JP2007064889A - Manufacturing method of pulse-generating plate, and manufacturing method of conductive plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a pulse-generating plate, capable of suppressing occurrence of a projection and a burr by resin formed in a rim section of the surface of a conductor. <P>SOLUTION: A plate material S is punched to form a conductive plate. When the conductive plate is formed, a die 101 for pressing the rim of a part becoming the conductor 62 of the plate S and the plate S are housed in a punch 107, having an inside surface 107a forming a shape corresponding to the outside surface 101b of the die 101, and the plate S is interposed, between a retainer plate 104 having a pressurized flat surface 104a facing the die 101, and the die 101. The rim is pressed against the surface 104a by the die 101 and the conductive plate is formed, by shaping the surface Sa at the surface 104a side of the plate S, and the side surface Sb of the plate S in response to the surface 104a and the inside surface 107a. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a conductive plate and a method for manufacturing a pulse generating plate including the conductive plate.

  2. Description of the Related Art Conventionally, an actuator that drives an inside / outside air switching door, an outlet switching door, a temperature adjusting air mix door, and the like of a vehicle air conditioner is disclosed in Patent Document 1, for example. The actuator disclosed in Patent Document 1 includes a direct current motor, and the rotation of the direct current motor is decelerated by a speed reduction mechanism composed of a plurality of gears, and the actuator is connected to the various doors. Output from the output shaft. The actuator is provided with a rotation angle detection sensor using a pulse generating plate in order to detect the rotation angle of the output shaft.

The pulse generation plate includes a conductive plate having a plurality of conductive portions extending along the radial direction of the output shaft around the output shaft. An insulating portion made of an insulating resin is interposed between the conductive portions adjacent in the circumferential direction. When the pulse generating plate rotates along with the rotation of the output shaft, the conductive brush alternately slides on the surface of the conductive portion and the surface of the insulating portion, whereby a pulse signal corresponding to the rotation of the output shaft is generated. can get. Based on this pulse signal, the rotation angle of the output shaft is detected.
JP 2004-9881 A

  By the way, the pulse generation plate as described above is generally filled with a high-temperature resin material in a mold after a conductive plate formed by press punching a conductive metal plate is placed in the mold. Formed. The pulse generating plate is taken out from the mold after the resin material in the mold is cooled and cured.

  When the conductive plate is formed by press punching, as shown in FIG. 9A, “sagging” occurs in the peripheral portion of the surface 131a of the conductive portion 131 in the conductive plate. When the conductive plate in which the “sag” has occurred is placed in the mold 141 and the mold 141 is filled with the resin material R, the portion between the part in which the “sag” has occurred on the surface 131a of the conductive part 131 and the mold The resin material R enters the. In this state, when the resin material R is cooled and hardened, the protruding portion P or “burr” as shown in FIG. 9B is formed on the portion where “sagging” occurs, that is, on the peripheral portion of the surface 131 a of the conductive portion 131. Will occur. The protrusion P is formed when the resin material R is contracted to cause “sinking” when the resin material is cured.

  When the pulse generating plate having the protrusion P formed on the peripheral edge of the surface 131a of the conductive portion 131 is used for the rotation angle detection sensor, the protrusion P may be lost due to the sliding contact of the conductive brush 151. is there. Then, the position where the conductive brush 151 first slidably contacts the conductive portion 131 differs between the state where the protrusion P is present and the state where the protrusion P is missing (see FIGS. 8B and 8C). Therefore, there is a problem in that the rising and falling timings of the output pulse signal are shifted between the state where the protrusion P is present and the state where the protrusion P is missing. If a deviation occurs in the timing of rising or falling of the pulse signal, it may be difficult to accurately detect the rotation angle of the output shaft. The same applies to the case where “burrs” are formed at the peripheral edge of the surface of the conductive plate.

  Although it is possible to reduce the amount of “sag” generated at the peripheral edge of the conductive plate by shaving, since “sag” occurs at the time of shaving, resin is applied to the peripheral edge of the surface of the conductive plate. As a result, protrusions and “burrs” are formed.

  The present invention has been made in view of such circumstances, and a method for manufacturing a pulse generating plate capable of suppressing the occurrence of protrusions and flashes caused by resin formed on the peripheral edge of the surface of the conductive portion, and The object is to provide a method of manufacturing a conductive plate.

  In order to solve the above-mentioned problem, the invention according to claim 1 is characterized in that the conductive plate having a plurality of conductive portions arranged at a predetermined interval with respect to the rotational direction and the resin material having insulating properties are adjacent to each other. An insulating portion provided between the conductive portions, and in response to the rotation, the conductive brush alternately slides on the surface of the conductive portion and the surface of the insulating portion according to the rotation. A method of manufacturing a pulse generating plate for generating a pulse signal, wherein a plate material punched and formed for forming the conductive plate and a peripheral portion of the portion to be the conductive portion in the plate material are pressed in the plate thickness direction. And a pressing portion having a flat pressure surface facing the pressing portion and the pressing portion. In between the plate The peripheral portion is pressed toward the pressing surface by the pressing portion, and the surface of the plate material on the pressing surface side and the side surface of the plate material are in accordance with the pressing surface and the inner surface. The gist of the invention includes a pressing step of forming the conductive plate in a shape and a filling step of filling the resin material between adjacent conductive portions to form the insulating portion.

  Invention of Claim 2 is a manufacturing method of the plate for pulse generation of Claim 1, Comprising: The said press part protrudes toward the said pressurization surface in the peripheral part of the surface by the side of the said pressurization surface Its gist is that it is a die formed with strips.

According to a third aspect of the present invention, in the method for manufacturing a pulse generating plate according to the second aspect, the relationship between the width w of the protrusion and the thickness t of the plate material is 0.5 t ≦ w ≦ 1.0t
The gist is that it is formed to satisfy the above.

  According to a fourth aspect of the present invention, in the method for manufacturing a pulse generating plate according to the second or third aspect of the present invention, the protruding portion includes a height h in the protruding direction of the protruding portion and the plate material. The gist of the present invention is that it is formed so that the relationship with the plate thickness t satisfies 0.05t ≦ h ≦ 0.2t.

  According to a fifth aspect of the present invention, in the method for manufacturing a pulse generating plate according to any one of the second to fourth aspects, the guide portion performs a shaving process on the plate material together with the die. The pressing step is performed following a shaving processing step in which the die and the punch are moved relative to each other along the plate thickness direction of the plate material to perform a shaving process on the plate material. The gist is to be.

  The invention according to claim 6 has an insulating resin which has a plurality of conductive parts which are arranged at predetermined intervals and in which a conductive brush is slidably contacted on the surface, and which serves as an insulating part between the adjacent conductive parts. A method for manufacturing a conductive plate filled with a material, wherein the plate material is punched to form the conductive plate, and the pressing is performed to press the peripheral portion of the portion to be the conductive portion of the plate material in the plate thickness direction. And the plate between the pressing portion and the pressing portion having a flat pressing surface opposite to the pressing portion, and the guide plate having an inner surface having a shape corresponding to the outer surface of the pressing portion. A material is interposed, the peripheral edge is pressed toward the pressing surface by the pressing portion, and the surface of the plate material on the pressing surface side and the side surface of the plate material are set according to the pressing surface and the inner surface. Shape the conductive plate And as its gist in that a pressing step of.

  Invention of Claim 7 is a manufacturing method of the electrically conductive plate of Claim 6, Comprising: The said press part is the protrusion part which protruded toward the said pressurization surface in the peripheral part of the said surface of the pressurization surface side The gist is that the die is formed.

  The invention according to claim 8 is the method of manufacturing a conductive plate according to claim 7, wherein the protrusion has a relationship between a width w and a plate thickness t of the plate material of 0.5 t ≦ w ≦. The gist is that it is formed to satisfy 1.0 t.

  According to a ninth aspect of the present invention, in the method for manufacturing a conductive plate according to the seventh or eighth aspect, the protruding portion has a height h in the protruding direction of the protruding portion and a plate of the plate material. The gist is that the relationship with the thickness t is formed so as to satisfy 0.05 t ≦ h ≦ 0.2 t.

  A tenth aspect of the present invention is the method for manufacturing a conductive plate according to any one of the seventh to ninth aspects, wherein the guide portion is a punch for performing a shaving process on the plate material together with the die. The pressing step is performed following a shaving processing step in which the die and the punch are moved relative to each other along the plate thickness direction of the plate material to perform a shaving process on the plate material. It is a summary.

(Function)
According to the first aspect of the present invention, in the pressing step, in the pressing step, the peripheral portion of the portion that becomes the conductive portion of the plate material is pressed toward the pressing surface by the pressing portion. Thereby, the surface of the plate material on the pressing surface side and the side surface of the plate material are shaped according to the pressing surface and the inner surface of the guide portion. That is, the surface of the plate material on the pressing surface side is flat as in the pressing surface. Therefore, in the filling process, the conductive plate is disposed in the mold so that the surface of the plate material that has been opposed to the pressing surface in the pressing process is in contact with the inner surface of the mold. The resin material is prevented from entering between the surfaces of the parts. As a result, it is possible to suppress the occurrence of protrusions and flash due to the resin formed on the peripheral portion of the surface of the conductive portion.

  According to invention of Claim 2, 7, since the said press part is a die | dye by which the protrusion part which protruded toward the said pressurization surface was formed in the peripheral part of the surface by the side of the said pressurization surface, The peripheral part of the site | part used as the electroconductive part in a raw material can be pressed stably.

  According to the third and eighth aspects of the invention, the width w of the protrusion is set so that the relationship between the width w of the protrusion and the thickness t of the plate material satisfies 0.5t ≦ w ≦ 1.0t. It is set. When the width w of the ridge is set to a value smaller than 0.5 t, the ridge is easily damaged when the plate material is pressed in the pressing step. On the other hand, if the width w of the protrusion is larger than 1.0 t, a portion where no “sag” is formed, that is, a portion that does not need to be pressed is unnecessarily pressed. On the other hand, if the width w of the protrusion is larger than 1.0 t, a large pressing force is required to make the surface of the plate material have a shape corresponding to the pressing surface. Therefore, by setting the width w of the ridge so that the relationship between the width w of the ridge and the thickness t of the plate material satisfies 0.5 t ≦ w ≦ 1.0 t, in the pressing step, the ridge While preventing the portion from being damaged, it is possible to reduce the pressure required to make the surface of the plate material a shape corresponding to the pressure surface.

  According to the fourth and ninth aspects of the present invention, the height of the ridge is such that the relationship between the height h of the ridge and the thickness t of the plate material satisfies 0.05t ≦ h ≦ 0.2t. h is set. Generally, when a plate material is formed by punching a metal plate material, “sag” occurs in the range of 10% to 20% of the plate thickness t from the front surface to the back surface of the plate thickness material. Accordingly, by setting the upper limit of the height h of the ridge to 0.2 t, the surface deformation of the plate material due to the “sag” generated during the punching formation is appropriately reduced to flatten the surface. can do. In addition, when the plate material formed by punching is subjected to a shaving process, the “sag” generated during the punching formation is reduced. In this case, if the height h of the protrusion is 0.05 t or more, the deformation of the surface of the plate material due to “sag” can be appropriately reduced to flatten the surface. Therefore, by setting the height h of the ridge so that the relationship between the height h of the ridge and the thickness t of the plate material satisfies 0.05 t ≦ h ≦ 0.2 t, in the pressing step, Appropriately reducing the deformation of the surface of the plate material due to “sag”, the surface can be flattened.

  According to the fifth and tenth aspects of the present invention, a highly accurate conductive plate can be formed by shaving the plate material. In addition, after the shaving process is performed on the plate material, the plate material is pressed by the protrusions by successively moving the die and the punch so as to approach each other. That is, with the same die and punch, the plate material can be shaved and the surface of the plate material can be shaped according to the pressure surface. Therefore, it is not necessary to prepare dies and punches for the shaving process and the pressing process, respectively, and an increase in processing time can be suppressed.

  According to the invention described in claim 6, in the pressing step, the plate material is pressed toward the pressing surface by the pressing portion at the peripheral portion of the portion that becomes the conductive portion in the plate material. Thereby, the surface of the plate material on the pressing surface side and the side surface of the plate material are shaped according to the pressing surface and the inner surface of the guide portion. That is, the surface of the plate material has a flat shape similar to the pressing surface. Therefore, in the conductive plate of the present invention, when the resin material is filled between the adjacent conductive portions, the surface of the plate material that has been opposed to the pressing surface in the pressing step is brought into contact with the inner surface of the mold. Thus, by arrange | positioning the said electroconductive plate in a metal mold | die, it is suppressed that a resin material enters between the inner surface of a metal mold | die and the surface of an electroconductive part. As a result, it is possible to suppress the occurrence of protrusions and flash due to the resin formed on the peripheral portion of the surface of the conductive portion.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the plate for pulse generation which can suppress generation | occurrence | production of the protrusion part and flash by the resin formed in the peripheral part of the surface of an electroconductive part, and the manufacturing method of an electroconductive plate are provided. it can.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, an embodiment of the invention will be described with reference to the drawings. FIG. 1 is a plan view of the motor actuator 1 of the present embodiment. The motor actuator 1 is for opening and closing doors such as an inside / outside air switching door, a blowout port switching door, and a temperature adjusting air mix door of a vehicle air conditioner. One motor actuator 1 is provided for each door.

  As shown in FIG. 1, the motor actuator 1 includes a case 2 including a case portion 2a and a cover portion (not shown) that closes an opening of the case portion 2a. The speed reduction mechanism 4 and the connector assembly 5 are accommodated.

  The motor 3 is disposed in a motor housing recess 2b formed at the bottom of the case portion 2a. The speed reduction mechanism 4 is a gear train including a worm 11 press-fitted into the rotation shaft 3 a of the motor 3, a worm wheel 12 that meshes with the worm, and a plurality of spur gears 13 to 16. And the output shaft 17 with which the said various doors are connected is formed in the center part of the last stage gearwheel 16 located in the output side. The output shaft 17 extends along the axial direction on both sides in the thickness direction of the final stage gear 16 at the center of the final stage gear 16. Accordingly, when the motor 3 is driven, the rotation of the rotating shaft 3 a is decelerated by the decelerating mechanism 4 and transmitted to the output shaft 17. Thereby, various doors are opened and closed by the output shaft 17.

  As shown in FIGS. 1 and 2, the connector assembly 5 includes a sensor portion 21 disposed between a bottom portion of the case portion 2 a and the final stage gear 16, and a connector formed integrally with the sensor portion 21. A portion 22 and a power feeding portion 23 extending from the connector portion 22 along the side wall of the case portion 2a and facing the end surface in the axial direction of the motor 3 are configured.

  The connector portion 22 includes a main body portion 31 having a substantially rectangular parallelepiped shape, and a plurality of connector pins 32 (see FIG. 1) are accommodated in the main body portion 31. The power supply unit 23 supports two power supply terminals 34. The two power supply terminals 34 are electrically connected to a vehicle battery (not shown) via the connector pins 32, and power is supplied to the motor 3 from these power supply terminals 34.

  The sensor unit 21 is provided to detect the rotation angle of the output shaft 17. As shown in FIG. 3, the sensor unit 21 includes a base 41 having a substantially cylindrical shape, and a disk-shaped pulse generation plate 51 is disposed inside the base 41. As shown in FIGS. 3 and 4, the pulse generating plate 51 includes a cylindrical portion 52 having a fitting hole 52 a into which an end of the output shaft 17 on the case portion 2 a side is fitted. The pulse generating plate 51 is fixed so as to be integrally rotatable with the output shaft 17 by inserting the output shaft 17 into the fitting hole 52 a of the cylindrical portion 52.

  The pulse generation plate 51 includes a plate-like conductive plate 54 and an annular resin portion 55 that covers the back surface of the conductive plate 54. In the pulse generating plate 51, the conductive plate 54 is disposed on the final gear 16 side (upper side in FIG. 3), and the resin portion 55 is disposed on the opposite side of the final gear 16 (lower side in FIG. 3). ing. In addition, the cylinder part 52 and the resin part 55 are integrally formed with the resin material which has insulation.

  As shown in FIG. 4, the conductive plate 54 includes an annular portion 61 disposed on the outer periphery of the cylindrical portion 52. The outer periphery of the annular portion 61 has a predetermined interval in the circumferential direction. A plurality of conductive portions 62 extending along the radial direction are formed. The leading ends of the conductive portions 62 are connected by an annular ring portion 63. In addition, a groove portion 64 along the radial direction is formed at one place in the circumferential direction of the annular portion 61. The conductive portion 62 formed on the side opposite to the groove portion 64 by approximately 180 ° is formed wider in the circumferential direction than the other conductive portions 62.

  An insulating portion 71 made of an insulating resin material is interposed between the conductive portions 62 adjacent in the circumferential direction. As shown in FIG. 5, the insulating portion 71 is formed integrally with the resin portion 55, and a brush 81 as a conductive brush described later is slidably contacted by the surface 71 a of the insulating portion 71 and the surface 62 a of the conductive portion 62. A sliding surface 85 is formed. The conductive portion 62 and the insulating portion 71 are formed in a radial shape with the rotation center of the pulse generating plate 51 as the center.

  As shown in FIG. 3, a brush accommodating portion 82 is fixed to the base 41 from the upper side of the pulse generating plate 51 in FIG. 3, and the upper surface of the brush accommodating portion 82 from the upper side of the brush accommodating portion 82 in FIG. A lid portion 83 is fixed.

  The brush 81 is fixed to the brush accommodating portion 82, and when the brush accommodating portion 82 is fixed to the base 41, the tip end portion of the brush 81 slides against the sliding contact surface 85 of the pulse generating plate 51. It comes to be touched. The brush 81 is electrically connected to the connector pin 32. Therefore, when the pulse generating plate 51 rotates as the output shaft 17 rotates, a pulse signal is detected from the pulse generating plate 51 via the brush 81. The pulse signal is output from the connector pin 32 electrically connected to the brush 81 to the outside of the motor actuator 1. The rotation angle of the output shaft 17 can be detected by counting the pulse signal by a rotation angle detection device (not shown) electrically connected to the connector pin 32.

Next, a method for manufacturing the pulse generating plate 51 according to the present embodiment will be described.
First, a processing apparatus for manufacturing the conductive plate 54 will be described. As shown in FIG. 6, the processing apparatus 100 is for performing a shaving process on a plate material S formed by punching a conductive metal plate material to complete a conductive plate 54. FIG. 6 illustrates a cross section of a portion of the processing apparatus 100 where one conductive portion 62 is processed along the circumferential direction of the conductive plate 54.

  The processing apparatus 100 includes a die 101 as a pressing portion. The die 101 has a shape as viewed from above in FIG. 6 that is the same as the shape of the conductive plate 54 viewed from the plate thickness direction or slightly smaller than the shape of the conductive plate 54 viewed from the plate thickness direction. . 6 is formed on the periphery of the upper surface 101a of the die 101 in FIG. 6 and protrudes upward in FIG. 6 and extends along the periphery of the surface 101a. ing. The width w of this ridge 102 (the width in the direction orthogonal to the direction in which the ridge 102 extends, and the width in the left-right direction in FIG. 6) is 0. It is set to satisfy 5t ≦ w ≦ 1.0t. Further, the height h in the projecting direction of the protrusion 102 is set so that the relationship with the plate thickness t of the plate material S satisfies 0.05t ≦ h ≦ 0.2t. By forming such a protrusion 102, a recess 103 is formed on the surface 101 a of the die 101. When the plate material S is processed by the processing apparatus 100, the plate material S is arranged on the surface 101a on which the ridge portion 102 is formed (specifically, on the ridge portion 102). Then, when the plate material S is processed to form the conductive plate 54, the protruding portion 102 abuts on the peripheral portion of the portion that becomes the conductive portion 62 in the plate material S. In the present embodiment, the protrusions 102 abut against the edges on both sides in the circumferential direction of the portion to be the conductive part 62 in the plate material S.

  At a position facing the surface 101a of the die 101, a pressing plate 104 as a pressing portion is disposed. The pressing plate 104 has a shape as viewed from the upper side in FIG. 6 that is the same as the shape of the die 101 as viewed from the upper side in FIG. Further, the surface of the pressing plate 104 facing the die 101 is a flat pressing surface 104a. The pressing plate 104 is moved along the direction in which the die 101 and the pressing plate 104 face each other (that is, the plate thickness direction of the plate material S arranged on the die 101) by a driving unit (not shown).

  On the outer periphery of the pressing plate 104, a punch 107 is disposed as a guide portion extending along a direction in which the die 101 and the pressing plate 104 face each other. The length of the punch 107 along the direction in which the die 101 and the pressing plate 104 face each other is longer than the plate thickness t of the plate material S. The inner surface 107 a of the punch 107 has a shape corresponding to the outer surface 101 b of the die 101. Further, the inner side surface 107 a of the punch 107 is perpendicular to the pressing surface 104 a of the pressing plate 104. The punch 107 is moved along a direction in which the die 101 and the pressing plate 104 face each other by a driving unit (not shown).

  A pressure plate 109 is disposed on the side opposite to the die 101 in the pressing plate 104 and the punch 107. The pressure plate 109 is moved along a direction in which the pressing plate 104 and the die 101 face each other by a driving unit (not shown).

Next, a method for manufacturing the conductive plate 54 using the processing apparatus 100 configured as described above will be described.
First, as shown in FIG. 6, the plate material S is arranged on the die 101 so that the plate thickness direction and the protruding direction of the protruding portion 102 coincide. As a result, the plate material S is interposed between the die 101 and the holding plate 104. In the present embodiment, the plate material S is such that the surface on which the “sag” is formed (the surface Sa of the plate material S and the surface 62 a of the conductive portion 62) is the pressing surface 104 a of the pressing plate 104. Are arranged on the die 101 so as to face each other. At this time, the pressing plate 104 is disposed at a position having a distance equal to or greater than the plate thickness t of the plate material S between the die 101 and the punch 107 and the pressing plate 109 are pressed against the pressing surface 104 a of the pressing plate 104. Rather than the upper side in FIG. In FIG. 6 and FIG. 7, “sole” generated in the plate material S is exaggerated.

  Next, the pressing plate 104 is moved to the die 101 side by the driving unit. Then, the pressing plate 104 is stopped when the pressing surface 104a comes into contact with the surface Sa of the plate material S. Thereby, the plate material S is held between the die 101 and the holding plate 104. At this time, almost no force is applied to the plate material S from the pressing plate 104 to press the plate material S in the plate thickness direction.

  Next, the punch 107 is moved to the die 101 side along the plate thickness direction of the plate material S by the drive unit. Then, as shown in FIG. 7, the outer periphery of the plate material S is scraped off by the die 101 and the punch 107. That is, shaving processing is performed on the plate material S (shaving processing step).

  Subsequently, the pressure plate 109 is moved to the die 101 side while the punch 107 is moved to the die 101 side, that is, the die 101, the holding plate 104, and the plate material S are accommodated in the punch 107. (Pressing step). When the pressure plate 109 is moved to the die 101 side, the pressing plate 104 and the punch 107 are pressed to the die 101 side by the pressure plate 109 as shown in FIG. Then, the plate material S is pressed to the surface 101a side of the die 101 by the pressing plate 104, and the peripheral edge portion of the plate material S is pressed to the pressing surface 104a side by the protrusion 102. As a result, in the material constituting the plate material S, a part of the material pressed to the pressing surface 104a side by the ridge 102 forms “sag” on the pressing surface 104a and the surface Sa of the plate material S. It moves so that the clearance gap G (refer FIG. 7) between the parts currently performed may be decreased. The surface Sa on the pressing surface 104 a side of the plate material S and the side surface Sb of the plate material S are shaped according to the corner C formed by the pressing surface 104 a and the inner side surface 107 a of the punch 107. Accordingly, the surface Sa of the plate material S has a flat shape corresponding to the pressing surface 104a. Since the corner portion C formed by the pressing surface 104a and the inner side surface 107a of the punch 107 forms a right angle, the surface Sa of the plate material S and the side surface (outer peripheral surface) of the plate material S approach a right angle.

  In this pressing step, since the concave portion 103 is formed on the surface 101a of the die 101 by forming the protrusion 102, the material constituting the plate material S is the surface Sa and the pressure surface of the plate material S. It moves so as to reduce the gap G with respect to 104 a and can move into the recess 103. Accordingly, when the plate material S is pressed by the protrusion 102, a part of the material constituting the plate material S moves into the recess 103, so that the gap between the bottom surface of the recess 103 and the pressure surface 104a is reached. It is possible to prevent an unnecessarily large pressure from being applied to the plate material S and to prevent the completed conductive plate 54 from being bent.

  Next, the pressing plate 104, the punch 107, and the pressure plate 109 are moved away from the die 101 by the driving unit. Then, the completed conductive plate 54 is taken out from the die 101.

  In order to manufacture the pulse generating plate 51 using the conductive plate 54 formed by the processing apparatus 100, the pulse generating plate 51 is formed in a mold (not shown) for forming a portion made of a resin material. A conductive plate 54 is disposed. At this time, the conductive plate 54 is disposed in the mold such that the surface 62a of the conductive portion 62 formed flat according to the pressure surface 104a contacts the inner surface of the mold. Thereafter, an insulating resin material is filled in the mold, and the resin material is filled between the adjacent conductive portions 62 (filling step). At this time, since the surface 62a of the conductive portion 62 is formed flat, the resin material is prevented from entering between the surface 62a and the inner surface of the mold. After the resin material is cured, the pulse generating plate 51 is taken out from the mold.

As described above, according to the present embodiment, the following actions and effects are obtained.
(1) In the pressing process, when the plate material S is pressed in the plate thickness direction by the pressing plate 104 and the die 101, the peripheral portion of the portion that becomes the conductive portion 62 in the plate material S is pressed by the protrusion 102. It is pressed toward 104a. As a result, the surface Sa on the pressing surface 104 a side of the plate material S and the side surface Sb of the plate material S are shaped according to the pressing surface 104 a and the inner surface 107 a of the punch 107. That is, the surface Sa and the side surface Sb of the plate material S approach a right-angled shape corresponding to the corner portion C formed by the pressing surface 104a and the inner side surface 107a, and the surface Sa of the plate material S (that is, the surface 62a of the conductive portion 62). ) Is formed flat similarly to the pressing surface 104a. Accordingly, when the resin material is filled between the adjacent conductive portions 62, the resin material is suppressed from entering between the surface 62a of the conductive portion 62 and the inner surface of the mold. As a result, in the completed pulse generating plate 51, as shown in FIG. 5, it is possible to suppress the occurrence of protrusions and flash due to the resin formed on the peripheral edge of the surface 62a of the conductive portion 62.

  (2) Since the surface Sa and the side surface Sb of the plate material S, that is, the surface 62a and the side surface of the conductive portion 62 form a right angle according to the pressing surface 104a and the inner surface 107a, The boundary between the surface 62a of the part 62 and the surface 71a of the insulating part 71 becomes clear. Therefore, even when the pulse generating plate 51 is downsized, pulses can be generated with high accuracy. Therefore, the pulse generating plate 51 can be downsized.

  (3) By using the die 101 in which the protruding portion 102 is formed on the surface 101a on the pressing surface 104a side, it is possible to stably press the peripheral portion of the portion that becomes the conductive portion 62 in the plate material S.

  (4) If the width w of the protrusion 102 is set to a value smaller than 0.5 t, the protrusion 102 is likely to be damaged when the plate material S is pressed in the pressing step. On the other hand, when the width w of the protrusion 102 is larger than 1.0 t, a portion where no “sag” is formed, that is, a portion that does not need to be pressed is unnecessarily pressed. Moreover, when the width w of the protrusion 102 is larger than 1.0 t, a large pressing force is required to make the surface Sa of the plate material S into a shape corresponding to the pressing surface 104a. Therefore, by setting the width w of the ridge 102 so that the relationship between the width w of the ridge 102 and the thickness t of the plate material S satisfies 0.5t ≦ w ≦ 1.0t, In addition, it is possible to suppress the pressurizing force necessary to make the surface Sa of the plate material S into a shape corresponding to the pressing surface 104a while preventing the protrusion 102 from being damaged.

  (5) When the plate material S formed by punching is subjected to a shaving process, the “sag” generated during the punching formation is reduced. In this case, if the height h of the protrusion 102 is 0.05 t or more, the gap G between the pressure surface 104a and the surface Sa of the plate material S due to “sag” is appropriately reduced. be able to. Therefore, by setting the height h of the protrusion 102 so that the relationship between the height h of the protrusion 102 and the plate thickness t of the plate material S satisfies 0.05t ≦ h ≦ 0.2t, In the process, the gap G between the surface Sa of the plate material S and the pressing surface 104a due to “sag” can be appropriately reduced.

  (6) By performing the shaving process on the plate material S, the conductive plate 54 with higher accuracy can be formed. In addition, after the shaving process is performed on the plate material S, the punch 107 is continuously moved toward the die 101 side, and the plate material S is pressed by the protruding portion 102. That is, the same die 101 and punch 107 can be used for shaving the plate material S, and the surface Sa of the plate material S can be flattened. Therefore, it is not necessary to prepare dies and punches for the shaving process and the pressing process, respectively, and an increase in processing time can be suppressed.

  (7) Since the surface 62a of the conductive portion 62 is a flat surface corresponding to the pressure surface 104a, generation of noise when the brush 81 slides on the sliding contact surface 85 of the pulse generating plate 51 is suppressed. be able to.

In addition, you may change embodiment of this invention as follows.
In the above-described embodiment, the edges on both sides in the circumferential direction of the portion that becomes the conductive portion 62 in the plate material S are pressed toward the pressing surface 104 a by the protrusion 102. However, the protruding portion 102 formed on the surface 101a of the die 101 may be formed so as to press only the edge on one side in the circumferential direction of the portion to be the conductive portion 62 in the plate material S. A pulse generating plate having a conductive plate formed using such a die 101 is suitable for use in detecting rotation of an output shaft that rotates only in one direction.

  In the above-described embodiment, after the shaving process, the peripheral edge portion of the plate material S that is the conductive portion 62 is pressed to the pressing surface 104a side by the protruding portion 102. However, the peripheral portion of the portion that becomes the conductive portion 62 in the plate material S may be pressed toward the pressing surface 104a by the protrusion 102 without performing the shaving process on the punched plate material S. Further, the protrusion 102 may be provided on a die for performing punching, and the peripheral edge of the portion to be the conductive portion 62 in the plate material S by the protrusion 102 may be pressed following the punching. Even in these cases, the height h of the protrusion 102 may be set so that the relationship between the height h of the protrusion 102 and the plate thickness t of the sheet material S satisfies 0.05 t ≦ h ≦ 0.2 t. . Generally, when a plate material S is formed by punching a metal plate material, “sag” occurs in the range of 10% to 20% of the plate thickness t from the front surface Sa to the back surface of the plate material S. Therefore, by setting the upper limit of the height h of the ridge 102 to 0.2 t, the gap G between the pressing surface 104a and the surface Sa of the plate material S caused by “sag” generated during punching formation. Can be reduced appropriately.

  In the above embodiment, the pressing plate 104 and the punch 107 are moved to the die 101 side during the pressing step, but the pressing plate 104 and the punch 107 and the die 101 are mutually connected during the shaving process and the pressing step. What is necessary is just to be relatively moved so that it may approach.

  In the above embodiment, the processing apparatus 100 includes the pressing plate 104, but may be configured without the pressing plate 104. In this case, the pressure plate 109 serves as a pressing portion, and the surface of the pressure plate 109 that faces the die 101 serves as the pressure surface.

  In the above-described embodiment, when the plate material S is pressed in the plate thickness direction by the pressing plate 104 and the die 101, the peripheral portion of the portion that becomes the conductive portion 62 in the plate material S is pressed by the protrusion 102 to the pressing surface 104 a. Is pressed toward. However, the member (pressing portion) that presses the plate material S together with the pressing plate 104 in the thickness direction may not be the die 101. For example, the plate material S may be pressed in the plate thickness direction by a member composed only of the protruding portion 102.

  In the above embodiment, when the conductive plate 54 is formed, the plate material S is disposed on the die 101 so that the surface on which “sag” is formed faces the pressing surface 104a. However, the plate material S may be disposed on the die 101 such that the surface on which the “sag” is formed faces the die 101 side. By doing so, the rim portion 102 presses the peripheral portion of the portion that becomes the conductive portion 62 of the plate material S toward the pressure surface 104a, thereby eliminating the “brick” that occurred in the plate material S during the punching formation. The surface of the plate material S has a flat shape corresponding to the pressing surface 104a. Then, by making the surface of the flat plate material S the surface 62a of the conductive portion 62, the same actions and effects as in the above embodiment can be obtained.

  In the above embodiment, the pulse generating plate 51 is provided in the motor actuator 1 for detecting the rotation angle of the output shaft 17. For example, a foreign object sandwiched between the vehicle body and the window glass of the vehicle. It may be provided in a power window device provided with a foreign object pinching detection function for detecting. In this case, the pulse generating plate is used to detect the rotation angle of the output shaft of the motor provided in the power window device in order to drive the window glass.

  In the above embodiment, the manufacturing method has been described by taking the conductive plate 54 provided in the pulse generating plate 51 as an example. However, when the conductive plate other than the conductive plate 54 is manufactured, the manufacturing method of the present invention is applied. Also good. For example, the vehicle wiper device includes a motor for driving the wiper. This motor includes a rotational position detector for detecting the rotational angle of the rotational shaft. For example, the rotational position detector is embedded in a contact plate (conductive brush) formed on the contact plate that rotates with the rotation shaft of the motor, and on the contact plate, and on the surface of the contact lever. It has a switching pattern in which the tip is slidably contacted. When the contact plate rotates with the rotation of the rotating shaft, the tip of the contact lever slides on the surface of the switching pattern to come into contact with or not contact with the switching pattern, thereby detecting the rotational position of the rotating shaft. The motor is energized so that the wiper is stopped at a fixed position based on the detected rotational position of the rotating shaft. The manufacturing method of the present invention may be applied to this switching pattern. Also in this case, the same operation and effect as the above embodiment can be obtained.

The top view of a motor actuator. The perspective view of a connector assembly. FIG. 3 is an exploded sectional view taken along line AA in FIG. 2. The top view of the plate for pulse generation. BB sectional drawing in FIG. The conceptual diagram of the processing apparatus for forming an electroconductive plate. The conceptual diagram of the processing apparatus in a shaving process. The conceptual diagram of the processing apparatus in a press process. (A) is the conceptual diagram which shows a mode that resin material is filled between the electroconductive parts of the conventional electroconductive plate, (b) is the conceptual diagram which expanded the electroconductive part vicinity of the conventional pulse generation plate, (c) is conventional. The conceptual diagram which expanded the electroconductive part vicinity of the plate for pulse generation of.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 51 ... Plate for pulse generation, 54 ... Conductive plate, 62 ... Conductive part, 62a ... Surface of conductive part, 71 ... Insulating part, 71a ... Surface of insulating part, 81 ... Brush as conductive brush, 101 ... As pressing part , 101a... Surface on the pressing surface side of the die, 101b... The outer surface of the die as the outer surface of the pressing portion, 102... Ridge portion, 104 ... the pressing plate as the pressing portion, 104a. Punch as a part 107a ... Inner side surface of the punch as an inner side surface of the guide part, S ... Plate material, Sa ... Surface of the plate material, Sb ... Side surface of the plate material, w ... Width of the ridge part, h ... Ridge The height of the part, t ... the thickness of the plate material.

Claims (10)

A conductive plate having a plurality of conductive portions arranged at a predetermined interval with respect to the rotation direction; and an insulating portion provided between adjacent conductive portions made of an insulating resin material; A method of manufacturing a pulse generating plate for generating a pulse signal corresponding to the rotation by alternately contacting a conductive brush with the surface of the conductive portion and the surface of the insulating portion in accordance with rotation. And
A plate material punched and formed for forming the conductive plate and a pressing portion for pressing the peripheral portion of the portion to be the conductive portion in the plate material in the plate thickness direction have a shape corresponding to the outer surface of the pressing portion. The plate material is interposed between the pressing portion and the pressing portion having a flat pressing surface facing the pressing portion, and the peripheral portion is moved by the pressing portion. A pressing step of pressing toward the pressing surface to form the conductive plate in a shape corresponding to the pressing surface and the inner side surface of the surface of the plate material and the side surface of the plate material;
A filling step of filling the resin material between adjacent conductive parts to form the insulating part;
A method of manufacturing a pulse generating plate, comprising: It is a manufacturing method of the plate for pulse generation according to claim 1,
The method of manufacturing a pulse generating plate, wherein the pressing portion is a die in which a protruding portion protruding toward the pressing surface is formed at a peripheral portion of the surface on the pressing surface side. In the manufacturing method of the plate for pulse generation according to claim 2,
The projecting portion has a relationship between the width w and the thickness t of the plate material.
0.5t ≦ w ≦ 1.0t
A method for manufacturing a pulse generating plate, wherein the plate is formed so as to satisfy the above. In the manufacturing method of the plate for pulse generation according to claim 2 or claim 3,
The ridge portion has a relationship between the height h in the protruding direction of the ridge portion and the plate thickness t of the plate material.
0.05t ≦ h ≦ 0.2t
A method for manufacturing a pulse generating plate, wherein the plate is formed so as to satisfy the above. In the manufacturing method of the plate for pulse generation according to any one of claims 2 to 4,
The guide portion is a punch for shaving the plate material together with the die,
The pressing step is performed following a shaving processing step in which the die and the punch are moved relative to each other along the thickness direction of the plate material so as to perform a shaving process on the plate material. A method for manufacturing a pulse generating plate. Manufacture of a conductive plate having a plurality of conductive portions arranged at predetermined intervals and having a conductive brush slidably contacted on the surface thereof and filled with an insulating resin material serving as an insulating portion between the adjacent conductive portions A method,
A plate material punched and formed for forming the conductive plate and a pressing portion for pressing the peripheral portion of the portion to be the conductive portion in the plate material in the plate thickness direction have a shape corresponding to the outer surface of the pressing portion. The plate material is interposed between the pressing portion and the pressing portion having a flat pressing surface facing the pressing portion, and the peripheral portion is moved by the pressing portion. A pressing step of pressing toward the pressing surface to form the conductive plate by forming the surface of the plate material on the pressing surface side and the side surface of the plate material into a shape corresponding to the pressing surface and the inner surface; A method of manufacturing a conductive plate, characterized in that: It is a manufacturing method of the conductive plate according to claim 6,
The method of manufacturing a conductive plate, wherein the pressing portion is a die in which a protrusion protruding toward the pressing surface is formed at a peripheral portion of the surface on the pressing surface side. In the manufacturing method of the electrically-conductive plate of Claim 7,
The projecting portion has a relationship between the width w and the thickness t of the plate material.
0.5t ≦ w ≦ 1.0t
A method for producing a conductive plate, wherein the conductive plate is formed to satisfy the above. In the manufacturing method of the electroconductive plate of Claim 7 or Claim 8,
The ridge portion has a relationship between the height h in the protruding direction of the ridge portion and the plate thickness t of the plate material.
0.05t ≦ h ≦ 0.2t
A method for producing a conductive plate, wherein the conductive plate is formed to satisfy the above. In the manufacturing method of the electroconductive plate in any one of Claims 7 thru | or 9,
The guide portion is a punch for shaving the plate material together with the die,
The pressing step is performed following a shaving processing step in which the die and the punch are moved relative to each other along the plate thickness direction of the plate material to perform a shaving process on the plate material. A method of manufacturing a conductive plate.

Images