part, that is, comprise from the front see the central plate 113 that slightly becomes the character cut in bas-relief shape, from about be arranged at intervals at the lower edge of this central plate 113 and the rear end of the joint fastener 114,114 that rearward stretches out to left or right-hand male of stretching out 115,115 ', and through engaging and regards as the joint fastener 116 of anti-L word shape and the terminal plate 117 of binding from the front with the upper end, right part of central plate 113.

Male 115,115 ' with described male 90,90 ' the same, form with injection moulding portion 100 by conductive part 99.

In addition, terminal plate 117 is banded sheets of direction extension to the left and right, and its Width is along fore-and-aft direction, and the upper limb of the lagging dege of its right part and described joint fastener 116 is connected as a single entity.

The male 115,115 of such contact element 77 ' be positioned at recess 84,84 with the state that stretches out from the inner end of housing main body 74 upside recesses 84,84, terminal plate 117 stretches out to left from the low slightly position, position of stretching out than described protruding 110 the above terminal plate 103, and the downside cascaded surface 112b of the projection 111 in its point and left side makes Elastic Contact.And the remainder of contact element 77 is embedded in the housing main body 74.

Strengthen sheet 78,79 and be respectively discoideus, their central portion forms through hole 118,118.And, strengthening the substantial middle portion that sheet 78 is embedded in the upside platform 80 of housing main body 74, its part near central authorities is exposed from the through hole 81 that this platform 80 forms.Strengthen the downside platform 80 that sheet 79 is embedded in housing main body 74 ' substantial middle portion, its near the part of central authorities from the through hole 81 of this platform 80 ' formation ' expose.

The 119th, vanity mirror, the 120th, its shell, shell 120 usefulness synthetic resin are made, and are seen as the oblong of growing crosswise from the front.

That the left part of shell 120 forms is vertically rectangular, set the recess 121 that illuminating lamp is used, the major part on these recess 121 right sides formed grow crosswise rectangular, set the opening 122 that mirror is used.

The front end that sets the opening 122 that mirror uses formed inwardly stretch out compress frame 123, and protrude to be provided with in the position at the right two ends that keep left of downside medial surface and compress projection 124,124.This compresses projection 124,124 and described compressing left the cooresponding interval of mirror thickness that will address with the back between the frame 123.

In addition, formed mirror engagement section 125,125 in the position at the right two ends that keep left of the upside medial surface that sets the opening 122 that mirror uses.This mirror engagement section 125 is the thin-walled spring portion 126 that linked by the upside medial surface that slightly becomes character cut in bas-relief shape and its both ends and opening 122 and the snap fit tabs 127 formed integral body protruded downwards from the central portion of the bottom surface left and right directions of this thin-walled spring portion 126, and the bottom surface 127a of this snap fit tabs 127 forms along with forwards extension and the dip plane of displacement upward.

The 128th, mirror is the oblong of growing crosswise that sets the opening 122 little circles that mirror uses than described.In addition, the thickness of this mirror 128 is bigger than the front end of the thin-walled spring portion 126 of described mirror engagement section 125 and the interval that compresses between the back of frame 123.Therefore, mirror 128 inserted lower edge with its lower edge heeling condition slightly forward from the rear side of shell 120 compress projection 124,124 and compress between the frame 123, make the central portion deflection upward of thin-walled spring portion 126,126, and the upper limb that makes mirror 128 moves forwards and is close to the back that compresses frame 123.And in case the power release that makes 126,126 deflections of thin-walled spring portion, this thin-walled spring portion 126,126 just tries hard to restore to the original state, and bottom surface 127a, the 127a of snap fit tabs 127,127 and the upper limb of mirror 128 are made Elastic Contact.Because bottom surface 127a, the 127a of this snap fit tabs 127,127 along with forwards extension and upward displacement tilt, so by described Elastic Contact, the upper limb of mirror 128 just has been applied in the power that forwards moves, and the state of just making Elastic Contact with the leading edge of mirror 128 peripheries and the trailing flank that compresses frame 123 is loaded in the shell 120 thus.

The back side and the 4 periderm shell walls that set the recess 121 that illuminating lamp uses surround, forwards opening.

The illuminating lamp shell 73 that described vanity mirror is used is loaded on and sets in the recess 121 that illuminating lamp uses.Part except the upper side wall left part that sets the recess 121 that illuminating lamp uses has formed the long through hole 129 of left and right directions, the projection 110 and 111 that this through hole 129 is located at illuminating lamp shell 73 upper ends connects, and should projection 110 and 111 protrude to the top of recess 121.Set in addition on the lower wall of the recess 121 that illuminating lamp uses and formed engaging calvus 130,130, under this engaging calvus 130,130 and the housing main body 74 that is formed at described illuminating lamp shell 73 sidewall engage otch 131,131 engagings, illuminating lamp shell 73 is remained on set in the recess 121 that illuminating lamp uses therefrom.

132, the 132nd, be formed at the exposed hole that sets on recess 121 right side walls that illuminating lamp uses with right side recess 84, the 84 cooresponding positions of illuminating lamp shell 73, the male 90 of illuminating lamp shell 73 ', 115 ' from this exposed hole 132,132 to exposing outside.In addition, when setting recess 121 that illuminating lamp uses and be in the right side of shell 120, form exposed hole 132,132 at this left side wall that sets the recess 121 that illuminating lamp uses, the male 90,115 in left side is exposed from this exposed hole 132,132.And illuminating lamp shell 73 why set up left side and 2 groups of male in right side 90,115 and 90 ', 115 ', as the above, be left side or the right side that illuminating lamp portion is in vanity mirror for no matter, all can deal with a kind of illuminating lamp shell 73.

As mentioned above, on illuminating lamp shell 73, pair of right and left male 90,115 and 90 ', 115 ' be positioned at recess 84,84 ... in, and these recesses 84,84 ... the position to the assembling of housing main body 74 with screw through hole 81,81 ' and fluorescent tube do not install and hinder.So not only can effectively utilize the space, also because these male 90,115,90 ', 115 ' not stretch out from the side of housing main body 74, be convenient to and set the recess 121 that illuminating lamp uses and assemble.More because a pair of male 90,115 and 90 ', 115 ' be that branch is opened in upside and the downside that fluorescent tube sets portion, so can with the roughly the same scope of fluorescent tube thickness in set, help realizing slimming.

As mentioned above, illuminating lamp shell 73 forms respectively with the shell 120 of vanity mirror 119, this illuminating lamp shell 73 is being fixed in when setting in the recess 121 that illuminating lamp uses, for example available white is as the color of the material resin of the housing main body 74 of illuminating lamp shell 73, can make the illumination of illuminating lamp brighter like this, perhaps available more heat-resisting material is as this material resin.

133,133 ' be the cloudy terminal of being located on the anti-dazzle device of adorning vanity mirror 119 not shown in the figures, by lead 134,134 ' and engage with power supply unit respectively.

Cloudy terminal 133 and 133 ' structure identical, so elaborate to 133,133 ' then same sections on 133 are marked with same symbol, and omit its explanation.

The integral body that cloudy terminal 133 is formed, also formed by the conductive metal plate by insertion section 135 and lead junction surface 136.Insertion section 135 roughly becomes the square tube shape, and the front panel of this insertion section 135 engages with lead junction surface 136.

The front end edge genesis of 135 front panel from the insertion section, the direction at elastic contact chip 137 guiding line junction surfaces 136 is folding, this elastic contact chip 137 regards 2 forked as from fore-and-aft direction, free end every 2 finger-like sheet 137a, 137a separating is bonded sheet 137b binding between the upper and lower, from above-below direction, form the chevron of top flat.And, forming forging convex strip portions 138,138 on the backplate of insertion section 135 with on the finger-like sheet 137a of described elastic contact chip 137, the cooresponding position of 137a towards this finger-like sheet 137a, 137a.

The 139th, and snap-latch piece described finger-like sheet 137a, 137a between rearward folding from the central portion of the front edge of the front panel of insertion section 135, it along with gradually away from the most advanced and sophisticated edge of front panel backward the direction displacement of panel tilt, near the free end the top that is positioned at described elastic contact chip 137 has formed the forging shape engaging pawl 140 that the direction of panel is backward stretched out.And formed through hole 141 engaging on the pawl 140 cooresponding positions with insertion section 135 rear panels described.

Then, described cloudy terminal 133,133 ' insert in the recess 84,84 of illuminating lamp shells 73 from described exposed hole 132,132, thus insertion section 135,135 in insertion male 90 ', 115 '.Be inserted into male 90 in the insertion section 135,135 ', 115 ' limit be formed at convex strip portions 138,138 on the rear panel ... and between finger-like sheet 137a, the 137a their interval is enlarged, insert on the limit, engages with aperture 100b, the 100b of injection moulding portion 100,100 up to the engaging pawl 140,140 of snap-latch piece 139,139.By engaging of engaging pawl 140,140 and aperture 100b, 100b, can prevent male 90 ', 115 ' and cloudy terminal 133,133 ' come off, and cloudy terminal 133,133 ' convex strip portions 138,138 and male 90 ', 115 ' plate-like portion 99a, the 99a of conductive part 99,99 make Elastic Contact.Also have, male 90 ', 115 ' inserted the insertion section at 135,135 o'clock, because of male 90 ', 115 ' front and back 4 face tilts up and down of point 100a, 100a, along with the extension to its tip, width and less thick up and down are so this insertion is carried out easily.

As mentioned above, in case male 90 ', 115 ' with cloudy terminal 133,133 ' engaging, because engaging pawl 140,140 with aperture 100b, the engaging of 100b just is not easy they are separated, but since on the described rear panel that sets the recess 121 that illuminating lamp uses with male 90 ', 115 ' conductive part 99,99 aperture 99c, the cooresponding position of 99c has formed through hole 142,142, as shown in figure 37, insert the instrument 143 of taper from this through hole 142, this instrument 143 just passes the through hole 141 on cloudy terminal 133 (or the 133 ') rear panel successively, the aperture 99c of male 90 ' (or 115 '), 100b, its tip is near engaging pawl 140, further push away forward again, this engaging pawl 140 is withdrawed from from aperture 100b, be pulled outwardly at following cloudy terminal 133 of such state (or 133 '), just be easy to cloudy terminal 133 (or 133 ') is taken off from male 90 ' (or 115 ').

As mentioned above, male 90,90 ', 115,115 ' why form with conductive part 99 and injection moulding portion 100, be because to carry out with cloudy terminal 133,133 ' engage the thickness that needs to a certain degree.Promptly, the thickness of slab of the metallic material that formation contact element 75 etc. are used is thinner, as intactly being used for and cloudy terminal 133,133 ' engage, just can't obtain sufficient contact pressure, so will obtain necessary thickness of slab by method injection moulding portion 100 and conductive part 99 stacks.And this injection moulding portion 100 can be shaped simultaneously inserting when being shaped, thus to cost without any influence.In addition, in described example, there is not the metal part at point 100a, self-evident, in order to strengthen the intensity of this point 100a, prevent to lose, also can extend to point 100a to the plate-like portion 99a of conductive part 99.

In addition, except 2 layers of structure that adopt conductive part and injection moulding portion, also can be as male shown in Figure 27 144, with conductive material form comprise tabular principal part 145 and be connected with the lateral edges of this principal part 145, width half a integral body of assisted parts 146,146 of principal part 145 slightly, and this assisted parts 146,146 also can be overlapped on the principal part 145.The 147th, the connecting hole of slip-off preventing.Male 148 that can also be as shown in figure 28 is such, inserts on cloudy terminals 133 or 133 ' time and its finger-like sheet 137a, 137a and convex strip portions 138, the 138 cooresponding positions at the tabular principal part of being made up of conductive material 149 and forms raised line 150,150.In addition, the 151st, the connecting hole of slip-off preventing.

Set on recess 121 back face wall that illuminating lamp uses through hole 81,81 ' cooresponding position with illuminating lamp shell 73 formed through hole 152,152 '.Make mounting screw not shown in the figures pass through hole 81,81 ', 118,118 and 151,152 ', combine with the framing member screw thread of anti-dazzle device not shown in the figures, promptly become vanity mirror 119 be installed on a kind of method on the anti-dazzle device.As mentioned above, by forming mounting hole used when being installed on the anti-dazzle device to vanity mirror 119, prevent the distortion or the scar that cause when mounting screw is fastening thus with being independent of metal sheet outside the contact element 75,76,77.In addition, owing to its intensity is better than partly forming through hole in the material resin of housing main body 74, so can realize the thin typeization of this part.

Then, the lamp holder 41,41 of fluorescent tube 42 is used holding piece 106,106 clampings of the holding piece 96,96 and the bulb socket 102 of bulb socket 88 respectively, be equipped in the illuminating lamp shell 73, and, constitute illuminating lamp 153 with the front openings of topped this illuminating lamp shell 73 of lens not shown in the figures.

154, the 154th, protrude the fluorescent tube backing block on the side walls 85,85 that is arranged at housing main body 74 respectively, their the position middle position with 106,106 of the holding pieces of the middle position of 96,96 of the holding pieces of bulb socket 88 and bulb socket 102 respectively is corresponding, and contact or approaching unnecessary the moving that is used for stoping fluorescent tube 42 with the end face of the lamp holder 41,41 of described fluorescent tube 42 to prevent the generation of accident such as short circuit.

The 155th, be used for topped described shell 120 fwd lids, be to make with synthetic resin, slightly become tabular, its upper end rotation is bearing in the upper end of shell 120 freely.

The end, the left and right sides of the upper end of lid 155 has formed the portion of being supported 156,156, and this is supported the through hole 157,157 that forms direction perforation to the left and right in the portion 156,156.And, be applied protruding 158,158 what this upper end, back formation that is supported portion 156,156 was rearward protruded.In addition, this is supported the inboard of portion 156,156,, is supported the right side of portion 156 in the left side and the right side is supported portion 156 that the left side adjacent forms recess 159,159 that is.And from left side recess 159 slightly to the right position spaced form rearward protrude compress projection 160.

Form the recess 161,161 of front openings at the both ends, the left and right sides of described shell 120 upper ends, on the position of the left and right sides that clips this recess 161,161, form mounting hole 162,162 that direction to the left and right extends ...

The aft bulkhead of described recess 161,161 all is removed except its bottom 163,163, and the rearward end of upper wall also is removed.Form the shallow recess 164,164 that direction is up and down extended in continuous position, the rearward end bottom surface of the back of shell 120 and described recess 161,161, protrude at the upper end of this shallow recess 164,164 central part and be provided with engaging pawl 165,165.

The portion that is supported 156,156 of lid 155 is positioned at the recess 161,161 of shell 120, run through its through hole 157,157 rest pin 166,166 both ends by the mounting hole 162,162 that forms in the both sides of recess 161,161 ... supporting, thus, the left and right sides portion of lid 155 upper ends is rotatably freely supported on the upper end of shell 120.

167, the 167th, state keeps spring, make with the leaf spring material, comprise band plate-like principal part 168,168 that direction is up and down extended and from the upper end of this principal part 168,168 service portion 169,169 of direction folded beneath in the past, form connecting hole 170,170 at the central part of the roughly centre portion of principal part 168,168 above-below directions.

Described state keeps spring 167,167 before lid 155 is installed, its principal part 168,168 is positioned at shallow recess 164,164 by the front side of the back face wall bottom 163,163 of recess 161,161, engages pawl 165,165 engagings in its connecting hole 170,170 and the recess 164,164.Under this state, as mentioned above, in case lid 155 is supported on the shell 120, then the projection 158,158 that is applied of lid 155 just keeps the service portion 169,169 of spring 167,167 to make Elastic Contact from front side and state.Thereby, state keeps the end parts on the upper side of the principal part 168,168 of spring 167,167 to be pushed to the front of the back face wall bottom 163,163 of recess 161,161, its on the lower side side part then be pushed to shallow recess 164,164, and, prevent to come off from shell 120 by of the engaging that engages pawl 165,165 of its connecting hole 170,170 with shallow recess 164,164.Thereby it is very simple that state keeps the maintenance structure at shell 120 of spring 167,167.

Closed condition when Figure 40 is expression lid 155 topped shells 120 fronts, under this closed condition, the projection 158,158 that is applied of lid 155 is made Elastic Contact in the location on the upper side as the dead aft of the through hole 157,157 of pivot point with the service portion 169,169 of state maintenance spring 167,167, thus, lid 155 promptly has been applied in to the direction of keeping described closed condition, the i.e. rotational force of the anti-clockwise rotation in Figure 40, and maintenance closed condition.Figure 41 then is that expression lid 155 is the open state of opening previously of shell 120, under this open state, the projection 158,158 that is applied of lid 155 is made Elastic Contact in the location on the lower side as the dead aft of the through hole 157,157 of pivot point with the service portion 169,169 of state maintenance spring 167,167, thus, lid 155 promptly has been applied in to the direction of keeping described open state, i.e. right handed rotational force in Figure 41, and maintenance open state.

In addition, when lid 155 is in closed condition, it compresses projection 160 and is in position in the face of the top of the terminal plate 103 of illuminating lamp shell 73, in case and lid 155 becomes open state, then as shown in figure 38, this compresses projection 160 and just pushes terminal plate 103, makes its deflection downwards, and the point of terminal plate 103 is contacted with the point of terminal plate 117.Thus, just form power supply-a side's cloudy terminal 133-male 115 '-joint fastener 114-central plate 113-joint fastener 116-terminal plate 117-terminal plate 103-joint fastener 104-bulb socket 102-fluorescent tube 42-bulb socket 88-reflecting part 87-link piece 89 '-male 90 '-the opposing party's cloudy terminal 133 '-loop of power supply, fluorescent tube 42 bright lamps.

In case fluorescent tube 42 bright lamps, its light directive the place ahead, and the rear side of fluorescent tube 42 has bigger reflecting part 87, the light that this reflecting part 87 can make fluorescent tube 42 is directive the place ahead more effectively.Particularly, formed on this reflecting part 87 rake 94,94 ', so the light that should be upward penetrates with the below is forwards reflected.In addition, this reflecting part 87 also has the function of the cleading that the heat that bright lamp produced of housing main body 74 and fluorescent tube 42 is separated, even also has the light that prevents fluorescent tube 42 function to the anti-dazzle device of the rear of housing main body 74 transmission.

171, the 171st, the buffering hill holder is made with rubber, forms an integral body by contact part 172,172 that becomes steamed bun shape and the installation foot 173,173 that rearward stretches out from the back of this contact part 172,172.Foot 173,173 is installed along with to the back-end extension and diameter is tapered, the slot part 174,174 of formation ring-type between foot 173,173 and the contact part 172,172 is installed at this.

175, the 175th, the mounting hole that on the position of the right both sides that keep left of shell 120 bottoms, forms, the installation foot 173,173 of described buffering hill holder 171,171 runs through this mounting hole 175,175 from the front side.Because of diameter that foot 173,173 leading sections are installed bore greater than described mounting hole 175,175, so the rearward end of the installation foot of extracting backward from mounting hole 175,175 173,173 is continued firmly to pull back, the limit makes its leading section distortion, the limit makes installation foot 173,173 pass mounting hole 175,175, until its leading section of arrival, and groove 174,174 is engaged with the edge of opening of mounting hole 175,175.So, buffering hill holder 171,171 just is installed on the shell 120, and then the rearward end excision that foot 173,173 is installed, to reduce rearward overhang.

So, when wanting close cap 155, in case the rotation of lid 155 has surpassed certain position, because state keeps spring 167,167 to have applied the power of rotating to off position for lid 155, so lid 155 can collide shell 120 more fiercely and send ear-piercing sound, but on described vanity mirror 119, because the bottom of lid 155 contacts with the contact part 172,172 of buffering hill holder 171,171, be subjected to buffering, so prevented the generation of harshness.

The manufacture method of described vanity mirror with illuminating lamp shell 73 below is described.

At first, form by 75,76,77 and 2 of 3 contact elements and strengthen contact element group that sheet 78,79 forms by the many groups of contact element group continuuies that are formed by connecting.

Figure 42 represents 1 contact element group 176.

177,177 ' be the band plate-like base band that separates each other, extends in parallel, 178,178 ... (only illustrating 2 among the figure) be along base band 177,177 ' bearing of trend separate set, base band 177 and 177 ' between the tabular spacing frame band of faciola that linked, formed 1 contact element group 176 by the part of 2 spacing frame bands 178,178 and base band 177,177 ' surrounded.

The 179th, from spacing frame band 178 right side edge by the position of base band 177 to the tabular related portion of the right-hand faciola that stretches out, this right-hand member of related 179 links with the left end that strengthens sheet 78, is then linking the left part of the central plate 113 of contact element 77 at midway location.

The 180th, from spacing frame band 178 left side edge by the position of base band 177 to the tabular related portion of faciola that left stretches out, this left end of related 180 leans on the position of upper end to be connected with the right part of the central plate 113 of contact element 77, and pars intermedia is connected with the part of the upper middle end of the joint fastener 104 of contact element 76.

The 181st, from spacing frame band 178 right side edge by base band 177 ' the position to the tabular related portion of the right-hand faciola that stretches out, its right-hand member is connected with the left end of the enhancing portion 92 of contact element 75.

The 182nd, from spacing frame band 178 left side edge by base band 177 ' the position to the tabular related portion of faciola that left stretches out, its left end links with the right-hand member that strengthens sheet 79, is linking the right-hand member of the enhancing portion 92 of contact element 75 in position intermediate roughly.

Such contact element group 176 along base band 177,177 ' a plurality of connections of bearing of trend, just form contact element group continuum 183 (omit diagram).

In addition, what show among the figure is each contact element 75,76,77 and strengthens state after sheet 78,79 has passed through press forming, identical with described the 1st embodiment, at first be by drawing, form the original shape contact element group continuum that a plurality of original shape contact element groups are formed by connecting, pass through press forming then, form graphic contact element group continuum 183.Also have, 184,184 ... be base band 177,177 ' last formed guide hole, locate with them during press forming.

The contact element group 176,176 on the described contact element group continuum 183 ... in an insertion have the housing main body that housing main body is shaped with the shaping machine of forming die and be shaped with in the forming die, the resin that housing main body is used is injected this housing main body shaping with in the forming die, form 176 one-tenth one single-piece illuminating lamp shell 73 of resinous housing main body 74 and contact element group.And, the formation of illuminating lamp shell 73 press each contact element group 176,176 on the contact element group continuum 183 ... order carry out successively, form the illuminating lamp shell continuum that a plurality of illuminating lamp shells 73 are formed by connecting (omitting diagram) therefrom.

Then, from described illuminating lamp shell continuum each illuminating lamp shell 73,73 ... separate, form a plurality of illuminating lamp shells 73,73 ...Illuminating lamp shell 73,73 ... be separated in each related 179,180,181,182 usefulness 185,185 ... carry out at the position that marks.In addition, this place of incision 185,185 ... be positioned at the side walls 85,85 of housing main body 74 concave part 86,86 ... therefore separate easily interior position along its inner face, and cut off to hold and can not stretch out from the side of housing main body 74.

When carrying out described separation, related 179,180,182 is cut off at the position that marks with 186a, 186a, 186b, contact element 75 with strengthen sheet 79, contact element 76 and 77, so that contact element 77 with strengthen sheet 78 and separate each other respectively.And when carrying out described cut-out, form described punching hole 82,82,82.

Above-mentioned structure adopts the power supply mode of terminal and lead, but only otherwise a position that marks with 186a, 186a is cut off, then same with described the 1st embodiment, also available screw clamp with electric conductivity is powered through strengthening sheet 78,79 and implementing.

Figure 43 to Figure 45 is the variation 73A of the illuminating lamp shell among described the 2nd embodiment.

On described illuminating lamp shell 73, form side and two sides, front and back opening recess 84,84 ... male 90,90 ', 115,115 ' from this recess 84,84 ... the inner stretch out, this illuminating lamp shell 73A then be the recess 187,187 that forms side and back opening ..., male from this recess 187,187 ... inner face stretch out.Like this, when the place ahead is seen, outside male is not exposed to, seem attractive in appearance.

About male, can adopt the style of guaranteeing required thickness of slab with method for folding, promptly male 144,144 as shown in figure 27 ...Self-evident, also can adopt the male of the sort of style of using among the 1st embodiment or the male 148 of the sort of style shown in Figure 28.

The part 188 of the joint fastener 104A of contact element 76A is embedded in the part than recess 187 front sides of side walls 85A, forms コ word shape, and lateral buckling forward.

The reflecting part 87A of contact element 75A forms flat large rectangle, stretch out from the lower edge mediad of this reflecting part 87A below and to be provided with link piece 189, forwards stretch out to be provided with from the both sides of this link piece 189 and erect sheet 190,190, be provided with described male 144,144 to left and right-hand stretching out respectively from this front edge that erects sheet 190,190.

Contact element 77A be provided with forwards stretch out from the edge, the left and right sides, bottom of the central plate 113A of perpendicular microscler shape erect sheet 191,191, be provided with described male 144,144 to left and right-hand protrusion respectively from this front edge that erects sheet 191,191.

Figure 46 to Figure 63 is of the present invention and the synthetic resin members of hard ware formation one reaches and the 3rd embodiment of the manufacture method of the synthetic resin members of hard ware formation one, is shell and the manufacture method thereof that the present invention is used for indoor illumination.

The 192nd, indoor illumination, the 193rd, its housing main body.

Housing main body 193 usefulness synthetic resin are made, and comprise a shallow punishment shape principal part 195 with recess 194 of front openings.

Central portion at the left and right directions of the part except the upper end of principal part 195 has formed more shallow recess 196, has formed the perpendicular long opening 197 of displacement slightly downwards at this recess 196.

The upper end 194a of recess 194 is darker slightly than remainder.And at the partition wall 198,198 that the central portion of the boundary member between this upper end 194a and the remainder is upright to be separated about being provided with.

Protrusion is provided with engaging pawl 199,199 on described partition wall 198,198.And, the connecting hole 201,201 that has separated about the inboard of the following portion of wall 200 has formed around recess 194 is surrounded.

Between described partition wall 198 and 198, formed the mounting hole 202 that connects before and after this place.

The lower position slightly of above-mentioned partition wall 198,198 in described recess 196 forms with described mounting hole 202 and is the center, lines up roughly circular-arc recess 203a, 203b, 203c.The edge of opening portion of this recess 203a, 203b, 203c forms convex surface.

Along recess 196 lateral edges positions by the upper end and by 4 positions of lower end formed through hole 204,204 ...This through hole 204,204 ... leading section 204a, 204a ... diameter be remainder 204b, 204b ... about 2 times.

And, be provided with strengthening rib 205 protruding along the substantial middle portion of the lower edge position of recess 196.

Wall 206a, 206b have rearward been formed from the upper limb of described opening 197 and the both ends up and down of lower edge and lateral edges.

Substantial middle portion in the cooresponding position of upper limb of principal part 195 back and described recess 196 forms the abutment wall 207 of rearward stretching out, partition wall 208,208 stretches out above the two ends, the close left and right sides of this abutment wall 207 upward, strengthens 209,209 middle positions that lean on from abutment wall 207 below of wall and stretching out downwards.

210 is the 1st contact elements, tabular by faciola, from the front see the joint fastener 211 that roughly becomes anti-C word shape, the tube clamping sheet 212 that engages with the bottom of described joint fastener 211, through about short link piece 213,213 arranged side by side and an integral body being formed with contact portion 214b, the 214c of the last dististyle binding of described joint fastener 211.

Described tube clamping sheet 212 is by seeing that from the side fluorescent tube maintaining part 215 that slightly becomes V word shape and the rectangular plate shape substrate 216 that engages with the lower end of this fluorescent tube maintaining part 215 form one, the position of substrate 216 is near the bottom rear side of described joint fastener 211, and the left-hand end of the bottom of the bottom of its left side edge and joint fastener 211 links.In addition, the sheet 215a with near the opposite opposite side of a side of substrate 216 of described fluorescent tube maintaining part 215 becomes the fluorescent tube contact disk, at the formation porcelain vasiform orifice 215b of substantial middle portion of this fluorescent tube contact disk 215a.

The central portion of the left and right directions of the described contact 214b of portion, 214c forwards becomes convex curvature.

And, on joint fastener 211, form a plurality of apertures 217,217 ...

Described the 1st contact element 210 is shaped by so-called insertion and described housing main body 193 forms one, the substrate 216 of its tube clamping sheet 212 is embedded in the bottom central authorities of the principal part 195 of housing main body 193,215 one-tenth states that protrude to the upside of wall 206b of fluorescent tube maintaining part.In addition, joint fastener 211 exposes from the front of recess 196, the fwd position of the 214b of contact portion part between topped recess 203a and 203b, the fwd position of the 214c of contact portion part between topped recess 203b and 203c.And, the aperture 217,217 of joint fastener 211 ... in filled up the resin material of housing main body 193, like this, joint fastener 211 just is not easy to break away from housing main body 193.

The 2nd contact element 218, tabular by faciola, see the joint fastener 219 that roughly becomes anti-コ word shape, an integral body of being formed with the lower end bonded assembly tube clamping sheet 220 of described joint fastener 219, with the upper end bonded assembly terminal plate 221 of described joint fastener 219 from the front.

Tube clamping sheet 220 is formed by seeing that from the front substrate 222 that roughly becomes rectangle reaches with the lower edge bonded assembly fluorescent tube contact disk 223 of this substrate 222, the leading section 223a of fluorescent tube contact disk 223 is forwards convexly curved, at the central portion formation porcelain vasiform orifice 223c of the main leaf 223b that rearward protrudes from the lower edge of this leading section 223a.

Terminal plate 221 is by seeing that from the side link piece 224 that roughly becomes L word shape and the insertion sheet 225 that stretches out upward from the rear end of this link piece 224 form an integral body, and the front end of link piece 224 is connected with the upper end of described joint fastener 219.

Form 2 apertures 217 on the joint fastener 219.

Described the 2nd contact element 218, except the bottom of the substrate 222 of tube clamping sheet 220, all be embedded in central portion near the upper marginal position of the opening 197 of the principal part 195 of housing main body 193, then stretch out downwards from the upside edge of opening of opening 197 its bottom, and fluorescent tube contact disk 223 rearward stretches out from its lower end.Thus, 2 fluorescent tube contact disks 223,215a just in opening 197 formation separate opposed state up and down.

The link piece 224 of terminal plate 221 is embedded in the abutment wall 207 of housing main body 193, inserts sheet 225 and stretches out upward above abutment wall 207.

And joint fastener 219 exposes from the left part of recess 196 upper ends, the material resin of having filled up housing main body 193 in its aperture 217,217, and like this, joint fastener 211 just is not easy to break away from housing main body 193.

The 3rd contact element 226 forms one by joint fastener 227 and 214d of contact portion and terminal plate 228.

The faciola of 227 one-tenth direction extensions to the left and right of joint fastener is tabular, forms aperture 217 in substantial middle portion.

The right-hand member of the 214d of contact portion is the convex curvature of displacement rearward, and its left part upper limb is connected with through the lower edge of link piece 229 with the end of taking back of joint fastener 227.

Terminal plate 228 is by seeing that from the side link piece 230 that roughly becomes く word shape and the insertion sheet 231 that extends upward from the upper end of this link piece 230 form one, and the bottom front edge of link piece 230 and the right-hand member edge of described joint fastener 227 fuse.

The link piece 230 of the terminal plate 228 of the 3rd contact element 226 is embedded in the enhancing wall 209 of housing main body 193, inserts the position spaced of stretching out to the right of the described insertion sheet 225 of sheet 231 above abutment wall 207 and stretches out upward.The 214d of contact portion is positioned at the position of left side edge of opening portion of the recess 203c of topped housing main body 193, and its link piece 229 and joint fastener 227 expose from the front of housing main body 193.And the material resin of having filled up housing main body 193 in the aperture 217 of joint fastener 227 is so joint fastener 211 is not easy to break away from housing main body 193.

The 4th contact element 232 be tabular and front shape slightly becomes U word shape by faciola joint fastener 233, with the upper right end bonded assembly contact 214a of portion of this joint fastener 233, from the part by the part of upper end and the left and right sides of the left and right sides of joint fastener 233 by the lower end protruding and through link piece 234,234 ... and the ground lug 235,235 that is connected with ... and the formation one.And, this link piece 234,234 ... on formed rising portions 234a, 234a ... thereby, joint fastener 233 and ground lug 235,235 ... between formed ladder.

Ground lug 235,235 ... be have through hole 235a, 235a ... annular, the left end of the 214a of contact portion is the convex curvature of displacement rearward, the upper end on joint fastener 233 right sides forms aperture 217,217, in addition, protrude to be provided with and bury sheet 236,236,236 underground at the left hand edge place of the left side sheet of joint fastener 233.

The joint fastener 233 of the 4th contact element 232, part except that the both ends up and down of its right side sheet all is embedded in the right wall of shallow recess 196 of housing main body 193, remainder is positioned at along the position of this recess 196 edges, and it buries the left wall that sheet 236,236,236 is embedded in recess 196 underground.In addition, filled up the material resin of housing main body 193 in the aperture 217,217, like this, joint fastener 211 just is difficult for breaking away from housing main body 193.

The 214a of contact portion is positioned at the position of right openings edge part of the recess 203a of topped housing main body 193, ground lug 235,235 ... be positioned at housing main body 193 through hole 204,204 ... large- diameter portion 204a, 204a ... the front, its surrounding edge is embedded in the housing main body 193, and, through hole 235a, 235a ... with through hole 204,204 ... minor diameter 204b, 204b, unanimity.

The 237th, switch knob.

This switch knob 237 is formed with the tab portion 239 that this injection moulding portion 238 becomes one by the injection moulding portion 238 that forms with synthetic resin and by inserting shaping.

Protrude from the front, upper end of the principal part that is thick plate-like 240 of injection moulding portion 238 and to be provided with grip part 241, the mounting hole 242 that before and after principal part 240 forms by the position of lower end, connects.

Tab portion 239 usefulness have electric conductivity and elastomeric material is made, and are long up and down band plate-like, see from above-below direction in its bottom formation to be the circular-arc contact part 243 that rearward protrudes.In addition, the roughly position intermediate at the above-below direction of tab portion 239 forms through hole 244.

The part except its bottom of tab portion 239 is inserted into grip part 241 from the lower end of the principal part 240 of injection moulding portion 238, and remainder is the state that stretches out from the lower ends downward side of injection moulding portion 238.And the through hole 244 of tab portion 239 is consistent with the mounting hole 242 of injection moulding portion 238.

The 245th, rivet is installed, have head 245a and foot 245b, this foot 245b is from the mounting hole 242 of the place ahead penetrating switch knob 237, and then run through the mounting hole 202 of described housing main body 193, with the point riveted joint that inner face from housing main body 193 stretches out, switch knob 237 is rotated be installed on freely on the housing main body 193.In addition, under such state, the circular-arc part that the contact part 243 of tab portion 239 can be lined up at the 214a of contact portion, 214b, 214c, the 214d by housing main body 193 moves.

As mentioned above, on switch knob 237, owing to the tab portion made from metal sheet 239 is crossed the mounting hole 242 that becomes rotating fulcrum and extended to grip part 241, so the bulk strength of switch knob 237 increases.

The 246th, lens, in the recess 194 of the topped described housing main body 193 of its big I from directly over the partition wall 198,198 to the part of downside.Inner face left and right sides position spaced in the upper part of four surrounding wall portion 247 of lens 246 forms snap fit tabs 248,248, the snap fit tabs 249,249 that separates about the outside of the end portion of four surrounding wall portion 247 also forms.And, the snap fit tabs 249,249 of bottom engages with the connecting hole 201,201 of the following portion inner face of wall 200 all around that is formed at housing main body 193, and the rear end inward flange of the end portion of four surrounding wall portion 247 contacted with the following of strengthening rib 205 that is formed at housing main body 193.And then, be formed at four surrounding wall portion 247 the upper part snap fit tabs 248,248 with engage pawl 199,199 engagings above the partition wall 198,198 that is formed at housing main body 193.Like this, lens 246 just are installed on the housing main body 193.

In addition, described switch knob 237 is passed in the central breach 250 that forms in upper part of four surrounding wall portion 247 of lens 246, and stretch out to the top of lens 246 its grip part 241.

251,251 ... be to be formed at the concave part that the front and back of the left and right sides lateral surface of housing main body 193 connect.

Before lens 246 are installed on housing main body 193, with the end and the porcelain vasiform orifice 215b of described fluorescent tube contact disk 215a, 223a of lamp head 253,253, the state support fluorescent tube 252 that 223c engages.

Before lens 246 are installed on housing main body 193, the mounting screw made from conductive material 254,254 ... run through from the front side through hole 204,204 ..., and combine with the framing member screw thread of car body not shown in the figures.In addition, mounting screw 254,254 ... head 254a, 254a ... with the ground lug 235,235 of the 4th contact element 232 ... contact, and be mounted screw 254,254 ... in the structure member of institute's screw thread combination at least one has electric conductivity, thus, the 4th contact element 232, promptly the 214a of contact portion becomes earth level.Also have, ground lug 235,235 ... there are 4 more than, and if 1 ground connection wherein, so can adapt to multiple different places.

In addition, described insertion sheet 225,231 engages with the adaptor union of being located at car body one side not shown in the figures.Make therefrom and insert sheet 225 and power connection, insert 231 process door switchs not shown in the figures of sheet and ground connection.That is, fluorescent tube contact disk 223 and power connection, the 214d of contact portion then passes through door switch and ground connection.

When switch knob 237 mediates, promptly is in its contact part 243 with the 214b of contact portion, 214c state of contact, lamp head 253 of fluorescent tube 252 and power connection, but because of another lamp head 253 unearthed, the lamp so fluorescent tube 252 does not work.And in case make switch knob 237 oblique to a square neck from described midway location, make its contact part 243 with the 214a of contact portion, reach 214b and contact, just ground connection of described another lamp head 253 of fluorescent tube 252 then, the bright lamp of fluorescent tube.In addition, as make switch knob 237 from as described in midway location to as described in the opposite direction of direction of tilt tilt, its contact part 243 is contacted with 214c of contact portion and 214d, then another lamp head 253 of fluorescent tube 252 passes through door switchs and ground connection, under such state (door closing state), fluorescent tube 252 lamp that do not work, but in case open door the door close switch, so 253 one-tenth ground states of another lamp head of fluorescent tube 252 then are fluorescent tube 252 bright lamps.

At this moment, because the contact surface of the contact part 243 of switch knob 237 becomes convex surface, and the 214a of contact portion, 214b, 214c, 214d also be crooked, so can make during switch knob 237 arrival assigned addresses the operator feel (so-called clatter is arranged) significantly.And switch knob 237 can remain on the appointed positions reliably, also can successfully the tilting of switch knob 237.

The following describes the manufacture method of described indoor illumination 192.

At first, how group connects the contact element group that with 4 contact elements 210,218,226,232 is a group, forms contact element group continuuies in addition.

Figure 57 is 1 contact element group 255.

Each contact element 210,218,226 made from metal sheet with electric conductivity and 232 through thin related 256,256 ... and form an integral body.

Each contact element the 210,218,226, the 232nd shown in the figure has passed through press forming, identical with described the 1st embodiment, at first pass through drawing, be formed with the original shape contact element group continuum that a plurality of original shape contact element groups form continuously, form the such contact element group 255 of diagram through press forming then.

As shown in the figure, under the state that forms contact element group 255, the tube clamping sheet 212 relative bonding sheets 211 of the 1st contact element 210 become to the folding state of rear side, and like this, its fluorescent tube contact disk 215a just forms relative configuration up and down with another fluorescent tube contact disk 223.If do not adopt such structure, but the state that when drawing, makes original shape tube clamping sheet and original shape fluorescent tube contact disk become to be arranged above and below, then 2 lower-upper length can be overlapping.So stagger about will making during punching press them mutually, when press forming,, be that tube clamping sheet 212 1 side's relative bonding sheets 211 are folded in described example wherein a side, make its fluorescent tube contact disk 215a relative up and down with fluorescent tube contact disk 223.

Because tube clamping sheet 212,220 substrate 216,222 separately is embedded in the housing main body 193, so when loading and unloading fluorescent tube 252, tube clamping sheet 212,220 can not break away from housing main body 193.

In addition, 4 ground lugs 235,235 ... be divided into 4 positions, and connect into the frame shape by joint fastener 233, thus the intensity of contact element group 255 strengthened, not yielding during assembling.

Also since ground lug 235,235 ... the link piece 234,234 that links with joint fastener 233 ... on formed rising portions 234a, 234a ... so by regulate this rising portions 234a, 234a ... bending angle, be easy to adjust ground lug 235,235 ... the position, and, this rising portions 234a, 234a ... can also absorb housing main body 193 and be shaped, prevent that contact element 232 from fatal distortion taking place with the contraction after the resin ejaculation.

More than 255 continuous (not shown) of such contact element group, form contact element group continuum 257.Such contact element group continuum 257 be by linking belt 258,258 ... adjacent contact element group 255,255 ... ground lug 235,235 ... between linked.

The contact element group 255,255 of being located at described contact element group continuum 257 ... in an insertion have the housing main body that housing main body is shaped with the shaping machine of forming die and be shaped with in the forming die, and in this housing main body is shaped with forming die, inject the housing main body resin, form the illuminating lamp shell 259 that resinous housing main body 193 and contact element group 255 become one.And, the formation of described illuminating lamp shell 259 press each contact element group 255,255 on the contact element group continuum 257 ... order carry out successively, just form the illuminating lamp shell continuum that a plurality of illuminating lamp shells 259 are formed by connecting (omitting diagram) thus.

And, in illuminating lamp shell 259, the major part of the substrate 216 of tube clamping sheet 212 and the substrate 222 of tube clamping sheet 220 is embedded in the material resin of housing main body 193, so strengthened the intensity of tube clamping sheet 212,220, the big application force in the time of can tolerating fluorescent tube 252 loading and unloading.

From described illuminating lamp shell continuum each illuminating lamp shell 259,259 ... separate, form a plurality of illuminating lamp shells 259,259 ...Illuminating lamp shell 259,259 ... be separated in each linking belt 258,258 ... last with 260,260 ... carry out at the position that marks.And this place of incision 260,260 ... be positioned at housing main body 193 lateral surfaces concave part 251,251 ... therefore separate easily interior position along its inner face, in addition, cuts off to hold and can not stretch out from the side of housing main body 193.

When doing described separation, the punching hole 261,261 of the principal part 195 of formation housing main body 193 ... because this punching hole 261,261 ... formation, link related 256,256 of each contact element 210,218,226,232 ... be cut off, become each contact element 210,218,226,232 state of independent and mutual electric insulating mutually thus.

Figure 58 to Figure 63 is switch knob and the modified example relevant with its installation on the described indoor illumination 192.

The example of Figure 58 is to stretch out to be provided with a mount pin 263, it has the grooving 262 that extends housing main body 193 front ends, this mount pin 263 is connected the mounting hole 242 of switch knob 237, and the formed snap fit tabs 264,264 of its leading section is engaged with the open front edge of mounting hole 242, switch knob 237 rotatably supports on housing main body 193.

The example of Figure 59 is with topped with the metal sheet 265,265 of housing main body 193 formation one by inserting shaping the surface of the mount pin in Figure 58 example 263.

The example of Figure 60 is that the metal sheet 266,266 that slightly becomes L word shape is formed one by inserting shaping with housing main body 193, its a part of 266a, 266a forwards stretch out with state near each other, the mounting hole 242 of this extension 266a, 266a penetrating switch knob 237, and bulge 266b, 266b that the leading section that makes extension 266a, 266a is bloated mutually round about engage with the front opening edge of mounting hole 242, thus switch knob 237 rotatably supports on housing main body 193.

The example of Figure 61 is to stretch out to be provided with the mount pin 268 that forms one with injection moulding portion 238, this mount pin 268 has the grooving 267 that extends the rear end from the back of switch knob 237, this mount pin 268 is run through the mounting hole 269 on the principal part 195 of housing main body 193, the snap fit tabs 270,270 that forms on the point of mount pin 268 is engaged with the rear openings edge of the mounting hole 269 of housing main body 193, thus, rotor switch 237 is rotatably installed on the housing main body 193.

The example of Figure 62 is to use the surface of the mount pin 268 from multiple 271,271 topped Figure 59 of portion of quilt that the edge part 244 of the through hole 244 of tab portion 239 stretches out with fusing.

The example of Figure 63 is rearward to stretch out to be provided with state near each other from the back of injection moulding portion 238 leg 272 is installed, 272, this installs leg 272,272 edge parts from the through hole 244 of tab portion 239 ground that fuses is protruding, this installs leg 272,272 run through the mounting hole 269 that forms on the principal part 195 of housing main body 193, and make this installation leg 272, the bulge 272a that 272 rearward end bloats mutually round about, 272a then engages with the open rearward end edge of mounting hole 269, thus switch knob 237 rotatably supports on housing main body 193.

By above explanation as can be known, synthetic resin members with hard ware formation one of the present invention is characterised in that, be to form a plurality of punching hole through inserting on the integrated synthetic resin system main body that forms after the shaping in the integrated hard ware group that is linked to be through connecting bridge by multiple hard ware, and at this punching hole place described connecting bridge is cut off, described a plurality of hard ware is independently formed separately.

In addition, the manufacture method that of the present invention and hard ware forms the synthetic resin members of one is characterised in that, be the integrated hard ware group that is linked to be through connecting bridge by multiple hard ware to be inserted synthetic resin system main body be shaped with in the forming die, be shaped with moulding mold-in injection synthetic resin system main body shaping resin to this synthetic resin system main body, after forming the synthetic resin members intermediate of synthetic resin system main body and hard ware group formation one, described connecting bridge is cut off, make described a plurality of hard ware independent separately, produce the synthetic resin members that forms one with hard ware thus.

Thereby, because the synthetic resin members with hard ware formation one of the present invention is to make the integrated hard ware group and the synthetic resin system main body that are formed by multiple hard ware be configured as one by inserting to be shaped, therefore need not multiple hard ware is respectively charged in the synthetic resin system main body, not only laborsavingly save time but also save cost.And, because each hard ware is packed into by inserting to be shaped, therefore can improve the assembly precision between each hard ware, and, because the nonuseable part of each hard ware is topped by resin institute, so avoided the danger of unexpected contact between the hard ware.

In addition, the manufacture method that of the present invention and hard ware forms the synthetic resin members of one is after carrying out the shaping of synthetic resin system main body in being shaped with forming die to the integrated hard ware group insertion synthetic resin system main body that is linked to be through connecting bridge by multiple hard ware, form the synthetic resin members intermediate, then, connecting bridge is cut off, make each hard ware independent separately on electric, produce the synthetic resin members that forms one with hard ware thus, so can efficient produce the synthetic resin members that forms one with hard ware highly, not only but cost-cutting also can improve the assembly precision between each hard ware.

In addition, concrete shape or structure, the method etc. shown in the described embodiment are just implemented several concrete example seldom of the present invention, can not come technical scope of the present invention is done restricted explanation with them.

Claims (4)

1. one kind forms the manufacture method of the synthetic resin members of one with hard ware, it is characterized in that, may further comprise the steps:

The integrated hard ware group that is linked to be through connecting bridge by multiple hard ware is inserted in the forming die of synthetic resin system main body with shaping usefulness;

The synthetic resin that synthetic resin system main body is used is injected in the forming die of described synthetic resin system main body shaping usefulness, forms a synthetic resin members intermediate that is formed one by synthetic resin system main body and described hard ware group;

Cut off described connecting bridge, make described various hard ware independent separately, produce the described synthetic resin members that forms one with hard ware thus.

2. manufacture method according to claim 1, it is characterized in that, the described synthetic resin that synthetic resin system main body is used injects under following state, that is, and and 2 pushing of pushing pin and location that adjacent and approaching hard ware is stretched out by 2 described forming die both sides from matched moulds.

3. manufacture method according to claim 1 is characterized in that described synthetic resin is ABS resin.

4. manufacture method according to claim 1 is characterized in that, described hard ware is with having electric conductivity and elastomeric metallic material is made.

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