DE19519752A1 - Plastic prod. mfr. for lamp assembly - 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

The present invention relates to a plastic part that is integrally molded with metal parts and a method for the production of a plastic part that is in one piece with Me tallteile is shaped. In particular, the invention relates a plastic part that is molded in one piece with metal parts is and a method for producing an integral with Metal parts molded plastic part, in which the together precise dimensions of the plastic part in relation to the me tallteile is improved, no risk of unwanted There is contact between metal parts and time to get together Menbau der Metallteile is won to reduce costs contribution.

A conventional lamp body for lamps, which is mounted in a make-up mirror, which is provided in the interior of a motor vehicle, is shown for example in FIGS. 64 and 65.

In the figures, reference symbol a denotes a lamp body in the form of a frame with a high height, the is mounted in an opening portion which is close to a Mirror mounting section of a mirror body (not ge shows) is formed.  

Metal sockets b and c for holding a light bulb are on attached to the back of the lamp body a, and a glow Bulb f is in the holding parts d and e of the metal frames b and c held. The reference symbol g denotes one Switch from which a connector h protrudes. A contact section i, which is provided in the metal frame b, is in contact with a connector (not shown) that to the lower surface of a case j of the switch e is exposed. When an operating rod k of the switch g is pressed, comes inside the housing j of the scarf ters g the connector h in contact with the connector (not shown) so that the contact portion i in contact therewith is.

A connector l of the metal socket c and the connector h of the switch g protrude into a hole m, which in the Lamp body a is shaped. This hole m and the connector parts h and l form a connector n.

If a make-up mirror on a sun visor (not ge shows) is attached, is a connector that on the distant End of a wire harness is provided, extending from the side the sun visor extends with the type described above plug n connected, and the light bulb f is through the switch g with a power supply on the body huge side of the motor vehicle connected.

In the conventional lamp body a for a metal mirror must have the metal frames b, c and Switches g that are individually molded in the lamp body can be assembled individually, so that the time to get together construction becomes longer and more arduous and the costs increase the.

Furthermore, since the metal sockets b, c and the switch g be installed individually in the lamp body a, exactly  in assembly between the metal frames b, d and the switch g can only be obtained with difficulty, and in some cases there is a risk of a short circuit ses.

Accordingly, the present invention has been made in view of this created to solve the problems described above and it's their job to create a plastic part that is integrally formed with metal parts, which is characterized is that a large number of separation holes in one Main body are molded from plastic, which is in one piece formed by insert molding with a metal element set is one piece with a variety of types of metal elements is formed by bridges, and being the bridges to be severed at the separation holes to accommodate the variety to be independent of types of metal elements.

It is another object of the present invention a method of manufacturing a plastic part create that molded in one piece with the metal elements , the method comprising the steps of: inserting a Metal part set that is integral with a variety of Types of elements formed by bridges, in dies for molding the main body from plastic, injection a plastic for a plastic main body in the Molds for molding the plastic main body to to form an intermediate body from a plastic part, where a plastic main body and the metal element set are integrally formed, and severing bridges to to make the variety of metal elements independent where through the plastic part in one piece with metal elements will be produced.

In the plastic part according to the present inven dung because one part that is integral with a variety of Types of metal elements are molded that are assembled  to be through as a one-piece plastic body Insert molds are molded, the time and arduous ar beit used to individually assemble a variety of types of metal elements in the one-piece plastic body can be saved, and there can be one Cost reduction can be made. Also, since the individual metal materials together by insert molds be built, the assembly accuracy between the Metal elements improved. Furthermore, there is no need agile sections covered by the metal with plastic are no possibility that an undesired contact un intentionally occurs between the metal elements.

In the process for manufacturing the plastic part according to of the present invention, which is integral with Metallele elements is formed, a metal element set, the one in pieces from a variety of metal elements through the Bridge is molded into the mold for molding an art used part of the material, and a plastic part as an intermediate limb is formed. The bridge is then punched out and each metal element becomes electrically independent to the Manufacture a variety of plastic parts in one piece have shaped metal elements. Accordingly, an art fabric part that is molded in one piece with metal elements, be produced with great efficiency, the cost can be reduced and the assembly accuracy between the metal elements can be improved.

The above and other objectives and advantages of present invention will become apparent from the following individual description obviously when in Read connection with the accompanying drawings.

The subjects of the invention are described below with the aid of Embodiments with reference to the drawings  explained in more detail.

Fig. 1 to 17 show a first embodiment of the invention, in which a plastic part, which is integrally formed with metal elements, is used in a lamp body for make-up mirror, and a manufacturing method therefor.

Fig. 1 is a partially cutaway front view showing the plastic part installed in a makeup mirror that is attached to a sun visor;

Fig. 2 is an enlarged sectional view genom men along the line 2-2 of Fig. 1 is essential;

Fig. 3 is an enlarged sectional view genom men taken along line 3-3 of Fig. 1;

Fig. 4 is a perspective view of the lamp body of Fig. 1;

Fig. 5 is a front view of the lamp body of Fig. 1;

Fig. 6 is a rear view of the lamp body of Fig. 1;

Fig. 7 is an enlarged sectional view taken substantially along line 7-7 of Fig. 5;

Fig. 8 is an enlarged sectional view taken substantially along the line 8-8 of Fig. 5;

Fig. 9 is an enlarged sectional view taken along the line 9-9 of men in Figure 6 we sentlichen genome.

Fig. 10 is an enlarged sectional view taken ge 5 is taken along line 10-10 in FIG we sentlichen.

FIG. 11 is an enlarged sectional view taken substantially along line 11-11 of FIG. 5;

Fig. 12 is an enlarged perspective view of the essential parts of the first embodiment of Fig. 1;

Fig. 13 shows schematically together with Figs. 14 to 17 an embodiment of the invention, in which a method for producing a plastic part, which is integrally formed with metal elements, is used in a method for producing a lamp body for makeup mirrors, and a perspective view showing a material for making a contact set;

Fig. 14 is a perspective view showing a prototype of a contiguous contact set formed by punching out unnecessary portions from the material of Fig. 13;

Fig. 15 is a perspective view showing a contact set formed by bending the prototype of the contact set;

Fig. 16 is a front view showing the contact set;

Fig. 17 is a perspective view showing a lamp body intermediate member which is formed by inserting the contact set;

Fig. 18 shows together with Figs. 19 to 42 a second embodiment of the invention, in which the plastic part, which is integrally formed with the metal elements, and its manufacturing process there from then used in a lamp body for makeup mirror, and a manufacturing process there of, as well as an enlarged, perspective view of the lamp body for make-up mirror.

Fig. 19 is a front view showing the makeup mirror with the makeup mirror cover opened and the lamp lens removed;

Fig. 20 is a rear view of the vanity mirror;

Fig. 21 is a rear view of the cover;

Fig. 22 is an enlarged cross-sectional view taken along the line 22-22 of FIG substantially 19, wherein the cover is in its closed state.

Fig. 23 is an enlarged cross-sectional view taken along the line 23-23 of FIG substantially 19, wherein the cover is in its closed state.

Figure 24 is an enlarged cross-sectional view taken substantially along line 24-24 of Figure 19 with the cover in its closed state;

Fig. 25 is a front view of the body of the makeup mirror;

Fig. 26 is an enlarged perspective view showing the essential part of a male terminal;

Fig. 27 is a view similar to Fig. 26, showing a modification of the male terminal;

Fig. 28 is a view similar to Fig. 26, showing another modification of the male terminal;

Fig. 29 is an enlarged cross-sectional view taken along the line 29-29 of FIG substantially 19, wherein the cover is in its closed state.

Fig. 30 is an enlarged cross-sectional view taken along the line 30-30 of FIG substantially 19, wherein the cover is in its closed state.

Fig. 31 is an enlarged perspective partially cutaway view showing a mirror engaging portion;

Fig. 32 is an enlarged perspective, partially cut-away view showing the mirror engagement portion in engagement with the edge of the mirror;

Fig. 33 is an enlarged perspective view showing a female terminal;

Fig. 34 is an enlarged sectional view taken substantially along line 34-34 of Fig. 33;

Fig. 35 is an enlarged front view of the female terminal;

Fig. 36 is an enlarged view of the female terminal with the female terminal angled;

Fig. 37 is an enlarged, partially cutaway sectional view of the main portion showing the state of the male terminal connected to the female terminal.

Fig. 38 is an enlarged, partially cutaway sectional view of the main portion, showing the state of a switch unit in the open state of the cover;

Fig. 39 is an enlarged, partially cutaway sectional view of the main portion, showing the state of the switch unit in the closed state of the cover;

Fig. 40 is an enlarged, partially cutaway sectional view of the main portion, showing a device for holding the cover in its closed state in this closed state;

Fig. 41 is an enlarged, partially cutaway sectional view of the main portion, showing a device for holding the cover in its open state in this open state;

Fig. 42 is an enlarged perspective view showing a contact set continuum;

Fig. 43 is an enlarged perspective view for makeup Spie gel according shows a modification of the lamp body to the second embodiment;

Fig. 44 is a sectional view taken substantially along line 44-44 of Fig. 43;

Fig. 45 is a sectional view taken substantially along line 45-45 of Fig. 43;

Fig. 46 shows, together with Figs. 47 to 62, a third embodiment of the invention, in which a piece of plastic molded with metal elements and the method for this are applied to a lamp body of a room lamp, and a manufacturing method therefor, and an enlarged one Front view showing the room lamp where part of the lens of the room lamp has been removed;

Fig. 47 is an enlarged rear view of the room lamp;

Fig. 48 is a sectional view taken substantially along line 48-48 of Fig. 47;

Fig. 49 is a sectional view taken substantially along line 49-49 of Fig. 47;

Fig. 50 is a sectional view taken substantially along line 50-50 of Fig. 47;

Fig. 51 is an enlarged sectional view showing a lamp holding unit;

Fig. 52 is an enlarged sectional view showing an engaging portion between the lower end portion of the lens and the main body;

Fig. 53 is an enlarged sectional view showing an engaging portion between the upper end portion of the lens and the main body;

Fig. 54 is an enlarged perspective view showing a switch button;

Fig. 55 is an enlarged front view showing the contact of the switch;

Fig. 56 is an enlarged perspective view showing a connector molded in the rear upper surface of the lamp body;

Fig. 57 is an enlarged perspective view showing a contact set continuum;

Fig. 58 is an enlarged, partially cutaway sectional view of the main portion, showing a change from the switch knob and the attachment of the knob;

Fig. 59 is an enlarged, partially cutaway sectional view of the main portion, showing another modification of the switch button and the attachment of the button;

Fig. 60 is an enlarged, partially cutaway sectional view of the main portion, showing yet another modification of the switch button and the button attachment;

Fig. 61 is an enlarged, partially cutaway sectional view of the main portion, showing another modification of the switch button and the attachment of the button;

Fig. 62 is an enlarged, partially cutaway sectional view of the main portion showing another modification of the switch button and the attachment of the button;

Fig. 63 is an enlarged, partially cutaway sectional view of the main portion, showing another modification of the switch button and the attachment of the button;

Fig. 64 is a perspective view showing a main portion of an example of a conventional lamp body for vanity mirror; and

Fig. 65 is an exploded perspective view of the conventional lamp body.

The present invention will hereinafter be according to the before preferred embodiments described, in which details a one-piece molded plastic with metal elements partly and a method for producing a plastic are partially shown, the ge with metal elements is formed.

Fig. 1 to 17 show a first embodiment of the constricting vorlie invention. The present invention is applied to a lamp body for makeup mirror and a manufacturing method therefor.

First, a description of the lamp body for make up Specified mirror of the present invention, and then follows a manufacturing process for it.

In Fig. 1, reference numeral 1 denotes a lamp body for make-up mirror. The lamp body 1 comprises a main body 2 , which is made of a plastic, and contacts 3 , 4 and 5 , which are installed in the main body 2 by so-called insert molding.

The main body 2 is made of a synthetic resin, such as an ABS resin, and is formed into a flat and flat box shape which is open at the front and which, when the front is viewed, is a vertically elongated rectangle.

At the upper and lower end portion of the inner bottom surface of the main body 2 , support portions 6 and 6 'are formed, which protrude slightly forward. In the essential central areas of the support sections 6 and 6 'through openings 7 and 7 ' are formed. At a position closer to the left end of the upper support section 6 there are four separation holes 8 , vertically two holes and two other holes which are arranged on the two lower sides of the opening 7 .

Further, a protrusion 9 extends upward from the left end of the upper surface of the main body 2 , and a protrusion 10 extends upward from a position slightly to the right of the side central portion of this upper surface. The upper end of the right surface of the left protrusion 9 is formed with an L-shaped notch portion 11 , while the upper end portion of the right protrusion 10 is bent into an L shape to form a downward engagement surface 12 .

A test hole 13 ( FIG. 4) is formed between the near portion of the projection 9 and the upper end of the peripheral wall portion of the main body 2 .

The reference numerals 14 and 14 denote positioning rips which project from the vertical central portions of the inner surfaces of the side walls 15 and 15 of the main body 2 in the front and rear directions of the main body 2 . As shown in Fig. 4, each positioning rib 14 has an inclined surface 14 a which gradually decreases toward the front end of the side wall 15 and ends at this front end.

Reference numeral 16 ( FIG. 5) denotes a pressure section which is tongue-shaped and which protrudes directly from the rear end of the inner surface of the left side wall 15 and is arranged slightly above the positioning rib 14 .

Reference numeral 17 denotes a positioning hole which is formed in a back plate 18 at a position slightly above the printing section 16 .

In the area of the back plate 18 , which excludes the support sections 6 and 6 ', that is, the back of the Abschnit tes, which corresponds to a central portion 19 , a plurality of small holes 20 is formed.

Reference numeral 21 denotes a protective plate which is integrally formed with the main body 2 so that the rear side is covered between the projections 9 and 10 except for the right end portion.

The contacts 3 , 4 , 5 are formed from a metal material that has conductivity and elasticity, for example stainless steel (e.g. SUS 304). The contacts can be formed from brass, phosphor bronze, etc. to increase the conductivity and durability.

The contact 3 is integrally formed with a jaw holder 22 , an upper connecting part 23 and a connecting portion 24 ( Fig. 12) which connects the holder 22 and the upper connecting part 23 . The jaw holder 22 consists of a base section 25 and clamping parts 26 and 26 which rise forward from the upper and lower ends of the base section 25 . The clamping members 26 and 26 are formed near the distal ends with fastening portions 27 and 27 which are curved so that they become closer to each other. An embedded part 25 a is embedded at the right end of the base portion 25 and bent so that it faces the oblique back.

The space between distal ends of the clamping parts 26 and 26 is smaller than the vertical width of the Basisab section 25th The near ends 26 'and 26 ' of the clamping parts 26 and 26 , which rise from the base portion 25 , are shaped with a so-called R-surface shape with a curvature, not at right angles.

The connecting portion 24 ( Fig. 15) of the contact 3 it extends substantially vertically in the form of a band and consists of an intermediate step portion 24 a, an upper half portion 24 b, which extends upward from the step portion 24 a, and one unte ren half section 24 c, which extends from the step section 24 a down. The upper half section 24 b is arranged somewhat further forward than the lower half section 24 c. The upper half portion 24 b is in the left end portion of the upper support portion 6 and the front Endab section of the left side wall 15 of the main body 2 is embedded. The elongated central section of the lower half section 24 c protrudes straight and is shaped in terms of width with a positioning hole 28 at the somewhat right position of the lower half section 24 c. The left, half portion of the lower half portion 24 c is embedded in the rear end portion of the left side wall 15 of the main body 2 , and the remaining part and the mouthpiece 22 are disposed within a flat recess portion 29 which is on the left end portion of the middle portion 19 the inner bottom surface of the main body 2 is shaped.

Note that the part to be embedded 25 a, which is formed in the base portion 25 of the jaw 22 , is embedded in the back plate 18 of the main body 2 . And the positioning hole 28 which is in the lower half portion 24c of the connecting portion 24 molded is aligned with the Posi tionierungsloch 17 which is formed in the back plate 18 of the main body. 2 Also, the pressure portion 16 , which protrudes from the left side wall 15 of the main body 2 , in contact with the front of the lower portion of the lower half portion 24 c of the connecting portion 24 ( Fig. 12) is arranged, thereby preventing the lower half portion 24th c of the Verbindungsab section 24 slides forward.

The upper terminal part 23 extends from the right surface of the notch 11 of the left projection 9 in the right direction, the surface of the part 23 being held in the up and down direction of the main body 2 . The right end of the upper connector 23 is located near the left surface of the upper portion of the right projection 10 .

Note that the intermediate portion 23 c of the upper connector 23 is reduced in width compared to the proximal end portion 23 a and the distal end portion 23 b.

The upper end portion of the connecting portion 24 near the upper connector 23 is formed with bent portions 30 ( Fig. 12). With this configuration, the upper connection part 23 can be moved somewhat downwards.

The contact 4 is integrally formed with a main portion 32 formed with a connection hole 31 , a lower terminal part 33 and a connection portion 34 . Two opposite engagement portions 31 a and 31 a are formed on the edge of the connecting hole 31 of the main portion 32 . The connecting section 34 is shaped like a crank, which has a shape of two "L" letters connected together when viewed from the front, and extends between the upper edge of the left end of the main section 32 and the left end of the lower connecting part 33 . Also, the lower connector 33 is bent at its proximal portion with respect to the connecting portion 34 so that the surface of the connector 33 is directed in the upward and downward direction of the main body 2 . The distal end of the connector 33 has a projection 33 a, which protrudes upwards.

In the above described contact 4 of the main portion 32, with the exception of the peripheral portion of the connection hole 31 in the upper bearing portion 6 of the main body 2 is an embedded, and the communication hole 31 is aligned with the passage hole 7 (Fig. 2). Note that the hole diameter of the communication hole 31 is slightly smaller than that of the through hole 7 , and the hole edge of the communication hole 31 is within the hole edge of the through hole 7 when viewed in the forward and backward direction of the main body 2 becomes.

The connecting portion 34 is embedded in the upper Auflageab section 6 , and the lower connecting part 33 he stretches from a point immediately under the Einker exercise 11 of the left projection 9 in the right direction. The lower terminal part 23 faces the lower surface of the upper terminal part 23 of the contact 3 described above in parallel to form the opening and closing contact portion of a switch.

Thus, by forming the opening and closing contact portion of a switch by the respective terminal parts 23 and 33 of the contacts 3 and 4 , the separate switch part g which is encountered in the prior art can be omitted, thereby reducing the time taken to assemble of such a switch part is required, can be saved and the manufacturing costs can be reduced.

Also, since the protective plate 21 is disposed on the back of these connecting parts 23 and 33 can be prevented, that the connecting parts 23 and 33 directly touching a vanity mirror, which will be described later, when the Lam is incorporated into the make-up mirror pen body 1, and as a result, the connecting parts 23 and 33 can be prevented from being deformed or damaged.

The end 33 remote b of the lower connecting part 33 is located further below the engaging surface 12 of the right projection 10 and is engaged by the upper surface 12 limited from moving upward. With this configuration, a predetermined gap can be provided between the connection parts 23 and 33 so that they can be prevented from short-circuiting. The following parts are exposed from the test hole 13 of the main body 2 ; the upper part near the left end of the connecting portion 34 of the contact 4 , the upper part near the right end of the connecting portion 24 of the contact 3rd

The contact 5 is integrally formed with a main portion 35 , a jaw 36 which extends from the almost central portion of the right end of the main portion 35 , and a connecting portion 38 which is continuous with the lower end of the main portion 35 and a connecting hole 37 has its central section.

The connecting section 38 and the main section 35 are connected by a connecting section 39 ( FIG. 3). The connecting portion 39 extends obliquely and has a step portion 39 a, which extends forward and backward, so that the connecting portion 38 is at a point slightly behind the main portion 35 .

The main section 35 has a generally U-shape when viewed from the front. The upper end portion of the Hauptab section 35 is formed at its right and left ends with an embedding parts 35 a and 35 a, and likewise the lower end portion is formed at its right and left ends with parts 35 a and 35 a to be embedded. Each part 35 a to be embedded is bent obliquely backwards.

The jaw holder 36 consists of a base section 40 and clamping parts 41 and 41 which rise upwards from the upper and lower ends of the base section 40 . The clamping parts 41 and 41 are formed at the upper ends with fastening sections 42 and 42 which are curved so that they approach each other.

The space between the distal ends of the clamping parts 41 and 41 is smaller than the vertical width of the base portion 40 . The near ends 41 'and 41 ' of the clamping parts 41 and 41 , which rise from the base portion 40 , are shaped into a so-called R-surface shape with a curve, not at right angles.

Two opposite engagement projections 37 a and 37 a are formed at the edge of the connecting hole 37 of the Verbindungsteilab section 38 .

In the contact 5 described above, the main portion 35 and the jaw 36 are located in a shallow recess portion 43 formed in the inner bottom surface of the main body 2 . The connector portion 38, with the exception of the peripheral portion of the connection hole 37 'is embedded the main body 2, and the communication hole 37 is to the through hole 7' in the lower support portion 6 at its front side aligned (Fig. 3). Note that the hole diameter of the communication hole 37 is slightly smaller than that of the through hole 7 ', and the hole edge of the communication hole 37 is located within the hole edge of the through hole 7 ' when viewed in the forward and backward direction of the main body 2 . The center of the right end of the jaw 36 contacts the surface of the rear end of a positioning rib 14 on the right side.

The parts 35 a, 35 a, 35 a and 35 a to be embedded here, which are formed in the main section 35 , are arranged in an embedded state in the rear plate 18 of the main body 2 .

On the bottoms of the small holes 20 of the main body 2 described above, the connecting portion 24 and the base portion 25 of the jaw part 22 of the contact 3 and the main portion 35 and the base portion 40 of the jaw part 36 of the contact 5 are arranged.

Reference numeral 44 denotes a makeup mirror, 45 a body of the mirror, 46 a mirror attached to the body 45 , and 47 a recess portion formed on the side of the mirror 46 .

The lamp body 1 for make-up mirror described above is firmly attached in the recess portion 47 . A tubular light bulb 49 is held firmly at its connecting parts 48 and 48 by the clamping parts 26 and 26 of the jaw holder 22 and the clamping parts 26 and 26 of the jaw holder 36 and is arranged in the lamp body 1 . The front opening of the lamp body 1 is covered with a lens body (not shown), whereby a lamp 50 is formed.

Note that the space between the opposite sides of the positioning ribs 14 and 14 described above is equal to or slightly larger than the length of the tubular bulb 49 described above. As has been described above be written, even if the position of the tubular incandescent lamp 49 would shifted somewhat to the right or left when attaching the tubular lamp 49 in the jaw holders 22 and 36, the end of the connection part 48 or 48 is in contact with brought inclined surface 14 a or 14 a of the positioning rib 14 or 14 and moved along the inclined surface 14 a, so that the tubular bulb 49 is positioned in a correct position. Also, these positioning ribs 14 and 14 limit the unnecessary movement of the tubular bulb 49 to prevent interference such as a short circuit.

Reference numeral 51 denotes a cover which is pivotally held on the body 45 in order to cover and open the front of the mirror 46 and the lamp 50 . When the cover 51 is open, an actuation projection 52 ( Fig. 2) presses the distal end 23 a of the upper terminal 23 of the contact 3 from above, and the distal end 23 b is bent downward, so that the upper connecting part 23rd brought into contact with the lower connection part 33 and current of the tubular incandescent lamp 49 is supplied.

Since the intermediate section 23 c of the upper connection part 22 has a smaller width compared to the near and distant end sections 23 a and 23 a, as has been described above, a local stress concentration can be avoided if the upper connection part 23 is bent by the actuating projection 52 , and the durability of the connector 23 can be increased.

Furthermore, since the distal end portion 33 b of the upper connector 33 is formed with the projection 33 a, which protrudes downward to the lower connector 23 , the upper and lower connectors 33 and 23 reliably touch each other when the upper connector 33 in Rich tion to the lower connector 23 is bent, and a faulty contact due to fluctuations in molding can be prevented.

Reference numeral 53 denotes a sun visor which is provided in the interior of a motor vehicle. The sun visor 53 is formed with a recess 54 ( Fig. 2) in which the make-up mirror 45 is introduced in the embedded state.

An upper and a lower structural part 45 and 56 are arranged in the recess 54 of the sun visor 53 , which are conductive and are each connected to the connections of a power supply of a motor vehicle. A screw 57 , which is inserted into the connecting hole 31 and the through hole 7, is screwed into the upper structural part 55 from the front side. Similarly, a screw 57 ', which is inserted into the connecting hole 37 and the through hole 7 ', is screwed into the lower structural part 56 from the front. The screws 57 and 57 'are made of a material which has a conductivity so that the contact 4 is electrically connected by the screw 57 to the upper structural part 55 and also the contact 3 is electrically connected by the screw 57 ' to the lower structure 56 is connected. Therefore, when the above-described upper and lower connectors 23 and 33 are in contact with each other, a closed power supply path - structure member 55 - contact 4 - contact 3 - a connector 48 of the tubular bulb 49 - another connector 45 of the tubular filament 49th - Contact 5 , structural part 56 - power supply formed, and the tubular bulb 49 lights up.

It should be noted that, since the engagement projections 31 a, 31 a, 37 a and 37 a of the connecting holes 31 and 37 engage in the grooves of the screws 57 and 57 'and reliably touch the contacts 4 and 5 with the screws 57 and 57 ' and also the hole diameter of the through holes 7 and 7 'of the main body 2 are larger than those of the connecting holes 31 and 37 , the screws 57 and 57 ' reliably brought into contact with the opening edges of the connecting holes 31 and 37 , even if a web is attached the opening edges of the through holes 7 and 7 'would occur when molding the main body 2 .

Next, a description will be given of the method for making the lamp body 1 described above for makeup mirror.

First, a contact set which is integrally molded by bridges is molded with the contacts 3 , 4 and 5 described above.

The reference numeral 58 denotes the contact set which has been integrally formed by bridges 59 , 59 , 59 and 59 with the contacts 3 , 4 and 5 . In particular, the two vertically spaced locations of the right edge of the upper end portion of the connecting portion 24 of the contact 3 and the two locations of the upper and lower ends of the left edge of the main portion 32 of the contact 4 are connected by the bridges 59 and 59 . Also, the two locations of the right and left ends of the lower edge of the main portion 32 of the contact 4 and the two portions of the right and left ends of the upper edge of the main portion 35 of the contact 5 are connected by the bridges 59 and 59 . With this configuration, the contact set 58 is formed in one piece with the contacts 3 , 4 and 5 .

Reference numeral 60 denotes a sheet from which the contact set 58 is formed, such as a thin plate made of SUS, brass or phosphor bronze, and the thickness thereof is approximately 0.25 mm.

The sheet 60 is punched by recess to form a proto type of contact set 61 , which includes the body 3 ', 4 ' and 5 'of the prototype, which are the contacts 3 , 4 and 5 .

Then the prototype body 3 ', 4 ' and 5 'of the prototype of the contact set 60 described above are bent to form the contact set 58 which is integrally molded with the three contacts 3 , 4 and 5 .

In particular, for the prototype of contact body 3 ', the mouthpiece equivalent 22 ' is bent to form the mouthpiece 22 , the near section of the connector part equivalent 23 'is bent up to form the connector part 23 , and the connection section equivalent 24 ' near the connector part equivalent 23 'is bent to form the bent portions 30 , whereby the connecting portion 24 is formed. In addition, the embedded portion 25 a is bent so that it is molded.

In the prototype of contact body 4 ', the close section of the connector part equivalent 33 is bent upward to form the connector part 33 .

Note that it is necessary that when the connector parts 23 and 33 are installed in the main body 2 , the respective surfaces of the connector parts are opposite to each other and come close to each other. But since the connection part equivalent 33 'continues a certain width in the direction of the connection part equivalent 23 ' ??? at the stage where the prototype was formed by contact set 60 , neither can be made close to each other. Therefore, when these equivalents are bent at their respective close portions, there is often a large space between the fittings 23 and 33 . In such a case, bent portions 30 are formed on the connecting portion 24 to adjust the space between the terminal parts 23 and 33 to an appropriate range.

In the prototype of contact body 5 ', the mouthpiece equivalent 36 ' is bent to form the mouthpiece 36 , and the connecting portion equivalent 39 is bent at the end of the mouthpiece equivalent 36 'side and also at the end on the side of the connecting part equivalent 38 ', to create a step portion between the jaw equivalent 36 and the connector equivalent 38 .

The above-described contact 58 is inserted into the mold for the main body of a molding machine, and a resin for the main body is injected into the mold for the main body, so that an intermediate body for the lamp body 1 is formed, in which the main body 2 is made of the resin is made and the contact set 58 is integrally molded.

Reference numerals 62 and 62 (only two are shown in FIG. 9) denote push pins. The pressure pins 62 and 62 are inserted into the through holes 64 and 64 formed in a mold 63 and protrude into a cavity 66 . The push pins 62 and 62 press the rear surface of the intermediate portion of the connecting portion 24 of the contact 3 , the rear surface of the central portion of the base portion 25 of the jaw 22 of the contact 3 , the rear surface of the right and left end portions of the upper end portion of the main portion 35 of the contact 5 , the rear surface of the right and left end portions of the lower portion of the main portion 35 , the rear surface of the right edge portion of the nearly central portion of the main portion 35 and the rear surface of the central portion of the base portion 40 of the jaw 36 . as a result, their front surfaces are pressed against the cavity surface of another mold 69 . Thus, the front surfaces of the connecting portion 24 and the base portion 25 of the jaw 22 of the contact 3 and the front surfaces of the main portion 35 and the bridge portion 40 of the jaw 36 of the contact 5 are pressed against the cavity surface of another mold 65 so that synthetic resin for the main body 2 can be reliably prevented from flowing to the front sides of these portions 24 , 25 , 35 and 40 , and these portions are exposed to the inner bottom surface of the body 1 to act as reflective surfaces. Further, since these portions 24 , 25 , 35 and 40 are exposed to the inner bottom surface of the body 1 , the heat radiation of the tubular bulb 49 to the main body 2 can be prevented during the lighting time of the filament tube 42 , and therefore the heat resistance property becomes the lamp body 1 ver strengthened.

In addition, the contacts 3 and 5 are pressed firmly against the cavity surface of the other mold 65 , so that the positions of these contacts 3 and 5 become stable and are prevented from being displaced by the injection pressure during the molding.

Furthermore, the part to be embedded 25 a, which is formed at the contact 3 , and the parts to be embedded 35 a, which are formed at the contact 5 , were arranged in an embedded state in the rear plate 18 of the main body 2 , as described above has been. As a result, when the tubular bulb 49 is replaced with a bulb, the old bulb 49 is removed, and at this time, although forces separating the base portions 25 and 40 from the back plate 80 are exerted on the jaws 22 and 36 , The base portion 25 or 40 of the jaw part 22 or 36 by the parts to be embedded 25 a and 35 a, which are embedded in the back 18 , prevented from being separated from the back plate 18 . It should be noted that the pressure section 16 , which covers part of the connection section 24 of the contact 3 from the front, helps to prevent such a separation.

Note that the portions where the pressure pins 62 have been positioned within the cavity 66 remain as small holes 20 after molding.

Reference numeral 67 ( Fig. 11) denotes a positioning pin which protrudes from the other mold 65 , which is inserted into a positioning hole 28 of the contact 3 and ends in the middle of a cavity 66 . With this configuration, the position of the contact 3 is stabilized, and the position of the contact 3 is prevented from being displaced by the injection pressure during molding.

Note that the portion at which this positioning pin 67 has been positioned within the cavity 66 during molding remains in the main body 2 as a positioning hole 17 after molding.

Reference numeral 68 ( FIG. 10) denotes a pressure pin protruding from a die 63 , and reference numeral 69 ( FIG. 10) denotes a pressure pin protruding from a position of another die 65 corresponding to the pressure pin 68 . When two dies 63 and 65 are assembled, the upper portion of the connecting portion 24 of the contact 3 and the upper portion of the connecting portion 34 of the contact 4 are held near this portion between the upper end of the pressure pin 68 and the lower end of the pressure pin 69 so that they can be prevented from moving and touching each other by the injection pressure during molding. Note that if these portions are shifted from the predetermined positions even if they do not touch each other, there is a problem that the positional relationship between the terminal parts 23 and 33 becomes wrong. The Hal th of the contacts 3 and 4 by the pressure pins 68 and 69 described above, prevents such a problem from occurring.

Note that the portions where the pressure pins 68 and 69 have been positioned within the cavity 66 remain in the main body 2 as the test hole 13 during molding. After molding, the states of the connecting sections 24 and 34 of the contacts 3 and 4 can be checked through this test hole 13 .

The distal end portion 33 b of the connecting part 33 of the contact 4 is shaped so that it is positio ned in surface contact with the engagement surface 12 of the main body 2 . Therefore, when the injection molding has been completed, the distal end portion 33 b is attached to the engaging surface 12 . However, if the lamp body 1 is installed in the make-up mirror 44 and the connecting part 33 is deflected once by the actuating projection 52 of the cover 51 through the connecting part 23 (pressed down ( FIG. 2)), then the distal end section 33 a of the connecting part 33 is separated from the engagement surface 12 .

When injection into cavity 66 is complete and the molds are released, they can be easily released without using a pusher core because the space between the distal ends of the clamp members 26 and 26 of the jaw 22 is smaller than the vertical width of the base portion 25 and the space between the clamping parts 41 and 41 of the jaw holder 36 is smaller than the vertical width of the base section 40 . That is, when alternative recess portions 70 and 70 (only one is shown in Fig. 8) in which the jaws 22 and 36 are arranged are formed in the other mold 65 , the clamp members 26 , 26 and 41 , 41 of the jaws can be formed 22 and 36 away from the escape recess portions 70 and 70 without being soft recessed portions on the inner surfaces of the off are caught 70 and 70th

Furthermore, the jaws 22 and 36 , since the near sections 26 ', 26 ', 40 'and 40 ' of the clamping parts 26 , 26 , 41 and 41 , which rise from the base sections 25 and 40 , are not right angles, but they are shaped with an R-surface shape with a curvature, their formability increases. More specifically, there is a tendency that when these sections 26 , 26 ', 40 ' and 40 'are right angles, cracks easily occur in these sections by processes such as molding or attaching and detaching an incandescent lamp, but, if these sections are shaped with an R-surface shape, cracks can be prevented and thereby the deformability can be improved.

After the above main body 2 is formed , the separation holes 8 are formed by recessing, and then the lamp body 1 is formed. Due to the formation of these separation holes 8 , the bridges 59 , which connect the contacts 3 , 4 and 5 with one another, are severed at the separation holes 8 , and the contacts 3 , 4 and 5 become electrically independent of one another.

In the lamp body for make-up mirror and its manufacturing method described above, since the contacts 3 , 4 and 5 , which are to be installed in the main body 2, are integrally formed and also integrally built into the main body 2 , thereby making the installation accuracy of the contacts 3 , 4 and 5 on the main body 2 is improved. Also, since the unnecessary portions of the contacts 3 , 4 and 5 are covered with the synthetic resin of the main body 2 , the risk of a short circuit is reduced. Assembly time is also saved, thereby reducing assembly costs.

Figs. 18 to 24 show a second embodiment of the integrally molded with the metal elements plastics part and a method for producing a plastic part, which is integrally molded with metal elements. This second embodiment is also applied in the present invention to a lamp body for make-up mirror and its manufacturing process.

The reference numeral 73 denotes a lamp body for make-up mirror, which comprises a plastic body 74 , three contacts 75 , 76 , 77 and two reinforcing parts 78 , 79 . The main body 74 is integrally molded with the three contacts 75 , 76 , 77 and the two reinforcement members 78 , 79 by insert molding.

The main body 74 is made of a synthetic resin, such as an ABS resin, and is molded into a flat and flat box shape that is open at the front thereof and which, when looking at the front, is a vertically elongated rectangle.

At the upper and lower end portion of the inner bottom surface of the main body 74 , support portions 80 and 80 'are formed, which protrude slightly forward. At the essential sections of the support sections 80 and 80 'through openings 81 and 81 ' are formed. Between the through opening 81 and the right and left ends of the upper support section 81 and between the through opening 81 'and the right end of the left support section 80 ', separation holes 82 , 82 and 82 are formed.

Between the support sections 80 and 80 'a Vertie tion section 83 is formed, which consists of three identical sections 83 a, 83 b and 83 b'. The vertical central portion 83 a has a lowermost flat surface, the upper portion 83 b has an inclined surface that extends obliquely from the flat surface portion 83 a to the upper support portion 80 , and the lower portion 83 b 'has an inclined surface that extends obliquely from the flat surface section 83 a to the lower support section 80 'extends.

At four locations near the upper and lower ends of the side surfaces of the main body 74 , that is, the locations corresponding to the opposite side portions of the support portions 80 and 80 ', four opening portions 84 are formed. The front end of the side portion of each opening portion 84 ends just before the front end of the side wall 85 , and the rear end reaches the rear surface of the main body 74 . At the support portion 80 or 80 ', the front end of each opening portion 84 reaches the front surface of the support portion and the rear end reaches the rear surface of the main body 74 .

At the locations near the upper and lower ends of the right and left side walls 85 of the main body 74 , Nutab sections 86 , 86 , 86 and 86 are formed which reach the front and rear ends of the side wall 85 .

The contact 75 ( Figs. 18 and 42) is integrally formed with a reflector section 87 , a jaw 88 which projects to the left from the vertical central section of the left side edge of the reflector section 87 , a male terminal 90 and 90 ', which is to the left and protrudes right from the lower ends of the connecting parts 89 and 89 'which extend downward from the left and right side edges of the reflector section 87 .

The reflector section 87 ( Fig. 42) is integrally formed with a central section 93 which faces the front and has a lateral, elongated, rectangular shape and has inclined sections 94 and 94 ', which extend from the upper and lower ends of the central section 93 extend and are inclined to extend forward as they move away from the central portion 93 . The connecting parts 89 and 89 'described above extend from the left and right ends of the middle section 93 of the reflector section 87 .

The jaw holder 88 ( FIG. 42) consists of a base section 95 and clamping parts 96 and 96 which rise from the upper and lower ends of the base section 95 . The clamping members 96 and 96 are formed at the upper end portions with fastening portions 97 and 97 which are curved so as to come closer to each other. A part 98 to be embedded protrudes from the left end of the base portion 95 .

Since the male terminals 90 and 90 'have an identical construction except that they are symmetrical, the description of one terminal is given, and the same reference numerals as for one terminal are applied to the other and the other is described Not.

The male terminal 90 is composed of a conductive portion 99 and a molded portion 100 which is integrally molded with the conductive portion 99 , as shown in FIG . The conductive portion 99 is integrally formed with a plate portion 99 a having a laterally elongated rectangular shape, which is connected to the above-described connecting member 89, and with Seitenteilab cut 99 b and 99 b ', the forwardly from the upper and the lower end of the plate portion 99 a protrude. In the substantially central portion of the distal end of the plate portion 99 a small holes 99 c are formed.

The mold portion 100 is formed of the same resin as the resin material of the main body 74 described above, and is integrally formed on the side of the side portions 99 b and 99 b of the plate portion 99 formed of a conductive section from 99th The thickness of the mold section 100 is the same as the width of the side sections 99 b and 99 b. The shaped portion 100 has a distal end portion 100 a, which protrudes from the distal end of the plate portion 99 a, and the distal end portion 100 a is chamfered so that its four surfaces ( Fig. 26) gradually towards the distant end can be reduced in width and thickness. At the point corresponding to the small hole 99 c of the mold section 100 described above, a small hole 100 c is formed, which has a slightly larger diameter than the small hole 99 c. The molding section 100 is molded together when the contact 75 in the main body 74 is molded by insert molding.

Therefore, the contact 75 is molded integrally in the main body 74 by the so-called insert molding, and the reflector section 87 is to keep the front surface of the substantially central portion of the main body 74 freige. That is, the central portion 93 is arranged at the front of the side central portion of the flat surface 83 a of the recess portion 83 of the Hauptkör pers 74 , the inclined portions 94 and 94 'are on the front surfaces of the lateral central portions of the inclined portions 83 b and 83 b 'of the recess section 83 is arranged, the mouthpiece 88 is arranged on the left end portion of the flat surface 83 a of the recess section 83 , and the distal end of an encased part 98 is embedded in the left side wall 85 of the main body 74 . The male terminals 90 and 90 'are arranged so that they protrude into the lower opening portions 84 and 84 of the main body 74 from the inner ends of the lower opening portions 84 and 84 . Note that the connecting parts 89 and 89 'are embedded within the main body 74 . Also in the front of the main body 74 a flat recess section 101 is formed, in which the reflector section 87 of the contact 75 and the base section 95 of the jaw 88 are arranged.

The contact 76 is integrally formed with a mouthpiece 102 , a connecting part 103 and a connecting part 104 ge, which extends between the mouthpiece 102 and the connection part 103 .

The jaw holder 102 consists of a base section 105 and clamping parts 106 and 106 which rise from the upper and lower ends of the base section 105 . The clamping parts 106 and 106 are formed at the upper end portions with fastening portions 107 and 107 which are curved so that they approach each other. A part 108 to be embedded protrudes from the left end of the base portion 105 .

The connecting part 104 is formed of a narrow width band part extending in the upward and downward direction of the main body 74 , and the lower end of the connecting part 104 is integrally connected to the right end of the base portion 105 of the jaw 102 . The lower one-third section 104 a of the connecting part 104 is inclined backwards when it runs downwards.

The connector 103 ( Fig. 42) is shaped as a laterally extending band member, the width of which extends along the forward and backward directions of the main body, and the rear end of the right end of the member 103 is integrally described with the upper end of the above NEN connecting part 104 connected.

The above-described contact 76 is arranged so that the jaw 102 is arranged on the right end portion of the front surface of the flat surface 83 a of the main body 74 , and the base portion 105 is arranged within a flat recess portion 109 which is in the right end portion of the flat surface 83 a is formed. The part to be embedded 108 is embedded in the flat portion 83 a, and the connecting part 104 is embedded in the right wall 85 . The connector 103 protrudes to the left from a protrusion 110 protruding from the right end of the upper surface of the main body 74 . A jump 111 protrudes upward from a position that is left of the side center portion of the upper end of the main body 74 . The upper end portion of the jump before 111 is cranked so that downward Stu fenfläche 112 a and 112 b are formed. The left Endab section of the connector 103 described above engages elastically on the upper step surface 112 a.

The contact 77 is integrally formed with a central portion 113 ( Fig. 42) which has a generally U-shape when viewed from the front, connecting portions 114 and 114 which protrude rearward from the lower right and left ends of the central portion 113 , male terminals 115 and 115 ', which project to the left and right of the rear ends of the connecting parts 114 and 114 ', and a connecting part 117 , which is connected by a connecting part 113 with an inverted L-shape when viewed from the front that is continuous to the upper end of the right end of the middle portion 13 .

The male terminals 115 and 115 'are similar to the case of the male terminals 90 and 90 ' from a lei tend section 99 and a molding section 100th

The connector 117 is formed as a laterally extending band member whose width extends along the front and back directions of the main body, and the rear end of the right end of the member 102 is integrally connected to the upper end of the connector 116 described above.

In the contact 77 described above, the male terminals 115 and 115 'are positioned so as to protrude into the upper opening portions 84 and 84 of the main body 74 from the inner ends of the upper opening portions 84 and 84 . The connector 117 protrudes to the left through the distal end of the connector 103 described above of the protrusion 110 , and the distal end of the connector 117 elastically engages the lower step surface 112 d of the left protrusion 111 . And the rest of the portion of the contact 77 is embedded in the main body 74 .

Each of the reinforcement members 78 and 79 is disc-shaped, and a through hole 118 is formed in the central portion thereof. The reinforcement member 78 is embedded in the substantially central portion of the upper support portion 80 of the main body 74 , and the area around the center of the portion 78 is exposed through the through hole 81 formed in the upper support portion 80 as shown in FIG. 18 is shown. Likewise, the reinforcement part 79 is embedded in the substantially central portion of the lower support portion 80 'of the main body 74 , and the area around the center of the part 79 is exposed through the through hole 81 ' which is formed in the lower support portion 80 ' .

In Fig. 19, reference numeral 119 denotes a make-up mirror and 120 denotes a body of the mirror. The body 120 is made of a synthetic resin and, when viewed from the front, has a laterally elongated, rectangular shape.

The body 120 is formed at its left end portion with a vertically elongated rectangular recess portion 121 for placing a lamp. In the portion of the body 120 to the right of the recess portion 121 , a laterally elongated rectangular opening portion 122 is formed for arranging a mirror.

At the front end of the opening portion 122 for arranging a mirror, an inwardly projecting stop edge 123 ( FIGS. 19 and 23) is provided, and stop projections 124 and 124 are provided on the left and right end portions of the lower inside of the opening portion 122 ( FIG . 20 and 23). Between the front surface of the impact projection 124 and the rear surface of the stop projection 123 there is a space ( FIG. 23) which corresponds to the thickness of a mirror, which will be described later.

Mirror engaging portions 125 and 125 are formed on the left and right end portions of the upper inside of the opening portion 122 ( Figs. 20 and 23). The mirror engaging portion 125 is integrally molded with a recess-shaped thin spring portion 126 which is connected at its opposite ends to the upper inside of the opening portion 122 , and an engaging projection 127 which is cut down from the side central portion of the lower surface of the opening protrudes thin spring portion 126 . The engagement projection 127 has a inclined surface 127 a ( Fig. 23) which is inclined so that it rises when one goes to its front end.

Numeral 128 denotes a mirror. The mirror 128 has a side, elongated, rectangular shape that is smaller in size than the opening portion 122 . The thickness of the mirror 128 is larger than the space between the front end of the thin spring portion 126 of the mirror engagement portion 125 and the rear surface of the stopper edge 123 . Then, the mirror 128 is inserted from the rear side of the body 120 into the area between the stop protrusions 124 , 124 and the stop edge 123 with the lower end of the mirror tilted forward and with the middle portions of the thin spring portion bent upward , The upper end of the mirror 128 is moved forward to abut against the rear surface of the stop edge 123 . Then, 126 and 126 released try when the Bie gekraft the thin spring portions, the thin spring portions 126 and 126, transition state to their off return, and therefore, 127 engage the lower surfaces a and 127 a of the engaging projections 127 and 127 elastically top at the end of the mirror 128 a. Since the lower surfaces 127 a and 127 a of the engaging projections ge 127 and 127 are inclined so that they increase as you go forward, a force for forward movement is exerted on the upper end of the mirror 128 by the elastic engagement described above so that the mirror 128 is mounted in the body 120 , the front surface of the peripheral edge of the mirror 128 being elastically engaged with the back of the stop edge 123 .

The recess portion 121 for arranging a lamp is surrounded by a rear surface and four side walls and opened to the front.

The lamp body 73 for makeup mirror is mounted in the recess portion 121 for arranging a lamp. A laterally elongated through hole 129 ( FIG. 25) is formed in the upper surface wall of the recess portion 121 except for the left end portion. Before the jumps 110 and 111 , which are provided at the upper end of the lamp body pers 73 , are inserted through the through hole 129 and protrude above the recess portion 121 . On the lower wall of the lamp recess portion 121 , engaging claw portions 130 and 130 are formed. The engaging claw portions 130 and 130 engage the engaging openings 131 and 131 formed in the lower wall of the main body 74 of the lamp body 73 , whereby the lamp body 73 is held within the lamp recess portion 121 .

In Fig. 23, reference numerals 132 and 132 denote end holes formed on the right wall of the lamp recess portion 121 at positions corresponding to the right opening portions 84 and 84 of the right wall of the lamp body 73 . The male terminals 90 'and 105 ' of the lamp body 73 face through the end holes 132 and 132 to the outside. Note that when the lamp recess portion 121 is formed on the right side of the body 120 , the end holes 132 are formed on the left wall of the lamp recess portion 121 , and the left male terminals 90 and 115 face out through the end holes 132 and 132 . The reason why two sets of left and right male terminals 90 , 115 and 90 ', 115 ' are provided in the lamp body 73 is that even if the lamp portion is molded on the left or right side of the makeup mirror, both cases can be handled with a kind of lamp body 73 .

Thus, in this lamp body 73 , since a left pair of male terminals 90 and 115 and a right pair of male terminals 90 'and 115 ' within the through holes 81 and 81 'for fixing the main body 74 and inside the openings 84 , 84 , 84 and 84 are arranged, which are formed in places that do not interfere with attaching an incandescent lamp, the space can be used effectively. Also, since these male terminals 90 , 90 ', 115 and 115 ' do not protrude from the sides of the main body 74 , the installation of the main body 74 in the lamp recess portion 121 is facilitated. Further, since a pair of male terminals 90 and 115 and a pair of male terminals 90 'and 115 ' are arranged above the portion for arranging the bulb 42 , it can be arranged within the range of the bulb thickness and can help make a device thinner.

Also, as described above, the lamp body 73 and the body 120 for the makeup mirror 119 are formed separately, and the lamp 73 is fixed within the recess portion 121 for arranging a lamp. Therefore, the lighting by the lamp portion can be made brighter when the color of the plastic material of the main body 74 of the lamp body 73 is made white, for example, and a material having greater heat resistance can be used than the synthetic resin material.

In Fig. 33, reference numerals 133 and 133 'female connections, which are provided in a sun visor (not shown) to which the make-up mirror 119 is attached. The female connections 133 and 133 'are connected to a power supply via cables 134 and 134 ', respectively.

Since 133 and 133, the female terminals tion 'in constructional, are identical, a description is only an on-circuit 133 thereto, and the same reference numerals are applied to the other, and a description thereof will be omitted.

The female terminal 133 consists of a receiving section 135 and a cable connecting section 136 . The receiving portion 135 and the cable connecting portion 136 are integrally molded from a conductive metal plate. The receiving portion 135 is shaped in a box shape, and the front plate of the receiving portion 135 is connected to the cable connecting portion 136 .

From the front edge of the front plate of the receiving portion 135 , an elastic contact member 137 is bent rearward toward the cable connecting portion 136 . The elastic contact member 137 is fork-shaped when viewed in the forward and backward directions of the main body, the free ends of the two-fingered, vertically spaced portions 137 a and 137 a being connected by a connecting member 137 , and when looking in the forward direction - And viewed backward direction of the main body, the Schei tel section is shaped into a flat hill shape. On the rear plate of the receiving portion 135 are formed before jump portions 138 and 138 , which protrude at points corresponding to the finger-shaped parts 137 a and 137 a of the elastic contact part 137 , towards the finger-shaped parts 137 a and 137 a.

The reference numeral 139 denotes an engaging part which is bent back from the central portion of the front edge of the receiving portion 135 so that it is arranged between the finger-shaped parts 137 a and 137 a. The engaging member 139 is inclined so that it comes closer to the rear plate when it moves away from the front edge of the front plate, and on the free end portion which is near the apex portion of the elastic contact member 137 described above, is an engagement claw 140 shaped that protrudes toward the rear plate. At a location corresponding to a grip claw 140 described above, a through hole 141 is formed in the rear plate of the receiving portion 135 .

Then, the female terminals 133 and 133 'are inserted from the end holes 132 and 132 described above into the opening portions 84 and 84 of the lamp body 73 , and therefore the male terminals 90 ' and 115 'are received in the receiving portions 135 and 135 . Each of the male terminals 90 'and 115 ', which was cut in the receiving sections 135 and 135 , is inserted between the projections 138 and 138 , which are formed on the rear plate, and the finger-shaped parts 137 a and 137 a, the are formed on the front plate until a claw 140 of the engaging part 139 engages with the small hole 100 b of the molding portion 100 of the male terminal. By engaging between a claw 140 ( 140 ) and the small hole 100 b ( 100 b), the female connector 133 ( 133 ') can be prevented from being separated from the male connector 90 ' ( 115 '). The projection portions 138 and 138 of the female to connections 133 and 133 'elastically touch the Plattenab sections 99 a and 99 a of the conductive portions 99 and 99 of the male terminals 99' and 115 '. Note that when the receiving portions 135 and 135 connections in the male at 90 'and 115' are inserted, the insertion is performed readily, since the remotely located end portions 100 a and a of the male terminals 90 'and 115' so bevelled 100 that their four surfaces ( Fig. 26) are gradually tapered in width and thickness toward the distal end.

Thus, when the male terminals 90 ', 115' and the female terminals 133 are coupled 133 ', these b not separate readily due to the engagement between the engagement claw 140 and the small hole 100 who the. However, the rear plates of the above-described recess portions 121 have been formed to arrange a lamp with the through holes 142 and 142 at the locations corresponding to the small holes 99 c and 99 c of the conductive portions 99 and 99 of the male terminals 90 'and 115 ' 37, and when, as shown in Fig. 37, a tool 143 having a narrow distal end from which the through hole 142 is inserted, the tool 143 is through the through hole 141 which in the rear plate of the female Terminals 133 (or 133 ') is formed and inserted through the small holes 99 c and 100 b of the male union 90 ' (or 115 '), the tool 143 being brought into contact with the engaging claw 140 , and will continue moved forward to bring the engaging claw 140 out of the small borehole 100 b, and in this state the female terminal 133 (or 133 ') can be pulled out are pulled, then the female union 133 (or 133 ') can easily be released from the male union 90 ' (or 115 ').

The reason why, as described above, the male terminals 90 , 90 ', 115 and 115 ' have been molded by the conductive portion 99 and the molding portion 100 is that a certain amount of thickness is required to make the connection to the female terminal 133 (or 133 ). That is, since the plate thickness of a metal material for forming the contact 75 and the like is thin, sufficient contact pressure could not be obtained even if the male terminals were connected to the female terminals 133 and 133 '. The molding portion 100 is then molded on the conductive portion to obtain a necessary plate thickness. Furthermore, since the molding portion 100 can be molded together when the insert molding is carried out, it has no cost impact. In the above From guide die of the remotely located end portion has to be a no metal portion, but may, of course, the panels portion 99 a of the conductive portion 99 continues 100 to the fernlie constricting end portion 100a to the Festig ness of the distal end portion 100 to increase a and prevent that it breaks.

In addition to the two-layer structure of a conductive portion and a molding portion may be a plat tenförmiger main section 145 and auxiliary portions 146 and 146 extending from the side margins of the main portion 145 and have substantially half the width of the Hauptab section 145, integrally TERIAL from a conductive Ma are formed, and the auxiliary portions 146 can be bent backward toward the main portion 145 , such as a male portion 144 shown in FIG. 27. Reference numeral 147 denotes an engagement hole for preventing separation. Furthermore, as with a male terminal 148 shown in Fig. 28, laterally elongated projections 150 and 150 may be formed at locations corresponding to the finger-shaped portions 137 a and 137 a and the projection portions 138 and 138 when a plate-shaped main portion 139 , which is made of a conductive material, is inserted into the female terminals 133 or 133 '. Numeral 151 denotes an engagement hole for preventing separation.

At the locations of the rear wall of the lamp recess portion 121 , which correspond to the through holes 81 and 81 'of the lamp body 73 , holes 152 and 152 ' are formed. Fastening screws (not shown) are inserted through the through holes 81 , 81 ', 118 , 118 ' and 152 , 152 'and screwed into the structure (not shown) of a sun visor. These screws form a means of attaching the makeup mirror 119 to the sun visor. Thus, since the holes for attaching the makeup mirror 119 to the sun visor are formed from a metal plate independently of the contacts 75 , 76 and 77 , deformation and damage when the fastening screws are tightened can be prevented. Also, since the rear wall of the main body 74 is increased in strength as compared to a case where the holes are formed in the plastic part of the main body 74 , this portion can be made thinner.

In the structure described above, the tubular bulb 42 is firmly held at its connecting parts 41 and 41 by the clamping parts 96 and 96 of the jaw 88 and the clamping parts 106 and 106 of the jaw 102 , which are arranged in the lamp body. The front opening of the lamp body 73 is covered with a lens body (not shown), whereby a lamp 153 is formed.

59740 00070 552 001000280000000200012000285915962900040 0002019519752 00004 59621Die reference numerals 154 and 154 (Fig. 19) designate stoppers for the incandescent bulb which the clamping parts 96 and 96 of the jaw holder 88 ent of a location on the lin-hand side wall 85 of the main body 74, the rule Zvi the center speaks, and protrude from a position of the right side wall 85 of the main body 74 which corresponds to the center between the clamping parts 106 and 106 of the jaw holder 102 . The stops 154 and 154 for the incandescent bulb are brought into contact with the end faces of the connecting parts 41 and 41 of the tubular bulb 42 described above, or are arranged near the end faces so that unnecessary movement of the tubular bulb 42 can be limited to one Fault, how to prevent a short circuit.

Reference numeral 155 denotes a cover for covering the front surface of the body 120 described above. The cover 155 is molded from a plastic in a plate shape, and the upper end is pivotally held at the upper end of the body 120 .

The cover 155 is formed at the opposite ends of its upper portion with holding portions 156 and 156 . The holding portions 156 and 156 are formed with through holes 157 and 157 that pass through them. As shown in FIG. 24, protrusions 158 and 158 to be operated protrude rearward from the upper ends of the rear surface of the holding portions 156 and 156, respectively. Recess portions 159 and 159 are formed in the inside of the holding portions 156 and 156 , that is, at the locations near the right side of the left holding portion 156 and the left side of the right holding portion 156 . Further, a pressure protrusion 160 is formed at a position to the right of the left recess portion 159 , which protrudes rearward.

In the right and left ends of the upper portion of the body 120 described above, recessed portions 161 and 161 are formed which are open to the front. Fastening holes 162 and 162 that extend laterally are formed over the left recess portion 151 . Similarly, mounting holes 162 and 162 are formed over the right deepening portion 161 .

The rear end walls of the recessed portions 161 and 161 described above are removed except for the lower end portions 163 and 163 , and the rear end portion of the upper surface wall is also removed. At the locations that are continuous with the lower surfaces of the rear end portions of the recessed portions 161 and 161 of the rear surface of the body 120 , flat recessed portions 164 and 164 ( FIG. 20) are formed, which extend in the up and down directions of the main body extend. Engagement claws 165 and 165 protrude into the upper central portions of the shallow recess portions 164 and 164, respectively.

The holding portions 156 and 156 of the cover 155 are arranged in the recessed portions 161 and 161 of the body 120 , and the opposite end of each of the holding pins 166 and 166 that pass through the through holes 157 and 157 becomes in the mounting holes 162 and 162 held. With this configuration, the right and left end portions of the upper end portion of the cover 155 are rotatably supported on the upper end portion of the body 120 .

Reference numerals 167 and 167 (FIGS . 20 and 40) denote position retaining springs which are made from a spring band material. Each of the position holding springs 167 and 167 consists of a vertically extending band-shaped main portion 168 and a working portion 169, the cut extending from the Hauptab is 168 extends rearwardly and downwardly bent. The main portion 168 is formed at its vertical central portion with an engaging hole 170 .

Before the cover 155 is attached, the main portions 168 and 168 of the position holding springs 167 and 167 are arranged in the flat recess portions 164 and 164 through the front sides of the lower end portions 163 and 163 of the rear walls of the recess portions 161 and 161 , and at the engaging holes 170 and 170 of the position retaining springs 167 and 167 engage through the engagement claws 165 and 165 in the flat recess portions 164 and 164 . In this state, when the cover 155 is held on the body 120 as described above, the front of the projections 158 and 158 of the cover 155 to be operated resiliently with the working portions 169 and 169 of the position holding springs 167 and 167 in Intervention. Therefore, the upper portions of the main portions 163 and 163 of the rear walls of the recess portions presses 161 and 161 ge against the front surface of the lower end portions 168 and 168, the lower portions of the main portions 168 and 168 are pressed against the shallow recess portions 164 and 164, and the engaging holes 170 and 170 of the main portions 168 and 168 are engaged with the engaging claws 165 and 165 so that the position holding springs 167 and 167 are prevented from being released from the body 120 . Therefore, the holding structure of the position holding springs 167 and 167 on the body 120 becomes easier.

Fig. 40 shows the closed state in which the cover 155 covers the front of the body 120 . In this closed condition, the projections 158 and 158 of the cover 155 to be operated are in elastic contact with the working portions 169 and 169 of the position holding springs 167 and 167 at positions higher than the rear ends of the through holes 156 and 156 which are the pivot supports . Therefore, a rotational force is applied to the cover 155 in the direction to hold the above-described closed state, that is, in the counterclockwise direction in Fig. 40, and the closed state is held.

Fig. 41 shows the open state wherein the cover 155 opens the front of the body 120. In this open state, the projections 158 and 158 of the cover 155 to be operated resiliently contact the working portions 169 and 169 of the position holding springs 167 and 167 at positions deeper than the lower ends of the through holes 156 and 156 which are the rotation supports. Therefore, a rotational force in the direction to maintain the open state described above, that is, in the clockwise direction in Fig. 41 from the cover 155 applied and the open state is held.

In the closed state of the cover 155 , the pressure projection 160 is arranged above the connection part 103 of the lamp body 73 , and when the cover 155 is rotated into the open state, as shown in FIG. 38, the pressure projection 160 presses the connection part 103 below. As a result, the connector 103 is bent downward, and the distal end of the connector 103 is brought into contact with the distal end of the connector 117 . This is a closed path of the Stromzu drove - a female connection 133 - male connection 115 '- contact part 114 - middle part 113 - connecting part 116 - connecting part 117 - connecting part 103 - connecting part 104 - jaw holder 102 - tubular bulb 42 - mouth holder 88 - reflector section 87 - Connection part 89 '- male terminal 90 ' - other female terminal 133 '- power supply formed, and the tubular bulb 42 is turned on.

When the tubular bulb 42 is turned on, the light is emitted forward, but since a relatively large reflector portion 87 is provided on the back of the tubular bulb 42 , the light from the tubular bulb 42 is effectively forward through the reflector portion 87 is sent. In particular, since the inclined portions 94 and 94 'have been formed in the reflector portion 87 , light which is emitted upwards or downwards is effectively emitted forward. The reflector portion 87 also functions as a heat interruption plate for protecting the main body 74 from the heat generated when the tubular bulb 42 is lit, and also works as a light shielding plate to prevent light from the bulb 42 from the main body 74 is transmitted through.

Reference numerals 171 and 171 ( Figs. 19 and 30) denote buffer stops made of rubber. Each buffer stop 171 is integrally formed with a round engaging head portion 172 and a mounting leg portion 173 which extends rearwardly from the rear surface of the head portion 172 . The mounting leg portion 173 is shaped so that its diameter decreases as it continues to its lower end. An annular groove 174 is formed between the head section 172 and the fastening leg section 173 .

Reference numerals 175 and 175 denote mounting holes formed in the right and left end portions of the lower end portion of the body 120 . The mounting leg portion 173 of the buffer stop 171 described above is inserted into the mounting hole 175 from the front. Since the front end portion of the mounting leg portion 173 is larger than the hole diameter of the mounting hole 175 , the mounting leg portion 173 is inserted into the mounting hole 175 by pulling the rear end portion of the mounting leg portion 173 rearward and deforming the front end portion. As a result, the annular groove 174 of the mounting leg portion 173 is engaged with the opening end of the mounting hole 175 . The buffer stops 171 and 171 are fixed in the body 120 in this way, and the Befestigungsbeinab sections 173 and 173 are cut off except for the front end portions. As a result, the size of the rear protrusion can be reduced.

When the rotation of the cover exceeds 155 in a specific position when the cover is closed 155, a rotational force in the direction to the closed position is applied to the cover 155 by the position holding springs 167 and 167, so that the possibility exists that the cover 155 moved into the body 120 and causes the appearance of a sound. However, since in the makeup mirror 119 described above, the lower end portion of the cover 155 is brought into contact with the head portions 172 and 172 of the buffer stops 171 and 171 and cushioned, the occurrence of a noise can be prevented.

Next, a method of manufacturing the make-up mirror body 73 described above will be described.

First, a continuous contact set comprising a plurality of contact sets, each comprising three contacts 75 , 76 and 77 and two reinforcement members 78 and 79 , is formed.

Fig. 42 shows a contact set 176th

Reference numerals 177 and 177 'denote base bands which are spaced apart and extend parallel to one another, and reference numerals 178 and 178 (only two are shown) denote narrow sub-frame bands which are laterally spaced apart and extend between the base bands 177 and 177 '. A contact set 176 is formed within a space which is delimited by the two sub-frame tapes 178 , 178 and the base tapes 177 , 177 '.

Reference numeral 179 denotes a connection band portion extending from the position toward the base band 177 at the right edge of the upper portion of the sub-frame band 178 . The right end of the connecting band portion 179 is connected to the left end of the reinforcing member 78 . The intermediate portion of the connecting band portion 179 is connected to the left end portion of the middle portion 113 of the contact 77 .

Reference numeral 180 denotes a connecting tape portion extending from the position toward the base tape 177 on the left edge of the upper portion of the sub-frame tape 178 . The left end of the connecting band section 180 is connected to the right end of the middle section 113 of the contact 77 . The inter mediate portion of the connecting band portion 179 is connected to the upper end portion of the connecting part 104 of the contact 76 .

Reference numeral 181 denotes a connecting band portion extending from the position toward the base band 177 'on the right edge of the lower portion of the sub- frame band 178 . The right end of the connecting band section 181 is connected to the left end of the reinforcing section 92 of the contact 75 .

Reference numeral 182 denotes a connecting band section extending from the position toward the base band 177 'on the left edge of the lower portion of the sub- frame band 178 . The left end of the connecting band portion 182 is connected to the right end of the reinforcing member 79 . The intermediate portion of the connecting band portion 182 is connected to the right end of the reinforcing portion 92 of the contact 75 .

A plurality of contact sets 176 (only one is shown) are formed side by side and form a Kontaktatzatzkon tinuum 183 .

In Fig. 42, the contacts 75 , 76 and 77 and the reinforcing members 78 and 79 have already been formed by die-cutting, but a prototype of a contact set continuum comprising a plurality of prototypes of contact sets is first cut out of unnecessary portions from one Sheet metal as in the case of the first embodiment has been formed.

Thereafter, a contact set continuum 183 , such as that shown in Fig. 42, is formed by die cutting. The reference characters 184 , 184 , 184 and 184 are guide holes which are formed in the base bands 177 and 177 'and used for alignment in die-cutting.

The above-described contact set continuum 183 is set so that one of the contact sets 176 is placed in the mold for the main body of a molding machine, and a resin for the main body is injected into the mold for the main body so that a lamp body 73 is molded in which the main body 74 is made of a synthetic resin and the contact set 176 is formed in one piece. The formation of the lamp body 73 is performed in turn for each contact set 176 of the contact set continuum 183 , thereby forming a lamp body continuum 65 (not shown) in which a plurality of lamp bodies 73 are continuously connected.

Each of the lamp bodies 73 is separated from the lamp body continuum described above to form a plurality of lamp bodies. The lamp bodies 73 are cut off at 185, 185, 185 and 185 of the connecting band sections 179 , 180 , 181 and 182 . The separation points 185 , 185 , 185 and 185 are located in the groove sections 86 , 86 , 86 and 86 of the side walls 85 and 85 of the main body 74 and along the inner sides of the groove sections. With this configuration, the separation becomes easy, and there are no separated ends protruding from the side walls of the main body 74 .

Simultaneously with the severing described above, the tie band sections 179 , 180 and 182 are severed at the locations shown by 186a, 186a and 186b. As a result, the contact 75 and the reinforcement member 79 are disconnected, the contacts 76 and 77 are disconnected, and the contact 77 and the reinforcement member 78 are disconnected.

At the time of the separation described above, the separation holes 82 , 82 and 82 are also formed.

In the above-described training, a current supply method was provided by connections and cables, but if a separation is not carried out at the points 186 a and 186 a, this structure can also be supplied with current via the reinforcing parts 78 and 79 by means of a screw connection, using conductive screws as in the first embodiment described above.

Figs. 43 to 45 show a modification of the lamp body 73 A in the above-described second embodiment.

While in the lamp body 73, the male terminals 90 , 90 ', 115 and 115 ' from the inner ends of the opening sections 84 , 84 , 84 and 84 , which are open to the side surfaces, the front surface and the rear surface of the main body, protrude in this lamp body 73 A, the male terminals from the inner ends of the recess portions 187 , 187 , 187 and 187 , which are open to the side surfaces and the rear surface of the skin body. In this embodiment, the male connections are not exposed when viewed from the front, and the lamp body 73 A is manufactured with a more attractive appearance.

In the male terminals, the male terminals 144 , 144 , 144 and 144 shown in Fig. 27 were used in the manner in which a required plate thickness is obtained by bending back. Of course, the male terminal of the type shown in the first embodiment can be used, or the male terminal 148 of the type shown in Fig. 28 can be used.

A part of a connecting part 104 A of a contact 76 A is shaped into a U-shape so that it can be embedded along the recess portion 187 of the side wall 85 A.

A contact 75 A consists of a reflector section 87 A, which is shaped into a large, flat, rectangular shape, a connecting part 189 which protrudes downward from the lower end of the reflector section 87 A, and rising parts 190 and 190 which follow protrude from the opposite ends of the connector 189 . The male ports 144 and 144 extend left and right from the front ends of the rising portions 190 and 190 .

A contact 77 A consists of a vertically elongated middle part 113 A and rising parts 191 and 191 , which project forward from the lower, opposite ends of the central part 113 A. The male terminals 144 and 144 extend to the left and right of the upstream portions 191 and 191 before their ends.

FIGS. 46-63 illustrate a third embodiment of the plastic part integrally formed with metal elements and the method for producing a plastic part, which is integrally molded with metal elements. This third embodiment of the present invention is applied to a lamp body for room lamps and its manufacturing method.

Reference numeral 192 denotes a room lamp and 1 93 a main body for it.

The main body 193 is made of a synthetic resin and is seen with a flat, bowl-shaped main portion 195 which has a recess portion 194 open to the front.

A shallow recess portion 196 having one of the vertically elongated opening 197 is further formed in the central side portion of the main body 195 except for its upper end portion.

The upper end portion 194 a of the recessed portion 194 a little deeper than the remaining part of the depression portion 194th In the middle portion of the edge portion between the upper end portion 194 a and the remaining portion, a pair of laterally spaced partitions 198 and 198 are attached.

Engagement claws 199 and 199 protrude from the upper surfaces of the partition walls 198 and 198 described above, respectively. In the inner surface of the lower portion of a peripheral wall 220 surrounding the recess portion 194 , engaging holes 201 and 201 ( Fig. 52) are formed which are laterally spaced.

Between the partition walls 198 and 198 , a mounting hole 202 ( FIGS. 48 and 55) is formed, which passes through the recess portion 196 in the forward and backward direction of the main body.

In places of the recess portion 196 slightly deeper than the partitions 198 and 198 , recess portions 203 a, 203 b and 203 c ( FIG. 55) are formed, which are arranged in an arc shape with respect to the mounting hole 202 described above. The lower opening end of each recess portion 203 a, 203 b and 203 c is formed into a convex surface.

Through holes 204 , 204 , 204 and 204 are formed in the vertically intermediate portions and lower end portions of the recess portion 196 . Each through hole 204 consists of a front, large hole portion 204 a and a rear, small hole portion 204 b. The diameter of the large hole section 204 a is Chen Chen wesentli two times larger than that of the small hole section 204 b.

A rib 205 protrudes from the central portion of the lower end portion of the recess portion 196 .

A wall 206 a ( Fig. 47 and 53) protrudes rearward from the upper end and the side portions of the recess portion 197 , and a wall 206 b ( Figs. 47 and 51) protrudes rearward from the lower end and the Seitenab of the recessed portion 197 .

A support wall 207 ( Fig. 48) protrudes rearward from the rear surface of the main portion 195 which corresponds to the central portion of the upper end of the recess portion 196 described above. Partitions 208 and 208 ( Figs. 48 and 56) protrude upward from the opposite ends of the upper surface of the holding member 207 . Ver reinforcement walls 209 and 209 ( Fig. 48 and 56) protrude downward from the central portion of the lower surface of the holding part 207 .

Reference numeral 210 ( Fig. 57) denotes a first contact which is integrally molded with a connecting part 211 which is formed into an inverted C-shape when viewed from the front, an incandescent lamp holder part 212 which is connected to the lower end portion of the connecting part 211 is connected, and contact portions 214 b and 214 c, which are connected to the upper end of the connecting part 211 via parallel spaced connecting parts 213 and 213 .

The bulb holder part 212 is integrally molded with a V-shaped bulb holder portion 215 when viewed from the side direction, and a plate-shaped base part 216 connected to the lower end of the bulb holder portion 215 . The base part 216 is located at a position slightly from the rear surface of the lower end of the connecting part 211 described above, and the lower end portion of the left edge is connected to the left end of the lower end portion of the connecting part 211 . The incandescent lamp holding section 215 has an incandescent lamp contact part 215 a on the side remote from the base part 216 . The light bulb contact part 215 a is formed at its central portion with a chamfered slot 215 b.

Each of the contact portions 214 b and 214 c is curved into a convex shape, so that the side central portion is arranged forward.

The connecting part 211 is formed with a plurality of small holes 217 .

The first contact 210 , constructed as described above, is integrally coupled to the main body 193 described above by the so-called insert molding. The base part 216 of the bulb holding part 212 is embedded in the middle portion of the lower end portion of the main portion 195 of the main body 193 so that the bulb holding portion 215 protrudes from the upper surface of the wall 206 b as shown in FIG. 51. The connecting part 211 is exposed to the front of the recess portion 196 . The contact portion 214 b is positioned so that it covers the front surface of a portion between the recess portions 203 a and 203 b, and the contact portion 214 c is arranged so that it covers the front surface of a portion between the recess portions 203 b and 203 c covered. The small holes 217 of the connecting part 211 are filled with the plastic material for the main body 193 , thereby preventing the connecting part 211 from being easily separated from the main body 193 .

A second contact 218 ( FIG. 57) is integrally molded with a connector 219 which is formed into a downward opening U-shape when viewed from the front, with an incandescent lamp holder 220 connected to the lower end of the connector 219 . and a connector 221 is connected to the upper end of the connector 219 .

The incandescent lamp holding part 220 consists of an almost quite corner-shaped base part 222 and an incandescent lamp contact part 223 which is connected to the lower end of the base part 222 . The front end 223 a of the bulb contact part 223 is curved into a convex shape in the forward direction. A main part 223 b protrudes rearward from the lower end of the front end portion 223 a and is formed at its central portion with a chamfered slot 223 c.

The connector 221 is integrally molded with an L-shaped connector 224 when viewed from the side and an insert 225 which protrudes from the rear end of the connector 224 . The front end of the connecting part 224 is connected to the upper end of the connecting part 219 .

The connecting part 219 is formed with two small holes 217 .

In the second contact 218 constructed in this manner, the base portion 222 of the bulb holder portion 220 is embedded in the main portion 195 of the main body 193 near the upper end of the opening 197 , with the lower portion of the base portion 222 downward from the upper end of the opening 197 protrudes, and the bulb holding contact 223 protrudes rearward from this lower portion ( Fig. 51). Therefore, two incandescent lamp contact parts 223 and 215 a are vertically spaced and opposite within the opening 197 .

In the connection part 221 described above, the connec tion part 224 is embedded in the support wall 207 of the main body 193 so that the insert part 225 protrudes upward from the upper surface of the holding wall 207 ( Fig. 56).

The connector 219 is exposed to the left end portion of the upper end portion of the recess portion 196 , and the small holes 217 are filled with the plastic material for the main body 193 , thereby preventing the connector 211 from easily separating from the main body 193 .

A third contact 226 is integrally formed with a connec tion part 227 , a contact portion 214 d and a connection part 228 .

The connecting part 227 comprises a laterally extending narrow band plate and is formed in its central portion with a small hole 217 .

The contact portion 214 is d bent at its right end to a convex shape, as shown in Fig. 57, and the Kontaktab d is the upper end of the left end portion of section 214 through the connection part 229 to the lower end of the left end of the connecting part 227 connected, as shown in Figs. 55 and 57.

The connector 228 is integrally formed with a generally L-shaped connector 230 when viewed from the side and an insert 231 which extends from the top of the connector 230 upward. The front end of the lower end portion of the connector 230 is continuous to the right end of the connector 227 described above.

Thus, in the connector 228 of the third contact 226, the connector 230 is embedded within the reinforcement wall 209 of the main body 193 so that the insert 231 protrudes upward from the upper surface of the support wall 207 ( Fig. 56). Therefore, the two insert members 225 and 231 are laterally spaced and opposite. The con tact section 214 d is arranged so that it covers the left edge portion of the recess portion 203 c of the Hauptkör pers 193 , and the connecting part 229 and the connecting part 227 are exposed at the front of the main body 193 . Then, the small hole 217 of the connec tion part 227 is filled with the synthetic resin material for the main body 193 , thereby preventing the connecting part 211 from being easily separated from the main body 193 .

A fourth contact 232 ( Fig. 57) is integrally formed with a generally U-shaped connecting part 233 in the form of a narrow band, a contact portion 124 a, which is connected to the upper right end portion of the connecting part 233 , and with grounding parts 235 , 235 , 235 and 235 connected to the connector 233 via connectors 234 , 234 , 234 and 234 protruding from the upper left end portion, the upper right end portion, the lower left end portion and the lower right end portion of the connector 233 . Each of the connecting parts 234 , 234 and 234 is formed with a rising portion 234 a to provide a step portion between the connecting part 233 and the grounding part 235 .

Each grounding part 235 is shaped in a ring shape, which has a through hole 235 A. The contact portion 214 a is bent into a convex shape so that its left end extends rearward. The upper right end portion of the connecting part 233 is formed with small holes 217 and 217 , and the upper left end portion is formed with embedding parts 236 , 236 and 236 .

The connection part 233 of the fourth contact 232 is embedded inside the right wall of the narrow recess portion 196 of the main body 193 except for the upper and lower ends of the right part of the connection part 233 , the grounding parts 235 , 235 , 235 and 235 are along the peripheral portion of the recess portion 196 arranged, and the embedding parts 236 , 236 and 236 are embedded in the left wall of the recess portion 196 . The small holes 217 and 217 of the connecting part 233 are filled with synthetic resin material for the main body 193 , thereby preventing the connecting part 211 from being easily separated from the main body 193 .

The contact portion 214 a is arranged so that it covers the right edge portion of the recess portion 203 a of the main body 193 . Each grounding member 235 is arranged on the front surface of the large diameter portion 204a of the through hole 204 of the main body 193 , and the peripheral portion of the grounding member 235 is embedded within the main body 193 so that the through hole 235a of the grounding member 235 to the section 204b small diameter of the through hole 204 is aligned.

Reference numeral 237 denotes a switch button. The switch button 237 consists of a molding portion 238 made of synthetic resin, and a connecting portion 239 which is integrally molded with the molding portion 238 by insert molding. The Formungsab section 238 consists of a thick, plate-shaped main portion 240 and a handle portion 231 , which protrudes from the upper end of the main portion 240 . The main portion 240 is formed at its lower portion with a through hole 242 therethrough.

The connecting portion 239 is formed into a vertically elongated band plate shape from a material that has conductivity and spring action. The connector portion 239 is formed at its lower end portion with a contact portion 234 protruding rearward in an arc shape when viewed in the upper and lower directions, and at its upper end portion with a through hole 244 .

The upper half portion of the connecting portion 239 is inserted from the lower end of the main portion 240 of the molding portion 238 into the grip portion 241 , and the lower half portion protrudes downward from the lower end of the molding portion 238 . The through hole 244 of the connecting portion 239 is aligned with the attachment hole 242 of the molding portion 238 .

The reference numeral 245 ( Fig. 48) denotes a fastening rivet that has a head portion 245 a and a shaft portion 245 b. The shaft portion 245 b is inserted into the mounting hole 242 of the switch button 237 and further into the mounting hole 202 of the main body 193 described above. The distal end portion of the rivet 245 protruding from the rear of the main body 193 is compressed, and the switch knob 237 is rotatably attached to the main body 193 . In this state, the contact portion 243 of the connecting portion 239 is movable on and along a portion where the contact portions 214 a, 214 b, 214 c and 214 d of the main body 139 are arranged in an arc.

As has been described above, there is the scarf button 237 , since the connecting portion 239 , which is formed with a metal plate, extends over the mounting hole 242 , which is a rotary support, and to the handle portion 241 , the advantage that Strength of the entire switch button 237 is increased.

Reference numeral 246 denotes a lens which is shaped to have a size such that it can cover the recessed portion 194 of the main body 193 from just above the partitions 198 and 198 to the lower portion. The lens 246 is at the inner left and right ends of the upper portion of the peripheral wall portion 244 with engaging protrusions 248 and 248 ( Fig. 53) and at the outer left and right ends of the upper portion of the peripheral wall portion 247 with engaging protrusions 249 and 249 ( Fig. 52 ) shaped. The lower engaging protrusions 249 and 249 engage the engaging holes 201 and 201 formed in the lower inner surface of the peripheral wall 200 of the main body 193 . The inner edge of the lower end portion of the peripheral wall portion 247 further contacts the lower surface of the rib 205 formed in the main body 193 as shown in FIG. 48. The upper engaging protrusions 248 and 248 formed in the upper end portion of the peripheral wall portion 247 also engage the engaging claws 199 and 199 formed on the upper surface of the partition walls 198 and 198 of the main body 193 as shown in FIG. 53 is shown. In this way, the lens 246 is attached to the main body 193 .

The above-described switch knob 237 passes through an opening portion 250 formed in the central portion of the upper end portion of the peripheral wall portion 247 of the lens 246 , and the grip portion 241 protrudes from the lens 246 .

Reference numerals 251 , 251 , 251 and 251 denote groove portions formed in the right and left side walls of the main body 193 .

Before the lens 246 is attached to the main body 193 , an incandescent lamp 252 is held with its connecting sections 253 and 253 , which engage in the chamfered slots 215 b and 223 c of the incandescent lamp contact parts 215 a and 233 .

Before the lens 246 is attached to the main body 193 , fastening screws 254 , 254 , 254 and 254 , which are formed from a conductive material, are inserted from the front into the through holes 204 , 204 , 204 and 204 , and into the structural elements ( not shown) screwed in a motor vehicle. Then, the Kopfab comes section 254 a of each fastening screw 254 to the grounding portion 235 of the fourth contact 232 in contact, and at least one of the structural elements in which the Fixed To setscrew is screwed in 254, a routing has ability. Therefore, the fourth contact 232 , that is, the contact portion 214 a, receives a ground level. Note that since the number of grounding parts 235 is four, any one of them can be grounded, so that this embodiment gives great flexibility in terms of a location.

A connector (not shown), which is seen on the vehicle side, is connected to the insert members 225 and 231 described above. Therefore, the insert part 225 is connected to a power supply, and the insert part 231 is connected to ground via a door switch (not shown). That is, the bulb contact portion 223 is connected to the power supply, and the contact portion 214 d is connected to the ground through the door switch.

Therefore, the filament lamp 252 does not light up when the switch knob is located 237 in its neutral position, where the contact portion 243 is the button 237 with the contact portions 214 b and 214 c in contact, because a terminal portion 253 of the bulb 252 connected to the power supply but the other terminal section 253 has not been connected to ground. If the switch button 237 from the above-described neutral position is inclined to one side, and the contact portion 243 of the button 237 in contact with the contact portions 214 a and 214 b, the other terminal portion 243 is connected to ground, and the bulb 252 lights . On the other hand, the switch knob 237 is tilted from the neutral position to the position in the opposite direction, and the contact portion 243 of the knob 237, the contact portions 214 c and contacts 214 d, the bulb 252 is not th Glow when the door is in the closed state, located (because the other connection section 253 is not connected to ground), whereas if the door is opened and the door switch is closed, the other connection section 253 is connected to ground and the light bulb 252 lights up.

At this time, an operator, since the con tact surface of the contact portion 243 of the switch knob is formed 237 with a convex surface, and the con tact sections 214 a, 214 b, 214 c and 214 d are also curved, know that the switch button 237 a predetermined Has reached position (there is a feeling when clicking). The switch button 237 can also be reliably held in a predetermined position. The switch button 237 can also be tilted gently.

Next, a method of manufacturing the room lamp 192 described above will be described.

First, a contact set continuum is formed that includes a plurality of contact sets, each including 4 contacts 210 , 218 , 226 and 232 .

Fig. 57 shows a contact set 255th Using a metal plate with conductivity, the contacts 210 , 218 , 226 and 232 are integrally formed by being connected by band sections 256 , 256 , 256 and 256 of small width.

In Fig. 57, the contacts 210, 218, 226 and 232 are shown in the state in which they have been ge already dies formed, whereby a prototype of a Kontaktsatzkon tinuums a plurality of prototypes of sets of contacts to only unnecessary by recessing portions of a Sheet material is shaped as in the case of the first embodiment. Thereafter, the contact set 255 , as shown in Fig. 57, is formed by stamping.

Then in the state in which the contacts have been formed as a contact set 255 , the bulb holder part 212 of the first contact 210 has been bent backwards with respect to the connec tion part 211 , so that the bulb contact part 215 a of the bulb holder part 212 vertically the other bulb contact part 223 is opposite. If such a structure is not adopted, and at the time of die-cutting, a prototype bulb holder part and a prototype bulb contact part are arranged in the forward and backward directions, the vertical lengths of the parts become longer and they will overlap each other. Therefore, they are displaced at the time of Ausstanz molding laterally to each other, and at the time of punching forming the incandescent is penhalteteil 212 bent in relation to the connecting part 211 so in the above example that the bulb contact portion 215 a of the lamp holding part 212 vertically to the bulb contact portion 223 against overlaps.

When the light bulb mounted 225 or is removed, the bulbs holding parts are not separated from 212 and 220 from the Hauptkör by 193, since the base portions 216 and 222 of the incandescent penhalteteile have been embedded in the main body 193 212 and 220th

The strength of the contact assembly 255 Additionally, since four grounding members 235 are disposed at the four functions Posi and connected by the connecting part 233 having the form of a frame structure is increased, and it is deformed during the handling not readily available.

Further, since each connecting part 234 that connects the grounding part 235 and the connecting part 233 is formed with the rising portion 234 a, the position of the grounding part 235 can be easily adjusted by adjusting the bending angle of the rising portion 234 a . In addition, the rising portion 234 a absorbs the contraction after the injection of the resin for molding the main body 193 and fulfills a function to prevent the dangerous deformation of the contact 232 .

A plurality of such contact sets 255 (not shown) are continuously formed to create the contact set continuum 257 . The contact set continuum 257 is produced by connecting the grounding parts 255 of adjacent contact sets 255 through coupling straps 258 .

The contact set continuum 257 described above is set so that one of the contact sets 255 in the mold for the. Main body of a molding machine is positioned, and a resin for the main body is injected into the mold for the main body, so that a lamp body 258 is formed, in which the main body 193 is made of the resin, and the contact set 255 is integrally formed. The formation of the lamp body 259 is performed sequentially for each contact set 255 of the contact set continuum 257 , thereby forming a lamp body continuum (not shown) in which a plurality of lamp bodies 259 are continuously connected.

In the lamp body 259, since most of the base part 216 of the lamp part 212 and most of the base part 222 of the lamp holding part are embedded in the plastic material of the main body 134 220, the strength of the incandescent lamp holding parts 212 and 220 is increased and they can withstand a large force that is generated when the incandescent lamp 252 is attached or removed.

Each of the lamp bodies 259 is separated from the lamp body continuum described above to form a plurality of lamp bodies 259 . The separation of the lamp body 259 is performed on the sections 260 , 260 , 260 and 260 of the coupling bands 258 , 258 , 258 and 258 . The separation points 260 , 260 , 260 and 260 are in the groove sections 251 , 251 , 251 and 251 on the outer side wall of the main body 139 and along the inner surfaces of the Nutenab sections. In this embodiment, the separation is a fold and there are no separated ends from the side walls of the main body 193 .

Simultaneously with the separation described above, separation holes 261 of the main portion 195 of the main body 193 are formed, and by forming the separation holes, the connecting band portions 256 through which the contacts 210 , 218 , 226 and 232 are connected are separated. This separation electrically isolates contacts 210 , 218 , 226 and 232 from one another.

Figs. 58 to 63 show modifications of the switch knob in the above-described space 192 and the air supply whose Fixed To.

In the modification shown in FIG. 58, a fastening piece 263 with a slit 262 protrudes from the main body 193 and reaches the front end of the main body 193 . The mounting pin 263 is inserted into a mounting hole 242 of a switch button 237 , and the engaging projections 264 and 264 of the mounting pin 263 engage the front open edge of the mounting hole 242 so that the switch button 237 is rotatably supported on the main body 193 .

In the modification shown in Fig. 59, the surface of the fixing pin 263 shown in Fig. 58 is covered with metal plates 265 and 265 which are integrally molded in the main body 193 by insert molding.

In the modification shown in Fig. 60, generally L-shaped metal plates 266 and 266 are integrally molded in the main body 193 by insert molding. The protruding portions 266 a and 266 a of the metal plates 266 and 266 are inserted into a mounting hole 242 of a switch button 237 , and the bulged portions 266 b and 266 b of the metal plates 266 and 266 engage the front, open edge of the mounting hole 242 so that the switch button 237 is rotatably supported on the main body 193 .

In the modification shown in FIG. 61, a mounting pin 268 having a slot 267 extending from the rear surface of a switch button 237 to the rear end is integrally molded in a molding portion 238 . The fixing pin 268 is inserted into a fixing hole inserted 269, which is formed in the main portion 195 of the main body 193, and the engagement projections 270 and 270 of the fixing pin 268 open edge of the main body 193 engage the rear of the mounting hole 269 so that the switch knob 237 is rotatably supported on the main body 193 .

In the modification shown in FIG. 62, the surface of the fixing pin 268 shown in FIG. 61 is covered with overlap portions 271 and 271 which protrude from the edge of the through hole 244 of the connecting portion 239 .

When in Fig. 63 shown modification are Fixed To supply leg portions 272 and 272, before projecting from the rear surface of the forming section 238, from the edge of the through hole 244 of the connecting member portion 239 ago. The mounting leg parts 272 and 272 are inserted into a mounting hole 269 , which is formed in the main portion 195 of the main body 193 , and bulging sections 272 a and 272 a of the mounting leg parts 272 and 272 are so engaged with the rear, open edge of the mounting hole 269 that the switch button 237 is rotatably supported on the main body 193 .

Therefore, the present examples and embodiments forms considered as illustrative and not restrictive and the invention is not to be given here Details limited, but can be within the range ches of the appended claims.

Claims (13)

1. A method for producing a plastic part, which is integrally formed with metal elements, characterized marked by the steps
Inserting a metal element set integrally formed with a plurality of kinds of elements by bridges into dies for molding a main body made of plastic,
Injecting plastic for a plastic main body into the molds for molding the main plastic body to form a plastic part as an intermediate body in which a plastic main body and the metal member set are integrally molded, and
Separating the bridges to make the plurality of metal elements independent, thereby producing the plastic part molded integrally with metal elements. 2. The method according to claim 1, characterized in that the plastic for a main body made of plastic un ter is injected under the condition that two neighboring bearded metal elements in a close condition by pressure pins are pressed and positioned by both compressed molds protrude. 3. The method according to claim 1, characterized in that the plastic mentioned is an ABS resin.   4. The method according to claim 1 or 2, characterized in net that the elements are formed from metal material that has conductivity and elasticity. 5. Plastic part that is integrally formed with metal elements GE, characterized in that a plurality of separation holes ( 8 ; 82 ; 261 ) are formed in a main body ( 2 ; 74 ; 193 ) made of plastic by a molded part with a Metal element set ( 176 ; 255 ) is formed, which is integrally formed with a plurality of types of metal elements with bridges ( 59 ), and that the bridges are separated at the separation holes ( 8 ; 82 ; 261 ) to the plurality of types of metal elements to make independent. 6. The plastic part according to claim 5, characterized in that a test hole ( 13 ) in the main body ( 2 ; 74 ; 193 ) is molded from plastic and that portions of two of the metal elements which are adjacent in a close state through the test hole ( 13 ) are exposed. 7. lamp body, which comprises the plastic part according to claim 5, characterized in that an electric light bulb ( 49 ; 252 ) of metal elements ( 22 , 23 ) of the lamp body ( 1 ) is held, to which electrical current for the light bulb through the metal elements and that a lens ( 246 ) covers the front of the lamp body. 8. Lamp body according to claim 7, characterized in that part of the metal elements form a connection of the switch section ( 214 a, ... , 214 d). 9. Lamp body according to claim 8, characterized in that the metal elements are formed by:
a section connecting one end of the incandescent lamp ( 49 ; 252 ) to a power source,
a section connecting the other end of the light bulb to the switch section, and
a section that connects the power source section to the switch. 10. The lamp body according to claim 7, characterized in that it further comprises a mirror ( 44 ), a make-up mirror body which holds the lamp body ( 1 ) and the mirror, and a cover ( 51 ) which is attached to the main body portion, to open and close the front of the mirror and lamp ( 49 ). 11. The lamp body according to claim 7, characterized in that there are further provided a mirror ( 44 ), a main body section which carries the lamp body and the mirror ( 44 ), and a cover ( 51 ) which is attached to the main body section, to open and close the front of the mirror and lamp ( 49 ), whereby the switch can be turned on or off according to the opening / closing of the cover. 12. Lamp body according to claim 8, characterized in that the switch section ge from two metal elements is formed, which are provided in parallel so that Switch is on when one of the Metallele elements in contact with the other metal element is brought. 13. The lamp body according to claim 8, characterized in that the switch section is further provided with a switch button ( 237 ) to switch on the switch when a conductive part ( 243 ), which is provided on the switch button ( 237 ), with the metal elements is brought into contact, the connections of the switch terabschnittes ( 214 a,..., 214d).