DE4426350A1 - Integrated switch system with injection-moulded plastic body for vehicle internal light - Google Patents

Abstract

The integrated switch assembly has a main housing (1) that is produced in what is termed a two shot moulding with the first operation using a metallised plastic. Projections (12, 25, 31) are formed that relate to the elements of three switches assemblies (18, 21, 24). Contacts and tracks (11, 27, 32, 8, 9) are formed on the surface of housing and a contact plate (10) is moulded into the body. Two of the switches are of a rocker type (18, 21) with plunger elements (14) engaging contact carriers (13). The other switch is a push button type with sliding contact (28).

Description

The known switches, in particular switch systems, are constructed from a variety of components, such as for example housing, buttons, contact bridges, sliders, Plug connection, base plate, conductor tracks, lamp housing etc. It is also known to simplify the Building contact connections and grinding systems, such as Sliding contacts and touch contacts on flat ge printed printed conductors. However, this sets ahead that such a trace in a surrounding Housing must be installed. By the used Individual parts and the assembly costs are such switches systems are therefore complex.

The research association for spatial electronic construction groups 3-D MID e.V. in Erlangen, on the other hand, has one Reprinted, in which it is proposed, spatial che structures, such as plastic housing, the same early for direct attachment and attachment of conductors webs and electronic components. Here In particular, a method has become known, injection Pour molded conductor body into the housing. These Molded conductor body in a "two-shot" injection molding techno be molded with the plastic housing  the property that their surface by metallization (in one with the production of printed circuit boards comparable processes) can be provided with conductor tracks can. Hoechst AG considers this to be suitable Plastics called Vectra C 810 or Vectra 820, which at play with an easy flowing other art fabric, e.g. B. Vectra C 115 or LCX 364, cast in this way can be that of the metallizable conductor molding per surfaces on the surface of the entire casting remain, which can later be metallized and as Conductor tracks or contact areas can serve.

The object of the invention is therefore to provide a switch system admit in which the technique described can be used and which by integrating the building mentioned above to produce elements inexpensively in large quantities and is easy to assemble.

The invention is therefore based on a switch system Gat resulting from the preamble of claim 1 tion and solves the task by knowing yourself drawing part of claim 1 resulting combination of features nation. In principle, the invention therefore consists in the housing by means of the molded conductor body connecting Form conductor tracks immediately. Parts can use the conductor tracks directly as switch contacts det be so that in the housing according to the teaching of Er Find essential parts of the switch system directly are shaped. While the teaching of claim 1 indirectly the possibility indicates the fixed contacts of a Forming the switch directly into the housing is recommended the feature regarding the moving contact  combination according to claim 2. Thereafter, the movable che contact by one of the molded conductor body end at its end movable leg or tongue forms, so that the movable switch contact directly is integrated in the housing. In the context of Invention one or more molded conductor body molded his. However, it is advisable to use only one if possible single molded body to use, the surface by a second injection molding into the corresponding one Conductor tracks is divided. The combination of features according to Claim 2 can also multiple times in a switch system be turned, with several on one leg electrically separated conductor tracks and contacts can be provided. It can be ent speaking arrangement and storage of the actuator determine its direction of movement leading to a contact hand over the thigh. For example, the springy thighs by a pressing, but also by a pushing or rotating movement of the actuation member brought into contact with the housing-fixed contact will.

According to the combination of features according to claim 3 it is also possible to use the switch system according to the invention To provide rocker contacts or snap contacts. Terms Lich the storage for the switching beam is not Cutting contact chosen because the very thin aufmetalli based conductor layer would be destroyed relatively quickly. A lot the control bar rolls more on the curved surface surface of the housing projection, so that a grinding movement is avoided on a linear contact surface. The basic design of the actuator is on  known. The switching principle according to claim 3 can ver both for on-off switch, but also for changeover switch turn.

The one that forms the bearing for the rocking switch beam Head start can be according to the combinations of features Claim 4 over the molded conductor body also in the Ge housing of the switch system. The Shaped conductor body designed so that it with its front jump protrudes over the surface of the housing. Preferably the longitudinal axis of the protrusion is parallel to the surface che surface of the housing.

To make a point contact with those described above to reach different switches is recommended in Development of the invention according to the combination of features Claim 5. Thereafter, the conductor tracks have contacts, for example, hemispherical protrusions for a good essentially point-like contact even then worry if the assigned, opposite contact has a flat contact surface.

In some cases, the size of the lei to be transferred leaves power or the frequency of switching movements to one or both communicating with each other Contacts are made of electroplated metal because the resulting metal layer is too thin. In In these cases, the use of the combination of features recommend according to claim 6. In doing so, the crit the current through a known con baffle plate passed through the interior of the housing. The Kon baffle plate can be used during the first casting process  be molded into the molded conductor body, so that one can conduct the conductor not only on the top galvanized layer holds, but also in a deeper through the housing body per walking shift. Contact plates can also be used poured into the housing in superimposed levels his. Because of the great mechanical strength of such Sheets can also be used as cutting bearings for Rocker contacts or as fixed contacts for larger lei serve to transfer messages.

In many cases it is necessary to switch the Currents or the lighting indicator in one of the Ge to lead away from the floor of the house, for example, for the switching of a contact a stroke of the key allow or to open a window in the button by a na to light up the button arranged light bulb. In the In these cases, it is advisable to use the combination of features nation according to claim 7. With the use of the description A pedestal-shaped approach is possible, which is represented by Gal vanize the conductor surface of the applied conductor track not only in the plane of the case bottom, but also the conductor tracks perpendicular to this plane to lead. The approaches can claim several wear parallel traces. This can be done by doing that during the second Injection molding the approach of the molded conductor body by opening inject corresponding webs into individual metallizable Areas divided. On these (parallel) conductor tracks then then, according to the combination of characteristics according to An Say 9 attack a moving contact that the parallel paths in the switching state with each other short closes. However, an incandescent lamp can also be switched on  which indicates the switching status of the switch or the position of the operating button of a switch. Such Approaches can be according to the features of claim 10 also serve to store actuation buttons and caps, but then they do not have to be metallized. Therefore, you can also from the during the second spray cast plastic material used, wel ches can not be metallized.

The combination of features according to claim 10 further shows the possibility of moving the button at the same time to form the switching contact directly. In this case the actuating cap, however, made of metallizable Plastic is made, you do not want a separate Attach the contact rivet or similar to the extension.

The approach of claim 10 can be according to the features according to claim 11 as a holder for an incandescent lamp evaluate that a suitable window in the cap shines. In this case, the approach must be made of metallized barem material, that is, a Lei approach Represent terformkörper. In terms of lighting but also exists, as will be explained below, the opportunity to see through for the molded conductor body to take the leader, so that at the same time can act as a light guide. So there is the possibility speed, the shaped conductor body at the same time for light conduction and to use for power line. The power line takes place taking place on the surface of the light guide body, wäh rend the light guide over the cross section of the conductor shape body takes place. So that with an elongated Conductor body also both forms of energy at the same time and  are transmitted parallel to each other. Finally, can the light energy also to the surface of a window of the Light guide body are guided, which, however, neither with the housing plastic of the second plastic casting may still be covered with the metallized metal. For this purpose certain masking techniques are used, which are known per se are and should not be explained in more detail here.

To the one that can be transferred via the electroplated conductor track To make energy as large as possible, the conductor track must be removed be kept speaking over a large area. She can do it too serve as a cooling surface. Finally, it is also possible to use the applied metal layer as a reflector, where they also serve as a conductor track can. In the case of switches, this is particularly possible where the light energy is concentrated on a viewing window shall be.

The use of the metallized conductor tracks and possibly (Additional) of the cast contact sheet create the Possibility of connecting the connector directly to the housing of the To form switch system. The Features according to claim 12. In an advantageous development the actuating cap can also be removed at the same time speaking the features of claim 13 in the housing la gladly. It can be both perpendicular to the cap Bottom pushing movement as well as a parallel pushing movement possible his.

According to the combination of features according to claim 14 can the housing of the switch system also in one piece with the  Housing of another electrical circuit, for example a car interior light. As part of the Er according to claim 15, it is also not necessary dig that the conductor tracks run at the bottom of the housing. The shaped conductor body can also be designed such that the conductor tracks laterally on the inner surface and / or The outer surface of the side walls of the housing run. This can apply, for example, to the conductor tracks that according to Claim 12 are led to the terminal block, so that the corresponding conductor tracks not through the lateral Ge house walls are guided, but over their surface.

According to the combination of features according to the claims 16 and 17, the form guide body in addition to the bil Formation of conductor tracks on the housing surface, how already explained above, also for the light conduction within of the housing material can be used. At the same time he additionally or exclusively to form a Re serve or take over the task of a cooling surface men by the heat radiation ability of the applied Metal surface and its reflectivity used becomes.

An embodiment of the invention is described below hand of the drawing explained. In it shows

Fig. 1 in sketched form a cross-section through an inventive switch system,

Fig. 2 shows a cross section through the switch system in height of section AA and

Fig. 3 is a plan view of the housing base of FIG. 1.

Fig. 1 shows the housing 1 with the housing base 2 and the housing walls 3. The housing is manufactured in a "two-shot" injection molding process, ie the housing is manufactured by two successive injection molding processes. A so-called. Molded conductor body made of a metallizable plastic, such as the. Material Vectra C 810 / C 820 from Hoechst AG. The molding thus obtained is constructed in such a way that when the casting is finished after the second injection molding, all the surface sections of the molding in the housing are still freely accessible and are later to be metallized. Thus, in the second casting section, the shaped conductor body is coated with easily flowing material, for example Vectra 115 or LCX 364, in such a way that the later conductor surfaces of the shaped conductor body are exposed. In a subsequent galvanizing process, the metal settles only on the accessible surface of the molded conductor body, but not on the easily flowing Vectra material of the second cast. In this way, the later conductive tracks can be precisely defined on the housing surface by an appropriate configuration of the cast part.

Fig. 3 shows a plan view of the visible and thus accessible sections of the molded conductor body and the non-metallizable remaining part of the housing. The conductor tracks 4 , 5 , 6 , 7 , 8 and 9 can be seen, while the conductor track 10 indicated in dashed lines in plan view runs essentially inside the housing base 2 and represents a cast-in contact sheet. The contour of the molded conductor body within the Ge housing bottom is not shown. It is also within the framework of the invention to form the individual conductor tracks 5 to 9 from a plurality of contact moldings. The conductor track 4 has a contact protrusion 11 , which can be a contact rivet applied to the plastic of the housing base 2 , but can also be molded out of the associated molded conductor body, which, like the surrounding conductor track 4, has been metallized.

The conductor track 5 shows a roller-shaped housing jump 12 , which is also part of the molded conductor body and is metallized. The housing projection has the shape of a halved circular cylinder. Is above the housing projection 12, as shown in FIG. 1 can be seen, a switching bar 13, which can tilt in dependence on the position of a contact pad 14 in two switching positions, which abruptly occurs in the form ei nes snap process.

The actuator 14 is guided in its longitudinal direction under spring tension in a rocker switch 15 , which wall in opposite openings 16 in the housing 3 is rotatably mounted by means of its latched bearing pins 17 ( Fig. 2).

The toggle switch 18 has next to the contact protrusion 11 is a second housing-fixed contact 20, which is the superior to the surface of the housing bottom end 2 of the contact plate 10 degrees.

A second toggle switch 21 has essentially the same structure as the first toggle switch 18th The main difference is that a switching bar 22 is not mounted on a housing projection, but at the upwardly projecting other end of the contact plate 10 , which forms in a manner known per se as a cutting bearing 23 .

The inventive structure of a pressure switch 24 can also be seen from the drawing. The pressure switch 24 be seated from the housing base 2 substantially vertically upwardly projecting first approach 25 , which is part of the molded conductor body molded into the housing and can thus be metallized. The first approach is covered during the second spraying process with casting compound in such a way that during the electroplating two electrically separate conductor tracks 26 , 27 run up on the outer walls of the first approach 25 , where they each end up at the level of a contact bridge 28 of the pressure switch 24 . In this case, the conductor track 26 is led up only on the right wall of the first attachment 25 in FIG. 1, while the conductor track 27, starting from the left wall of the attachment 25 via the attachment itself, leads the right wall of the attachment 25 back down a bit. So that there are two current-carrying contacts in one of the contact bridge 28 ge opposite level, in the position shown, the two contacts are connected to each other via the contact bridge 28 .

The contact bridge 28 itself is located at the end of an extension 29 , the resilient extension 29 being cast onto a button 30 . Assuming that, in the position shown in FIG. 1, the two conductor tracks 26 , 27 are connected to one another via the contact bridge 28 , the switch shown is a normally closed contact. If you press the button 30 down, the contact bridge 28 leaves the conductor track 27 which is guided around the end of the first extension 25 and the connection is interrupted.

Of course, within the scope of the invention, the course of the two conductor tracks 26 , 27 can easily be designed in such a way that the pressure switch 24 can also be configured as a work contact or as a changeover switch. The present description is only intended to show the basic possibility of being able to integrate the contacts directly into the housing wall with a pressure switch. Another possibility with regard to the routing of the conductor on the first attachment 25 is to pull up parts of the two conductor tracks 6 , 7 on the right wall in FIG. 1 parallel to one another up to approximately half the height of the first attachment 25 and to dispense with the conductor track 27 . In this case, the above-mentioned work contact arises in which the contact bridge 28 connects the conductor tracks 6 and 7 to one another when the button 30 is depressed. The configuration described last can also be combined with the conductor track 27 , so that there is a changeover switch.

The pressure limiter 24 also includes a second attachment 31 , which has the shape of a circular cylinder and can also be metallized as part of a molded conductor body, two separate metallizable surface areas being formed in the second injection molding by sections of the surface of the second attachment 31 with non-metallizable plastic be covered. This results in two conductor tracks 32 , 33 , onto which the connecting lines of an incandescent lamp 34 are soldered or contacted in some other way. In conjunction with a corresponding window 35 in the button 30 , there is a functional lighting of the pressure switch or a search lighting.

However, it is also possible for the second projection 31 un ter waiver extracts on the light bulb 34 as a light guide Stalten. In this case, the molded conductor body takes on the task of light guide in addition to the formation of the conductor tracks. A corresponding light source can then be installed at the other end of the light guide, whereby several switches or search lights can be operated by a single light bulb at the same time.

In the context of the invention, it is not absolutely necessary that the spatially extending conductor tracks with the help cast conductor molded body can be produced. Much more can the conductor tracks by a known Semi-additive process or by another etching process ren, which acts on a copper layer his. The copper layer can also be evaporated tion process, such as laser evaporation be put. Such methods are particular suitable if the conductor tracks are only on the surface should run. A scarf made according to claim 18 tersystem can be successfully with the in the claims 2 to 17 disclosed features combine, so that this An claims can also be related to claim 18.  

In contrast, the use of molded conductor bodies is in particular which is then suitable if these shaped conductor bodies simultaneously can also be used as an optocoupler or the Shaped conductor body due to one compared to the rest Different color scheme at the same time serve for display purposes. Further details can be found in the parallel patent application P 7645 (luminaire with a spatially injection molded circuit carrier, in particular Automotive interior light) explained.

Claims (18)

1. Switch system with a system housing ( 1 ), in which at least one switch ( 18 , 21 , 24 ) is arranged, which has at least one first switch contact ( 11 , 20 , 26 , 27 ) fixed to the housing, a second switch contact ( 13 , 28 , 22 ) and conductor tracks ( 4 to 9 ), which leads to the switch contacts GE, characterized in that the conductor tracks ( 4 to 9 ) are formed by means of at least one molded conductor body, which in the housing ( 1 ) by a Injection molding process is cast. 2. Switch system according to claim 1, characterized records that the movable switch contact on an outgoing from a shaped conductor body derenden leg is arranged, the associated Switch contact fixed to the housing sits on the conductor track, preferably by the same molded conductor body is formed. 3. Switch system according to claim 1, characterized in that the movable contact on egg NEM switching bar ( 13 , 22 ) is arranged, which in the form of a rocker around the curved outer surface of a cylindrical housing projection ( 12 ) tilts, while it from one lengthways the switching bar ( 13 ) sliding actuating member ( 14 ) is resiliently loaded. 4. Switch system according to claim 3, characterized in that the housing projection ( 12 ) provided with an electrically conductive layer is part of a shaped conductor body which at the same time carries the conductor projection ( 5 ) extending to the housing projection ( 12 ). 5. Switch system according to one of the preceding Ansprü surface, characterized in that the contact points ( 11 ) of the switch on the molded conductor body by molded, metallized contact projections of the molded conductor body. 6. Switch system according to one of the preceding claims, characterized in that in addition to the molded conductor body, a contact plate ( 10 ) is cast into the housing ( 1 , 2 ), the end projecting above the surface as a fixed switching contact ( 20 ), as Bearing ( 23 ) for a rocker switch ( 22 ), as a connector or as a connection point for connection to a conductor track ( 27 ). 7. Switch system according to one of the preceding claims, characterized in that the shaped conductor body has lugs ( 25 , 31 ) which are essentially vertical from a housing wall ( 1 , 2 ), the lug ( 25 , 31 ) at least one Lei terbahn ( 27 , 26 , 31 , 33 ) carries. 8. Switch system according to claim 7, characterized in that the approach ( 25 , 33 ) with two substantially parallel conductor tracks ( 27 , 26 , 6 and 32 , 33 ) is provided. 9. Switch system according to claim 8, characterized in that the conductor tracks ( 32 , 33 ) to the free end of the neck ( 31 ) open into contacts to which the connections of a light bulb ( 34 ) are ruled out or to which the movable contact piece ( 28 ) of a switch ( 24 ) can be connected. 10. Switch system according to claim 9, characterized in that a further approach is provided, on which an actuating button (cap) ( 30 ) is mounted counter to the force of a spring, the button ( 30 ) being one of the housing wall ( 2 ) pointing white transmission ( 29 ), which carries the movable contact ( 28 ). 11. Switch system according to one of the preceding and workman surface, characterized in that the key covers the bulb ( 34 ) bearing approach ( 31 ) and is provided with an illuminable window ( 35 ) through the bulb ( 34 ). 12. Switch system according to one of the preceding claims che, characterized in that too at least part of the conductor tracks to one of the Ge molded housing connector is guided on the a plug on the parallel to each other Lanes can be plugged on. 13. Switch system according to one of the preceding Ansprü surface, characterized in that a toggle button ( 15 ) is rotatably or displaceably guided in openings ( 16 ) laterally opposite housing walls which engage on bearing pins ( 17 ) which are cast on fe derenden side walls of the key . 14. Switch system according to one of the preceding claims che, characterized in that it is in an automotive interior light is integrated. 15. Switch system according to one of the preceding claims che, characterized in that the partly to the connecting strip running conductor tracks over the inner and / or outer side wall of the housing ses are led. 16. Switch system according to one of the preceding Ansprü surface, characterized in that from sections of the form guide body serve as a light guide that indicate the functional state and / or the position of the actuating elements ( 15 , 30 ) of the switch system. 17. Switch system according to one of the preceding claims che, characterized in that me tallized sections of a form guide as cooling surface and / or reflector. 18. Switch system with a system housing ( 1 ), in which at least one switch ( 18 , 21 , 24 ) is arranged, the at least one first switch contact ( 11 , 20 , 26 , 27 ) fixed to the housing, a second switch contact ( 13 , 28 , 22 ) and printed conductors ( 4 to 9 ) which lead to the switch contacts ge, characterized in that the spatially extending surface tracks, preferably on the housing surface, by means of an etching method known per se (e.g. semi- additive process) or an evaporation process (laser process).