JP3180178B2 - Synthetic resin part having integral metal member and method of manufacturing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a synthetic resin part having a novel integral metal member and a method of manufacturing the same. More specifically, a synthetic resin is formed by integrally forming two metal members which are arranged to face each other in a use state and which overlap each other when they are arranged in the arrangement direction in a developed state. It is possible to form a synthetic resin part having an integral metal member by being integrated with a main body made of a synthetic resin.

[0002]

2. Description of the Related Art A metal member set in which a plurality of types of metal members are integrated via a bridge is inserted into a synthetic resin body molding die, and the synthetic resin body is inserted into the synthetic resin body molding die. After injecting a resin for molding and forming a synthetic resin part intermediate body in which a synthetic resin body made of synthetic resin and a metal member set are integrated, the bridge is cut to separate the plurality of metal members. By manufacturing a synthetic resin component having an integral metal member, the accuracy of assembling the metal member to the synthetic resin body is improved, and the risk of inadvertent contact between the metal members is eliminated, and There is an advantage that labor for assembling the metal member can be saved, which contributes to cost reduction.

[0003]

By the way, a metal member which is arranged in a part of the above-mentioned metal member so as to be opposed to each other in a use state, and overlaps when arranged in the arrangement direction in a developed state. When there are two metal members, there is a problem that they cannot be integrally punched from the same metal plate.

[0004]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and a synthetic resin part having an integral metal member is provided by connecting a plurality of types of metal members through a bridge. A plurality of punched holes are formed in a synthetic resin body in which an integrated metal member set is integrated by insert molding, and the bridge is cut in the punched holes to separate the plurality of metal members into an integrated metal member. One of two metal members which are arranged opposite to each other in a use state, and which are overlapped with each other when they are arranged in the arrangement direction in a deployed state. It is intended to be arranged to face the other metal member by being folded over the portion that is doing, and the manufacturing method thereof,
A metal member set in which a plurality of types of metal members are integrated via a bridge is inserted into a synthetic resin body molding die, and the synthetic resin body resin is injected into the synthetic resin body molding die. After molding a synthetic resin part intermediate body in which a synthetic resin body made of synthetic resin and a metal member set are integrated, the bridge is cut to separate the plurality of metal members to form an integrated metal member. In the method of manufacturing a synthetic resin component having a member, a metal member set is formed by first punching a metal plate and then bending the metal plate, and is a metal member arranged to face each other in a use state, and in a developed state. Two metal members that overlap each other when they are arranged in the arrangement direction are formed so that one of them is located out of the arrangement direction in the punched state, The metal member by folding to the portion to which it is contiguous in which were arranged to face the other metal member.

[0005]

Therefore, according to the present invention, two metal members which are arranged to face each other in the use state and which overlap each other when they are arranged in the arrangement direction in the unfolded state are combined with one metal. It can be formed integrally from a plate.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The details of a synthetic resin part having an integral metal member and a method of manufacturing the same according to the present invention will be described below with reference to the illustrated embodiments. In the illustrated embodiment, the present invention is applied to a lamp body of a room lamp and a method of manufacturing the same.

Reference numeral 1 denotes a room lamp, and reference numeral 2 denotes a body of the room lamp.

The body 2 is made of synthetic resin and has a shallow dish-shaped main part 4 having a concave part 3 opened forward.

A shallow recess 5 is formed at the center of the main part 4 except for the upper end in the left-right direction. The recess 5 has a vertically elongated opening 6 displaced slightly downward.

The upper end 3a of the recess 3 is formed slightly deeper than the remaining portion. In the center of the boundary between the upper end portion 3a and the remaining portion, the partition wall 7, which is separated left and right,
7 is erected.

The engaging claws 8, 8 are provided on the upper surfaces of the partition walls 7, 7, respectively.
Are protruding. Engagement holes 10 and 10 are formed on the inner surface of the lower side of the peripheral wall 9 surrounding the recess 3 so as to be separated from each other.

A mounting hole 11 is formed between the partition walls 7 and 7 so as to penetrate the partition walls 7 back and forth.

At positions slightly below the partition walls 7 in the recess 5, recesses 12a, 12b and 12c are formed in a substantially arc shape centered on the mounting hole 11. The concave portions 12a, 12b, 12c are formed in a concave curved surface when viewed in a cross section along the arrangement direction, and the opening edges are formed in a convex curved surface.

Insert holes 13, 13,... Are formed at four positions near the upper end and lower end of the position along the side edge of the concave portion 5. The insertion holes 13, 13,...
3a,... Are large diameter portions having a diameter approximately twice that of the remaining portions 13b, 13b,.

A rib 14 protrudes from a substantially central portion of the recess 5 along a lower edge thereof.

Walls 15a and 15b are formed rearward from upper and lower ends of the upper and lower edges and side edges of the opening 6.

Further, a support wall 16 protruding rearward is formed substantially at the center of the rear surface of the main part 4 at a position corresponding to the upper edge of the recess 5, and a partition wall 17 is formed from the upper surface near both right and left ends of the support wall 16. , 17 project upward, and reinforcing walls 18, 18 project downward from a position near the center of the lower surface of the support wall 16.

Reference numeral 19 denotes a first contact, which is a connection piece 20 formed in a substantially inverted C-shape as viewed from the front by a thin band-shaped portion, and a bulb holding piece connected to the lower end of the connection piece 20. 21, a contact portion 23b connected to the upper end piece of the connection piece 20 via short connection pieces 22, 22 side by side,
23c are integrally formed.

The bulb holding piece 21 is substantially V-shaped when viewed from the side.
The lamp holder 24 having a U-shape and a rectangular plate-shaped base 25 continuous with the lower end of the lamp holder 24 are integrally formed. Side, and the lower end of the left edge thereof is
Is connected to the left end of the lower end of the. The bulb holding portion 24 has a piece 24a on the side opposite to the base piece 25 serving as a bulb contact piece, and a reaching hole 24b is formed at a substantially central portion of the bulb contact piece 24a.

The contact portions 23b and 23c are curved in a convex shape with the center in the left-right direction located forward.

The connecting piece 20 has a number of small holes 26,
26,... Are formed.

The first contact 19 as described above is integrally connected to the body 2 by so-called insert molding, and the base 25 of the bulb holding piece 21 is located at the center of the lower end of the main part 4 of the body 2. Buried, the bulb holding part 24 is
5b. The connection piece 20 is exposed on the front surface of the concave portion 5, the contact portion 23b covers the front surface of the portion between the concave portions 12a and 12b, and the contact portion 23c is the portion between the concave portions 12b and 12c. Is located so as to cover the front of the camera. And the connecting piece 20
Are filled with the material resin of the body body 2 so that the connecting piece 20 is connected to the body body 2.
So that it is not easily peeled off.

The second contact 27 is connected to a connecting piece 28 having a narrow strip shape and a substantially inverted U-shape viewed from the front, and a bulb holding piece 29 connected to the lower end of the connecting piece 28. Piece 28
Is formed integrally with a terminal piece 30 connected to the upper end.

The bulb holding piece 29 comprises a base 31 having a substantially rectangular shape as viewed from the front, and a bulb contact piece 32 connected to the lower edge of the base 31. The bulb contact piece 32 has a front end 32a facing forward. The main piece 32b protrudes rearward from the lower edge of the front end 32a and has a through-hole 32 at the center.
c is formed.

The terminal piece 30 is formed by integrally forming a connecting piece 33 having a substantially L-shape as viewed from the side and an insertion piece 34 projecting upward from the rear end of the connecting piece 33.
Is connected to the upper end of the connection piece 28.

The connection piece 28 has two small holes 26 formed therein.

Thus, the second contact 27 is
The base piece 31 of the bulb holding piece 29 except for its lower end is buried in the center of the main body 4 of the body 2 at a position near the upper edge of the opening 6, and the lower end is located at the upper opening edge of the opening 6. The lamp contact piece 32 is projected downward, and the bulb contact piece 32 is projected backward from the lower end. Thereby, two bulb contact pieces 3
2, 24a are spaced apart vertically in the opening 6 and face each other.

The terminal piece 30 is connected to the connecting piece 3
3 is embedded in the support wall 16 of the body body 2 and
4 is projected upward from the upper surface of the support wall 16.

The connecting piece 28 is exposed at the left end of the upper end of the concave portion 5, and its small holes 26, 26 are filled with the resin material of the body body 2, thereby forming the connecting piece 20. It is configured not to easily peel off from the body body 2.

The third contact 35 is formed by integrally forming a connection piece 36, a contact portion 23d, and a terminal piece 37.

The connecting piece 36 is in the form of a narrow strip extending in the left-right direction, and the small hole 26 is formed substantially at the center.

The contact portion 23d is convexly curved so that the right end thereof is displaced rearward, and the upper edge of the left end portion is connected to the connecting piece 38.
Is connected to the lower edge of the connection piece 36 near the left end.

The terminal piece 37 is formed by integrally forming a connection piece 39 having a substantially rectangular shape as viewed from the side and an insertion piece 40 extending upward from the upper end of the connection piece 39. The front edge of the lower end is integrally connected to the right edge of the connection piece 36.

The terminal piece 37 of the third contact 35 is connected to the reinforcing wall 1 of the body 2 by the connecting piece 39.
8, the insertion piece 40 projects upward from a position on the upper surface of the support wall 16 that is separated rightward from the projecting position of the insertion piece 34. The contact portion 23d is located so as to cover the left opening edge of the concave portion 12c of the body 2, and the connecting piece 38 and the connecting piece 36 are exposed on the front surface of the body 2. And the small hole 26 of the connecting piece 36
Is filled with the material resin of the body body 2, so that the connecting piece 20 does not easily peel off from the body body 2.

The fourth contact 41 has a narrow U-shaped connecting piece 42 in the form of a narrow strip, a contact piece 23a connected to the upper right end of the connecting piece 42, Connection piece 4
Are connected via connecting pieces 43, 43,... So as to protrude outward from the left and right upper end portions and the left and right lower end portions. It is formed integrally. The connecting pieces 43, 43,...
, In order to provide a step between the connecting piece 42 and the ground pieces 44, 44,.
・ Is formed.

The grounding pieces 44, 44,...
a, 44a,..., the contact portion 23a is convexly curved such that the left end is displaced rearward, and the small hole 26, 2
6 are formed, and buried pieces 45, 45, 45 protrude from the left edge of the left piece of the connection piece 42.

The connecting piece 42 of the fourth contact 41 has its right part except the upper and lower ends buried in the right wall of the shallow recess 5 of the body body 2 and has the remaining part in the recess. 5 are located along the periphery of the
5 and 45 are buried in the left wall of the recess 5. The small holes 26, 26 are filled with the resin material of the body 2 so that the connecting pieces 20 are not easily separated from the body 2.

The contact portion 23a is formed in the concave portion 12a of the body body 2.
Are positioned so as to cover the right opening edge of the main body 2, and the grounding pieces 44, 44,.
Are located in front of the large-diameter portions 13a, 13a,... Of which peripheral edges are embedded in the body body 2, and
The insertion holes 44a, 44a,.
Are arranged so as to coincide with the small diameter portions 13b, 13b,.

Reference numeral 46 denotes a switch knob.

The switch knob 46 comprises a molded part 47 made of a synthetic resin and a contact piece 48 integrated with the molded part 47 by insert molding.

The molded portion 47 has a shape in which a grip portion 50 protrudes from the front surface of the upper end portion of a thick plate-shaped main portion 49. 51 are formed.

The contact piece 48 is formed of a material having conductivity and spring properties and has a vertically long strip shape. A contact portion 52 protruding rearward in an arc shape when viewed from above and below is provided at the lower end thereof. Is formed. An insertion hole 53 is formed at a substantially middle position in the vertical direction of the contact piece portion 48.

The portion of the contact piece 48 except for the lower end thereof is separated from the lower end of the main part 49 of the mold part 47 by the grip 50
And the remaining part is molded part 4
7 is projected downward from the lower end. Then, the insertion hole 53 of the contact piece 48 and the mounting hole 51 of the mold part 47 are aligned.

Reference numeral 54 denotes a mounting rivet having a head portion 54a and a foot portion 54b.
Of the body main body 2, the tip protruding to the back side of the body main body 2 is caulked, and the switch knob 46 is turned to the body main body 2. Mounted freely. Then, in this state, the contact portion 52 of the contact piece portion 48 is moved in a portion where the contact portions 23a, 23b, 23c and 23d of the body 2 are arranged in an arc.

As described above, in the switch knob 46, since the contact piece 48 formed of a metal plate extends to the grip 50 beyond the mounting hole 51 serving as the rotation fulcrum, the entire switch knob 46 is formed. This has the effect of increasing the strength.

Reference numeral 55 denotes a lens which is formed to have a size to cover a portion of the concave portion 3 of the body 2 from immediately above the partition walls 7 to below. Engagement projections 5 are provided on the inner surface of the upper end portion of the peripheral wall portion 56 of the lens 55 at positions spaced apart left and right.
7 and 57 are formed, and engaging projections 58 and 58 are formed on the outer surface of the lower end portion of the peripheral wall portion 56 so as to be separated from each other in the left and right directions. Engagement projections 58, 58 at the lower end are formed in engagement holes 10, 1 formed on the inner surface of the lower side of the peripheral wall 9 of the body body 2.
0 and the inner edge of the rear end of the lower end portion of the peripheral wall portion 56 is in contact with the lower surface of the rib 14 formed on the body 2. Further, the engagement protrusions 57 formed on the upper end portion of the peripheral wall portion 56 engage with the engagement claws 8 formed on the upper surfaces of the partition walls 7 of the body 2. Thus, the lens 55 is attached to the body 2.

The switch knob 46 is connected to the lens 5
Notch 59 formed at the center of the upper end of peripheral wall portion 56 of No. 5
The grip 50 projects above the lens 55.

Reference numerals 60, 60,... Denote recessed portions formed on the left and right outer surfaces of the body main body 2 so as to reach the front and rear.

Before the lens 55 is attached to the body 2, the bulb 61 is connected to the end portions of the bases 62, 62 by the contact holes 24 b, 32 c of the bulb contact pieces 24 a, 32.
Is supported in a state of being engaged with.

Further, before the lens 55 is mounted on the body 2, the mounting screws 63, 63,... Made of a conductive material are inserted from the front through the insertion holes 13, 13,.
.. and screwed into a structural member of a vehicle body (not shown). And the mounting screws 63, 63, ...
Are structural members whose heads 63a, 63a,... Are in contact with grounding pieces 44, 44,... Of the fourth contact 41, and mounting screws 63, 63,. At least one is electrically conductive, so that the fourth contact 41, that is, the contact portion 23a is at the ground level. Since there are four grounding pieces 44, 44,..., Any one of the grounding pieces 44 may be grounded.

A connector (not shown) provided on the vehicle body side is connected to the insertion pieces 34 and 40. Thereby, the insertion piece 34 is connected to the power source, and the insertion piece 40 is grounded via a door switch (not shown). That is, the bulb contact piece 32 is connected to a power source, and the contact portion 23d is grounded via the door switch.

When the switch knob 46 is in the neutral position,
That is, when the contact portion 52 is brought into contact with the contact portions 23b and 23c, one base portion 62 of the light bulb 61 is connected to the power source, but the other base portion 62 is not grounded. The light bulb 61 does not light. When the switch knob 46 is tilted to one side from the neutral position so that the contact portion 52 comes into contact with the contact portions 23a and 23b, the other base portion 62 of the light bulb 61 is grounded and turned on. When the switch knob 46 is tilted in the opposite direction to the tilt from the neutral position so that the contact portion 52 comes into contact with the contact portions 23c and 23d, the other base 62 of the light bulb 61 operates the door switch. The light bulb 61 does not light up as it is (the door is closed), but when the door is opened and the door switch is closed, the other base 62 of the light bulb 61 is grounded.
The light bulb 61 lights up.

At this time, the contact portion 52 of the switch knob 46
Is a convex curved surface, and the contact portions 23a,
23b, 23c, and 23d are also curved, and each contact portion 2
Since the recesses 3a, 23b, 23c, and 23d are recessed, the operator can easily feel that the switch knob 46 has reached the predetermined position (there is a so-called click feeling), and the switch knob 46 has The holding at the predetermined position is assured, and the switch knob 46 can be tilted smoothly.

Next, a method of manufacturing the above-described room lamp 1 will be described.

First, the four contacts 19, 27, 3
A contact set continuum is formed by connecting a plurality of contact sets each having a set of 5, 41.

FIG. 14 shows one contact set 64.

Each of the contacts 19, 27, 35, and 41 is formed of a conductive metal plate so that the narrow joints 65, 65,
Are formed integrally with each other.

In the figure, each contact 19, 27, 3
5 and 41 are shown in a state where their shapes have already been adjusted by press molding.
A contact set 64 'as shown in the figure is formed by forming a continuous contact form of a plurality of original contact sets 64' as shown in FIG.

Then, as shown, the first contact 19 is formed as a contact set 64.
In this case, the bulb holding piece 21 is folded back with respect to the connection piece 20, whereby the bulb contact piece 24a and another bulb contact piece 32 are vertically opposed to each other. ing. If the original lamp holding pieces and the original lamp contact pieces are vertically arranged at the time of stamping and molding without employing such a structure, the vertical length of each of them is long and the two overlap. Therefore, when punching, it should be shifted to the left and right, and at the time of press molding, on the other hand, in the above example, the bulb holding piece 21 is connected to the connecting piece 2
The lamp contact piece 24a is folded so as to face the light bulb contact piece 32 vertically.

FIG. 13 shows a prototype contact set 6
4 ', the lower end of the right side edge of the original base piece 25' is connected to the left end of the original connection piece 20 ', so that the arrangement of the original bulb holding piece 29' is shown. The position is displaced to the left from the position.
1 'and the original shape bulb holding piece 29' can be integrally formed. When bending the original contact set 64 ′ formed in this way, the light bulb is folded so that the lower end of the base piece 25 of the light bulb holding piece 21 is positioned to overlap the rear side of the connection piece 20. Holding pieces 21 and 29
Are arranged to face each other vertically.

Since the base pieces 25 and 31 of the bulb holding pieces 21 and 29 are embedded in the body 2,
The bulb holding pieces 21 and 29 do not separate from the body body 2 when the bulb 61 is attached or detached.

The four grounding pieces 44, 44,...
Are arranged at four locations, and these are connected by the connecting pieces 42 to form a frame, so that the strength of the contact set 64 is increased, and the contact set 64 is not easily deformed during handling.

Further, rising portions 43a, 43a,... Are formed in the connecting pieces 43, 43,... Connecting the ground pieces 44, 44,. Therefore, it is easy to adjust the position of the ground pieces 44, 44,... By adjusting the bending angle of the rising portions 43a, 43a,.
.. perform the function of absorbing shrinkage of the molding resin of the body 2 after injection and avoiding fatal deformation of the contact 41.

Although not shown, a large number of such contact sets 64 are continuously formed to form a continuous contact set 66. The formation of such a contact set continuum 66 is based on the ground pieces 44, 44,... Of the adjacent contact sets 64, 64,.
-It is performed by connecting between with the connection band 67,67, ....

The contact set continuum 66 described above is
The contact sets 64, 64,.
Is inserted so as to be positioned in the body body molding die of a molding machine having a body body molding mold, and the body body resin is injected into the body body molding mold to form a resin body. The lamp body 68 in which the body body 2 and the contact set 64 are integrated with each other is formed. The lamp body 68 is formed sequentially for each of the contact sets 64, 64,... Provided on the contact set continuum 66, whereby the lamp body continuum (see FIG. The illustration is omitted).

In the lamp body 68, the base 25 of the bulb holding piece 21 and the base 31 of the bulb holding piece 29 are almost completely buried in the resin material of the body 2, so that the bulb holding The strength of the pieces 21 and 29 is increased, and can withstand a large force applied when the bulb 61 is attached and detached.

Then, each lamp body 68, 68,... Is cut off from the lamp body continuum to form a large number of lamp bodies 68, 68,. The lamp bodies 68, 68,.
, 69, 69,... Are performed. .. Are located along the inner surface of the recesses 60, 60,... On the outer surface of the body 2, thereby facilitating separation. Further, the cut end does not protrude from the side surface of the body 2.

Simultaneously with the separation, punched holes 70, 70,... Of the main part 4 of the body 2 are formed.
The solidarity portion 6 connecting the contacts 19, 27, 35, 41 by forming the punched holes 70, 70,.
Are cut off, so that the contacts 19, 27, 35, 41 are independently electrically insulated from each other.

FIGS. 15 to 20 show modifications of the switch knob of the room lamp 1 and the mounting thereof.

The one shown in FIG. 15 is provided with a mounting pin 72 having a slot 71 reaching the front end of the body main body 2.
The mounting pin 72 is inserted into the mounting hole 51 of the switch knob 46, and engagement projections 73, 73 formed at the front end thereof are engaged with the front opening edge of the mounting hole 51, and the switch knob 46 is moved to the body main body. 2 so as to be rotatable.

FIG. 16 shows a structure in which the surface of the mounting pin 72 in the structure shown in FIG. 15 is covered with metal plates 74, 74 integrated with the body body 2 by insert molding.

In FIG. 17, the metal plates 75, 75 having a substantially L-shape are integrated into the body body 2 by insert molding, and the parts 75a, 75a are protruded forward in a state of being close to each other. The protrusions 75a, 75a are inserted into the mounting holes 51 of the switch knob 46, and the protrusions 75a, 75a
The switch knob 46 is rotatably supported on the body body 2 by engaging bulging portions 75b, 75b formed at the front end of the body so as to project in opposite directions to the front end opening edge of the mounting hole 51. is there.

FIG. 18 shows a mounting pin 7 having a slot 76 extending from the rear surface to the rear end of the switch knob 46.
7 is integrally protruded from the mold part 47, and the mounting pin 77 is inserted through a mounting hole 78 formed in the main part 4 of the body 2,
Engagement projections 79, 79 formed at the tip of the mounting pin 77
Is engaged with the rear opening edge of the mounting hole 78 of the body 2, whereby the switch knob 46 is rotatably mounted on the body 2.

FIG. 19 shows a case in which the surface of the mounting pin 77 in FIG. 18 is covered by covering portions 80, 80 integrally projecting from the edge of the insertion hole 53 of the contact piece portion 48.

FIG. 20 shows a mounting leg piece 8 projecting rearward from the rear surface of the mold part 47 in a state of being close to each other.
1 and 81 are integrally protruded from the edge of the insertion hole 53 of the contact piece 48, and the mounting leg pieces 81 and 81 are inserted into mounting holes 78 formed in the main part 4 of the body 2, and the mounting legs The bulges 81a, 81a formed at the rear ends of the pieces 81, 81 so as to protrude in opposite directions are engaged with the rear opening edges of the mounting holes 78, and the switch knob 46 is rotated to the body body 2. It has been supported as much as possible.

[0076]

As is clear from the above description, the synthetic resin part having the metal member integrated with the present invention is as follows.
A plurality of punched holes are formed in a synthetic resin body in which a metal member set in which a plurality of types of metal members are integrated via a bridge is integrated by insert molding, and the bridge is cut in the punched holes to form the plurality of metal members. The member is a synthetic resin part having an independent integrated metal member, and is a metal member arranged to face each other in a use state, and overlaps each other when they are arranged in the arrangement direction in a developed state. It is characterized in that one of the two metal members is arranged to be opposed to the other metal member by being folded over a portion where the two metal members are continuous.

The method of manufacturing a synthetic resin part having an integral metal member according to the present invention is a method of inserting a metal member set in which a plurality of types of metal members are integrated via a bridge into a synthetic resin body molding die. Then, the synthetic resin body resin was injected into the synthetic resin body molding die to form a synthetic resin part intermediate body in which the synthetic resin body and the metal member set were integrated. Thereafter, in a method of manufacturing a synthetic resin part having an integral metal member by cutting the bridge to separate the plurality of metal members, a metal member set is formed by first punching a metal plate and then bending the metal plate. In the punching state, two metal members that are arranged to face each other in the use state and that overlap each other when they are arranged in the arrangement direction in the unfolded state are used. The one metal member is formed so as to be located out of the arrangement direction, and the one metal member is arranged so as to be opposed to the other metal member by folding the one metal member on a portion where it is continuous at the time of the bending process. It is characterized by being made.

Therefore, according to the present invention, two metal members which are arranged in opposition to each other in the use state, and which are overlapped with each other when they are arranged in the arrangement direction in the unfolded state, are replaced with one metal member. It can be formed integrally from a plate.

Incidentally, the specific shapes and structures of the respective parts shown in the above embodiments are merely examples for realizing the present invention, and the technical scope of the present invention is thereby reduced. It should not be interpreted restrictively.

[Brief description of the drawings]

FIG. 1 shows an example in which a synthetic resin part having an integral metal member of the present invention and a method for manufacturing the same are applied to a lamp body of a room lamp and a method for manufacturing the same, and FIG. FIG. 3 is an enlarged front view showing a part of the lens cut away.

FIG. 2 is an enlarged rear view of a room lamp.

FIG. 3 is a sectional view taken along the line III-III in FIG. 2;

FIG. 4 is a sectional view taken along the line IV-IV in FIG. 2;

FIG. 5 is a sectional view taken along the line VV in FIG. 2;

FIG. 6 is an enlarged cross-sectional view showing a bulb holding unit.

FIG. 7 is an enlarged sectional view showing an engagement portion of the lower end of the lens with the body main body.

FIG. 8 is an enlarged sectional view showing an engagement portion of the upper end of the lens with the body main body.

FIG. 9 is an enlarged perspective view of a switch knob.

FIG. 10 is an enlarged front view showing a contact portion of the switch.

FIG. 11 is an enlarged cross-sectional view showing a contact portion of the switch cut along the arrangement direction.

FIG. 12 is an enlarged perspective view showing a connector portion formed on the rear surface of the lamp body.

FIG. 13 is an enlarged plan view showing a prototype contact set.

FIG. 14 is an enlarged perspective view showing a continuous contact set body.

FIG. 15 is an enlarged cross-sectional view of a main part showing a modified example of a switch knob and its attachment.

FIG. 16 is an enlarged sectional view of a main part showing another modification of the switch knob and its attachment.

FIG. 17 is an enlarged sectional view of a main part showing still another modified example of the switch knob and its attachment.

FIG. 18 is an enlarged sectional view of a main part showing still another modified example of the switch knob and its attachment.

FIG. 19 is an enlarged sectional view of a main part showing still another modified example of the switch knob and its attachment.

FIG. 20 is an enlarged cross-sectional view of a main part showing still another modified example of the switch knob and its attachment.

[Explanation of symbols]

Reference Signs List 19 first contact (metal member) 21 light bulb holding piece 27 second contact (metal member) 29 light bulb holding piece 35 third contact (metal member) 41 fourth contact (metal member) 64 contact set (metal member) Set) 65 Solidarity part (bridge) 68 Lamp body (synthetic resin part having integral metal member) 70 Punched hole

────────────────────────────────────────────────── ─── Continuation of front page (56) References JP-A-4-19114 (JP, A) JP-A-2-6246 (JP, A) JP-A-5-50458 (JP, A) JP-A-5-458 50459 (JP, A) JP-A-5-77270 (JP, A) JP-A-6-284619 (JP, A) JP-A-3-124089 (JP, A) JP-A-6-293041 (JP, A) JP-A-5-129735 (JP, A) U.S. Pat. No. 4,783,532 (US, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 45/00-45/84

Claims (4)

(57) [Claims] A metal member set in which a plurality of types of metal members are integrated via a bridge is inserted into a synthetic resin body molding die, and a synthetic resin body is inserted into the synthetic resin body molding die. After injecting a resin for molding and forming a synthetic resin part intermediate body in which a synthetic resin body made of synthetic resin and a metal member set are integrated, the bridge is cut to separate the plurality of metal members. In a method of manufacturing a synthetic resin part having an integral metal member, the metal member set is formed by first punching a metal plate and then bending the metal plate, and the metal members are arranged to face each other in a use state. Forming two metal members that overlap each other if they are arranged in the arrangement direction in the unfolded state so that one of them is located out of the arrangement direction in the above-described punched state; A synthetic resin having an integral metal member, wherein the one metal member is folded against a portion where the one metal member is continuous at the time of construction so as to be arranged so as to face the other metal member. The method of manufacturing the part. 2. A light bulb in which the metal member is a contact, the synthetic resin component is a lamp body of a room lamp, and the metal members arranged to face each other in the use state form a part of another contact. The method for manufacturing a synthetic resin component having an integral metal member according to claim 1, wherein the component is a holding piece. 3. A plurality of punched holes are formed in a synthetic resin body in which a plurality of types of metal members are integrated by insert molding a metal member set integrated through a bridge, and the bridge is cut in the punched holes. The plurality of metal members is a synthetic resin component having an independent integral metal member, wherein the metal members are arranged so as to face each other in a use state, and are arranged side by side in the arrangement direction in a developed state. Then, one of the two metal members overlapping each other is folded against a portion where the two metal members are continuous with each other, so that the two metal members are arranged so as to be opposed to the other metal member. Synthetic resin parts. 4. A light bulb in which the metal member is a contact, the synthetic resin component is a lamp body of a room lamp, and the metal members arranged to face each other in the use state form a part of a separate contact. The synthetic resin part having an integral metal member according to claim 3, wherein the synthetic resin part is a holding piece.