JP2010176893A - Method of manufacturing conductive component for wiring device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a component for a wiring device, in which pure copper is work hardened by forging to thereby secure rigidity equivalent to rigidity obtained by using copper alloy. <P>SOLUTION: In the method of manufacturing the component for the wiring device in which a flat pure copper material 10 is bent into a conductive component 11 having a solid shape, predetermined parts of the material 10 that need to be rigid as the conductive component 11 are forged to be work hardened. The material 10 is a wire 12, and predetermined parts of the wire 12 are pressed flat by forging and work hardened. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a conductive component for a wiring device.

  Conventionally, as a wiring instrument, for example, a switch box 1 shown in FIGS. 10 to 11 is arranged with a terminal plate 2 in the box 1, and the wiring (copper wire) 4 is connected to the terminal plate by the spring force of the lock spring 3. 2 is held. Further, the contact terminal 5 and the contact terminal 6 are arranged to face each other, and the open / close terminal 7 having the contact parts 7a and 7b is arranged between the contact parts 5a and 6a. The contact portion 7a is held by the contact portion 6a.

  A conductive component such as the contact terminal 5 (same for the contact terminal 6 and the terminal plate 2) is generally made of a copper alloy material having a flat (flat) shape (two-dimensional) and a three-dimensional (three-dimensional) conductive component. Manufactured by bending with a press or the like. For example, in a metal mold called a progressive metal mold, a process of punching a material into a planar shape (a developed shape of a conductive part) and a process of bending are performed in parallel.

  Here, since the conductive component has a structure in which a contact force is held by a spring force at a connection portion with another component or wiring, a portion that receives the spring force needs to have appropriate rigidity. For this reason, when pure copper is used as a material, the required rigidity cannot be obtained. Therefore, in order to increase the rigidity, a copper alloy in which an additive such as tin is added to copper is used. Here, pure copper means the thing which has not added the additive for improving rigidity.

  In addition, as a technique for rolling a material in order to control the spring property, there is a technique in which a spring portion forming portion is rolled and thinned so as to make the spring deflection as large as possible (see Patent Document 1). However, although the deflection can be made larger than that of the original member, that is, the rigidity can be lowered, the rigidity is not increased.

  In addition, as a technology for turning parts into wire rods, spring wire and conductive wire rods are bent to form blade receiving springs for connecting devices such as relay sockets and outlets, and the contact portions of the blade receiving springs are crushed into a flat plate shape There is a blade receiving spring structure (see Patent Document 2). However, in order to expand the contact area of the electrical contact portion, it is only crushed into a flat plate shape, and the place where the spring property is generated remains as a wire, so in order to increase the rigidity of the spring property, It is necessary to make the material highly rigid or use a thicker wire.

JP 2001-43953 A JP 57-163969 A

  However, the copper alloy has a problem that the price is higher than that of pure copper and the manufacturing cost is increased.

  The present invention has been made to solve the above-mentioned problems. By increasing the hardness by forging and hardening pure copper by forging, it is possible to ensure the same rigidity as when copper alloy is used. It aims at providing the manufacturing method of components.

  In order to solve the above-mentioned problem, the present invention requires a rigidity as the conductive component in a method for manufacturing a conductive component for a wiring device in which a pure copper material having a planar shape is bent into a three-dimensional conductive component. The present invention provides a method for manufacturing a conductive component for a wiring device, wherein a predetermined portion of the material is work hardened by forging.

  As in claim 2, in claim 1, the material is a wire, and the predetermined portion of the wire can be work-cured while being crushed into a plate shape by forging.

  As in claim 3, in claim 2, the wire is bent in advance in a planar shape in accordance with the developed shape of the conductive component, and then a predetermined portion of the wire is crushed into a plate shape by forging. Can do.

  As in claim 4, when the wire is continuously bent into a planar shape in claim 3, the bending die is divided into a plurality of pieces in the longitudinal direction of the wire, and one end of the wire is fixed with a fixing jig. After that, bending and forging can be performed simultaneously with a plurality of bending dies from one end side to the other end side of the wire.

  As in claim 5, when the wire is forged with a concave forging die and a convex forging die, the wire is set at a position offset from the center position of the concave forging die to one side in the width direction. Can do.

  As in claim 6, in claim 2, the wire can change the direction in which the wire is forged according to the bending direction after forging.

  As in claim 7, in claim 1, when a locally thin portion is formed in the material, the corresponding portion of the material before forging can be crushed in advance.

  As in claim 8, in claim 1, a knurled impression can be performed simultaneously with forging at a corresponding portion of the material.

  According to the present invention, a predetermined portion of a pure copper material that requires rigidity as a conductive component is processed and hardened by forging to increase the rigidity. That is, in the past, an expensive copper alloy material in which tin or the like was added to copper was used in order to increase the rigidity. However, in the present invention, the work hardening by forging has a rigidity equivalent to that of the copper alloy material. Since it goes up, an inexpensive pure copper material can be used.

  According to the second aspect, if the material is a wire, even if it is crushed, the cross-sectional area is constant with respect to the flow direction of electricity, and the electric resistance is constant, so there is no local electric heat generation, and the wiring device It is optimal as a conductive part for industrial use. In addition, there is almost no material loss and the yield is very good. Further, since no punching burrs are generated, the pressure resistance is excellent.

  According to the third aspect, by bending the wire in a planar shape in advance according to the developed shape of the conductive component, even a conductive component having a complicated three-dimensional shape can be easily manufactured.

  According to claim 4, when a wire is continuously bent into a planar shape, if a complicated bending shape is bent at the same time with one bending die, the wire is subject to a large tensile stress and is thus divided. is there. On the other hand, if the bending and forging are performed sequentially with a plurality of bending dies from one end side where the wire is fixed to the other end side (free end), the wire is occasionally bent from the other end side. Therefore, the tensile stress is not easily applied, and the wire is not divided. Further, since bending and forging are performed simultaneously, the production efficiency is improved.

  According to the fifth aspect, when dimensional accuracy or shape accuracy is required on one side in the width direction of the conductive component, the offset side can be processed with high accuracy by contacting the inner surface of the concave forging die. Moreover, since the other side does not contact the inner surface of the concave forging die, the radius of the other side end surface is increased, and the pressure resistance characteristics are improved.

  According to the sixth aspect, by changing the direction in which the wire is forged according to the bending direction after forging, the bending directions can be combined in various ways, and more complicated shapes of conductive parts can be realized.

  According to the seventh aspect, when it is necessary to locally form a thin portion in the conductive component, when the material is forged, a surplus of material is generated at that portion and enters the gap of the forging die to become a burr. On the other hand, since the material surplus does not arise by crushing the applicable part of the raw material before forging beforehand, a burr | flash does not generate | occur | produce.

  According to claim 8, two types of processing, forging and knurled coining, can be performed in one step.

BRIEF DESCRIPTION OF THE DRAWINGS It is 1st Embodiment of this invention, (a) is a top view of a planar-shaped raw material, (b) is a perspective view of the electrically-conductive component which bent the raw material into the solid shape. It is 2nd Embodiment of this invention, (a) is a top view of a planar wire, (b) is a top view after carrying out work hardening, crushing a wire to plate shape by forging, (c) These are the perspective views of the electrically-conductive component which bent the wire to the three-dimensional shape. (A) and (b) are side views schematically showing the primary bending process of a wire, (c) to (f) are cross-sectional views of the main part of the wire, and (g) and (h) are burrs. It is principal part sectional drawing of a wire which shows a state without a burr | flash. It is 3rd Embodiment of this invention, (a)-(e) is a side view which shows the operation | movement order of the metal mold | die which carries out the bending process of the wire continuously by planar shape. (A) (b) is a side view of a wire for explaining a state in which the wire is continuously subjected to primary bending and forging and then divided, and (c) to (e) are a set of bending shapes of the wire. It is a side view of the wire for demonstrating the state processed simultaneously only by the up-and-down bending type | mold. It is 4th Embodiment of this invention, (a) (b) is a front view which shows the operation | movement order of the metal mold | die which a burr | flash does not produce in a wire, (c) (d) is a metal mold | die with a burr | flash produced in a wire The front view which shows an operation | movement order, (e) is a front view of the metal mold | die which a burr | flash does not produce in a wire, (f) is a perspective view of the electrically-conductive component in which the burr | flash produced. It is 5th Embodiment of this invention, (a)-(d) is a perspective view for demonstrating changing the direction which forges a wire according to the bending direction after forging. It is 6th Embodiment of this invention, (a)-(c) is a front view which shows the operation | movement order of the metal mold | die which crushes a part of raw material thinly, (d) is a front which shows the state which forges a raw material as it is. FIG. 4E is a front view showing a state in which a part of the material is finely crushed and forged. It is a 7th embodiment of the present invention, (a) is a perspective view of a conductive component, (b) is an enlarged view of a knurled coin, and (c) is a cross-sectional view taken along line II of (b). is there. (A) is a perspective view of a switch box using a conductive component, and (b) is a perspective view of main parts of a contact terminal and an opening / closing terminal. It is a principal part side view of a contact terminal and an opening-and-closing terminal.

  Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to the drawings.

  1A and 1B show a first embodiment, in which FIG. 1A is a plan view of a planar (two-dimensional) pure copper material 10, and FIG. 1B is a three-dimensional (three-dimensional) shape of the material 10 of FIG. It is a perspective view of the electrically-conductive component 11 bent into 2 parts. The conductive component 11 is the contact terminal 5 as described above as an example. 1A and 1B has a slightly different outer shape from the contact terminal 5, but has the same function.

  First, as shown in FIG. 1A, a planar material 10 is punched out from a flat pure copper plate with a press or the like.

  Next, a predetermined portion (for example, a range of nn) of the material 10 that requires rigidity as the conductive component 11 is work-hardened by forging. The predetermined portion may be the entire material 10 or only a portion requiring rigidity. In addition, before punching out the raw material 10 with a press or the like, a predetermined portion of the raw material 10 can be work-hardened by forging, and then the raw material 10 can be punched out with a press or the like.

  Thereafter, the material 10 is bent into a three-dimensional conductive component 11 with a press or the like as shown in FIG. Specifically, by bending the material 10 along the dashed lines a ′, b ′, c ′, d ′, and e ′ shown in FIG. Bending is performed at the portions of chain lines a, b, c, d, and e.

  If it is 1st Embodiment, the predetermined location of the raw material 10 which requires rigidity as the electrically-conductive component 11 is work-hardened by forging, and it raises rigidity. This work hardening improves the hardness from about Hv60 to about Hv110.

  Therefore, in the past, an expensive copper alloy material in which tin or the like was added to copper was used in order to increase rigidity. However, in the first embodiment, it is equivalent to a copper alloy material by work hardening by forging. Since the rigidity increases, an inexpensive pure copper material 10 can be used.

  2A and 2B show a second embodiment, in which FIG. 2A is a plan view of a planar wire rod (material) 12, and FIG. 2B is a work hardened while forging a predetermined portion of the wire rod 12 into a plate shape by forging. (C) is a perspective view of the conductive component 11 obtained by bending the wire 12 of (b) into a three-dimensional shape.

  First, as shown in FIG. 2 (a), the wire 12 is bent in a planar shape in advance in accordance with the developed shape of the conductive component 11 in the same manner as the material 10 punched by the press of FIG. 1 (a) (1). Next bend). This primary bending process can be bent by the upper and lower bending dies 20, 21 as shown schematically in FIGS. 3 (a) and 3 (b). In addition, it can be bent with a wire forming machine. In addition, the cross-sectional shape of the wire 12 may be round or square.

  Next, as shown in FIG. 2B, a predetermined portion (for example, a range of nn) of the wire 12 that requires rigidity as the conductive component 11 is work-cured while being crushed into a plate shape by forging.

  Thereafter, the wire 12 is bent into a three-dimensional conductive component 11 as shown in FIG. 2C (secondary bending). Specifically, by bending the wire 12 at the portions of the alternate long and short dash lines a ′, b ′, c ′, d ′, and e ′ of FIG. 2B, the conductive component 11 is one point of FIG. Bending is performed at the portions of chain lines a, b, c, d, and e.

  If it is 2nd Embodiment, if a raw material is the wire 12, even if it crushes, a cross-sectional area will be constant with respect to the flow direction of electricity, and an electrical resistance will become constant. For example, FIG. 3 (f) shows a cross section of part A in FIG. 2 (b), FIG. 3 (e) shows a cross section of part B, and FIG. 3 (d) shows a cross section of part C. A cross section of the portion D is shown in FIG. This eliminates local electrical heat generation and is optimal as a conductive component for a wiring device.

  Further, unlike the case of punching out a metal plate, by making the wire 12 pass only at a necessary portion in the primary bending stage, there is almost no material loss and the yield is very good.

  Further, when the metal plate is punched, a burr p is always generated as in the material 10 in FIG. 3G, and this may become a starting point of discharge, which may cause a breakdown voltage failure. On the other hand, by forging the wire 12, punching burrs are not generated as shown in FIG.

  Furthermore, the wire 12 is bent in advance in a planar shape in accordance with the developed shape of the conductive component 11, and then a predetermined portion of the wire 12 is forged into a plate shape by forging, thereby conducting a conductive material having a complicated three-dimensional shape. Even parts can be easily manufactured. That is, if the wire 12 is forged as it is without primary bending, the direction of secondary bending is limited and only a very simple shape can be produced. On the other hand, by adopting a method in which the developed shape of the conductive component 11 is previously created in two dimensions, a complicated three-dimensional shape can be produced.

  FIG. 4 is a third embodiment, and (a) to (e) are side views showing an operation sequence of a mold for bending the wire 12 continuously in a planar shape.

  If the wire 12 of the second embodiment is bent into a planar shape after being divided into predetermined lengths, the manufacturing efficiency is deteriorated. Therefore, as shown in FIG. 5 (a), forging (primary bending and forging) is performed continuously while being fed in the direction of the arrow q, that is, while being connected and bent in a planar shape, and thereafter FIG. 5 (b). It is preferable to divide like this and to perform secondary bending.

  Here, as shown in FIG. 5 (c), if it is attempted to simultaneously process a complicated bending shape of the wire 12 with only one set of upper and lower bending dies 20, 21, the shaft of the wire 12 as shown in FIG. 5 (d). A tensile stress r is generated in the direction, and the wire 12 may be cut as shown in FIG. In this case, there is no problem if a wire forming machine is used. However, it is necessary to divide after the bending process, and since it is sent to the forging process in the divided state, the production efficiency is deteriorated.

  Therefore, as shown in FIG. 4A, in the primary bending process, a fixing jig 22 for fixing one end (tip on the feeding side) of the wire 12 and a plurality of (in this example) the wire 12 in the longitudinal direction. The upper and lower bending dies 23a to 23c and 24a to 24c are provided.

  Then, one end of the wire 12 is fixed with a fixing jig 22 as shown in FIG. This prevents the bent wire 12 from being drawn into the mold during bending of the wire 12, and the unprocessed wire 12 is drawn.

  Thereafter, from the one end side of the wire 12 toward the other end side, as shown in FIGS. 4B to 4D, the first bending process and the forging process are simultaneously performed in a plurality of bending dies 23a to 23c and 24a to 24c. Do.

  When this is finished, as shown in FIG. 4 (e), the fixing jig 22 and the bending dies 23a-23c, 24a-24c are opened, and the wire 12 is fed by one pitch in the direction of the arrow q, and FIG. Return and repeat the next primary bending and forging.

  In the case of the third embodiment, the bending and forging are sequentially performed by a plurality of bending dies 23a to 23c and 24a to 24c from one end side to which the wire 12 is fixed to the other end side (free end). is there. Therefore, since the wire 12 is drawn from the other end side to the bending dies 23a to 23c and 24a to 24c at any time, the tensile stress is hardly applied and the wire 12 is not divided. Further, since bending and forging are performed simultaneously, the production efficiency is improved.

  FIG. 6 is a fourth embodiment, and (a) and (b) are front views showing an operation sequence of a mold for forging the wire 12.

  When forging the wire 12 of the second embodiment with the concave forging die 25a and the convex forging die 25b as shown in FIG. 6C, when the wire 12 is set at the center position C of the concave forging die 25a, FIG. As shown in (d), the wire 12 may flow in the gap between the forging dies 25a and 25b and a burr t may occur.

  In this case, as shown in FIG. 6E, if the cross-sectional area of the forging dies 25a and 25b is sufficiently large with respect to the wire 12, no burr t is generated, but instead, the side surfaces of the forging dies 25a and 25b. Therefore, the shape transfer of the wire 12 becomes insufficient, and the shape accuracy of the wire 12 is lowered.

  Here, as shown in FIG. 6 (f), in the shape of the conductive component 11 (see the contact terminal 5 in FIG. 10 (a)), in order to increase the pressure resistance performance on one side of the cross section of the wire rod 12, However, it is not preferable to take out, however, shape accuracy may be required on one side. For example, if there is a burr t at the edge portion where the distance between the contact terminal 5 and the open / close terminal 7 is closest, a defect that causes a discharge u starting from the burr t occurs.

  Moreover, in order to perform positioning accurately in the secondary bending process after forging, it is necessary to accurately bring out the shape on at least one side of the cross section of the wire 12.

  Therefore, as shown in FIG. 6 (a), when the wire 12 is forged with the concave forging die 25a and the convex forging die 25b, the center C of the concave forging die 25a is shifted to a position C ′ offset to one side in the width direction. The wire rod 12 is set and forging is performed in that state as shown in FIG.

  Then, on the inner surface of the concave forging die 25a on the side closer to the wire 12, the wire 12 is strongly pressed and a burr t is generated, but the shape is accurately transferred. Conversely, the inner surface of the concave forging die 25a on the side away from the wire 12 is forged into a shape that leaves a sufficient radius R on the other end face (edge).

  In the case of the fourth embodiment, when dimensional accuracy or shape accuracy is required on one side in the width direction of the conductive component 11, high accuracy can be achieved by contacting the offset side with the inner surface of the concave forging die 25a. . Further, since the other side does not contact the inner surface of the concave forging die 25a, the radius R of the other side end surface is increased, and the pressure resistance characteristics are improved.

  FIG. 7 shows a fifth embodiment. When the shape of the conductive component 11 is complicated as shown in FIG. 7D, it may not be possible to simply punch it out with a press or the like as in the material 10 of FIG.

  Therefore, in the wire 12 as shown in FIG. 7A, the longitudinal bending v and the lateral bending w are performed in advance as shown in FIG. 7B. And the direction which forges the wire 12 is changed according to the bending direction after forging like FIG.7 (c). Specifically, the portion 12a of the longitudinal bending v of the wire 12 and the intermediate portion 12b of the longitudinal bending v of the wire 12 are forged x to be crushed in the longitudinal direction, and the portion 12c of the transverse bending w of the wire 12 is , Forging y to crush in the lateral direction.

  Thereafter, when the secondary bending is performed, the portion 12c of the wire 12 in the lateral direction w is laterally bent like the portion 11c in FIG. 7D (see arrow g). Further, the intermediate portion 12b of the longitudinal bending v of the wire 12 is vertically bent as shown by the portion 11b in FIG. 7D (see arrow h). In addition, the part 12a of the vertical bending v of the wire 12 becomes like the part 11a of FIG.7 (d).

  If it is 5th Embodiment, according to the bending direction after forging, by changing the direction which forges the wire 12, a bending direction can be combined variously and the shape of more complicated conductive parts 11 is also realized. Can do.

  FIG. 8 shows a sixth embodiment, and FIGS. 8A to 8C are front views showing an operation sequence of a mold for thinly crushing a part of the material (the same applies to the wire 12).

  In the conductive component 11 shown in FIG. 1 (b) or FIG. 2 (c), when it is necessary to form a locally thin portion (a portion having a small cross-sectional area) i, as shown in FIG. When forging is performed by setting 10 to the forging die 26 as it is, a material surplus is generated at a location i where the cross-sectional area is small, and the material 10 may flow in the gaps of the forging die 26 to generate burrs.

  Therefore, as shown in FIG. 8 (e), at the location i where the cross-sectional area is small, the cross-sectional area of the material 10 is reduced before the forging.

  As the means, as shown in FIGS. 8 (a) and 8 (b), by hitting the material 10 with the molds 27a and 27b, the material 10 is caused to flow in the direction of the arrow in FIG. ), The corresponding portion of the material 10 is crushed in advance. In addition, the location i with a small cross-sectional area can also be formed by cutting or punching.

  In the sixth embodiment, when it is necessary to locally form a thin portion i in the conductive component 11, the material surplus is obtained by previously crushing the corresponding portion i of the material 10 (12) before forging. Since it does not occur, burrs do not occur.

  9A and 9B show a seventh embodiment, in which FIG. 9A is a perspective view of the conductive component 11, FIG. 9B is an enlarged view of a knurled impression, and FIG. 9C is a cross-sectional view taken along line II in FIG. is there.

  The knurled shape k is a shape for preventing slipping on the contact surface between the conductive component 11 and the wiring (copper wire), and has a stepped pattern, for example. For example, the knurled shape k is formed in the falling portion 11 a of the conductive component 11.

  The forging die (see 25a and 25b in FIG. 6) is knurled in advance, so that the forging and knurling k impression steps are usually divided into two steps: forging and knurling k impression. These two types of processing can be performed in one step.

DESCRIPTION OF SYMBOLS 10 Material 11 Conductive component 12 Wire rod 22 Fixing jig 23a-23c Bending die 24a-24c Bending die 25a Concave forging die 25b Convex forging die k Knurled shape

Claims (8)

In the method for manufacturing a conductive component for wiring equipment, bending a flat copper material into a three-dimensional conductive component
A method for manufacturing a conductive component for a wiring device, wherein a predetermined portion of the material that requires rigidity as the conductive component is processed and hardened by forging.   The method for manufacturing a conductive component for a wiring device according to claim 1, wherein the material is a wire, and the predetermined portion of the wire is work-cured while being crushed into a plate shape by forging.   The wiring apparatus according to claim 2, wherein the wire is bent in advance in a planar shape in accordance with a developed shape of the conductive component, and then a predetermined portion of the wire is crushed into a plate shape by forging. Manufacturing method for conductive parts.   When the wire is continuously bent into a planar shape, the bending die is divided into a plurality of pieces in the longitudinal direction of the wire, one end of the wire is fixed with a fixing jig, and then the wire is moved from one end to the other end. 4. The method of manufacturing a conductive component for a wiring device according to claim 3, wherein bending and forging are sequentially performed with a plurality of bending dies at the same time.   3. The wiring device according to claim 2, wherein when the wire is forged with a concave forging die and a convex forging die, the wire is set at a position offset from the center position of the concave forging die to one side in the width direction. Manufacturing method for conductive parts.   The method for manufacturing a conductive component for a wiring device according to claim 2, wherein the wire changes a direction in which the wire is forged according to a bending direction after forging.   The method for manufacturing a conductive component for a wiring device according to claim 1, wherein when forming a locally thin portion on the material, the corresponding portion of the material before forging is crushed in advance.   The method for manufacturing a conductive component for a wiring device according to claim 1, wherein a knurled impression is performed simultaneously with forging on a corresponding portion of the material.

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