JPH081425U - Method of manufacturing electric contact - Google Patents

Abstract

(57) [Abstract] [Purpose] The present invention is to cut a contact composite wire rod in which an annealed copper wire rod is plated with a noble metal material into a desired length in order to make the contact an ideal semicircular cross-section contact, Pressing the upper and lower punches into the rectangular holes that were previously drilled in the thin plate base material,
Then, a method for producing an electric contact, which is formed by caulking around a rectangular hole to form a contact having a semicircular cross section substantially concentric with the axis of the contact composite wire and a drum-shaped bulge in the longitudinal direction. [Structure] A cylindrical composite electrical contact material made by cutting a contact composite wire material in which a round bar-shaped annealed copper wire material is plated with a precious metal material such as platinum, gold, or silver to a desired length, and a rectangular shape for contact mounting. Corresponding to this rectangular hole, a thin plate base material, and a mold for caulking the composite electrical contact material on the upper and lower surfaces, and a lower punch with a semi-circular cross section that is approximately concentric with the axis of the composite electrical contact material. A lower punch that also has a drum-shaped bulge in the longitudinal direction,
An upper punch that flatly covers the rectangular hole at this corresponding position is used.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a method for manufacturing an electrical contactor such as a relay or a switch, which uses a contact wire material plated with a precious metal such as platinum, gold or silver as a contact material.

[0002]

[Prior art]

 Electrical contactors and electrical mechanism parts that use mechanical contact structures include switches such as relays, micro switches, leaf switches, push switches, and lever switches, those with a brush structure, and rotary slides. Some have. FIG. 8 illustrates the structure of a leaf switch as a typical representative example of this electric mechanism component. It has a fixed contact piece 52 sequentially arranged in parallel to the main body 51, and a movable contact piece 53 that can come into contact with the fixed contact piece 52. The fixed contact piece 52 and the movable contact piece 53 have an appropriate distance. The actuator 54 fixed to the movable contact piece 53 is pressed to separate and contact the contact 55 to open and close the electric circuit configuration to perform the switch operation. The distance between the movable contact piece 53 and the fixed contact piece 52 of a general switch is set in relation to the operation stroke and the operation pressure. The movable member 53 and the fixed contact member 52 are thin plate base materials made of, for example, phosphor bronze, and have elasticity to such a degree that distortion occurs when the movable contact member 53 is pressed. Conventionally, as shown in FIGS. 10 to 12, a method of making a rivet-type electric contactor having a single-headed contact is performed by cutting a contact wire made of a noble metal such as platinum, gold, silver, etc. The rivet-type contact (spherical contact) material 21 that has been forged is inserted into the circular hole 23 provided in the thin plate base material 22 in advance, and then the leg portion 24 is inserted into the circular hole 23 on the back surface of the thin plate base material 22. The rivet-type electric contact 20 is made by caulking the periphery. In general, a single-headed contact is one in which the head of the contact is formed on one surface of the mounting hole and the other surface of the mounting hole is caulked. As shown in FIGS. 12 (a) and 12 (b), the manufacturing process is such that the rivet type contact material 21 of the lower punch 25 is a spherical and substantially spherical concave portion 27 of the rivet type contact material 21, and the circular hole of the thin plate base material 22. It is brought to the lower surface of 23, and as the lower punch 25 rises, it is inserted through the circular hole 23 of the thin plate base material 22 and pressed by the lowering of the upper punch 26, and the upper surface of the thin plate base material 22 1 is pressed to the upper punch 26. The rivet-type electric contactor 20 is manufactured by caulking the leg portion 24 to the thin plate base material 22 by utilizing the plastic deformation along the shape of the shallow spherical concave portion 28. As another conventional method for making a rectangular electric contact, as shown in FIGS. 13 to 16, in order to save precious metal materials, a contact tape 39 made of precious metal such as platinum, gold, silver, etc. is used. A composite contact strip 31 is formed by joining the entire non-metallic material base strip 40 over the entire head portion, and the composite contact strip 31 is cut to a required length to form a prismatic composite electrical contact square 32 (that In the manufacturing process, first, the composite contact strip 31 formed by pasting gold and silver together and then pasting it on the copper base strip 40 is cut into a required width with a cutting blade in a width direction of 0.63 to 0.67 mm. Then, in order to machine the width dimension to an accuracy of 0.6 ± 0.05 mm, the blade interval is made within 0.6 ± 0.05 mm by passing the ironing process a couple of times. Is a 0.6 mm square and has a length of 1.5 to 2 mm in the longitudinal direction. A rectangular composite electric contact square member 32), the composite electric contact square member 32 is inserted into a rectangular hole 34 previously drilled in the thin plate base material 33, and then the rectangular hole 34 on the back surface of the thin plate base material 33. As shown in FIG. 16 (a), the dimension relation of the side A of the composite electric contact square 32 on the insertion direction side and the dimension B of the side of the rectangular hole 34 is A <B. The dimensional relationship in the longitudinal direction is such that the rectangular hole 34 of the thin plate base material 33 is slightly longer than the composite electrical contact square member 32. This is a size configuration in which the composite electrical contact square member 32 can be easily inserted. Further, as shown in FIG. 16 (a), a cut-and-raised portion 35 for facilitating the insertion of the composite electrical contact square 32 is provided on the surface of the thin plate base 33 perpendicular to the longitudinal direction of the rectangular hole 34. The composite electrical contact square 32 is inserted from the lower portion of the surface of the cut-and-raised portion 35 of the hole 34, pre-pressed by the upper and lower punch dies, and temporarily crimped to form the composite as shown in FIG. 16 (b). The electrical contact corner material 32 is formed in a drum shape to prevent falling. Without this step, there is a possibility that the composite electrical contact square member 32 will fall and the contact surface will be inverted in the next process. In the next step, as shown in FIG. 16 (c), the composite electric contact square member 32 is pressed by the upper die punch 36 so that the head of the laminated material is prevented from biting into the contact angle of the contact members. In the lower die punch 38, the inner composite electrical contact square 32 is slightly flattened under the mounting hole 34 in the lower die punch 38, and spreads from the inner side toward the outer peripheral direction to cover and fix the thin plate base 33. The square electric contact 42 shown in FIG. 14 is made.

[0003]

[Problems to be solved by the device]

 With the rivet type contact (spherical type contact) of the rivet type electric contactor, the contact section is semicircular, so if there is contact pressure or a sliding stroke, a force that tries to slip acts and the contact surface is always mechanically cleaned. Therefore, sliding breakage is easy and the effect is great because it is used in extremely small current circuits of relays and micro switches, but the disadvantage is that the contact part of the rivet type electric contact is point contact, so the position of the contact Alignment accuracy is required, and when molding the contact material into the rivet mold, dents are made on the contact surface, and it takes time to mold the contact material into the rivet mold, resulting in poor manufacturing efficiency. Since the supply is a single item, it is not possible to continuously obtain rivet type electric contacts, which not only hinders the speedup in the automatic production line but also the contacts themselves are made of precious metal. In addition, the manufacturing cost is high, and in the case of a thin plate with a thickness of about 0.1 mm, the contact mounting hole of the thin plate base due to the variation in the amount of crushing when crimping the rivet type contact material. Some parts may be deformed by warping, kinking, distorting, and breaking around the edges, and the dimensional accuracy is poor, and the quality is often poor.Be very careful in managing the dimensional accuracy and clearance. In addition, there was a drawback that the contact function could not be fully exerted due to rattling of the contact unless paying attention to workability. In addition, in the rectangular electrical contactor, in the process of making a square material for composite electrical contacts, it is rolled at high temperature in the process of bonding gold, silver and the base material copper. It is also exposed to high temperatures due to ironing and heat generated during extraction. Silver forms an extremely thin oxide film under high temperature conditions, and sliding damage is easy when the stroke is large because the silver hardness is low, but when the stroke is extremely small, this extremely fine oxide film slides. It cannot be destroyed dynamically, resulting in poor contact. Furthermore, since the thin plate base material has been cut and raised, residual strain may occur in the thin plate base material and warp may occur in the thin plate base material, and depending on the biting state of the contact, it may become a thin plate base material. The reliability of the connection with the composite electrical contact square is poor, and there is a risk of warping the thin plate base material if it is caulked strongly, and the pulling force is small and the quality is unstable. Etc. had problems. Further, in the above composite electric contact square member, as shown in Fig. 9 when the contacts are contacted with each other, an angle (edge) contact is caused to cause severe wear, which greatly affects the service life due to an unstable element of the contact and is further joined. Since the adhesiveness of the gold foil is large, the adhesive phenomenon between contacts occurs, and because it is shaped like a kamaboko, the contact point of the contact part is not a point contact or a line contact, but a surface contact, Even if there is foreign matter on the surface, it does not work to remove it.By making the semi-circular shape of the ideal contact shape the semi-circular shape of the ideal contact shape, large caulking distortion occurs at the pasted part and the surface becomes wrinkled and molding occurs. There was a big defect that problems such as being unable to occur occurred. The present invention eliminates the above-mentioned problems and eliminates the need to form the contact material into a rivet type, and utilizes the great advantage that the contact cross section of the rivet type contact (spherical contact) is semicircular, and the manufacturing cost is low. As a structure that enables continuous contact supply, the production automation line can be speeded up by the upper and lower punches of the mold, and there is no risk of conduction failure due to the oxide film due to plating processing. We provide a manufacturing method for stable electrical contacts without dents on the base plate, caulking so that the base material of the thin plate does not deform, and has a large holding force. It is something to do.

[0004]

[Means for Solving the Problems]

 In order to solve the above-mentioned conventional problems and achieve the intended purpose, the gist of the present invention is to provide a round rod-shaped annealed copper wire material as a contact material and platinum, gold, silver on the annealed copper wire material. Contact composite wire made by plating precious metal material such as, for example, cylindrical composite electrical contact wire made by cutting this contact composite wire to a desired length, and at the required position corresponding to this composite electrical contact wire. As shown in Fig. 4 (a), the diameter A of the composite electrical contact wire and the dimension B of one side of the rectangular hole are the thin plate base material in which the rectangular hole for contact mounting having the dimension relationship of A> B is formed, Corresponds to the outer peripheral edge of the rectangular hole of the thin plate base. A mold for caulking the composite electrical contact material on the upper and lower surfaces. It has upper and lower punches. It has a bulge and a concave shape that covers a flat rectangular hole on the upper surface A semi-circular type consisting of a lower punch and an upper punch with a blunt triangular protrusion in a shallow recess that covers the flat rectangular hole on the lower surface at a position corresponding to this lower punch. It is intended to provide a method for manufacturing an electric contact.

[0005]

[Work]

 In order to naturally make a semi-circular contact that has the best contact condition with the mechanical contact structure and the electromechanical parts that utilize such a semi-circular electric contact, the round wire rod must have the required length. Cutting or caulking or spot welding is proposed, but in the process of manufacturing the electric contact of the present invention, first, annealed copper wire material is plated with a noble metal material such as platinum, gold, silver, etc. A wire is made, and this contact composite wire is cut into a desired length to form a composite electrical contact wire, and the composite electrical contact wire is made to have the same shape as the cross section with a substantially outer diameter, and a drum-shaped bulge in the longitudinal direction. It is fed into the lower punch with a lower plate, and the upper and lower punches are pressed from both sides of the thin plate base material, and the low-hardness annealed copper wire material is inserted into the rectangular hole previously drilled in the thin plate base material. After press-fitting on the base material, insert the insertion parts into rectangular holes on the front and back of the base material. Caulking the outer peripheral edge using the amount of plastic deformation, the lower part of the boundary of the rectangular hole of the thin plate base material has a semicircular cross section approximately concentric with the axis of the composite electrical contact wire and a contact head with a drum-shaped bulge in the longitudinal direction. And a semicircular cross-sectional shape and a drum-shaped bulge contact in the longitudinal direction thereof.

[0006]

【Example】

 An embodiment of a method of manufacturing an electric contact according to the present invention will be described below with reference to FIGS. 1 to 5 as a specific embodiment. FIG. 1 is a perspective view showing a semi-circular cross-sectional shape of a partial cross-section of the semi-circular electric contactor of the present invention. The manufacturing process is as shown in FIG. 2 and FIG. As for the composite wire rod 1 with contacts, the annealed copper wire rod 1b is plated with a noble metal material 1a such as platinum, gold, or silver. For example, an annealed copper wire having a diameter of 0.6 mm has good conductivity, and cost is low. This is a contact composite wire 1 having a diameter of 0.6 ± 0.02 mm, which is a wire that is plated with 0.5 micron of gold on a base of 10 micron of cheap silver. The composite wire contact material 1 is cut into 1.5 mm in the longitudinal direction to form a cylindrical composite electrical contact material 2. This composite electric contact material 2 is preliminarily formed in a thin plate base material 3 having a hardness higher than that of the annealed copper wire material 1b, and the dimension of one side is set to 0.55 mm, and a rectangular hole for contact attachment of 1.8 mm in the longitudinal direction. Position under 4. On the upper and lower corresponding surfaces of the rectangular hole 4 of the thin plate base material 3, there are a mold upper die and a lower punch arranged as shown in FIG. 4, and the lower punch 5 is the center of the composite electrical contact material 2. As shown in FIG. 5, a substantially concentric semi-circular cross-section recess 6 and a drum-shaped bulge 13 in the longitudinal direction of the semi-circular cross-section recess 6 are provided, and the short side width of the rectangular hole 4 of the thin plate base material 3 is further increased. It has a slightly wider shallow recessed shape 10, and the upper punch 7 has a dull triangular protrusion 9 in the shallow recessed portion 8. Moreover, these shapes are provided so as to extend in the longitudinal direction corresponding to the rectangular holes 4. FIG. 7 shows the relation with the composite electric contact material 2 supplied to the thin plate base material 3, and a leaf switch member is attached to the hoop-shaped thin plate base material 3 slit to a thickness of 0.2 mm and a width of 2.5 mm. The contact piece has a shape cut into a length of 15 mm, and is provided with a pilot hole 11 (the hole 11 is used for preventing the resin body from coming off and being used as a hole for the feeding device). A rectangular hole 4 having a width of 0.55 mm and a length of 1.8 mm is formed at an angle of 30 degrees with respect to the longitudinal direction. A cylindrical composite electrical contact material 2 cut into a diameter of 0.6 mm and a length of 1.5 mm is continuously supplied to the rectangular hole 4 from below the thin plate base material 3 at an angle of 30 degrees with respect to the longitudinal direction. It shows the state. Next, FIGS. 4 (a), (b), and (c) show the manufacturing process sequence. First, as shown in FIG. 4 (a), the bottom of the rectangular hole 4 of the thin plate base material 3 arranged on the lower corresponding surface. The composite electrical contact material 2 is positioned in a semicircular cross-section recess 6 of the punch 5 which is substantially concentric with the axis of the composite electrical contact material 2, and the diameter A of the composite electrical contact material 2 and the thin plate stand. The relation between the dimension B of one side of the rectangular hole 4 provided in the material 3 is A> B, and as the lower punch 5 is raised, the rectangular hole 4 of the thin plate material 3 is formed as shown in FIG. 4 (b). And is pressed by the lowering and lowering of the upper punch 7, and the upper surface of the thin plate base material 3 is flattened on the lower surface of the upper punch 7 as shown in FIGS. 4 (c) and 5 (b). Plastic deformation is performed along the shape of the blunt triangular projection 9 of the shallow recess 8 that covers the rectangular hole 4, and the composite electrical contact material 2 on the upper side of the rectangular hole 4 is deformed. And flatly with flared radially outward from the inner while 圧漬, sticking a thin plate base member 3 so as to cover caulking, a rectangular hole 4. It should be noted that a semi-circular cross-section concave portion 6 substantially concentric with the axis of the composite electrical contact material 2, a drum-shaped bulging concave portion 13 in the longitudinal direction of the semi-circular cross-sectional concave portion 6 and a concave portion 10 for covering a flat rectangular hole 4 on the upper surface thereof. The lower punch 5 having the lower punch 5 has a semicircular cross-section on the lower surface of the thin plate base 3, and a drum-shaped bulge 14 is provided in the longitudinal direction. While the contact material 2 is slightly flattened and expanded from the inside toward the outer peripheral direction, it is plastically deformed according to the shape of the lower punch 5, is caulked to the thin plate base material 3, and is fixed so as to cover the rectangular hole 4, A semi-circular electric contact 15 having a drum-shaped bulge 14 shown in FIG. 1 is produced. Further, in the embodiment, a round bar having a diameter of 0.6 mm and a thickness of 0.2 mm are used for the thin plate base material, but the range is not limited, and the diameter is 0.4 to 1.5 mm, The length can be 0.4 to 2 mm, and the thickness of the thin plate base material can be about 0.05 to 0.4 mm. Further, for the thin plate base material, a material having elasticity such as phosphor bronze plate or nickel silver and having higher hardness than the wire material is used. The semi-circular electric contactor 15 having the drum-shaped bulge 14 shown in FIG. 1 has an extremely large amount of swelling like a rivet-type electric contactor. Therefore, the amount of swelling is determined based on the amount of plastic deformation. Further, electroless gold plating can be applied to the gold plating process. Further, in the embodiment, the upper and lower mold dies are movable, and the lower punch has a semicircular cross-section concave portion in the manufacturing process. However, this configuration is not limited to this, and the upper and lower mold dies are also included. The punch can be a single type or a continuous type. Thus, any configuration is possible as long as the contact shape is a semicircular cross section and a drum-shaped bulge is formed in the longitudinal direction.

[0007]

[Effect of device]

 Molding die that saves the usage fee of expensive precious metal materials and keeps it to the minimum necessary amount, and while taking advantage of the great advantage of rivet type contact (spherical contact), low manufacturing cost and continuous contact supply, There is no problem of contact failure due to oxide film due to gold and silver plating processing because upper and lower punches can speed up the production automation line, and there is no need to mold the contact material into a rivet type. , No dents are made on the contact surface, the thin plate base is crimped so as not to deform, and the holding force is large, and there is no unstable element due to the rectangular electric contactor, and it is possible to obtain a stable electrical contact. It is possible to produce stable electric contacts that have never existed before. When the base material of a round bar plated with precious metal is pressed into a thin plate base material, it can be press-fitted with a material having a different hardness to facilitate press-fitting and prevent deformation and distortion of the base material. The outer diameter of the round bar and the contact shape that you want to use for the lower punch are almost the same, and there is a great advantage that the contact surface is not distorted or scratched by press fitting and caulking in that state. Since the contact head has a semi-circular cross-sectional shape and a drum-shaped bulge in the longitudinal direction, the composite electrical contact square bar has an edge contact as shown in Fig. 9 when the contacts contact each other. However, as shown in FIG. 6, the drum-shaped bulges are in contact with each other and are smooth, and the contact area is small. Removes dust, chemical substances (carboxylic acid groups), oxidation generated by gas and heat, and insulating film due to sulfurization that mechanically slides on the contact surface with the same radius and the contact surface slides with a small force. And destroy. Due to the rolling friction of the contact state, the load required for smooth movement and sliding of the contact surface can be reduced. The greatest advantage of reducing the load is that the life of the switch and the stability of the quality depend on the structure of the electric contactor, but it has a circuit configuration depending on the contact state, so it is as easy to operate as possible. The biggest advantage is that the switch can be operated reliably and reliably. Reduce the force to operate. Therefore, an undesired force is not applied to the entire switch, leading to improvement in life and quality. Therefore, the switch structure can be downsized. In terms of cost comparison, a composite electrical contact material made by plating 10 μm silver and 0.5 micron gold on a round material with an annealed copper diameter wire of 0.6 mm and a bonding material with silver on an annealed copper wire of 0.6 mm square are used. The processing cost of the composite electric contact material of round wire is very low compared with the composite electric contact angle material with 10 micron and 0.5 micron of gold, and the composite electric material is silver plated and gold plated to prevent sulfidation. The contact material has excellent mass productivity. The adhesiveness of gold foil is used to make the laminated gold contacts. Because of the adhesiveness, when the contact is pressed with a light motion, the contact points remain sticky, and 3 to 4 grams of force is required to release it, so 10 to 15% of gold is You can mix silver, a step back from pure gold. The fact that it is sticky has the drawback that it also draws in impurities. When gold is plated, a small amount of cobalt, which does not affect contact continuity, is added to increase the surface hardness, and there is no such adhesion phenomenon. Since the entire circumference is plated, there is no directivity compared to the process of caulking the pasted square bar chips, and a stable contact surface can always be obtained. There is no deformation or breakage around the rectangular hole for contact mounting, and the contact material is mounted horizontally and completely fixed to the thin plate base material, making it easy to make an electrical contact with extremely high dimensional accuracy and good quality. The effect that can be obtained is great.

[Submission date] February 24, 1994

[Procedure 3]

[Document name to be amended] Statement

[Compensation target item name] Detailed explanation of the device

[Correction method] Change

[Correction content] [Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a method for manufacturing an electrical contactor such as a relay or a switch, which uses a contact wire material plated with a precious metal such as platinum, gold or silver as a contact material.

[0002]

[Prior art]

 Electrical contactors and electrical mechanism parts that use mechanical contact structures include switches such as relays, micro switches, leaf switches, push switches, and lever switches, those with a brush structure, and rotary slides. Some have. FIG. 8 illustrates the structure of a leaf switch as a typical representative example of this electric mechanism component. It has a fixed contact piece 52 sequentially arranged in parallel to the main body 51, and a movable contact piece 53 that can come into contact with the fixed contact piece 52. The fixed contact piece 52 and the movable contact piece 53 have an appropriate distance. The actuator 54 fixed to the movable contact piece 53 is pressed to separate and contact the contact 55 to open and close the electric circuit configuration to perform the switch operation. The distance between the movable contact piece 53 and the fixed contact piece 52 of a general switch is set in relation to the operation stroke and the operation pressure. The movable member 53 and the fixed contact member 52 are thin plate base materials made of, for example, phosphor bronze, and have elasticity to such a degree that distortion occurs when the movable contact member 53 is pressed. Conventionally, as shown in FIGS. 10 to 12, a method of making a rivet-type electric contactor having a single-headed contact is performed by cutting a contact wire made of a noble metal such as platinum, gold, silver, etc. The rivet-type contact (spherical contact) material 21 that has been forged is inserted into the circular hole 23 provided in the thin plate base material 22 in advance, and then the leg portion 24 is inserted into the circular hole 23 on the back surface of the thin plate base material 22. The rivet-type electric contact 20 is made by caulking the periphery. In general, a single-headed contact is one in which the head of the contact is formed on one surface of the mounting hole and the other surface of the mounting hole is caulked. As shown in FIGS. 12 (a) and 12 (b), the manufacturing process is such that the rivet type contact material 21 of the lower punch 25 is a spherical and substantially spherical concave portion 27 of the rivet type contact material 21, and the circular hole of the thin plate base material 22. It is brought to the lower surface of 23, and as the lower punch 25 rises, it is inserted through the circular hole 23 of the thin plate base material 22 and pressed by the lowering of the upper punch 26, and the upper surface of the thin plate base material 22 1 is pressed to the upper punch 26. The rivet-type electric contactor 20 is manufactured by caulking the leg portion 24 to the thin plate base material 22 by utilizing the plastic deformation along the shape of the shallow spherical concave portion 28. As another conventional method for making a rectangular electric contact, as shown in FIGS. 13 to 16, in order to save precious metal materials, a contact tape 39 made of precious metal such as platinum, gold, silver, etc. is used. The non-ferrous metal material base strip 40 is bonded to the entire surface of the head portion to form a composite contact strip 31, and the composite contact strip 31 is cut to a required length to form a prismatic composite electrical contact square 32 ( The manufacturing process is as follows. First, a composite contact strip 31 made by laminating gold and silver and then pasting it on a copper base strip 40 is cut to a required width with a cutting blade. It is cut and then manufactured by passing the blade through a squeezing process two or three times in a blade interval of 0.6 ± 0.05 mm in order to process the width dimension to an accuracy of 0.6 ± 0.05 mm. The cross section is a square of 0.6 mm and has 1.5 to 2 mm in the longitudinal direction. A rectangular composite electrical contact square 32. The composite electrical contact square 32 is inserted into a rectangular hole 34 previously drilled in a thin plate base 33, and then a rectangular hole on the back surface of the thin plate base 33. As shown in Fig. 16 (a), the dimension A of one side of the composite electrical contact square member 32 on the insertion direction side and the dimension B of one side of the rectangular hole 34 are A <B. Therefore, the dimensional relationship in the longitudinal direction is such that the rectangular hole 34 of the thin plate base material 33 is slightly longer than the composite electrical contact angle member 32. This is a size configuration in which the composite electrical contact angle member 32 can be easily inserted. Also, as shown in Fig. 16 (a), a cut-and-raised portion 35 for facilitating the insertion of the composite electrical contact square 32 is provided on the surface of the thin plate base 33 perpendicular to the longitudinal direction of the rectangular hole 34. From the bottom of the cut-and-raised part 35 surface of the rectangular hole 34 The composite electrical contact square 32 is inserted and pre-pressed with the upper and lower punch dies to perform temporary caulking to form the composite electrical contact square 32 into a drum shape as shown in FIG. 16 (b). Without this step, without this step, the composite electrical contact square member 32 may fall during the next step and the contact surface may be inverted. The composite electrical contact square member 32 is formed by an upper die punch 36 into a chamfered die 37 to prevent the head portion of the laminated material from biting into the corner when the contacts come into contact with each other. On the lower side, the inner electric contact square 32 is slightly flattened and expanded from the inner side toward the outer peripheral side, and the rectangular electric contact 42 shown in FIG. create.

[0003]

[Problems to be solved by the device]

 With the rivet type contact (spherical type contact) of the rivet type electric contactor, the contact section is semicircular, so if there is contact pressure or a sliding stroke, a force that tries to slip acts and the contact surface is always mechanically cleaned. Therefore, sliding breakage is easy and the effect is great because it is used in extremely small current circuits of relays and micro switches, but the disadvantage is that the contact part of the rivet type electric contact is point contact, so the position of the contact Alignment accuracy is required, and when molding the contact material into the rivet mold, dents are made on the contact surface, and it takes time to mold the contact material into the rivet mold, resulting in poor manufacturing efficiency. Since the supply is a single item, it is not possible to continuously obtain rivet type electric contacts, which not only hinders the speedup in the automatic production line but also the contacts themselves are made of precious metal. In addition, the manufacturing cost is high, and in the case of a thin plate with a thickness of about 0.1 mm, the contact mounting hole of the thin plate base due to the variation in the amount of crushing when crimping the rivet type contact material. Some parts may be deformed by warping, kinking, distorting, and breaking around the edges, and the dimensional accuracy is poor, and the quality is often poor.Be very careful in managing the dimensional accuracy and clearance. In addition, there was a drawback that the contact function could not be fully exerted due to rattling of the contact unless paying attention to workability. In addition, in the rectangular electrical contactor, in the process of making a square material for composite electrical contacts, it is rolled at high temperature in the process of bonding gold, silver and the base material copper. It is also exposed to high temperatures due to ironing and heat generated during extraction. Under high temperature conditions, silver forms an extremely thin oxide film. When the stroke is large, the silver hardness is low and sliding damage is easy, but when the stroke is extremely small, sliding damage cannot be caused in this ultrafine oxide film, resulting in poor contact. Furthermore, since the thin plate base material has been cut and raised, residual strain may occur in the thin plate base material and warp may occur in the thin plate base material, and depending on the biting state of the contact, it may become a thin plate base material. There was a problem in that the reliability of the connection with the composite electrical contact square was poor, and there was a risk of warping the thin plate base material if it was caulked strongly, and there was little pull-out force and the quality was unstable. Further, in the above composite electric contact square member, as shown in Fig. 9 when the contacts are contacted with each other, an angle (edge) contact is caused to cause severe wear, which greatly affects the service life due to an unstable element of the contact and is further joined. If the gold foil has a lot of stickiness, the sticking phenomenon occurs between contacts, and because it is shaped like a kamaboko, the contact point of the contact part is not a point contact or a line contact but a surface contact. Even if there is a foreign substance in between, the removal action does not work, and making the semi-circular shape of the ideal contact shape a large caulking distortion at the bonded part will cause the surface to wrinkle. There was a big defect that problems such as inability to mold occur. The present invention eliminates the above-mentioned problems and eliminates the need to form the contact material into a rivet type, and utilizes the great advantage that the contact cross section of the rivet type contact (spherical contact) is semicircular, and the manufacturing cost is low. As a structure that enables continuous contact supply, the production automation line can be speeded up by the upper and lower punches of the mold, and there is no risk of conduction failure due to the oxide film due to plating processing. We provide a manufacturing method for stable electrical contacts without dents on the base plate, caulking so that the base material of the thin plate does not deform, and has a large holding force. It is something to do.

[0004]

[Means for Solving the Problems]

 In order to solve the above-mentioned conventional problems and achieve the intended purpose, the gist of the present invention is to provide a round rod-shaped annealed copper wire material as a contact material and platinum, gold, silver on the annealed copper wire material. Contact composite wire material made by plating precious metal material such as etc., cylindrical composite electric contact material made by cutting this contact composite wire material to a desired length, and corresponding composite electric contact material. As shown in FIG. 4 (a), the diameter A of the composite electrical contact material and the dimension B of one side of the rectangular hole are the thin plate base material in which the rectangular holes for contact attachment having the dimension relationship of A> B are drilled, Corresponding to the outer peripheral edge of the rectangular hole of this thin plate base material, it has upper and lower punches for caulking and molding the composite electrical contact material on the upper and lower surfaces, and has a semi-circular cross section approximately concentric with the axis of the composite electrical contact material and the longitudinal direction. It has a drum-shaped bulge and a concave shape that covers the flat rectangular hole on the upper surface. A semi-circular electric punch consisting of a lower punch and a lower punch with a blunt triangular protrusion in a shallow recess that covers a flat rectangular hole on the lower surface at a position corresponding to this lower punch. It is intended to provide a method of manufacturing a contactor.

[0005]

[Work]

 In order to naturally make a semi-circular contact that has the best contact condition with the mechanical contact structure and the electromechanical parts that utilize such a semi-circular electric contact, the round wire rod must have the required length. Cutting or caulking or spot welding is proposed, but in the process of manufacturing the electric contact of the present invention, first, annealed copper wire material is plated with a noble metal material such as platinum, gold, silver, etc. A wire is made, and this contact composite wire is cut into the required length to form a composite electrical contact material.The composite electrical contact material is made approximately concentric with the axial center in the cross section and has a drum-shaped bulge in the longitudinal direction. It is fed into the lower punch, and the upper and lower molds are pressed from both sides of the thin plate base material to press the lower punch into rectangular holes that have been drilled in the thin plate base material in advance. Then, press-fit it on a thin plate base material with high hardness, and then insert the fitting part on the front and back of the base material. By caulking the outer peripheral edge of the rectangular hole using the amount of plastic deformation, the boundary lower part of the rectangular hole of the thin plate base material has a semicircular cross section substantially concentric with the axis of the composite electrical contact material and a drum-shaped bulge in the longitudinal direction. A method for manufacturing a semi-circular electric contact, which comprises forming a head of the contact, and having a contact having a semi-circular cross-sectional shape and a drum-shaped bulge in its longitudinal direction.

[0006]

【Example】

 An embodiment of a method of manufacturing an electric contact according to the present invention will be described below with reference to FIGS. 1 to 5 as a specific embodiment. FIG. 1 is a perspective view showing a semi-circular cross-sectional shape of a partial cross-section of the semi-circular electric contactor of the present invention. The manufacturing process is as shown in FIG. 2 and FIG. As a result, the annealed copper wire rod 1b is plated with a noble metal material 1a such as platinum, gold or silver to make a contact composite wire rod 1. For example, a wire material 1b having a round diameter of 0.6 mm and a conductive material of 10 μm, which is inexpensive and has a low conductivity, is plated with 0.5 μm of gold, and has a diameter of 0. It is a contact point composite wire rod 1 having a size of 6 ± 0.02 mm. The composite wire contact material 1 is cut into 1.5 mm in the longitudinal direction to form a cylindrical composite electrical contact material 2. This composite electric contact material 2 is preliminarily formed in a thin plate base material 3 having a hardness higher than that of the annealed copper wire material 1b, and the dimension of one side is set to 0.55 mm, and a rectangular hole for contact attachment of 1.8 mm in the longitudinal direction. Position under 4. On the upper and lower corresponding surfaces of the rectangular hole 4 of the thin plate base material 3, there are a mold upper die and a lower punch arranged as shown in FIG. 4, and the lower punch 5 is the center of the composite electrical contact material 2. As shown in FIG. 5, a substantially concentric semi-circular cross-section recess 6 and a drum-shaped bulge 13 in the longitudinal direction of the semi-circular cross-section recess 6 are provided, and the short side width of the rectangular hole 4 of the thin plate base material 3 is further increased. The shallower recess 10 is slightly wider, and the upper punch 7 has a dull triangular protrusion 9 in the shallower recess 8. Moreover, these shapes are provided so as to extend in the longitudinal direction corresponding to the rectangular holes 4. FIG. 7 shows the relation with the composite electric contact material 2 supplied to the thin plate base material 3, and a leaf switch member is attached to the hoop-shaped thin plate base material 3 slit to a thickness of 0.2 mm and a width of 2.5 mm. The contact piece has a shape cut into a length of 15 mm, and is provided with a pilot hole 11 (this hole 11 is used for preventing the resin body from coming off and being used as a hole for the feeding device). A rectangular hole 4 having a width of 0.55 mm and a length of 1.8 mm is formed at an angle of 30 degrees with respect to the direction. A cylindrical composite electrical contact material 2 cut into a diameter of 0.6 mm and a length of 1.5 mm is continuously supplied to the rectangular hole 4 from below the thin plate base material 3 at an angle of 30 degrees with respect to the longitudinal direction. It shows the state. Next, FIGS. 4 (a), (b), and (c) show the manufacturing process sequence. First, as shown in FIG. 4 (a), the bottom of the rectangular hole 4 of the thin plate base material 3 arranged on the lower corresponding surface. The composite electrical contact material 2 is positioned in a semicircular cross-section recess 6 of the punch 5 which is substantially concentric with the axis of the composite electrical contact material 2, and the diameter A of the composite electrical contact material 2 and the thin plate stand. The relation between the dimension B of one side of the rectangular hole 4 provided in the material 3 is A> B, and as the lower punch 5 is raised, the rectangular hole 4 of the thin plate material 3 is formed as shown in FIG. 4 (b). And is pressed by the lowering and lowering of the upper punch 7, and the upper surface of the thin plate base material 3 is flattened on the lower surface of the upper punch 7 as shown in FIGS. 4 (c) and 5 (b). Plastic deformation is performed along the shape of the blunt triangular projection 9 of the shallow recess 8 that covers the rectangular hole 4, and the composite electrical contact material 2 on the upper side of the rectangular hole 4 is deformed. And flatly with flared radially outward from the inner while 圧漬, sticking a thin plate base member 3 so as to cover caulking, a rectangular hole 4. It should be noted that a semi-circular cross-section concave portion 6 substantially concentric with the axis of the composite electrical contact material 2, a drum-shaped bulging concave portion 13 in the longitudinal direction of the semi-circular cross-sectional concave portion 6 and a concave portion 10 for covering a flat rectangular hole 4 on the upper surface thereof. The lower punch 5 having the lower punch 5 has a semicircular cross-section on the lower surface of the thin plate base 3, and a drum-shaped bulge 14 is provided in the longitudinal direction. The electrical contact material 2 is slightly flattened and expanded from the inside toward the outer peripheral direction, plastically deformed along the shape of the lower punch 5, caulked to the thin plate base material 3, and fixed so as to cover the rectangular hole 4. Then, a semicircular electric contact 15 having a drum-shaped bulge 14 shown in FIG. 1 is made. Further, in the embodiment, a round bar having a diameter of 0.6 mm and a thickness of 0.2 mm are used for the thin plate base material, but the range is not limited, and the diameter is 0.4 to 1.5 mm, The length can be 0.4 to 2 mm, and the thickness of the thin plate base material can be about 0.05 to 0.4 mm. Further, for the thin plate base material, a material having elasticity such as phosphor bronze plate or nickel silver and having higher hardness than the wire material is used. The semi-circular electric contactor 15 having the drum-shaped bulge 14 shown in FIG. 1 has an extremely large amount of swelling like a rivet-type electric contactor. Therefore, the amount of swelling is determined based on the amount of plastic deformation. Furthermore, electroless gold plating can be applied to the gold plating process. Further, in the embodiment, the upper and lower mold dies are movable, and the lower punch has a semicircular cross-section concave portion in the manufacturing process. However, this configuration is not limited to this, and the upper and lower mold dies are also included. The punch can be a single type or a continuous type. Thus, any configuration is possible as long as the contact shape is a semicircular cross section and a drum-shaped bulge is formed in the longitudinal direction.

[0007]

[Effect of device]

 Molding die that saves the usage fee of expensive precious metal materials and keeps it to the minimum necessary amount, and while taking advantage of the great advantage of rivet type contact (spherical contact), low manufacturing cost and continuous contact supply, There is no problem of contact failure due to oxide film due to gold and silver plating processing because upper and lower punches can speed up the production automation line, and there is no need to mold the contact material into a rivet type. , No dents are made on the contact surface, the thin plate base is crimped so as not to deform, and the holding force is large, and there is no unstable element due to the rectangular electric contactor, and it is possible to obtain a stable electrical contact. It is possible to produce stable electric contacts that have never existed before. When press-fitting the base material of a round bar plated with a precious metal into a thin plate base material, press-fitting with a material with a different hardness facilitates press-fitting and prevents deformation and distortion of the base material. The outer diameter of the round bar and the contact shape that you want to use for the lower punch are almost the same, and there is a great advantage that the contact surface is not distorted or scratched by press fitting and caulking in that state. Since the contact head has a semi-circular cross-sectional shape and a drum-shaped bulge in the longitudinal direction, the composite electrical contact square bar has an edge contact as shown in Fig. 9 when the contacts contact each other. However, as shown in FIG. 6, the drum-shaped bulges are in contact with each other and are smooth, and the contact area is small. Removes dust, chemical substances (carboxylic acid groups), oxidation generated by gas and heat, and insulating film due to sulfurization that mechanically slides on the contact surface with the same radius and the contact surface slides with a small force. And destroy. Due to the rolling friction of the contact state, the load required for smooth movement and sliding of the contact surface can be reduced. The greatest advantage of reducing the load is that the life of the switch and the stability of the quality depend on the structure of the electric contactor, but it has a circuit configuration depending on the contact state, so it is as easy to operate as possible. The biggest advantage is that the switch can be operated reliably and reliably. Reduce the force to operate. Therefore, an undesired force is not applied to the entire switch, leading to improvement in life and quality. Therefore, the switch structure can be downsized. In terms of cost comparison, a composite electrical contact material made by plating 10 μm silver and 0.5 micron gold on a round material with an annealed copper diameter wire of 0.6 mm and a bonding material with silver on an annealed copper wire of 0.6 mm square are used. The processing cost of the composite electric contact material of round wire is very low compared with the composite electric contact angle material with 10 micron and 0.5 micron of gold, and the composite electric material is silver plated and gold plated to prevent sulfidation. The contact material has excellent mass productivity. The adhesiveness of gold foil is used to make the laminated gold contacts. Due to its adhesiveness, the contacts will stick to each other when they are pressed lightly. It takes 3-4 grams of force to pull this off, so we mix 10-15% silver with gold, a step back from pure gold. The fact that it is sticky has the disadvantage that it also draws in impurities. When gold is plated, a small amount of cobalt, which does not affect contact conduction, is contained, so the surface hardness is high and there is no such adhesion phenomenon. Since the entire circumference is plated, there is no directivity in the step of caulking the laminated square chips, and a stable contact surface can always be obtained. There is no deformation or breakage around the rectangular hole for contact mounting, and the contact material is mounted horizontally and completely fixed to the thin plate base material, making it easy to make an electrical contact with extremely high dimensional accuracy and good quality. The effect that can be obtained is great.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional perspective view of an electric contactor of the present invention.

FIG. 2 is a perspective view of a contact material used for the electric contact of the above.

FIG. 3 is a plan view (a) of FIG.
Sectional view (b) taken along the line -X and sectional view (c) taken along the line YY.

4A, 4B, and 4C are cross-sectional views showing a manufacturing process sequence of the electric contact of the present invention.

FIG. 5 is a half sectional view (a) of FIG. 4 (c) showing a manufacturing process sequence of the electric contactor of the above, and a sectional view (b) taken along line YY.

FIG. 6 is an enlarged view showing a contact state of a contact portion of the electric contact of the present invention.

FIG. 7 is a plan view showing the same manufacturing process as above.

FIG. 8 is a perspective view of a leaf switch using a general electric contactor.

FIG. 9 is an enlarged view showing a contact portion of the above leaf switch.

FIG. 10 is a partial cross-sectional perspective view of a conventional rivet-type electric contactor.

FIG. 11 is a plan view (a) and a cross-sectional view (b) taken along the line XX in a projection view of the rivet-type electric contactor of the same.

12 (a) and 12 (b) are cross-sectional views showing a manufacturing process sequence of the rivet-type electric contactor of the same.

FIG. 13 is a perspective view of a contact material used in another conventional rectangular electric contactor.

FIG. 14 is a perspective view showing a cross section of a part of the rectangular electric contactor of the same.

FIG. 15 is a plan view (a) and a cross-sectional view (b) taken along the line XX in a projection view of the rectangular electric contactor of the same.

16 (a), (b), and (c) are cross-sectional views showing the manufacturing process sequence of the rectangular electric contactor of the same.

[Explanation of symbols]

 1a precious metal material 1b annealed copper wire material 1 contact composite wire material 2 composite electrical contact material 3 thin plate base material 4 rectangular hole 5 lower punch 6 semi-circular cross-section recess 7 upper punch 8 shallow recess 9 triangular protrusion 10 recess 13 drum-shaped recess 14 drum-shaped swelling 15 Semi-circular electric contactor

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[Procedure amendment]

[Submission date] February 24, 1994

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be amended] Scope of utility model registration request

[Correction method] Change

[Correction content]

[Scope of utility model registration request]

Claims (1)

[Scope of utility model registration request] 1. A contact composite wire made by plating a non-metal element wire with a noble metal material such as platinum, gold or silver, and a composite electrical contact made by cutting the contact composite wire into a required length in the longitudinal direction. Material, a thin plate base material having mounting square holes corresponding to this composite electric contact material, and a molding die punch that caulks and molds from the front and back of this thin plate base material. Attaching this molding die punch to the thin plate base material A punch 1 having a semicircular sectional shape substantially concentric with the axis of the composite electric contact material and a drum-shaped bulging concave portion in the longitudinal direction for caulking and molding the composite electric contact material on the outer peripheral edge of the opening of the square hole, An electrical contact characterized by making an electrical contactor of a contact having a semicircular cross-sectional shape and a drum-shaped bulge in the longitudinal direction with a punch 2 having a shape of covering a mounting hole while slightly pressing it. Child manufacturing method.