WO2016104387A1

WO2016104387A1 - Electrical contact, and production method and production device therefor

Info

Publication number: WO2016104387A1
Application number: PCT/JP2015/085604
Authority: WO
Inventors: 靖久橋本; 井上　茂; 後藤　愛
Original assignee: 橋本精密工業株式会社
Priority date: 2014-12-22
Filing date: 2015-12-21
Publication date: 2016-06-30
Also published as: JP2016119227A; JP5960789B2

Abstract

Provided are an electrical contact and a production method and production device therefor which make it possible not only to simplify production steps by not requiring extra steps such as an intermediate plating step, but also to comparatively stably support the electrical contact and easily work the same into a complicated shape. The present invention pertains to an electrical contact obtained by press-fitting a thin metal wire into a through-hole provided in a busbar having a flat plate or a rectangularly shaped cross-section, and as a result, connecting the wire and the busbar to one another, the electrical contact being characterized in that: the one or more through-holes are provided in a straight line for a desired distance in the lengthwise direction of the press-fit thin metal wire from the edge of the end section on one side of the busbar having the flat plate or the rectangularly shaped cross-section; the pressing surfaces of the thin metal wire and the busbar having the flat plate or the rectangularly shaped cross-section are flat or are flat with a concavity in a section thereof; and one end of the thin metal wire has a molded and rolled section formed therein in a direction perpendicular to the direction of pressing during the press-fitting.

Description

Electrical contact and method and apparatus for manufacturing the same

In the present invention, in order to electrically connect an electrical / electronic device or a mechanical component, the flat plate or the rectangular shape is obtained by press fitting (accan) a thin metal wire into a through hole provided in a bus bar having a flat plate or a rectangular cross section. The present invention relates to an electrical contact in which a bus bar having a cross section is connected to the thin metal wire, and a method and apparatus for manufacturing the electrical contact.

As an electrical contact for electrical connection, such as portable electronic devices and personal computers, or electrical parts or mechanism parts, it has a columnar contact section with a substantially circular or rectangular cross section at one end and a strip or flat plate at the other end A pin contact having a terminal portion is known. As this pin contact, there is a structure having a plate-like standing part having a thickness substantially equal to the thickness of the terminal part between the contact part and the terminal part, and a structure in which the standing part is not provided as an independent part. There are two types. For example, the former is disclosed in

Patent Documents

1 and 2, and the latter is disclosed in Patent Document 3. Each of the pin contacts described in Patent Documents 1 to 3 is at least one of press punching, coining (pressing), and press bending using a lead frame made of a single metal plate or metal rod. Is manufactured by processing into a desired shape.

Moreover, as an electrical contact, in addition to using the contact portion by inserting it into a board, a connector or the like to obtain an electrical connection, it can also be used as a contact element at the tip of an electrical connection bus bar installed in a housing in the connector. Some are used. For example, Patent Document 4 proposes an electrical connector in which a plurality of ground contacts are integrally connected to each other by a bus bar in a housing to reduce ground loop inductance. Patent Document 5 proposes an automobile ignition coil in which the contact element is a part of a bus bar, and the contact element is electrically connected to the ground potential, thereby reducing functional interference in the electrical unit of the automobile. Has been.

JP 2008-218295 A JP-A-8-306418 JP-A-5-166561 JP 2013-4518 A JP-T-2001-515565

The pin contacts described in Patent Documents 1 to 3 are processed into a desired shape in a continuous manner using a lead frame made of a single metal plate or metal rod. There are various technical problems, and application as an electrical contact is limited.

First, when a lead frame made of one metal plate or metal rod is formed into a desired shape in a series, it is generally processed by press punching and then processed into a desired shape by press bending or the like. It is. In the pin contact, the columnar contact portion having a substantially circular or rectangular cross section needs to be subjected to an intermediate plating treatment on the metal exposed portion of the punched and cut portion in order to obtain corrosion prevention and good electrical contact. If one metal plate or metal bar is pre-plated before press punching, the number of times of plating is twice, which not only increases the process, but also prevents an increase in manufacturing cost. Absent. Although it is possible to perform the plating process only once when all the processes are completed, the shape of the pin contact after the process is complicated, so that the amount of sample processing when performing the plating process is limited. In particular, the lead frame shape having multiple pin contacts makes the handling of the sample during the plating process complicated. In addition, it is extremely difficult to perform a uniform plating process on a necessary portion of the pin contact. This problem similarly occurs when the bus bar described in Patent Documents 4 and 5 is processed and formed from a single metal plate.

In addition, pin contacts are difficult to be post-processed in multiples using a lead frame made of a single metal plate or metal rod as the shape of the contact part and terminal part becomes complicated, and advanced knowledge and skill in design and processing Is required. For example, even when a partial shape or structure is changed, it is necessary to comprehensively consider the overall shape or structure of the pin contact, and it may not be possible to quickly respond to a fine design change. A bus bar having a contact element at the tip has a similar technical problem, and a method capable of processing a complicated shape easily and at low cost is demanded.

Furthermore, when the contact part and terminal part of the pin contact, or the bus bar and the contact element are made of different metals, the manufacturing method by processing from one metal plate or metal bar cannot be applied, and the two are connected by another method. Or matching is done. For example, bonding or connection is generally performed by welding such as TIG welding or laser welding, solder bonding, brazing bonding, or a conductive adhesive. In that case, in order to increase the reliability of the bonding or connection, a method of securely fixing the bonded portion or the bonded portion of the dissimilar metal so as not to move is necessary. In addition, although electrical strength and reliability equivalent to those of bonding or adhesion are not required, electrical contact can be made by a simple method that can make electrical connection only by bringing different metals into contact with each other and can maintain the connection for a long period of time. Therefore, the development is strongly desired because the scope of application expands.

The present invention has been made in view of the above-described conventional problems, and does not require an extra process such as an intermediate plating process and can simplify the process, and can also process a complicated shape. It is an object of the present invention to provide an electrical contact that can be easily maintained and can maintain the electrical contact relatively stably, and a method and an apparatus for manufacturing the electrical contact.

The present inventor separates the contact portion and the portion corresponding to the terminal portion as an electrical contact for electrical connection of an electric / electronic device, and each comprises a strip-shaped flat plate and a thin metal wire, and is provided at a predetermined position on the flat plate. It is found that an electrical contact manufactured by press-fitting the fine metal wire into the through-hole and forming the pressing surface of the flat plate and the fine metal wire into a flat shape by the press-fitting can solve the above problem. Invented.

That is, the configuration of the present invention is as follows.
[1] In the present invention, an electric wire in which a thin metal wire is press-fitted into a through hole provided in a flat bar or a bus bar having a rectangular cross section to connect the bus bar having the flat plate or the rectangular cross section and one end of the thin metal wire. 1 or 2 or more of the through-holes are provided in a straight line at a desired distance from one side edge of the bus bar having the flat plate or the rectangular cross section along the longitudinal direction of the thin metal wire to be fitted. The bus bar having the flat plate or the rectangular cross section and the metal thin wire have a flat shape or a flat shape in which each pressing surface after the press fitting has a concave portion, and the through hole and the flat plate Or between one side end edge of a bus bar having a rectangular cross section, or between the one side end edge of the flat plate or the bus bar having a rectangular cross section and between the two or more through holes, Providing an electrical contact, wherein a molding roll portions in the vertical direction is formed at one end of the serial thin metal wire with respect to the pressing direction when the press fit.
[2] In the present invention, the through hole is provided with a coining recess having a stepped shape or a tapered shape on the side opposite to the side to which the fine metal wires are connected by the press fitting. An electrical contact according to claim 1 is provided.
[3] In the present invention, in the through hole, the diameter (D) or the length (A) of the side facing the longitudinal direction of the fine metal wire is on the diameter (d) of the fine metal wire or the side in contact with the through hole. [1] or [2], characterized in that it is the same as or shorter than the length (a) of the side of the thin metal wire and is 0.6 or more times d or a. Provide electrical contacts.
[4] The present invention is characterized in that the metal thin wire is a flat thin wire having a length of a cross-sectional side of 0.3 to 1.5 mm on the side press-fitted into a through hole provided in the flat plate. An electrical contact according to any one of [1] to [3] is provided.
[5] The present invention provides the electrical contact according to any one of [1] to [4], wherein the flat bar or the bus bar having a rectangular cross section is formed of a conductive member.
[6] The present invention provides the electrical contact according to any one of [1] to [5], wherein at least one of the flat bar or the bus bar having a rectangular cross section and the metal thin wire is bent or cut. And an electrical contact having a portion subjected to at least one of edge cutting and processing.
[7] The present invention includes a step of providing one or more protrusions on one end of a thin metal wire by pressing, and the protrusion is straightened at a desired distance from one side edge along the longitudinal direction of the thin metal wire. A step of transferring the metal thin wire to a position where the through hole of a bus bar having a flat plate or a rectangular cross section in which one or two or more through holes are formed on a line, a bus bar having the flat plate or a rectangular cross section, and the Pressing one end of the metal thin wire provided with the protrusions from above and below simultaneously, press fitting one end of the metal thin wire into a through hole provided in the flat bar or a bus bar having a rectangular cross section; and A process of taking out the thin metal wire connected to the flat plate by press-fitting into a through hole provided in the flat bar or a bus bar having a rectangular cross section together with the bus bar having the flat plate or the rectangular cross section. And between the through hole and one side end edge of the flat plate or the bus bar having a rectangular cross section, or between the through hole and one side end edge of the bus bar having the flat plate or the rectangular cross section, and Between the two or more through holes, a part formed and rolled in a direction perpendicular to the pressing direction at the time of the press fitting is formed at one end of the thin metal wire. I will provide a.
[8] In the present invention, the thin metal wire uses a wire obtained by a cutting step of cutting a long thin metal wire into a desired length, and the cutting step is performed before the press fitting step. Alternatively, the method for producing an electrical contact according to [7], which is performed later, is provided.
[9] The present invention includes means for forming one or more of the through holes along a longitudinal direction of the thin metal wire in a straight line at a desired distance from one side edge of the bus bar having a flat plate or rectangular cross section. A pressing means for providing one or more protrusions on one end of a thin metal wire having a desired length, and one or two through holes formed in the bus bar having the protrusion or the rectangular cross section. The means for transferring the fine metal wires, the flat plate or the bus bar having a rectangular cross section, and one end portion of the fine metal wires provided with the projections to the through holes provided in the flat plate from above and below, at the position in contact with Press means for press-fitting, and the metal thin wire connected to the flat bar or the bus bar having a rectangular cross section by press fitting into a through hole provided in the flat plate, the bus bar having the flat plate or rectangular cross section When Between the through hole and the one side end edge of the bus bar having the flat plate or the rectangular cross section, or the one side end edge of the bus bar having the flat plate or the rectangular cross section. Between the two and the two or more through holes, an electric contact is formed at one end of the thin metal wire in a direction perpendicular to the pressing direction at the time of the press fitting. A manufacturing apparatus is provided.
[10] According to the present invention, the electrical contact manufacturing apparatus according to [9] further includes a cutting device for cutting a long thin metal wire, and the desired thin metal wire is the long wire. Provided is an electrical contact manufacturing apparatus obtained by cutting a thin metal wire.

The electrical contact of the present invention has a structure in which the contact portion of the pin contact and the portion corresponding to the terminal portion are separated from each other, and the both portions are connected by press fitting, so that the metal thin wire corresponding to the terminal portion By using the press punching process becomes unnecessary. Accordingly, the intermediate plating process can be omitted, and the process can be simplified. In addition, if the portions corresponding to the contact portion and the terminal portion are prepared in advance in a desired shape, it becomes easy to process a complicated shape. In addition, even when the partial shape or structure of the pin contact is changed, the contact portion and the terminal portion can be handled independently, so that an effect that it is easy to quickly respond to a fine design change is also obtained. It is done. This effect can be obtained in the same way for a bus bar having a contact element at the tip, and in particular, when a complicated shape is required, processing becomes easy, so the shape and structure of the product to which the bus bar is applied. Can increase the degree of freedom.

In the electrical contact of the present invention, each pressing surface of the flat plate functioning as the contact portion and the metal thin wire functioning as the terminal portion is formed into a flat shape by press fitting. Therefore, there are no projections that would become interference parts when assembling products such as electrical / electronic parts and mechanical parts, and conventional electrical contacts manufactured from a lead frame made of a single metal plate or metal rod, etc. It can be a simple shape that is inferior even when compared. Further, when the metal fine wire is press-fitted into a through-hole provided in the flat bar or a bus bar having a rectangular cross section, by optimizing the forming method of the part formed and rolled by press-fitting and the shape of the through-hole, Both connections can be made reliably and firmly. In addition, the establishment of the manufacturing method suitable for the electrical contact of the present invention and the construction of the manufacturing apparatus make the connection between the contact portion and the terminal portion strong, and the electrical contact is maintained relatively stably. Contact can be obtained easily and at low cost.

It is a figure which shows the example of the electrical contact of this invention by Embodiment 1. FIG. It is sectional drawing of the through-hole part which the electrical contact manufactured by the conventional press fitting method has. It is sectional drawing which shows the modification of the shape of the through-hole which the electrical contact of this invention by Embodiment 1 has. FIG. 6 is a cross-sectional view showing a modification of the bottom portion of the through hole included in the electrical contact according to the first embodiment of the present invention. It is a figure which shows the example of the electrical contact of this invention by Embodiment 2. FIG. FIG. 10 is a schematic diagram showing steps of a method for manufacturing an electrical contact according to the second embodiment. In the manufacturing method of the electrical contact of Embodiment 2, it is a mimetic diagram showing the process of cutting and forming a metal wire material into a metal fine wire with desired length. It is a cross-sectional schematic diagram which shows the process of another manufacturing method for manufacturing the electrical contact of Embodiment 2. FIG. In Embodiment 2, it is a perspective view which shows the example of the electrical contact which shows another form manufactured by a bending process. 6 is a schematic diagram showing an example of a manufacturing apparatus for manufacturing an electrical contact according to Embodiment 2. FIG. In Embodiment 3 of this invention, it is a figure which shows an example when the structure of an electrical contact is applied as a connector terminal. In Embodiment 4 of this invention, it is a figure which shows the example of an electrical contact when using the bus-bar which has a rectangular-shaped cross section.

DETAILED DESCRIPTION OF EMBODIMENTS Embodiments for carrying out the present invention will be described in detail with reference to the drawings based on the following embodiments.

<Embodiment 1>
FIG. 1 shows an example of the electrical contact of the present invention. The electrical contact shown in FIG. 1 is formed by press-fitting a thin metal wire 3 into a through-hole 2 provided in a metal flat plate 1, and (a), (b), (c), (D), (e), and (f) are respectively a front view, a plan view, a right side view, a cross-sectional view at the position AA in the plan view, a bottom view, and a perspective view when viewed from the bottom.

As shown in FIG. 1 (d), the electrical contact according to the present invention is provided at positions P1 and P2 that are separated from each other by a desired distance on a straight line from one side end edge 4 of the metal flat plate 1 in the longitudinal direction of the thin metal wire 3. Through-holes 2 are provided, and when one end portion of the fine metal wires 3 is press-fitted in the press direction using a press or the like, the fine metal wires 3 are rolled into the through-holes 2 and the metal 6 The metal flat plate 1 and the metal fine wire 3 are connected by filling the metal. Then, as shown in FIG. 1C, the metal flat plate 1 and the fine metal wire 3 after the press fitting are formed such that the pressing surfaces by the press fitting each have a flat shape. At this time, it is press-fitted between the through-hole 2 provided at the position of P1 and the one-side end edge 4 of the flat plate 1 and between the respective through-holes 2 provided at the two positions of P1 and P1. Two forming and rolling portions 5 of the fine metal wires 3 are formed in a direction perpendicular to the pressing direction at the time of the above. Thereby, one end of the thin metal wire 3 is connected to the metal flat plate 1 in a state of being firmly fixed. As described above, the electrical contact of the present invention allows the surface of the pressing surface of the metal flat plate 1 and the metal thin wire 3 to escape by rolling the rolled portion 5 of the metal thin wire 3 formed at the time of press fitting in a direction perpendicular to the pressing direction. It is characterized by having a flat shape.

The electrical contact shown in FIG. 1 has two through holes 2. However, the present embodiment may be one in which one through hole 2 is provided at the position of P1, for example. In that case, the shaped and rolled portion 5 is formed between one edge portion 4 of the metal flat plate 1 and the through hole 2 located at P1. The number of through holes 2 provided in the metal flat plate is not limited to 1 or 2, and may be 3 or more.

In the conventional press-fitting method, the connection strength is generally maintained by sandwiching the metal flat plate 1 between the metal thin wire 3 and the rolled portion thereof. For example, as shown in FIG. 2, the pressing portion of the fine metal wire 3 is formed as a concave portion, and the fine metal wire 3 is pushed out in the pressing direction to form a protrusion 7 on the surface of the metal flat plate 1 ((a of FIG. In addition, there is a case where the metal thin wire 3 is pushed out in the pressing direction and the protrusion 7 is formed on the surface of the metal flat plate 1 while the pressing portion of the metal thin wire 3 remains flat ((b) in FIG. 2). On the other hand, in the electrical contact according to the present embodiment, the surface of the pressing portion after press fitting is flattened in both the metal flat plate 1 and the metal thin wire 3, so that the rolling of the metal thin wire 3 formed at the time of press fitting is performed. The portion 5 escapes in a direction perpendicular to the pressing direction, and is formed on the side where the fine metal wires 3 are arranged in a flat, substantially circular or elliptical shape as shown in Fig. 1B. Assembly of products such as electrical / electronic parts and mechanical parts using contacts The interference portion become such projection when performing stand is eliminated, not only the assembly is facilitated, it is possible to miniaturize the assembly product.

As can be seen from the cross-sectional view of the press-fitting portion shown in FIG. 1 (d), the electrical contact according to the present embodiment has a connection strength between the metal flat plate 1 and the metal fine wire 3 of the metal 6 filling the through-hole 2. It is maintained by the tightening force generated as a reaction of the press-fitting force from the metal flat plate 1 located around. Furthermore, in the present invention, it is preferable to optimize the shape of the through hole 2 provided in the metal flat plate in order to increase the connection strength for the purpose of improving the durability during use.

FIG. 3 is a diagram showing a modification of the shape of the through hole 2 of the present embodiment in order to increase the connection strength between the metal flat plate 1 and the metal thin wire 3. 3 (a) and 3 (b), there are provided coining recesses having a step shape 8 and a taper shape 9 respectively on the side opposite to the side to which the fine metal wires 3 are connected by press fitting, that is, the lower hole portion. A cross-sectional view of the through hole 2 is shown. As shown in FIG. 3, the stepped or tapered coined recesses 8 and 9 formed in the lower hole portion of the through hole 2 are formed of the metal 6 filled with the fine metal wire 3 press-fitted in the through hole 4. The central portion is formed to be held by the metal 6 filling the lower hole portion of the through hole 2. Thereby, since the upper and lower sides of the metal flat plate 1 have a structure sandwiched by the rolled metal of the metal thin wire 3, the connection strength between the metal flat plate 1 and the metal thin wire 3 can be further improved.

The height of the step-shaped coining recess 8 or the taper-shaped coining recess 9 is arbitrarily determined according to the thickness of the metal flat plate 1 and the metal thin wire 3 and the connection strength between the metal flat plate 1 and the metal thin wire 3. However, considering not only the connection strength but also the workability, it is preferably in the range of 1/10 to 1/2 of the thickness of the metal flat plate 1. When the height is less than 1/10, since the coining recesses 8 and 9 are thin, the connection strength is hardly improved. On the other hand, when the height exceeds 1/2, the thickness of the metal flat plate 1 to be sandwiched becomes thin, and the connection strength is reduced. When the through hole 2 has a circular cross section, the outer diameter of the opening forming the coining recesses 8 and 9 is preferably formed to be 1.5 times or less the diameter of the through hole 2. In addition, when the through hole 2 has a rectangular shape such as a square, it is preferable that the length of one side of the opening for forming the coining recesses 8 and 9 is 1.5 times or less than one side of the through hole 2. Even if the outer diameter or the length of one side exceeds 1.5 times, the connection strength between the metal flat plate 1 and the metal thin wire 3 only saturates, and conversely, the metal 6 filled in the through hole 2. It only increases the load that is done to increase the amount of. In addition, since the area of the coining recesses 8 and 9 is increased, the proportion of the metal 6 into which the fine metal wires 3 are press-fitted in the plane of the metal flat plate 1 increases. May be impaired.

In the present embodiment, in addition to the change of the shape of the through hole 2 shown in FIG. 3, the connection strength between the metal flat plate 1 and the metal thin wire 3 can be further increased by adopting another method. One of the methods is a

structure having recesses

10 and 11 at a substantially central portion of the lower part of the metal 6 filled in the through hole 2 by press fitting (the side opposite to the side to which the metal thin wire 3 is connected by press fitting). It is. A cross-sectional view thereof is shown in FIG. FIG. 4 (a) shows a stepped coining recess 8 formed in the lower hole of the through hole 2, and a recess 10 formed in a step below the metal 6 filled with the metal thin wire 3 by press fitting. It is the structure which has. FIG. 4B shows a structure having a tapered coining recess 9 formed in the pilot hole of the through hole 2 and a recess 11 formed in a tapered shape. The press-fitting portion structure of the present invention is not limited to the structure shown in FIG. 4, but the lower hole portion of the through-hole 2 has a step-shaped coining recess 8 and the lower portion of the metal 6 is tapered 11. Or a structure having the opposite shape.

The

concave portions

10 and 11 shown in FIG. 4 have a function and an action of pressing the lower part of the metal 6 filled in the through hole 2 against the outer wall of the through hole 2 by press-fitting the metal thin wire 3. The tightening force due to the contraction force from 1 can be increased. In addition, the formation of the

recesses

10 and 11 has an effect of promoting the penetration of the metal 6 rolled by the press fitting of the fine metal wires 3 into the gaps between the coining recesses 8 and 9. Therefore, even if a slight gap occurs between the outer wall of the through-hole 2 and the coining recesses 8 and 9 during the press-fitting, the gap can be filled. Thereby, the coining recesses 8 and 9 can be sufficiently and precisely filled with the metal 6.

The height of the step-shaped recess 10 or the tapered recess 11 can be arbitrarily determined according to the thickness of the metal flat plate 1 and the metal thin wire 3 and the connection strength between the metal flat plate 1 and the metal thin wire 3. From the viewpoint of workability as well as connection strength, the thickness is preferably in the range of 1/5 to 2/3 of the thickness of the metal flat plate 1. In the present invention, the height of the

recesses

10 and 11 is determined not with respect to the thickness of the coining recesses 8 and 9 but with respect to the thickness of the metal plate 1, so that the connection strength between the metal flat plate 1 and the thin metal wire 3 is determined. This is because good correlation can be obtained. When the height of the

recesses

10 and 11 is less than 1/5, the connection strength is hardly improved. Moreover, when the height exceeds 2/3, the height of the metal 6 filled in the through-hole 2 is lowered due to the press fitting of the fine metal wires 3, and the amount of the metal 6 to be filled cannot be secured sufficiently. Therefore, the connection strength is reduced. When the through-hole 2 is circular, it is preferable that the outer diameter for forming the

recesses

10 and 11 is the same as or smaller than the diameter of the through-hole 2. In addition, when the through hole 2 has a rectangular shape such as a square, it is preferable that the length of one side forming the opening of the

recesses

10 and 11 is equal to or shorter than the length of one side of the through hole 2. When the outer diameter or the length of one side of the

recesses

10 and 11 is larger than the diameter or one side of the through hole 2, the shape of the coining recesses 8 and 9 itself is changed, and the connection strength between the metal flat plate 1 and the metal thin wire 3 is changed. This is undesirable because it adversely affects

As shown in FIG. 4, the electrical contact according to the present embodiment has a

recess

10 or 11 formed in the bottom of the metal 6 press-fitted and filled in the through hole 2, and only the pressing portion of the metal flat plate 1. Has a flat shape partially having a recess. As described above, the pressing portion of the metal flat plate 1 constituting the electrical contact according to the present embodiment has a different shape of the pressing surface after press-fitting depending on the presence or absence of the

recess

10 or 11. When there is no recessed

part

10 or 11, the pressing surface after press fitting becomes a flat shape. On the other hand, when the recessed

part

10 or 11 is formed, the pressing surface after press fitting becomes a flat shape which has a recessed part partially. On the other hand, although it is practical that the pressing surface after press-fitting is a flat shape, the fine metal wire 3 may have a flat shape in which the pressing portion is partially formed as a concave portion.

In the present embodiment, the through-hole 2 shown in FIG. 1 (e) has a diameter (D) or a length (A) of a side facing the longitudinal direction of the fine metal wire 3 that is equal to the diameter (d) of the fine metal wire 3 or It is preferably the same as or less than the length (a) of the side of the fine metal wire 3 located on the side in contact with the through hole 2 and 0.6 or more times d or a. When the D or A is larger than the d or a, the metal thin wire 3 is rolled not only in the depth direction of the through-hole 2 but also in the radial direction by press fitting, so that the rolled metal 6 However, it is not possible to sufficiently fill up the lower hole portion of the through hole 2, and the problem arises that the connection strength between the metal flat plate 1 and the metal thin wire 3 is lowered. Further, when the D or A is less than 0.6 times the d or a, the diameter of the through hole 2 is too small, so that the rolled metal 6 can be filled up to the lower hole portion of the through hole 2. It becomes difficult. It is possible to fill the rolled metal 6 up to the lower hole portion of the through-hole 2 by increasing the press pressure at the time of press fitting. In this case, the metal flat plate 1 and the metal fine wire are pressed by the high pressure of the press. 3 is likely to be deformed, and in the worst case, the electrical contact itself may be damaged or broken.

As the thin metal wire 3 used in the present embodiment, a rectangular, circular or elliptical cross section is used. Examples of the material of the metal thin wire 3 include copper, aluminum, nickel, and the like. Among them, since the alignment when the fine metal wire 3 is abutted with the through-hole 2 provided in the metal flat plate 1 is easy and the pressing pressure when applying the load at the time of press-fitting can be made uniform, the rolled metal 6 From the point that the filling property to the through hole 4 is excellent, it is preferable to use a rectangular thin wire having a rectangular cross-sectional shape, and a soft copper material wire is preferable as the material. As the flat thin wire, it is practical to use a wire having a cross-sectional side length of 0.3 to 1.5 mm on the side press-fitted into the through hole 4 provided in the metal flat plate 1. Flat thin wires in this range are easily available, and the rolling property to the metal flat plate 1 is good. Moreover, in order to improve the electrical contact with the metal flat plate 1, the thin metal wire 3 may be used in which the outer periphery is plated with a noble metal material such as platinum, gold, or silver. At this time, the through hole provided in the metal flat plate 1 has a diameter (D) or a length of the side facing the longitudinal direction of the metal thin wire 3 (A) according to the length (a) of the cross-sectional side of the flat thin wire actually used. ) Is defined in the above range, that is, equal to or less than a and 0.6 times or more of a.

In the present embodiment, for example, brass or phosphor bronze is used as the material of the metal flat plate 1. The metal flat plate 1 is suitable as a component constituting the electric contact of the present invention because it can be easily electrically connected to the metal thin wire by press fitting. However, in this invention, it is not limited to the metal flat plate 1, You may use the flat plate of a plastic composite containing a plastic, glass, ceramics, or an inorganic fiber and an inorganic powder. In the case of using a plastic softer than a metal or a glass or ceramic having a brittle property as a flat plate, deformation, damage or breakage is likely to occur if the pressing force of the press is large in the metal thin wire press-fitting process. Therefore, in the press-fitting process, the occurrence of these problems is avoided by inserting a stress buffering member between the flat plate and the press-fitting press die. Examples of the stress buffer member include thin film paper having a thickness of 0.1 mm to 30 mm, soft plastic, rubber, and the like.

In the present embodiment, among the above-mentioned flat plates, a flat plate made of at least a conductive member is preferable in order to achieve the purpose of the electrical contact of the present invention. As a flat plate made of a conductive member, a conductive wire or an electrode portion may be locally formed around the through hole 2. Therefore, the electrical contact according to the present invention is not limited to a flat plate that is a uniform conductive member as a whole, and a conductive wiring or an electrode portion can be formed on an insulator and electrically connected to the conductive wiring or the electrode portion. A flat plate provided with a through-hole serving as a part is included.

<Embodiment 2>
Next, the method and apparatus for manufacturing an electrical contact according to the present invention will be described using the example of the electrical contact shown in FIG. The electrical contact shown in FIG. 5 has the same press-fitting section sectional structure as that shown in FIG. (A), (b), (c), (d), (e), and (f) of FIG. 5 are a front view, a plan view, a right side view, and a sectional view at the BB position in the plan view, respectively. It is a perspective view when it sees from a bottom view and a bottom face.

As shown in FIG. 5, the electrical contact according to the present embodiment has a tapered hole (inner diameter: 0.6 mm) with a tapered coining recess 9 provided in the metal substrate 1 (a thin metal wire). 3 is formed on the opposite side to the side to which 3 is connected, and a tapered recess 11 is formed in the lower portion of the through hole 2. In the present embodiment, for example, the tapered coining recess 9 is formed with a height that is 1/5 of the height of the through hole 2, and the outer diameter is 1.2 times the outer diameter of the through hole 2. Form. The tapered recess 11 is formed with a height that is ½ of the height of the through-hole 2, and has an outer diameter that is approximately 0.7 times the diameter of the through-hole 2. The flat metal plate 1 has a thickness of 0.3 mm, and the fine metal wire 3 has a square cross-sectional shape with a cross-sectional side length of 0.64 mm on the side press-fitted into the through hole 2 provided in the flat metal plate 1. It is a thin line.

FIG. 6 shows a process example of the method of manufacturing the electrical contact shown in FIG. In FIG. 6, the left side is a plan view showing each step (a) to (d), and the right side is each step (a) to (d) corresponding to each step (a) to (d). It is a figure which shows sectional drawing of CC position. The present embodiment is an example in which a part of a long metal lead frame 12 formed and cut into a rectangular shape is used as the metal flat plate 1. FIG. The part comprised from the metal flat plate 1 of the sheet | seat is shown.

In the manufacturing method of the electrical contact in the present embodiment, the long metal lead frame 12 is intermittently fed in the direction of the arrow (←) in the figure, and the metal thin wire 3 is pressed in a portion corresponding to the predetermined metal flat plate 1 sequentially. It is a method to be fitted. In FIG. 6A, the fine metal wire 3 is already press-fitted in the corresponding portion (H1) of the metal flat plate 1 of the lead frame 12, and then the fine metal wire is formed in the central portion (H2) of the lead frame 12. The process just before 3 press fitting is shown concretely. When the lead frame 12 is intermittently fed, the metal plate 1 is aligned by passing a mold pin through the sprocket hole 13, and the lead frame 12 is prevented from rattling during subsequent press molding and cutting. .

The electrical contact according to the present embodiment basically includes (1) a step of providing one or more protrusions on one end of a metal fine wire by pressing, and (2) the protrusion in the longitudinal direction of the metal thin wire. A step of transferring the fine metal wire to a position in contact with the through-hole of a metal flat plate in which one or more of the through-holes are formed on a straight line at a desired distance from one side end edge, and (3) the metal One end of the thin metal wire provided with the flat plate and the protrusion is pressed simultaneously from above and below, and one end of the fine metal wire is press-fitted into a through hole provided in the metal flat plate or a bus bar having a rectangular cross section. And (4) the bus bar having the metal flat plate or the rectangular cross section by connecting the metal thin wire connected to the metal flat plate by press-fitting into a through-hole provided in the bus bar having the flat plate or the rectangular cross section. And a step of taking out together. The steps (2), (3) and (4) correspond to the steps shown in FIGS. 6 (b), (c) and (d), respectively. The steps (1) to (4) will be described below.

(1) Step of Providing Protrusion at One End of Fine Metal Wire As shown in the solid line frame on the right side of FIG. 6 (a), one end of fine metal wire 3 obtained by cutting long metal wire 14 to a desired length The protrusion 15 is formed on the part by press molding. In the present embodiment, as an example, the fine metal wire 3 has two protrusions 15. On the other hand, the long metal lead frame 12 is intermittently transferred from (H1) to (H2) while being fixed to the mold, and as shown on the left side of FIG. It is waiting for the metal thin wire 3 to be press-fitted to the metal flat plate 1 at the position. A tapered coining recess not shown in FIG. 6 is formed in advance in the prepared hole of the through hole 2 provided in the metal flat plate 1.

(2) Step of transferring the fine metal wire to a position where it abuts with the through hole of the metal flat plate As shown in the right view of FIG. 6B, the two protrusions 15 provided at one end of the fine metal wire 3 are the metal flat plate. The fine metal wire 3 is transferred to a position where it comes into contact with the through hole 2 provided in 1. The thin metal wire 3 is transferred automatically by recognizing the position of the through hole 2 provided in the metal flat plate 1 by a camera or the like.

(3) Press-fitting step As shown in FIG. 6C, after the step (2), one end of the metal thin wire 3 provided with the metal flat plate 1 and the protrusion 15 is pressed from above and below simultaneously. The protrusion 15 formed at one end of the thin metal wire 3 is press-fitted into the through hole 2 provided in the metal flat plate 1. This press-fitting process is further divided into three processes [c1], [c2] and [c3] as shown on the right side of FIG. That is, a step of pressing the metal flat plate 1 and the thin metal wire 3 by press molding using a press-fitting press die 16 (step [c1]), and then forming the tapered recess 11 in the lower portion of the through hole 2. A step of performing molding by protruding from a part of the lower press die 16 using another die 17 (step [c2]), and then lowering the other die 17 downward and opening the press-fitting press die 16 up and down. And demolding ([c3] step). As a modification of the electrical contact according to the present embodiment, when the tapered recess 11 is not formed in the lower portion of the through hole 2, the step [c2] is omitted, and the pressure is increased by the steps [c1] and [c3]. A fitting process is performed.

(4) Step of taking out the metal thin wire together with the metal flat plate As shown in FIG. 6 (d), the metal thin wire 3 connected to the metal flat plate 1 by the step (3) is transferred together with the metal flat plate 1 by the lead frame 12. Taken out. Next, the lead frame 12 is transferred, and the process of press-fitting the metal thin wire 3 to the metal flat plate 1 at the position (H3) is repeatedly performed. As a result, there is no metal between the through hole 2 and the one side end edge 4 of the metal flat plate 1 or between the through hole 2 and the one side end edge 4 of the metal flat plate 1 and between two or more through holes 2. A portion that is formed and rolled in a direction perpendicular to the pressing direction at the time of press fitting is formed at one end of the thin wire 3.

In this embodiment, by repeating the steps shown in FIGS. 6A to 6D, after the metal thin wires 3 are press-fitted to all the metal flat plates 1 cut and formed in the lead frame, the leads The metal flat plate 1 is separated into individual pieces by cutting the frame, and the electrical contact according to the present embodiment is manufactured.

In the manufacturing method according to the present embodiment, in the step (1), a protrusion is formed in advance on one end of the metal wire 14 by press molding before the cutting step of cutting the long metal wire 14 into a desired length. The portions 15 may be formed at a predetermined interval. FIG. 7 schematically shows a process of forming the protrusion 15 on the long metal wire 14 and cutting and forming the metal wire 14 into the metal thin wire 3 with a desired length. First, a long metal wire 14 is prepared (FIG. 7A), and protrusions 15 are sequentially formed by a protrusion forming press die 18 while the metal wire 14 is intermittently fed at a desired length (FIG. 7). 7 (b)), and then cut into a desired length using the cutting die 19, and the metal fine wire 3 having the protrusion 15 is formed. Thereafter, the fine metal wire 3 is transferred to a process of press fitting into the through hole 2 provided in the metal flat plate 1. By performing the process shown in FIG. 7 continuously, the fine metal wires can be easily obtained in a short time, so that the production time can be shortened and the quality can be improved by automation.

The method shown in FIG. 7 is an example in which the fine metal wire 3 having the protrusion 15 is cut off from the metal wire 14 and then press-fitted into the through hole 2 of the metal flat plate 1 with a piece. On the other hand, in the present embodiment, as shown in FIG. 8, the protrusion 15 formed on the metal wire 14 is press-fitted into the through hole 2 provided on the metal flat plate 1 without separating the metal thin wire 3 from the metal wire 14. After that, the electrical contact can also be manufactured by cutting off the thin metal wire 3 connected to the metal flat plate 1. FIG. 8 schematically shows the process. First, the protrusion 15 provided on the metal wire 14 is conveyed to a position where it comes into contact with the through hole 2 provided on the metal flat plate 1 ((a) of FIG. 8). Next, the protrusion 15 formed on the metal wire 14 by press molding using the press-fitting press die 16 is press-fitted into the through-hole 2 provided in the metal flat plate 1, and the metal wire 14 is desired by the cutting die 19 immediately thereafter. (B in FIG. 8). After that, the press-fitting press die 16 is opened, and the electrical contacts 20 are manufactured by taking out the fine metal wires 3 connected to the metal flat plate 1 as individual pieces ((c) in FIG. 8). The method shown in FIG. 8 not only simplifies the process by automation, but also eliminates the need to handle the fine metal wires 3 individually, so that the work efficiency can be greatly improved.

As described above, in the electrical contact manufacturing method according to the present embodiment, the metal thin wire 3 is formed to a desired length by the cutting process of the long metal wire before the press-fitting process. By going through any of the processes shown, the process can be shortened and the work efficiency can be improved.

The electrical contact 20 manufactured as described above is subjected to at least one of a bending process, a cutting process, and an edge cutting process, so that, for example, an electrical contact 20 having another form as shown in the perspective view of FIG. Contact products can be manufactured. In FIG. 9, (a) and (b) are obtained by bending a portion corresponding to the electric wire 3 of the electric contact and a portion corresponding to the metal flat plate 1 into an L shape. At this time, before or after the bending process, a cutting process or an edge cutting process may be performed to adjust the length or width. In addition, at least one of bending, cutting, and edge cutting may be performed as a separate process after the electrical contact is manufactured. In some cases, in the electrical contact manufacturing process shown in FIGS. 4 to 8, at least one of bending, cutting, and edge cutting is inserted between each process to the extent that the subsequent processes are not hindered. Thus, a continuous process can be constructed. As described above, the electrical contact of the present invention can be applied to a wider range by processing relatively freely according to a desired product shape.

The electrical contact manufacturing apparatus according to the present embodiment has at least the following configurations (I) to (V), that is, (I) one or more through holes corresponding to each step of the above manufacturing method. Means for forming along a longitudinal direction of the fine metal wire in a straight line at a desired distance from one side edge of the bus bar having a flat plate or rectangular cross section, and (II) one end of the fine metal wire having a desired length Pressing means for providing one or more protrusions on the metal, and (III) the metal at a position where the protrusion contacts one or more of the through holes formed in the flat bar or the bus bar having a rectangular cross section. A means for transferring the fine wire, and (IV) a press for fitting one end of the metal thin wire provided with the projection and the bus bar having the flat plate or the rectangular cross section into the through hole provided in the flat plate from above and below. Means, (V) before It said thin metal wire connected to the bus bar with the flat or rectangular cross section by press fit in a through hole provided flat, and means for taking out together with the bus bar having a flat or rectangular cross-section. Furthermore, (VI) when the said thin metal wire is obtained by cut | disconnecting a long metal wire to desired length, the cutting device for cut | disconnecting the said long metal wire is provided.

FIG. 10 shows an example of a manufacturing apparatus for manufacturing the electrical contact according to the present embodiment. The manufacturing apparatus illustrated in FIG. 10 is used in the manufacturing process illustrated in FIG. 8, and each configuration of the manufacturing apparatus corresponds to a portion surrounded by a dotted frame. That is, the through hole forming means 21 corresponding to the above configuration (I), the pressing means 22 for providing the projection corresponding to the above configuration (II), and the transfer of the fine metal wire corresponding to the above (III) configuration It comprises means 23, pressing means 24 for performing press fitting corresponding to the above configuration (IV), and means 25 for taking out the fine metal wire 3 corresponding to the configuration (V). The 25 means has a cutting die 19 for taking out the metal thin wire 3 together with the lead frame having the metal flat plate 1, and the metal thin wire 3 is separated from the metal wire 14 by the cutting die 19. Further, the lead frame 12 composed of the fine metal wire 3 and the metal flat plate 1 is separated into pieces by the cutting means 26 of the lead frame 14, and finally a metal contact 27 connecting the fine metal wire 3 and the metal flat plate 1 is obtained. Can do.

Here, the cutting die 19 is provided as one part of the means 25 for taking out the fine metal wire 3, but the cutting device 28 having the cutting die 19 may be arranged as another configuration separated from the means 25. . The cutting device 28 corresponds to the configuration (VI). The apparatus configuration shown in FIG. 10 is used for the step of press-fitting one end portion of the portion corresponding to the thin metal wire 3 to the metal flat plate 1 in the state of the long metal wire 14. After cutting the thin metal wire 3 from the long metal wire 14, one end of the thin metal wire 3 can be press-fitted to the metal flat plate 1. In that case, the cutting device 28 may be provided in the middle (position indicated by E in FIG. 10) between the press means 22 for providing the protrusion 15 and the metal thin wire transfer means 23. As a result, the metal wire 14 on which the protrusions 15 are formed can be cut to a desired length to form a piece of fine metal wire 3 and then press-fitted to the metal flat plate 1 of the lead frame.

The through-hole forming means 21 shown in FIG. 10 has a through-hole at a position corresponding to the flat metal 1 while intermittently feeding the lead frame 12 provided with a groove 29 at the boundary between the sprocket hole 13 and the metal flat plate 1 in advance. 2 to form 2. The DD cross section shown in the upper right part of FIG. 10 is a cross section at the DD position of the lead frame. Further, in the press means 24 for press-fitting, the longitudinal direction of the lead frame 12 intersects perpendicularly to the paper surface, while the longitudinal direction of the metal wire 14 intersects the horizontal direction of the paper surface at right angles. Are arranged.

The press means 24 for press-fitting shown in FIG. 10 is formed by protruding from the inside of the lower press die 16 in order to form the tapered recess 11 in the lower portion of the through hole 2 in the step [c2] of FIG. Although another mold 17 for molding is not shown, the mold configuration is the same as that shown in the step [c2] in FIG. In the present embodiment, when the concave portion 11 having a tapered shape or a step shape is not provided in the lower portion of the through-hole 2, it is not necessary to use another die 17 for performing molding by protruding.

Further, in the apparatus shown in FIG. 10, the means 25 for cutting the lead frame 12 to a desired length and taking out the fine metal wire and the cutting means 26 for the lead frame are configured separately, but in this embodiment, By using a device having a lead frame cutting means 26 inside the means 25 for taking out the fine metal wires, a metal contact in which the fine metal wires 3 and the metal flat plate 1 are connected in one step by simultaneous cutting is manufactured. Also good.

As described above, by using the manufacturing apparatus shown in FIG. 10, it is possible to simplify and automate the steps performed by the manufacturing method shown in FIG.

<Embodiment 3>
FIG. 11 is a diagram illustrating an example when the configuration of the electrical contact described above is applied as a connector terminal. First, using a metal lead frame 12 having a thickness of 0.3 mm, the portion corresponding to the metal flat plate 1, the through hole 2, and the sprocket hole 12 are press-punched in the shape shown in FIG. FIG. 11A shows one extracted portion corresponding to the metal flat plate 1 formed on the lead frame 11. Here, eight flat plate portions corresponding to the connector terminals 30 are provided on one side (the upper side in the drawing) of the portion corresponding to the metal flat plate 1. In addition, grooves 29 are formed on both the upper and lower sides at the boundary between the lead frame 11 and the portion corresponding to the metal flat plate 1 so that it can be easily cut later. The portions corresponding to the metal flat plate 1 are separated from each other with sufficient space so that the metal thin wire 3 can be easily set in the process of press fitting the metal thin wire 3 into the through hole 2 (inner diameter: 0.6 mm). Are arranged. Here, as the thin metal wire 3, for example, a flat thin wire having a square cross-sectional shape with a cross-sectional side length of 0.64 mm on the side to be fitted is used.

Next, as shown in FIG. 11B, six metal wires 3 are individually press-fitted on the left and right sides of the portion corresponding to the metal flat plate 1, and the six metal wires 3 are connected as contact terminal portions. The flat metal plate 1 is produced. In FIG. 11B, the left diagram and the right diagram show the front and back surfaces of the lead frame 12, respectively. The press fitting of the thin metal wire 3 to the portion corresponding to the metal flat plate 1 is performed according to basically the same method as that shown in FIG. After the lead frame 12 is fixed to the mold by the sprocket holes 13, first, a press-fitting stage is provided in a through hole 2 (a through hole located on the left side in the drawing) provided in one of the portions corresponding to the metal flat plate 1. Are fitted in the order of the

fine metal wires

3a, 3b, 3c, respectively. Next, the lead frame 12 is fed forward, and in the through hole 2 (the through hole located on the right side in FIG. 2) provided on the other side corresponding to the metal substrate 1, the metal thin wires 3d, The press fitting is performed in the order of 3e and 3f. Thereafter, the portion corresponding to the metal portion 1 is cut from the groove 29 portion of the lead frame 12 and separated into individual pieces.

Next, as shown in FIG. 11C, the metal flat plate 1 separated into pieces from the lead frame 12 is bent so that the surface on the side to which the fine metal wires 3 are connected is arranged outside. Is called. Thereafter, the tip of the flat plate portion corresponding to the connector terminal 30 is bent in accordance with the shape of the connector terminal 30, and a connector having six contact end portions and eight connector terminals shown in FIG. 31 is manufactured.

The connector according to the present embodiment is not limited to the number and shape of the contact terminal portions made of the fine metal wires 3a to 3f and the connector terminals 30 as shown in FIG. 11 (d). Changes can be made within the range of design items that are normally implemented. Similarly, the connector shape is not limited and may be changed to a desired shape. By doing so, even when a partial shape or structure of the pin contact is changed, the contact portion and the terminal portion can be handled independently, so that it is easy to respond quickly to fine design changes. The effect is also obtained

<Embodiment 4>
Next, an example of an electrical contact when a bus bar having a rectangular cross section is used in place of the metal flat plate will be described with reference to FIG. FIG. 12 shows two examples of the electrical contact manufacturing method using the bus bar according to the present embodiment. One is a manufacturing method shown in (a) to (d) of FIG. 12 in which the pole bar between the bus bar and the fine metal wire is not resin-molded. The other is a method in which the connection portion between the bus bar and the fine metal wire is resin-molded, and is the manufacturing method shown in FIGS. 12A to 12B and 12E to 12G.

First, the steps shown in FIGS. 12A to 12D will be described. Using a metal lead frame 12 having a thickness of 0.5 mm, the portion corresponding to the metal flat plate 1, the through hole 2 and the sprocket hole 13 are press punched in the shape shown in FIG. FIG. 12A shows two extracted portions corresponding to the bus bar 32 formed on the lead frame 12. Here, in the portion corresponding to the bus bar 32, two through holes 2 are provided in four rows on one side (portion located in the upper portion of the bus bar 32 in the drawing), and are located in the lower portion of the bus bar 32 in the vertical direction in the drawing. Similarly, two through holes 2 are provided in four rows on the other side. Further, in the lead frame 12, two grooves 29 are formed in the portion corresponding to the bus bar 32 through the portion where the sprocket hole 13 is formed in the boundary portion so that the cutting process is easy. The lead frame 12 is intermittently transferred so that the fine metal wires 3 are press-fitted from both sides into through holes 2 (inner diameter: 0.6 mm) provided at one end and one other end of the portion corresponding to the bus bar 32, respectively. Is processed. Here, as the metal thin wire 3, for example, a flat thin wire having a square cross-sectional shape in which the length of the cross-sectional side on the press-fitting side is 0.64 mm is used.

Next, as shown in FIG. 12B, first, eight metal fine wires 3 are individually press-fitted into one side and the other side of the portion corresponding to the bus bar 32, and the eight metal fine wires 3 are brought into contact with each other. The bus bar 32 connected as a terminal part is produced. The press fitting of the metal thin wire 3 to the portion corresponding to the bus bar 32 is performed according to basically the same method as that shown in FIG. After the lead frame 12 is fixed to the mold by the sprocket hole 13, first, it is press-fitted into a through hole (a through hole located above the bus bar 32 in FIG. 12) provided on one side of the portion corresponding to the bus bar 32. The metal thin wires 3g, 3h, 3i, and 3j are press-fitted in order while moving the stage. Next, while moving the press-fitting stage again into a through hole provided in the other side of the portion corresponding to the bus bar 32 (a through hole located below the bus bar 32 in FIG. 12), the fine metal wires 3k, 3 l, 3 m and 3 n are fitted in order. This operation is repeated for all corresponding portions of the bus bar 32 formed on the lead frame 12.

Next, the portion corresponding to the bus bar 32 is cut from the groove 29 portion of the lead frame 12 and separated into individual pieces as shown in FIG. Next, as shown in FIG. 12 (d), the thin metal wire 3 connected to the bus bar 32 is bent to a desired shape and has eight thin metal wires 3 connected to the bus bar 32. Contacts 33 are manufactured. In FIG. 12 (d), the thin metal wires 3g, 3h, 3i, and 3j are bent into semicircles or U shapes, and the thin metal wires 3k, 3l, 3m, and 3n are bent into L shapes. An example is shown. In the electrical contact 33, the eight fine metal wires 3 connected to the bus bar 32 function as contact end portions. In the electrical contact 33 shown in FIG. 12, after the step shown in FIG. 12D, the connecting portion between the through hole 2 provided in the bus bar 32 and the thin metal wire 3 is joined by a known method such as TIG welding or laser welding. For this purpose, a method for improving electrical connection reliability may be employed.

The electrical contact shown in FIG. 12D is an example manufactured using the metal lead frame 12, but in this embodiment, a portion corresponding to the bus bar 32 is provided in place of the metal lead frame 12. It is also possible to perform press fitting with the fine metal wire 3 by press punching in the form of a piece. In that case, as the fine metal wires 3g, 3h, 3i, and 3j, those whose tips are processed in a semicircle or U shape in advance can be used and can be press-fitted into the through holes 2 provided in the portion corresponding to the bus bar 32. . In addition, for the thin metal wires 3k, 3l, 3m, and 3n, a method in which the middle is bent in advance in an L shape and is press-fitted into the through hole 2 provided in a portion corresponding to the bus bar 32. It may be adopted. Thereby, even when the partial shape or structure of the pin contact is changed, the contact portion and the terminal portion can be individually and individually handled, so that it is easy to quickly cope with a fine design change.

Next, the steps shown in FIGS. 12A to 12B and FIGS. 12E to 12G will be described. By going through the steps shown in FIGS. 12A and 12B, a portion corresponding to the bus bar 32 in which eight metal thin wires 3 are connected as contact terminal portions is produced.

Next, as shown in FIG. 12 (e), the lead frame 12 is molded with the resin 34 in a state where the fine metal wires 3 are connected. Examples of the resin used for molding include thermoplastic resins such as polyethylene, polypropylene, and polyester, engineering plastics such as polybutylene phthalate, polyphenylene sulfide, polyphenylene oxide, and liquid crystalline polymers, and thermosetting resins such as epoxy resins. Can be mentioned.

The portion corresponding to the bus bar 32 that has been resin-molded is transferred to the cutting process of the lead frame 12 as shown in FIG. 12 (f), and is cut from the groove 29 and separated into individual pieces. Next, as shown in FIG. 12G, the metal thin wire 3 connected to the bus bar 32 is bent in accordance with a desired shape, and the resin mold die having eight metal thin wires 3 connected to the bus bar 32. The electrical contact 35 is manufactured. 12 (g), like the electrical contact 33 shown in FIG. 12 (d), the tips of the fine metal wires 3g, 3h, 3i, 3j are U-shaped, and the fine metal wires 3k, 3l, 3m 3n shows an example in which an L-shaped bending process is performed in the middle. In the resin-molded electrical contact 35, the eight fine metal wires 3 connected to the bus bar 32 function as contact end portions.

The resin-molded electrical contact 35 shown in FIG. 12G has a structure in which the fine metal wire 3 connected to the bus bar 32 is sealed with resin, so that it is compared with the electrical contact 33 shown in FIG. Thus, connection reliability can be improved. In addition, since the effect of greatly reducing the influence of moisture, corrosive gas in the atmosphere, etc. can be obtained, it can be used as an electrical contact having excellent durability, and the application range can be expanded.

As described above, the electrical contact of the present invention has a structure in which the portions corresponding to the contact portion and the terminal portion of the pin contact are configured separately, and both portions are connected by press fitting, so that the intermediate plating process The process can be omitted, and the process can be simplified. In addition, if the portions corresponding to the contact portion and the terminal portion are prepared in advance in a desired shape, it becomes easy to process a complicated shape. Since this effect can be obtained in the same way for a bus bar having a contact element at the tip, it is easy to process especially in a case where a complicated shape is required. The degree of freedom of structure can be increased.

Furthermore, the electrical contact of the present invention is manufactured from a lead frame or the like made of a single metal plate or metal rod, without projections that would interfere with the assembly of products such as electrical / electronic parts and mechanical parts. Compared with the conventional electrical contact, it can be made a simple shape comparable to that of the conventional electrical contact. Further, by optimizing the press-fitting method and the structure and shape when the metal thin wire is press-fitted into the through hole provided in the flat bar or the bus bar having a rectangular cross section, the connection between the two is ensured, and It can be done firmly.

In the electrical contact of the present invention, an electrical contact in which the connection between the contact portion and the terminal portion is strong and the electrical contact is maintained relatively stably can be obtained easily and at low cost. Therefore, its usefulness is extremely wide.

DESCRIPTION OF SYMBOLS 1 ... Metal flat plate, 2 ... Through-hole, 3 ... Metal fine wire, 4 ... One edge part edge of a metal substrate, 5 ... Rolled part of metal fine wire, 6 ... Through-hole Metal filled therein 7 ... Projections formed on the surface of the metal flat plate, 8 ... Step-shaped printing pressure depression, 9 ... Taper-shaped printing depression, 10 ... Step shape , 11 ... tapered portion, 12 ... metal lead frame, 13 ... sprocket hole, 14 ... metal wire, 15 ... formed on one end of the metal wire Projection part, 16 ... press fitting press fit, 17 ... another mold, 18 ... press mold for forming projection part, 19 ... cutting die, 20 ... electrical contact, 21 ...・ Through hole forming means, 22... Press means for providing a protrusion, 23... 24 ... Pressing means for press-fitting, 25 ... Means for taking out fine metal wires, 26 ... Cutting means, 27 ... Metal contacts, 28 ... Cutting device, 29 ... -Groove, 30 ... connector terminal, 31 ... connector, 32 ... busbar, 33 ... electrical contact, 34 ... resin, 35 ... resin-molded electrical contact.

Claims

An electrical contact that connects the bus bar having the flat plate or the rectangular cross section and one end of the metal thin wire by press fitting the metal thin wire into a through hole provided in the bus bar having the flat plate or the rectangular cross section,
One or more of the through-holes are provided in a straight line at a desired distance from one side edge of the bus bar having the flat plate or rectangular cross section along the longitudinal direction of the fine metal wire to be press-fitted,
The bus bar having the flat plate or the rectangular cross section and the thin metal wire have a flat shape or a flat shape in which each pressing surface after the press fitting has a concave portion, and
Between the through hole and one side end edge of the flat plate or bus bar having a rectangular cross section, or between the through hole and one side end edge of the bus bar having a flat plate or rectangular cross section and two or more of the through holes An electrical contact characterized in that a portion formed and rolled in a direction perpendicular to the pressing direction at the time of the press fitting is formed between the holes at one end of the thin metal wire.
2. The electrical contact according to claim 1, wherein the through hole is provided with a coining recess having a stepped shape or a tapered shape on a side opposite to a side to which the fine metal wires are connected by the press fitting.
The through-hole has a diameter (D) or a length (A) of a side facing the longitudinal direction of the fine metal wire, the diameter (d) of the fine metal wire or the side of the fine metal wire located on the side in contact with the through-hole. 3. The electrical contact according to claim 1, wherein the electrical contact is equal to or less than a length (a) of the first electrode and is 0.6 times or more of d or a.
The thin metal wire is a flat thin wire having a length of a cross-sectional side of 0.3 to 1.5 mm on the side press-fitted into a through hole provided in the flat plate. Electrical contacts as described in
The electrical contact according to any one of claims 1 to 4, wherein the bus bar having a flat plate or a rectangular cross section is made of a conductive member.
The electrical contact according to any one of claims 1 to 5, wherein at least one of a bending process, a cutting process and an edge cutting process is performed on at least one of the flat bar or the bus bar having a rectangular cross section and the thin metal wire. An electrical contact, characterized by having a portion to which is applied.
Providing one or more protrusions on one end of the fine metal wire by pressing;
The projecting portion abuts the through hole of the bus bar having a flat plate or a rectangular cross section in which one or more of the through holes are formed in a straight line at a desired distance from the edge of one side along the longitudinal direction of the thin metal wire. Transferring the thin metal wire to a position;
The metal thin wire is pressed into a through hole provided in the bus bar having the flat plate or the rectangular cross section by simultaneously pressing one end portion of the bus bar having the flat plate or the rectangular cross section by pressing from above and below. A step of press-fitting one end of
A step of taking out the metal thin wire connected to the flat plate by press-fitting into a through hole provided in the flat plate or a bus bar having a rectangular cross section together with the bus bar having the flat plate or the rectangular cross section;
Between the through hole and one side end edge of the flat plate or bus bar having a rectangular cross section, or between the through hole and one side end edge of the bus bar having a flat plate or rectangular cross section and two or more of the through holes A method for manufacturing an electrical contact, characterized in that a portion formed and rolled in a direction perpendicular to a pressing direction at the time of the press fitting is formed at one end portion of the fine metal wire between the holes.
The thin metal wire uses a wire obtained by a cutting step of cutting a long thin metal wire into a desired length, and the cutting step is performed before or after the press-fitting step. A method for manufacturing an electrical contact according to claim 7.
Means for forming one or more of the through holes along a longitudinal direction of the fine metal wire in a straight line at a desired distance from a side edge portion edge of the bus bar having a flat plate or a rectangular cross section;
Press means for providing one or more protrusions at one end of a fine metal wire having a desired length;
Means for transferring the fine metal wire to a position where the protrusion comes into contact with one or more of the through holes formed in the flat bar or a bus bar having a rectangular cross section;
A pressing means for press-fitting one end portion of the thin metal wire provided with the protrusion and the bus bar having the flat plate or the rectangular cross section into the through-hole provided in the flat plate from above and below;
Means for taking out the thin metal wire connected to the flat bar or the bus bar having a rectangular cross section together with the flat bar or the bus bar having a rectangular cross section by press-fitting into a through-hole provided in the flat plate;
Between the through hole and one side end edge of the flat plate or bus bar having a rectangular cross section, or between the through hole and one side end edge of the bus bar having a flat plate or rectangular cross section and two or more of the through holes Between the holes, a part formed and rolled in a direction perpendicular to the pressing direction at the time of the press fitting is formed at one end of the thin metal wire.
The electrical contact manufacturing apparatus according to claim 9 further includes a cutting device for cutting a long thin metal wire, and the desired thin metal wire cuts the long thin metal wire. An electrical contact manufacturing apparatus obtained by: