JP2010114023A - Electric appliance, and manufacturing method of electric appliance - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an electric appliance to secure waterproofness of a case while realizing reduction of a manufacturing cost, and a manufacturing method of the electric appliance. <P>SOLUTION: This is the electric appliance (1) connected to a commercial power supply, and equipped with a resin case (2) to house a functional member, a plug blade (31) respectively equipped with an exposed part (32) which is insert-molded in the case, and connected to the commercial power supply, and a resin facing part (34) surrounded by a resin, an annular elastic member (80) which is engaged with the resin facing part, and adhered to the plug blade by pressure of the resin at the time of insert molding, and a flange member (70) having a pressing face (74) which is engaged with the resin facing part, in which the elastic member is receivably formed, which is contracted in the diameter as it is separated from the exposed part, and which presses in the elastic member toward the axial line of the plug blade at the time of insert molding. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an electric appliance connected to a commercial power source and a method for manufacturing the electric appliance.

This type of electric appliance, for example, an AC adapter has a metal plug configured to be connectable to a commercial power source. This plug is composed of a pair of blades (plug blades) and is insert-molded in a waterproof case made of resin.
The adapter converts AC power into DC power, and heat is generated during the conversion. Since the expansion / contraction rate of the case and the expansion / contraction rate of the blade are different, this heat causes a gap between the case and the blade, which causes a reduction in the airtightness of the case.

  Then, the technique which improves the airtightness of a case using an encapsulating resin material is known (for example, refer patent document 1). Specifically, a guard wall is formed around the blade, and an encapsulating resin material is filled inside the guard wall to ensure the waterproofness of the case.

International Publication No. 07/116791 Pamphlet

  However, the encapsulating resin material as in Patent Document 1 is expensive, and if the encapsulating resin material is filled in the case, there is a problem that the number of steps until the case is completed becomes very long. This is because the encapsulating resin material takes about 8 hours to be injected and dried, and the drying time of the resin material is further added to the solidification time of the resin forming the case.

  Here, it is conceivable to arrange the O-ring on the blade to ensure the waterproofness of the case. However, if the O-ring is simply provided on the blade, the position of the O-ring with respect to the blade can be determined by the pressure of the resin during insert molding. There arises a problem that the O-ring is displaced from the blade.

  SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide an electric appliance that solves the above-mentioned problems and ensures the waterproofness of the case while reducing the manufacturing cost, and a method for manufacturing the electric appliance.

  1st invention for achieving the said objective is an electric appliance connected to a commercial power source, Comprising: The resin-made case which accommodates a functional member, The case is insert-molded, and is connected to a commercial power source A plug blade provided with an exposed portion and a resin facing portion surrounded by the resin, an annular elastic member that is engaged with the resin facing portion and is in close contact with the plug blade by the pressure of the resin at the time of insert molding, and a resin A hook that is engaged with the counter part, is formed so that the elastic member is receivable, has a diameter that decreases as it moves away from the exposed part, and has a pressing surface that pushes the elastic member toward the axis of the plug blade during insert molding Member.

According to the first invention, the plug blade is insert-molded in the case, and the plug blade has a resin facing portion surrounded by the resin. An annular elastic member and a flange member are engaged with the resin facing portion, respectively. The flange member has a pressing surface, and the pressing surface can receive the elastic member, and the diameter thereof is reduced as the distance from the exposed portion increases.
The elastic member is pressed toward the axis of the plug blade by the pressing surface by the pressure of the resin at the time of insert molding, and is in close contact with the plug blade.

In other words, the elastic member is closed by the flange member and is called to the plug blade side by its pressing surface, and is in close contact with the plug blade in a contracted state due to the injection pressure by the insert molding, through this elastic member The airtightness between the blade and the resin is improved. More specifically, since the elastic member that has shrunk at the time of molding acts in a direction in which it swells after molding, no gap is generated between the plug blade and the resin. As a result, the waterproofness of the case is ensured, which contributes to improving the reliability of the electric appliance.
In addition, according to this structure, an encapsulating resin material is not required as compared with the conventional case, and the man-hour is extremely shortened, so that the manufacturing cost of the electric appliance can be reduced.

According to a second aspect of the invention, in the configuration of the first aspect of the invention, the flange member further has a pressure receiving surface to which a force due to mold clamping at the time of insert molding is applied at a position opposite to the pressing surface. And
According to the second invention, in addition to the action of the first invention, in addition to the injection pressure by the insert molding, the force by the mold clamping at the previous stage also acts on the elastic member. Therefore, the airtightness between the plug blade and the resin via the elastic member is further improved.

  More specifically, first, the force applied to the pressure receiving surface by closing the mold causes the elastic member to contract, and the elastic member is brought into close contact with the plug blade. Next, the injection pressure further shrinks the elastic member to make it tightly adhere to the plug blade. The resin formed by the insert molding is solidified while the pressure is applied, and a larger repulsive force to the outside remains inside the elastic member. Accordingly, the airtightness between the plug blade and the resin via the elastic member is further improved, and for example, an external force is applied to the plug blade with the use of an electric appliance. Even if a gap is formed between them, the moisture that has entered the gap can be reliably dammed by the elastic member.

According to a third invention, in the configuration of the first or second invention, the resin facing portion has a step portion for positioning the elastic member on the outer periphery thereof.
According to the third invention, in addition to the effects of the first and second inventions, if the resin facing portion of the plug blade has a stepped portion, the elastic member is interposed between the pressing surface and the plug blade. The elastic member can be securely fixed, and the elastic member is more closely adhered to the stopper blade.

According to a fourth invention, in the configuration of the first to third inventions, the electric appliance is an AC adapter that generates DC power from a commercial power source.
According to the fourth aspect of the invention, in addition to the effects of the first to third aspects of the invention, since the airtightness of the case is secured by utilizing the contraction of the elastic member, the AC power is converted into DC power. The adapter that generates heat produces particularly good effects.

5th invention is a manufacturing method of the electric appliance which has the case made from resin which accommodates a functional member, and has the plug blade connected to a commercial power source.
Then, the step of disposing the annular elastic member on the outer periphery of the resin facing portion facing the resin in the plug blade, and the elastic member can be received and separated from the exposed portion of the plug blade connected to the commercial power source. Accordingly, the step of disposing the flange member having the pressing surface reduced in diameter on the outer periphery of the resin facing portion, the step of disposing the exposed portion on the fixed mold, the fixed mold and the movable mold The mold is clamped, and the movable mold is brought into contact with a pressure receiving surface formed at a position opposite to the pressing surface of the flange member, and the elastic member and the plug blade are brought into contact with each other through the pressing surface. A step of contacting, a step of injecting a resin between the fixed side mold and the movable side mold, and further abutting the elastic member and the plug blade through the pressing surface with the pressure of the resin; Solidifying step.

According to the fifth aspect of the present invention, the annular elastic member and the flange member are disposed in the resin facing portion of the plug blade, and the exposed portion of the plug blade is disposed in the fixed mold. The elastic member is shrunk by the force of closing the mold through the pressing surface, and then further shrunk by the injection pressure and tightly adhered to the plug blade.
Subsequently, the resin formed by the insert molding is solidified while the pressure is applied, and the elastic member is provided with a larger repulsive force to the outside, and this force acts in the direction of swelling after molding. Therefore, the airtightness between the plug blade and the resin via the elastic member is further improved.

In addition, according to this structure, the sealing step of the encapsulating resin material into the inside of the case becomes unnecessary as compared with the conventional case, and the man-hour is extremely shortened, so that the manufacturing cost of the electric appliance can be reduced.
According to a sixth aspect of the present invention, in the configuration of the fifth aspect, before the step of disposing the elastic member on the outer periphery of the resin facing portion, a step of forming a step for positioning the elastic member on the outer periphery of the resin facing portion It is characterized by providing.
According to the sixth aspect of the invention, in addition to the action of the fifth aspect, the elastic member is securely fixed between the pressing surface and the stepped portion of the plug blade, and can be more securely adhered by the plug blade.

  According to the present invention, the hook member that prevents the positional displacement of the annular elastic member is provided on the plug blade, and the electric appliance that can achieve both reduction in manufacturing cost and securing of waterproofness of the case, and the electric appliance The manufacturing method of can be provided.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows an AC adapter (electric appliance) 1 of this embodiment. In this adapter 1, DC power is generated from AC power, which is a commercial power supply, and this DC power is used for driving an electric device or charging a secondary battery.

The adapter 1 has a waterproof case (case) 2 made of a synthetic resin having heat resistance and insulation, and the case 2 includes an upper case body 3 and a lower case body as shown in FIG. 13.
Specifically, the case body 3 has a cup shape opened downward, and the opening end 4 is formed in a substantially square shape. Further, a protrusion 6 is formed on the right side of the opening end 4 as viewed in FIGS. 1 and 2, and this protrusion 6 also opens downward.

  On the other hand, the case main body 13 has a cup shape opened upward, and the opening end 14 is also formed in a substantially square shape, and is also directed upward on the right side of the opening end 14 as seen in FIGS. A projecting portion 16 is formed to open. Further, the bottom surface side of the case body 13 bulges downward, and a plug 30 is formed at the bulged portion, so that the case 2 can be directly inserted into an outlet (direct plug-in method).

  Then, the case main body 3 is put on the case main body 13, and the openings of the opening ends 4 and 14 and the protrusions 6 and 16 are ultrasonically welded. Thereby, the case main body 3 is airtightly fitted to the case main body 13, and the case 2 having a space inside is formed. The case main bodies 3 and 13 may be fitted using screws.

  Inside the case 2, as shown in FIG. 3 and FIG. 4 in addition to FIG. An electronic component as a functional member is mounted on the substrate 10, and the AC power is converted into DC power having a predetermined voltage in the component. Further, an AC input terminal (not shown) of the substrate 10 is electrically connected to the plug 30 via the connection portion 11 (FIG. 4).

The plug 30 of this embodiment has a pair of metal blades (plug blades) 31, 31, and is disposed on the lower case body 13 by insert molding.
More specifically, a plate-like blade 31 is arranged side by side on the case body 13 so as to face the wide surface, and the blade 31 includes an exposed portion 32, a resin facing portion 34, and a rear end portion 38. (FIG. 5).

The exposed portion 32 is disposed outside the lower case body 13 and is configured to be plugged into an outlet. On the other hand, the resin facing portion 34 continues to the exposed portion 32 and is surrounded by the case body 13. Further, the rear end portion 38 is connected to the resin facing portion 34 and is connected to the connection portion 11 further inside the case main body 13.
Here, a positioning step (step) 36 is formed on the outer peripheral surface of the resin facing portion 34 of the present embodiment.

More specifically, as shown in FIG. 5, the stepped portion 36 of the present embodiment protrudes in a direction substantially perpendicular to the bus bar of the blade 31 and is formed on both sides of the wide surface. The step portion 36 may be configured to be inclined so as to compete toward the rear end portion 38.
Then, an O-ring (elastic member) 80 and a closing sleeve (saddle member) 70 are engaged with the stepped portion 36, respectively.

Specifically, the O-ring 80 is formed in an annular shape that can be engaged with the outer peripheral surface of the resin facing portion 34.
Further, the closing sleeve 70 of the present embodiment has a stepped substantially rectangular tube shape, is formed of a material having heat resistance superior to that of the case main bodies 3 and 13, and a resin facing portion is disposed inside the small diameter portion thereof. 34 is provided with an inner peripheral surface 71 engaged with the outer peripheral surface 34 (FIGS. 5 and 6). The longitudinal direction of the inner peripheral surface 71 coincides with the formation direction of the wide surface of the blade 31.

On the other hand, the outer side of the large-diameter portion of the sleeve 70 is partitioned by an outer peripheral surface 72, and the outer and outer peripheral surfaces 72 of the inner peripheral surface 71 are connected by a covering surface 75, and the front end is viewed in the extending direction of the blade 31. 73 and a pressure receiving surface 76. The front end 73 faces the O-ring 80, and the pressure receiving surface 76 faces the connection portion 11.
Here, inside the outer peripheral surface 72, a front taper (pressing surface) 74 is formed between the front end 73 and the inner peripheral surface 71.

Specifically, the front taper 74 gradually decreases in diameter as it is separated from the exposed portion 32, and has a size that can receive the O-ring 80.
And in manufacturing the case 2 mentioned above, the external shape and the positioning step part 36 are formed in the braid | blade 31 by press work. Next, an O-ring 80 and a deadline sleeve 70 are prepared.

  In the present embodiment, first, the O-ring 80 is passed through the blade 31 from the rear end portion 38 side, and the O-ring 80 extending along the outer peripheral surface of the resin facing portion 34 is disposed on the step portion 36. Next, the sleeve 70 is also passed through the blade 31 from the rear end 38 side. Specifically, the front end 73 is moved toward the O-ring 80 with the front end 73 as the head, and the O-ring 80 is covered with the front taper 74.

Subsequently, the blades 31, 31 having the O-ring 80 and the sleeve 70 are loaded into an insert molding die that forms the lower case body 13.
Specifically, as shown in FIG. 7, the exposed portion 32 is inserted into a cabinet (fixed mold) 90 that forms the outer surface of the lower case body 13. Next, as shown in FIG. 8, the core (movable mold) 92 that forms the inner surface of the case body 13 is lowered from above the rear end portion 38 toward the cabinet 90 and then clamped.

  More specifically, in this mold clamping, in order to withstand the injection pressure of the molten resin, a force is applied to the mold 90 and the core 92 to close the mold. The core 92 and the pressure-receiving surface 76 are brought into contact with each other, and then the force is applied to the cavity 90 and the core 92. As a result, the front taper 74 pushes the O-ring 80 toward the axis of the blade 31, and the O-ring 80 is pressed against the step portion 36 of the blade 31.

Subsequently, when molten resin is injected between the cavity 90 and the core 92, the open end 14 and the protruding portion 16 are formed, and as shown in FIG. 9, the outer peripheral surface 72 and the covering surface 75 of the sleeve 70 are formed. Is formed (FIGS. 2 to 4).
Further, the molten resin reaching the front end 73 of the sleeve 70 further presses the O-ring 80 against the front taper 74 with a predetermined injection pressure. However, since this O-ring 80 is already blocked by the front taper 74, the O-ring 80 is further pressed against the stepped portion 36.

  Thereafter, the resin is solidified in a pressure-holding state, and in the lower case body 13 taken out from the mold 90 and the core 92, the O-ring 80 in a compressed state by the mold clamping or the injection pressure is replaced with the sleeve 70, the blade 31, and It is interposed between the resins constituting the main body 13.

  Returning to FIG. 2 again, a DC output terminal (not shown) of the power supply board 10 is electrically connected to the cable 50. The cable 50 has a cable main body 51, and a bush 54 is integrally formed on the outer cover of the main body 51 by injection molding. The outer cover of the main body 51 and the bush 54 are made of a synthetic resin having flexibility.

Further, the power supply board 10 is attached to the case body 13, the board 10 is connected to the plug 30, the board 10 is connected to the cable 50, and the bush 54 is disposed on the protruding portion 16 of the case body 13. 50 is pulled out of the protrusion 16.
Subsequently, an upper case body 3 that is also injection-molded is prepared, and the open ends 4 and 14 and the protrusions 6 and 16 are fitted in an airtight manner by ultrasonic welding, whereby the case 2 is configured.

  In the adapter 1 having the case 2, the plug 30 is directly connected to a commercial power outlet, while a connector (not shown) of the cable 50 is connected to an electrical device or the like. Thereby, in the adapter 1, alternating current power is converted into direct current power, and an electric device is driven and a secondary battery is charged.

By the way, the above-described O-ring 80 and sleeve 70 may be attached to the blade 31 inserted into the cabinet 90.
To describe this point in more detail, before clamping the mold 90 and the core 92, first, the stepped portion 36 for positioning the O-ring 80 is formed on the outer periphery of the resin facing portion 34 facing the resin in the blade 31. To do.

  Next, the exposed portion 32 connected to the commercial power source in the blade 31 is disposed in the cabinet 90. Subsequently, the O-ring 80 is disposed on the outer periphery of the resin facing portion 34. Next, the sleeve 70 that can receive the O-ring 80 and has a front taper 74 that is reduced in diameter as it is separated from the exposed portion 32 is disposed on the outer periphery of the resin facing portion 34.

  As described above, according to this embodiment, the blade 31 is insert-molded in the lower case body 13 and the blade 31 has the resin facing portion 34 surrounded by the resin. An O-ring 80 and a closing sleeve 70 are engaged with the outer periphery of the resin facing portion 34, respectively. The sleeve 70 has a front taper 74, which can receive the O-ring 80 and is reduced in diameter as it is separated from the exposed portion 32.

The O-ring 80 is pushed toward the axis of the blade 31 by the front taper 74 by the pressure of the resin at the time of insert molding, and comes into close contact with the blade 31.
That is, the O-ring 80 is closed by the sleeve 70 and is called to the blade 31 side by the front taper 74, and is closely attached to the blade 31 in a contracted state due to the injection pressure by the insert molding. The airtightness between the blade 31 and the resin through the gap is improved. More specifically, since the O-ring 80 that has shrunk at the time of molding acts in the direction of swelling after molding, no gap is generated between the blade 31 and the resin. As a result, the waterproofness of the case main body 13 is ensured, which contributes to improving the reliability of the AC adapter 1.

In addition, according to the structure, an encapsulating resin material is not required as compared with the conventional one, and the number of parts of the adapter 1 is increased because the sleeve 70 and the O-ring 80 are required, but if the resin is solidified. Since the process is completed without waiting for the encapsulating resin material to dry, the number of man-hours is extremely shortened, and the manufacturing cost of the adapter 1 can be reduced.
In addition, when the O-ring 80 is used, the lower case body 13, particularly the bulging portion, can be downsized as compared with the case where a belt-like ring is used.

Furthermore, in addition to the injection pressure due to insert molding, the O-ring 80 is also subjected to the force due to the clamping at the previous stage. The airtightness between the blade 31 and the resin via the ring 80 is further improved.
More specifically, first, the core 92 is brought into contact with the sleeve 70 by this mold closing, and the force from above applied to the pressure receiving surface 76 contracts the O-ring 80 so that the O-ring 80 is brought into close contact with the blade 31. .

  Next, the injection pressure from the lower side further shrinks the O-ring 80 and causes the blade 31 to closely adhere. The resin formed by the insert molding is solidified while the pressure is applied, and a larger repulsive force to the outside remains in the O-ring 80 inside. Therefore, the airtightness between the blade 31 and the resin via the O-ring 80 is further improved. For example, when the AC adapter 1 is used, a force is applied to the blade 31 from the outside. Even if a gap is formed between the main body 13 and the water entering the gap, the O-ring 80 can reliably dam the moisture.

Furthermore, if the resin facing portion 34 has the positioning step portion 36, the O-ring 80 can be reliably fixed between the front taper 74 and the blade 31, and the O-ring 80 is more reliably secured by the blade 31. Close contact with.
Further, since the airtightness of the case main body 13 is ensured by utilizing the contraction of the O-ring 80, the AC adapter 1 that generates heat when AC power is converted into DC power has a particularly good effect.

The present invention is not limited to the above embodiments, and various modifications can be made without departing from the scope of the claims.
For example, in the above embodiment, an example in which an AC adapter is embodied as an electric device is shown. However, the present invention incorporates a functional member such as an electric component or an electronic component in a waterproof case, and the case has a plug blade. As a matter of course, the present invention can be applied to various electric devices.

Moreover, the shape and number of the above-described plug blades are only examples, and may be a known shape such as a round bar shape or an L shape, or may be composed of three or more plug blades. .
In any of these cases, similarly to the above, it is possible to reduce the manufacturing cost and secure the waterproofness of the case.

It is a perspective view of the AC adapter in a present Example. It is a partial cross section side view of the adapter of FIG. It is a fragmentary sectional top view of the adapter of FIG. It is arrow sectional drawing seen from the IV-IV line of FIG. FIG. 5 is an exploded perspective view of a deadline sleeve, an O-ring, and a blade of FIG. 4. (A) is the perspective view which looked at the deadline sleeve of FIG. 5 from the lower side, (b) is the arrow sectional drawing seen from the VI-VI line of FIG. It is a figure explaining the insert molding of the braid | blade of FIG. It is a figure explaining the insert molding of the braid | blade of FIG. It is a figure explaining the insert molding of the braid | blade of FIG.

Explanation of symbols

1 AC adapter (electric appliance)
2 Waterproof case
30 plug 31 blade (plug blade)
32 Exposed part 34 Resin facing part 36 Positioning step part (step part)
70 Deadline sleeve
74 Front taper (pressing surface)
76 Pressure-receiving surface 80 O-ring (elastic member)
90 mold (mold on the fixed side)
92 core (mould on the movable side)

Claims (6)

An appliance connected to a commercial power source,
A resin case for storing functional members;
A plug blade that is insert-molded in the case and has an exposed portion connected to the commercial power source and a resin facing portion surrounded by resin,
An annular elastic member that is engaged with the resin facing portion and is in close contact with the plug blade by the pressure of the resin during the insert molding;
Engaged with the resin facing portion, the elastic member is formed so as to be receivable, and the diameter is reduced as it is separated from the exposed portion, and the elastic member is directed toward the axis of the plug blade during the insert molding. And an eaves member having a pressing surface to be pressed. The electrical appliance according to claim 1,
The appliance further includes a pressure receiving surface to which a force by clamping at the time of insert molding is applied at a position opposite to the pressing surface. The electrical appliance according to claim 1 or 2,
The electric appliance according to claim 1, wherein the resin facing portion has a stepped portion for positioning the elastic member on an outer periphery thereof. An electrical appliance according to any one of claims 1 to 3,
The electrical appliance is an AC adapter that generates DC power from the commercial power source. A method for producing an electric appliance having a resin case for storing a functional member and having a plug blade connected to a commercial power source,
A step of disposing an annular elastic member on the outer periphery of the resin facing portion facing the resin among the plug blades;
The elastic member is receptive, and a flange member having a pressing surface whose diameter is reduced as it is separated from the exposed portion connected to the commercial power source in the plug blade is disposed on the outer periphery of the resin facing portion. And a process of
Placing the exposed portion in a fixed mold;
The mold on the fixed side and the mold on the movable side are clamped, and the mold on the movable side is brought into contact with a pressure receiving surface formed at a position opposite to the pressing surface of the flange member, Contacting the elastic member and the blade through the pressing surface;
Injecting a resin between the fixed mold and the movable mold, and further bringing the elastic member and the plug blade into contact with each other through the pressing surface with the pressure of the resin;
A method for producing an electric appliance, comprising: solidifying the resin. It is a manufacturing method of the electric appliance of Claim 5, Comprising:
Before the step of disposing the elastic member on the outer periphery of the resin facing portion, a step of forming a step for positioning the elastic member on the outer periphery of the resin facing portion is provided. Method.

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