WO2020184298A1 - Method for manufacturing breaker - Google Patents

Method for manufacturing breaker Download PDF

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Publication number
WO2020184298A1
WO2020184298A1 PCT/JP2020/008924 JP2020008924W WO2020184298A1 WO 2020184298 A1 WO2020184298 A1 WO 2020184298A1 JP 2020008924 W JP2020008924 W JP 2020008924W WO 2020184298 A1 WO2020184298 A1 WO 2020184298A1
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WO
WIPO (PCT)
Prior art keywords
piece
movable
terminal
movable piece
contact
Prior art date
Application number
PCT/JP2020/008924
Other languages
French (fr)
Japanese (ja)
Inventor
孝太 八木
大輔 佐中
将起 吉岡
Original Assignee
ボーンズ株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ボーンズ株式会社 filed Critical ボーンズ株式会社
Priority to CN202080017609.3A priority Critical patent/CN113508448A/en
Publication of WO2020184298A1 publication Critical patent/WO2020184298A1/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H11/00—Apparatus or processes specially adapted for the manufacture of electric switches
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H37/00—Thermally-actuated switches
    • H01H37/02—Details
    • H01H37/32—Thermally-sensitive members
    • H01H37/52—Thermally-sensitive members actuated due to deflection of bimetallic element
    • H01H37/54—Thermally-sensitive members actuated due to deflection of bimetallic element wherein the bimetallic element is inherently snap acting

Definitions

  • the present invention relates to a method for manufacturing a small breaker suitable for use in a safety circuit of an electric device.
  • a configuration is adopted in which a terminal piece or the like is insert-molded into the case body, and a movable piece is connected to the terminal piece exposed from the opening of the case body.
  • the present invention has been made to solve the above problems, and an object of the present invention is to provide a breaker capable of satisfactorily connecting a terminal piece and a movable piece regardless of a case body to be miniaturized.
  • the present invention includes a fixed contact, a movable piece having a movable contact at an elastic portion and one end of the elastic portion, and pressing the movable contact against the fixed contact to bring them into contact with each other, and a terminal piece connected to the movable piece.
  • a heat-responsive element that shifts the state of the movable piece from a conductive state in which the movable contact contacts the fixed contact to a blocking state in which the movable contact is separated from the fixed contact by deforming with a temperature change.
  • a first case having an opening for accommodating the fixed contact, the movable piece, the terminal piece, and the heat-responsive element, and a second case attached to the first case to close the opening.
  • a method for manufacturing a breaker provided, wherein the first step of arranging the fixed contact and the heat-responsive element in the first case, and the movable piece and the terminal piece are integrated to form a composite piece. It includes a second step, a third step of arranging the composite piece in the first case, and a fourth step of sandwiching and fixing the composite piece between the first case and the second case.
  • the movable piece and the terminal piece are made of different materials from each other.
  • the movable piece and the terminal piece have different thicknesses from each other.
  • the movable piece and the terminal piece are integrated by laser welding, resistance welding or ultrasonic welding in the second step.
  • the movable piece and the terminal piece are welded at a plurality of places in the second step.
  • the movable piece and the terminal piece are integrated by brazing, caulking or screwing in the second step.
  • the movable piece in the third step, is located closer to the heat-responsive element than the terminal piece in the thickness direction of the composite piece. It is desirable that the movable piece and the terminal piece are integrated in the two steps.
  • the manufacturing method of the present invention includes the second step of integrating the movable piece and the terminal piece to form the composite piece.
  • This second step is performed prior to the third step of arranging the composite piece in the first case. That is, the terminal piece is integrated with the movable piece before being arranged in the first case to form the composite piece. Therefore, the movable piece and the terminal piece can be easily and surely integrated without being bothered by the existence of the first case. As a result, even when the terminal piece, the movable piece, and the first case become smaller due to the miniaturization of the breaker, the terminal piece and the movable piece can be satisfactorily connected. Become.
  • FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method.
  • FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method.
  • FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method.
  • FIG. 1 to 3 show the configuration of the breaker 1 manufactured by the present invention.
  • the breaker 1 is mounted on an electric device or the like to protect the electric device from an excessive temperature rise or overcurrent.
  • the breaker 1 includes a fixed piece 2 having a fixed contact 21, a movable piece 4 having a movable contact 41 at one end, a heat-responsive element 5 that deforms with a change in temperature, and a PTC (Positive Temperature Coefficient) thermistor 6. It is composed of a fixed piece 2, a movable piece 4, a heat-responsive element 5, a case 10 for accommodating a PTC thermistor 6, and the like.
  • the case 10 is composed of a case body (first case) 7, a lid member (second case) 8 mounted on the upper surface of the case body 7, and the like.
  • the fixed piece 2 is formed by, for example, pressing a metal plate containing copper or the like as a main component (in addition, a metal plate such as a copper-titanium alloy, nickel silver, brass, etc.), and is formed by insert molding into the case body 7. It is embedded.
  • a terminal 22 electrically connected to an external circuit is formed on one end side of the fixed piece 2, and a support portion 23 for supporting the PTC thermistor 6 is formed on the other end side.
  • the PTC thermistor 6 is placed on a convex protrusion (dowel) 24 formed at three positions on the support portion 23 of the fixed piece 2 and supported by the protrusion 24.
  • the fixed contact 21 is formed at a position facing the movable contact 41 by clad, plating or coating of a highly conductive material such as a copper-silver alloy or a gold-silver alloy in addition to silver, nickel and nickel-silver alloy. , It is exposed from a part of the opening 73a formed inside the case body 7.
  • the terminal 22 protrudes outward from the edge of the case body 7.
  • the support portion 23 is exposed from the opening 73d formed inside the case body 7.
  • the surface on the side where the fixed contact 21 is formed (that is, the upper surface in FIG. 1) is referred to as the A surface, and the surface on the opposite side is referred to as the B surface in the fixed piece 2. doing.
  • the A surface faces the first direction
  • the B side faces the second direction.
  • the terminal piece 3 is formed of a metal plate containing copper or the like as a main component.
  • a terminal 32 electrically connected to an external circuit is formed on one end side of the terminal piece 3, and a connecting portion 33 electrically connected to the movable piece 4 is formed on the other end side.
  • the terminal 32 protrudes outward from the edge of the case body 7.
  • the connecting portion 33 is electrically connected to the movable piece 4.
  • the movable piece 4 is formed in an arm shape symmetrical with respect to the center line in the longitudinal direction by pressing a plate-shaped metal material containing copper or the like as a main component.
  • a movable contact 41 is formed at one end of the movable piece 4 in the longitudinal direction.
  • the movable contact 41 is formed of, for example, a material equivalent to that of the fixed contact 21, and is joined to one end of the movable piece 4 by a method such as welding, clad, or crimping.
  • a connecting portion 42 that is electrically connected to the connecting portion 33 of the terminal piece 3 is formed at the other end of the movable piece 4.
  • the A surface of the connection portion 33 of the terminal piece 3 and the B surface of the connection portion 42 of the movable piece 4 are fixed by welding, for example.
  • the B surface of the connecting portion 33 is in contact with the case body 7, and the A surface of the connecting portion 42 is in contact with the lid member 8.
  • the movable piece 4 and the terminal piece 3 are sandwiched and fixed by the case body 7 and the lid member 8.
  • the movable piece 4 has an elastic portion 43 between the movable contact 41 and the connecting portion 42.
  • the elastic portion 43 extends from the connecting portion 42 to the side of the movable contact 41.
  • the movable piece 4 is a connecting portion 42 on the base end side of the elastic portion 43, and is cantilevered by the case 10 and the terminal piece 3, and in that state, the elastic portion 43 elastically deforms to the tip portion of the elastic portion 43.
  • the formed movable contact 41 is pressed against the fixed contact 21 and comes into contact with each other, so that the fixed piece 2 and the movable piece 4 can be energized. Since the movable piece 4 and the terminal piece 3 are electrically connected to each other, the fixed piece 2 and the terminal piece 3 can be energized.
  • the movable piece 4 is curved or bent by press working in the elastic portion 43.
  • the degree of bending or bending is not particularly limited as long as the heat-responsive element 5 can be accommodated, and may be appropriately set in consideration of the elastic force at the operating temperature and the return temperature, the pressing force of the contact, and the like.
  • a pair of protrusions (contact portions) 44a and 44b are formed on the B surface of the elastic portion 43 so as to face the heat-responsive element 5. The protrusions 44a and 44b come into contact with the heat-responsive element 5, and the deformation of the heat-responsive element 5 is transmitted to the elastic portion 43 via the protrusions 44a and 44b (see FIGS. 1, 2 and 3).
  • the heat-responsive element 5 shifts the state of the movable piece 4 from the conductive state in which the movable contact 41 contacts the fixed contact 21 to the cutoff state in which the movable contact 41 is separated from the fixed contact 21.
  • the heat-responsive element 5 is formed in a plate shape by laminating thin plate materials having different coefficients of thermal expansion, and has an initial shape with a curved cross section in an arc shape. When the reversing operating temperature is reached due to overheating, the curved shape of the heat responding element 5 reversely warps with a snap motion, and is restored when it falls below the normal rotation return temperature due to cooling.
  • the initial shape of the heat-responsive element 5 can be formed by press working.
  • the material and shape of the heat-responsive element 5 are particularly limited as long as the elastic portion 43 of the movable piece 4 is pushed up by the reverse warp deformation of the heat-responsive element 5 at the desired temperature and is restored by the elastic force of the elastic portion 43. Although it is not, a rectangular shape is desirable from the viewpoint of productivity and efficiency of reverse warp deformation.
  • the material of the heat-responsive element 5 two kinds of materials having different coefficients of thermal expansion, which are made of various alloys such as nickel silver, brass, and stainless steel, are used in combination according to the required conditions.
  • a combination of a copper-nickel-manganese alloy on the high expansion side and an iron-nickel alloy on the low expansion side is desirable.
  • a combination of an iron-nickel-chromium alloy on the high expansion side and an iron-nickel alloy on the low expansion side can be mentioned.
  • a combination of an iron-nickel-chromium alloy on the high expansion side and an iron-nickel-cobalt alloy on the low expansion side can be mentioned.
  • the PTC thermistor 6 conducts the fixed piece 2 and the movable piece 4 when the movable piece 4 is in the cutoff state.
  • the PTC thermistor 6 is arranged between the fixed piece 2 and the heat-responsive element 5. That is, the support portion 23 of the fixing piece 2 is located directly below the heat-responsive element 5 with the PTC thermistor 6 interposed therebetween.
  • the type can be selected according to the needs such as operating current, operating voltage, operating temperature, and recovery temperature.
  • the material and shape are not particularly limited as long as these properties are not impaired.
  • a ceramic sintered body containing barium titanate, strontium titanate, or calcium titanate is used.
  • a so-called polymer PTC in which conductive particles such as carbon are contained in the polymer may be used.
  • the case body 7 and the lid member 8 constituting the case 10 are molded from a thermoplastic resin such as flame-retardant polyamide, polyphenylene sulfide (PPS) having excellent heat resistance, a liquid crystal polymer (LCP), and polybutylene terephthalate (PBT). Has been done.
  • a material other than the resin may be applied as long as the characteristics equal to or higher than those of the above-mentioned resin can be obtained.
  • the case body 7 is formed with a recess 73, which is an internal space for accommodating a movable piece 4, a heat-responsive element 5, a PTC thermistor 6, and the like.
  • the recess 73 has openings 73a and 73b for accommodating the movable piece 4, an opening 73c for accommodating the movable piece 4 and the heat-responsive element 5, an opening 73d for accommodating the PTC thermistor 6, and the like. ing.
  • the movable piece 4 and the edge of the heat-responsive element 5 incorporated in the case body 7 are brought into contact with each other by the frame forming the recess 73, and are guided when the heat-responsive element 5 is deformed in the reverse direction.
  • the lid member 8 is configured to cover the recess 73.
  • the lid member 8 may be in a form that covers at least a part of the recess 73.
  • a cover piece 81 made of a metal plate or stainless steel containing copper or the like as a main component may be embedded in the lid member 8 by insert molding.
  • the cover piece 81 appropriately contacts the A surface of the movable piece 4, regulates the movement of the movable piece 4, and increases the rigidity and strength of the lid member 8 and thus the case 10 as a housing to reduce the size of the breaker 1. To contribute.
  • the lid member closes the openings 73a, 73b, 73c, etc. of the case body 7 accommodating the fixed piece 2, the terminal piece 3, the movable piece 4, the heat responding element 5, the PTC thermistor 6, and the like. 8 is attached to the case body 7.
  • the case body 7 and the lid member 8 are joined by, for example, ultrasonic welding.
  • FIG. 2 shows the operation of the breaker 1 in a normal charging or discharging state.
  • the heat-responsive element 5 maintains the initial shape before the reverse warp.
  • the movable contact 41 is pressed toward the fixed contact 21 by the elastic portion 43, the movable contact 41 and the fixed contact 21 come into contact with each other, and the fixed piece 2 and the terminal of the breaker 1 are brought into contact with each other via the elastic portion 43 of the movable piece 4.
  • the piece 3 and the piece 3 are made conductive.
  • the elastic portion 43 of the movable piece 4 and the heat-responsive element 5 may be in contact with each other.
  • the terminal piece 3, the movable piece 4, the heat-responsive element 5, the PTC thermistor 6 and the fixed piece 2 are conducting as a circuit.
  • the resistance of the PTC thermistor 6 is overwhelmingly larger than the resistance of the movable piece 4, the current flowing through the PTC thermistor 6 is substantially larger than the amount flowing through the fixed contact 21 and the movable contact 41. It can be ignored.
  • FIG. 3 shows the operation of the breaker 1 in an overcharged state or an abnormal state.
  • the heat-responsive element 5 that has reached the reversing operating temperature deforms in the reverse direction and comes into contact with the elastic portion 43 of the movable piece 4, and the elastic portion 43 is pushed up to reach the fixed contact 21 and the movable contact. It is separated from 41. At this time, the current flowing between the fixed contact 21 and the movable contact 41 is cut off.
  • the heat-responsive element 5 comes into contact with the movable piece 4, and a small leakage current flows through the heat-responsive element 5 and the PTC thermistor 6.
  • the PTC thermistor 6 conducts the fixed piece 2 and the movable piece 4 via the heat-responsive element 5 that shifts the movable piece 4 to the cutoff state.
  • the PTC thermistor 6 continues to generate heat as long as such a leakage current flows, and the resistance value is drastically increased while maintaining the heat responding element 5 in a reverse warp state. Therefore, the current is a path between the fixed contact 21 and the movable contact 41.
  • This manufacturing method includes a first step to a fourth step.
  • FIG. 4 shows the first step.
  • the fixed contact 21, the PTC thermistor 6, and the heat-responsive element 5 are arranged in the case body 7.
  • the first step of the present embodiment includes a step of forming a fixed contact 21 on the fixed piece 2, a step of inserting the fixed piece 2 into the mold, and a step of injecting a resin material into the cavity space to form the case body 7. It includes a step of forming.
  • openings 73c and 73d are formed in the case body 7.
  • the PTC thermistor 6 is arranged in the case body 7 from the opening 73d and the heat-responsive element 5 is arranged in the recess 73 from the opening 73c.
  • FIG. 5 shows the second step.
  • the movable piece 4 and the terminal piece 3 are integrated to form the composite piece 9.
  • the movable piece 4 and the terminal piece 3 constituting the composite piece 9 are prepared in separate pre-processes.
  • the terminal piece 3 is integrated with the movable piece 4 before being arranged in the case main body 7, and the composite piece 9 is formed.
  • a jig or the like for positioning and fixing the movable piece 4 and the terminal piece 3 is appropriately used.
  • FIG. 6 shows the third step.
  • the composite piece 9 is arranged in the case body 7.
  • the composite piece 9 is arranged in the case main body 7 from the openings 73a, 73b, 73c formed in the case main body 7 in the first step, and is housed in the recess 73.
  • the composite piece 9 in which the movable piece 4 and the terminal piece 3 of the present invention are integrated can be arranged in the case body 7 in the same manner as the movable piece started in WO2011 / 105175, for example.
  • FIG. 7 shows the fourth step.
  • the lid member 8 is attached to the case body 7.
  • the composite piece 9 is sandwiched between the case body 7 and the lid member 8. Then, when the case body 7 and the lid member 8 are fixed by ultrasonic welding or the like, the composite piece 9 is fixed by the case body 7 and the lid member 8.
  • the manufacturing method of the present invention includes a second step of integrating the movable piece 4 and the terminal piece 3 to form the composite piece 9.
  • the second step is executed prior to the third step of arranging the composite piece 9 in the case body 7. That is, the terminal piece 3 is integrated with the movable piece 4 before being arranged in the case main body 7, and the composite piece 9 is formed. Therefore, the movable piece 4 and the terminal piece 3 can be easily and surely integrated without being bothered by the existence of the case body 7. As a result, even when the terminal piece 3, the movable piece 4, and the case body 7 become smaller due to the miniaturization of the breaker 1, the terminal piece 3 and the movable piece 4 can be satisfactorily connected. ..
  • the second step can be executed on a separate line independent of the first step and the third step in which each part is arranged on the case body 7. That is, the integration of the terminal piece 3 and the movable piece 4 can be carried out on a line independent of the first step and the third step by using equipment such as a jig suitable for integrating the two. As a result, even when the terminal piece 3, the movable piece 4, and the case body 7 become smaller due to the miniaturization of the breaker 1, the terminal piece 3 and the movable piece 4 can be satisfactorily connected. ..
  • first step and the second step can be executed at the same time, that is, in parallel.
  • first step, the third step, and the fourth step may be executed on a series of lines, and the second step may be executed simultaneously on lines in different lanes. Therefore, the effect on the productivity of the breaker 1 is small.
  • the movable piece 4 and the terminal piece 3 can be made of different materials from each other.
  • the movable piece 4 may be made of a material having excellent conductivity
  • the terminal piece 3 may be made of a material in consideration of connection with a tab lead or the like constituting an external circuit, corrosion, or the like.
  • the movable piece 4 and the terminal piece 3 with plate materials having different thicknesses from each other.
  • a composite piece 9 having a thickness of the terminal piece 3 larger than the thickness of the movable piece 4 or a composite piece 9 having a thickness of the terminal piece 3 smaller than the thickness of the movable piece 4 can be easily formed.
  • the resistance value of the terminal piece 3 is reduced and the voltage drop is suppressed.
  • the contact pressure between the fixed contact 21 and the movable contact 41 is easily increased, and the contact resistance between the two is suppressed.
  • the thickness of the movable piece 4 By setting the thickness of the movable piece 4 to be small, the heat-responsive element 5 having a small pushing force can be applied, and the temperature characteristics of the heat-responsive element 5 can be easily improved.
  • the movable piece 4 and the terminal piece 3 are integrated by a welding method.
  • the type of welding include laser welding, resistance welding, ultrasonic welding and the like.
  • the movable piece 4 and the terminal piece 3 are firmly integrated in a short time.
  • the movable piece 4 and the terminal piece 3 are integrated in a state independent of other parts. Therefore, when the movable piece 4 and the terminal piece 3 are integrated by laser welding, the laser beam can be irradiated from either the A side of the movable piece 4 or the B side of the terminal piece 3.
  • the movable piece 4 and the terminal piece 3 are welded at a plurality of places. As a result, the movable piece 4 and the terminal piece 3 are more firmly integrated.
  • the degree of freedom of the welded portion is high, and a plurality of welded portions can be easily set.
  • the method of integration in the second process is not limited to welding.
  • the movable piece 4 and the terminal piece 3 may be integrated by brazing, caulking, or screwing.
  • connection portions 33 and 42 are housed in the case 10.
  • the connecting portions 33 and 42 may be configured to extend toward the terminal 32 and project to the outside of the case 10 together with the terminal 32. With such a configuration, the movable piece 4 and the terminal piece 3 are more firmly integrated.
  • FIG. 8 shows a composite piece 9A which is a modified example of the composite piece 9 formed in the second step of the present manufacturing method.
  • the above-described configuration of the composite piece 9 may be adopted for a portion of the composite piece 9A that is not described below.
  • the composite piece 9A is different from the composite piece 9 in that the terminal piece 3A having the step-bent portion 35 bent in a stepped manner is applied between the terminal 32 and the connection portion 33.
  • the step bent portion 35 is formed by, for example, press working. After the step bending portion 35 is formed on the terminal piece 3A, the movable piece 4 and the terminal piece 3A are integrated. After the movable piece 4 and the terminal piece 3A are integrated, the step bending portion 35 may be formed on the terminal piece 3A.
  • FIG. 9 shows a composite piece 9B which is another modification of the composite piece 9 formed in the second step of the present manufacturing method.
  • the configuration of the composite pieces 9 and 9A described above can be adopted for the portion of the composite piece 9B that is not described below.
  • the composite piece 9B is different from the composite piece 9A in that the connecting portion 33 connected to the movable piece 4B extends beyond the step bending portion 35 toward the terminal 32. That is, the step bending portion 35 is formed in the connecting portion 33.
  • the connecting portion 42 of the movable piece 4B also extends toward the terminal 32, and the step bending portion 45 is formed in the connecting portion 42.
  • the step bent portions 35 and 45 are formed by, for example, press working. It is desirable that the movable piece 4B and the terminal piece 3B are integrated after the step bending portion 35 is formed on the terminal piece 3B and the step bending portion 45 is formed on the movable piece 4B. After the movable piece 4B and the terminal piece 3B are integrated, the step bending portions 35 and 45 may be formed on the composite piece 9B.
  • the step bending portions 35 and 45 may be arranged on the case main body 7 in the third step, or may be arranged so as to project to the outside of the case main body 7 together with the terminals 32.
  • FIG. 10 shows a composite piece 9C which is still another modification of the composite piece 9 formed in the second step of the present manufacturing method.
  • the configuration of the composite pieces 9, 9A, and 9B described above may be adopted for the portion of the composite piece 9C that is not described below.
  • the composite piece 9C is different from the composite piece 9 and the like in that the movable piece 4C is located closer to the heat-responsive element 5 than the terminal piece 3C in the thickness direction. That is, the B surface of the connecting portion 33 of the terminal piece 3C and the A surface of the connecting portion 42 of the movable piece 4C are fixed by welding or the like. Along with this, the A surface of the connecting portion 33 is in contact with the lid member 8, and the B surface of the connecting portion 42 is in contact with the case body 7.
  • the composite piece 9C is formed by exchanging the arrangement of the movable piece 4C and the terminal piece 3C in the second step and integrating the two.
  • the movable piece 4C can be mounted at a low position inside the breaker 1, and the breaker 1 can be easily lowered in height. ..
  • FIGS. 11 and 12 show composite pieces 9D and 9E, which are still another modification of the composite piece 9 formed in the second step of the present manufacturing method.
  • the above-described configuration of the composite pieces 9 and 9A can be adopted for a portion not described below.
  • a curved portion 46 bent so that the B surface of the movable piece 4D is located inside is formed between the connecting portion 42 of the movable piece 4D and the elastic portion 43.
  • the connecting portion 42 projects toward the case body 7 (lower side in FIG. 11) with respect to the elastic portion 43.
  • a curved portion 36 bent so that the B surface of the terminal piece 3D is located inside is formed between the connection portion 33 of the terminal piece 3D and the terminal 32.
  • a curved portion 36 bent so that the B surface of the terminal piece 3D is located inside is formed.
  • the connection portion 33 projects from the terminal 32 toward the case body 7.
  • the case body 7 into which the composite piece 9D is incorporated is formed with, for example, a recess for avoiding interference with the connecting portion 42 and the connecting portion 33.
  • the connecting portion 42 and the connecting portion 33 are connected by facing each other (that is, the A surface after both are bent). Bending of the movable piece 4D and the terminal piece 3D is performed before the second step. Then, in the second step, the heights of the A surface of the elastic portion 43 and the A surface of the terminal 32 are made uniform, and the movable piece 4D and the terminal piece 3D are integrated. As a result, the overlapping of the movable piece 4D and the terminal piece 3D in a plan view is avoided, so that the movable piece 4D can be mounted at a low position inside the breaker 1 to easily reduce the height of the breaker 1. It will be possible.
  • a curved portion 46 bent so that the A surface of the movable piece 4E is located inside is formed between the connecting portion 42 of the movable piece 4E and the elastic portion 43.
  • the connecting portion 42 projects toward the lid member 8 (upward in FIG. 12) with respect to the elastic portion 43.
  • a curved portion 36 bent so that the A surface of the terminal piece 3E is located inside is formed between the connection portion 33 of the terminal piece 3E and the terminal 32.
  • a curved portion 36 bent so that the A surface of the terminal piece 3E is located inside is formed.
  • the connecting portion 33 projects from the terminal 32 toward the lid member 8.
  • the lid member 8 in which the composite piece 9E is used is formed with, for example, a recess for avoiding interference with the connecting portion 42 and the connecting portion 33.
  • the connecting portion 42 and the connecting portion 33 are connected by facing each other (that is, the B surface after both are bent). Bending of the movable piece 4E and the terminal piece 3E is performed before the second step. Then, in the second step, the movable piece 4E and the terminal piece 3E are integrated by aligning the heights of the A surface of the elastic portion 43 and the A surface of the terminal 32. As a result, the overlapping of the movable piece 4E and the terminal piece 3E in a plan view is avoided, so that the movable piece 4E can be mounted at a low position inside the breaker 1 to easily reduce the height of the breaker 1. It will be possible.
  • the present invention is not limited to the above specific embodiment, but is modified to various embodiments. That is, the present invention is movable with at least a fixed contact 21, a movable piece 4 having a movable contact 41 at one end of the elastic portion 43 and the elastic portion 43, and pressing the movable contact 41 against the fixed contact 21 to bring them into contact with each other.
  • the movable contact 41 is separated from the fixed contact 21 from the conductive state in which the movable contact 41 contacts the fixed contact 21.
  • the manufacturing method of the present invention can be applied to a breaker in which the PTC thermistor 6 is omitted.
  • the arrangement of the PTC thermistor 6 is omitted in the first step shown in FIG.
  • the manufacturing method of the present invention can also be applied to a breaker in which the movable piece 4 and the heat-responsive element 5 are integrally formed (for example, the movable piece 4 is formed of bimetal). In this case, in the first step shown in FIG. 4, the arrangement of the heat-responsive element 5 is omitted.

Abstract

This method for manufacturing a breaker includes: a first step for placing a fixed contact and a thermal response element inside a case body; a second step for integrating a movable piece 4 and a terminal piece 3 to form a composite piece 9; a third step for placing the composite piece 9 inside the case body; and a fourth step for sandwiching and fixing the composite piece 9 using the case body and a lid member.

Description

ブレーカーの製造方法How to make a breaker
　本発明は、電気機器の安全回路に用いて好適な小型のブレーカーの製造方法に関する。 The present invention relates to a method for manufacturing a small breaker suitable for use in a safety circuit of an electric device.
　従来から、固定接点、可動接点を有する可動片、端子片、熱応動素子及びケースとを備えたブレーカーが知られている（例えば、特許文献１参照）。 Conventionally, a breaker including a fixed contact, a movable piece having a movable contact, a terminal piece, a heat-responsive element, and a case has been known (see, for example, Patent Document 1).
特開２０１６－３１９１７号公報Japanese Unexamined Patent Publication No. 2016-31917
　上記ブレーカーでは、端子片等がケース本体にインサート成形され、ケース本体の開口から露出する端子片に可動片が接続される構成が採用されている。 In the above breaker, a configuration is adopted in which a terminal piece or the like is insert-molded into the case body, and a movable piece is connected to the terminal piece exposed from the opening of the case body.
　しかしながら、上記構成では、ブレーカーの小型化の進展に伴い、ケース本体の開口も小さくなり、端子片と可動片とを良好に接続することが困難となる虞がある。 However, in the above configuration, with the progress of miniaturization of the breaker, the opening of the case body also becomes smaller, and there is a possibility that it becomes difficult to connect the terminal piece and the movable piece well.
　本発明は、上記課題を解決するためになされたものであり、小型化されるケース本体に関わらず、端子片と可動片とを良好に接続できるブレーカーを提供することを主たる目的とする。 The present invention has been made to solve the above problems, and an object of the present invention is to provide a breaker capable of satisfactorily connecting a terminal piece and a movable piece regardless of a case body to be miniaturized.
　本発明は、固定接点と、弾性部及び前記弾性部の一端部に可動接点を有し、前記可動接点を前記固定接点に押圧して接触させる可動片と、前記可動片と接続される端子片と、温度変化に伴って変形することにより、前記可動片の状態を前記可動接点が前記固定接点に接触する導通状態から前記可動接点が前記固定接点から離隔する遮断状態に移行させる熱応動素子と、前記固定接点、前記可動片、前記端子片及び前記熱応動素子を収容するための開口を有する第１ケースと、前記開口を閉鎖するために前記第１ケースに装着される第２ケースとを備えたブレーカーの製造方法であって、前記固定接点、及び前記熱応動素子を前記第１ケース内に配置する第１工程と、前記可動片と前記端子片とを一体化して複合片を形成する第２工程と、前記複合片を前記第１ケース内に配置する第３工程と、前記第１ケースと前記第２ケースとによって、前記複合片を挟み込んで固定する第４工程とを含む。 The present invention includes a fixed contact, a movable piece having a movable contact at an elastic portion and one end of the elastic portion, and pressing the movable contact against the fixed contact to bring them into contact with each other, and a terminal piece connected to the movable piece. A heat-responsive element that shifts the state of the movable piece from a conductive state in which the movable contact contacts the fixed contact to a blocking state in which the movable contact is separated from the fixed contact by deforming with a temperature change. A first case having an opening for accommodating the fixed contact, the movable piece, the terminal piece, and the heat-responsive element, and a second case attached to the first case to close the opening. A method for manufacturing a breaker provided, wherein the first step of arranging the fixed contact and the heat-responsive element in the first case, and the movable piece and the terminal piece are integrated to form a composite piece. It includes a second step, a third step of arranging the composite piece in the first case, and a fourth step of sandwiching and fixing the composite piece between the first case and the second case.
　本発明に係る前記ブレーカーの前記製造方法において、前記可動片と前記端子片とは、互いに別の材料からなる、ことが望ましい。 In the method for manufacturing the breaker according to the present invention, it is desirable that the movable piece and the terminal piece are made of different materials from each other.
　本発明に係る前記ブレーカーの前記製造方法において、前記可動片と前記端子片とは、互いに厚さが異なる、ことが望ましい。 In the method for manufacturing the breaker according to the present invention, it is desirable that the movable piece and the terminal piece have different thicknesses from each other.
　本発明に係る前記ブレーカーの前記製造方法において、前記第２工程において、前記可動片と前記端子片とは、レーザー溶接、抵抗溶接又は超音波溶接によって一体化される、ことが望ましい。 In the manufacturing method of the breaker according to the present invention, it is desirable that the movable piece and the terminal piece are integrated by laser welding, resistance welding or ultrasonic welding in the second step.
　本発明に係る前記ブレーカーの前記製造方法において、前記第２工程において、前記可動片と前記端子片とは、複数箇所にて溶接される、ことが望ましい。 In the manufacturing method of the breaker according to the present invention, it is desirable that the movable piece and the terminal piece are welded at a plurality of places in the second step.
　本発明に係る前記ブレーカーの前記製造方法において、前記第２工程において、前記可動片と前記端子片とは、蝋付け、かしめ又はねじによって一体化される、ことが望ましい。 In the manufacturing method of the breaker according to the present invention, it is desirable that the movable piece and the terminal piece are integrated by brazing, caulking or screwing in the second step.
　本発明に係る前記ブレーカーの前記製造方法において、前記第３工程で、前記複合片の厚さ方向で、前記可動片が前記端子片よりも前記熱応動素子の側に位置するように、前記第２工程において、前記可動片と前記端子片とが一体化される、ことが望ましい。 In the method for manufacturing the breaker according to the present invention, in the third step, the movable piece is located closer to the heat-responsive element than the terminal piece in the thickness direction of the composite piece. It is desirable that the movable piece and the terminal piece are integrated in the two steps.
　本発明の前記製造方法では、前記可動片と前記端子片とを一体化して前記複合片を形成する前記第２工程を含む。この第２工程は、前記複合片を前記第１ケース内に配置する前記第３工程に先だって実行される。すなわち、前記端子片は、前記第１ケース内に配置される前に、前記可動片と一体化され、前記複合片が構成される。従って、前記第１ケースの存在に煩わされることなく、容易かつ確実に前記可動片と前記端子片とを一体化することが可能となる。これにより、前記ブレーカーの小型化に伴い、前記端子片、前記可動片及び前記第１ケースが小型になる場合であっても、前記端子片と前記可動片とを良好に接続することが可能となる。 The manufacturing method of the present invention includes the second step of integrating the movable piece and the terminal piece to form the composite piece. This second step is performed prior to the third step of arranging the composite piece in the first case. That is, the terminal piece is integrated with the movable piece before being arranged in the first case to form the composite piece. Therefore, the movable piece and the terminal piece can be easily and surely integrated without being bothered by the existence of the first case. As a result, even when the terminal piece, the movable piece, and the first case become smaller due to the miniaturization of the breaker, the terminal piece and the movable piece can be satisfactorily connected. Become.
本発明によって製造されるブレーカーの組立前の状態を示す斜視図。The perspective view which shows the state before assembling the breaker manufactured by this invention. 通常の充電又は放電状態における上記ブレーカーを示す断面図。The cross-sectional view which shows the said breaker in a normal charge or discharge state. 過充電状態又は異常時などにおける上記ブレーカーを示す断面図。A cross-sectional view showing the breaker in an overcharged state or an abnormal state. 本製造方法の第１工程を示す断面図。The cross-sectional view which shows the 1st step of this manufacturing method. 本製造方法の第２工程を示す断面図。The cross-sectional view which shows the 2nd step of this manufacturing method. 本製造方法の第３工程を示す断面図。The cross-sectional view which shows the 3rd process of this manufacturing method. 本製造方法の第４工程を示す断面図。The cross-sectional view which shows the 4th process of this manufacturing method. 本製造方法の第２工程にて形成される複合片の変形例を示す断面図。The cross-sectional view which shows the modification of the composite piece formed in the 2nd step of this manufacturing method. 本製造方法の第２工程にて形成される複合片の別の変形例を示す断面図。The cross-sectional view which shows another modification of the composite piece formed in the 2nd step of this manufacturing method. 本製造方法の第２工程にて形成される複合片のさらに別の変形例を示す断面図。FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method. 本製造方法の第２工程にて形成される複合片のさらに別の変形例を示す断面図。FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method. 本製造方法の第２工程にて形成される複合片のさらに別の変形例を示す断面図。FIG. 5 is a cross-sectional view showing still another modification of the composite piece formed in the second step of the present manufacturing method.
　本発明の一実施形態によるブレーカーの製造方法について図面を参照して説明する。図１乃至図３は、本発明によって製造されるブレーカー１の構成を示している。ブレーカー１は、電気機器等に実装され、過度な温度上昇又は過電流から電気機器を保護する。 A method for manufacturing a breaker according to an embodiment of the present invention will be described with reference to the drawings. 1 to 3 show the configuration of the breaker 1 manufactured by the present invention. The breaker 1 is mounted on an electric device or the like to protect the electric device from an excessive temperature rise or overcurrent.
　ブレーカー１は、固定接点２１を有する固定片２と、一端部に可動接点４１を有する可動片４と、温度変化に伴って変形する熱応動素子５と、ＰＴＣ（Positive Temperature Coefficient）サーミスター６と、固定片２、可動片４、熱応動素子５及びＰＴＣサーミスター６を収容するケース１０等によって構成されている。ケース１０は、ケース本体（第１ケース）７とケース本体７の上面に装着される蓋部材（第２ケース）８等によって構成されている。 The breaker 1 includes a fixed piece 2 having a fixed contact 21, a movable piece 4 having a movable contact 41 at one end, a heat-responsive element 5 that deforms with a change in temperature, and a PTC (Positive Temperature Coefficient) thermistor 6. It is composed of a fixed piece 2, a movable piece 4, a heat-responsive element 5, a case 10 for accommodating a PTC thermistor 6, and the like. The case 10 is composed of a case body (first case) 7, a lid member (second case) 8 mounted on the upper surface of the case body 7, and the like.
　固定片２は、例えば、銅等を主成分とする金属板（この他、銅－チタニウム合金、洋白、黄銅などの金属板）をプレス加工することにより形成され、ケース本体７にインサート成形により埋め込まれている。固定片２の一端側には外部回路と電気的に接続される端子２２が形成され、他端側には、ＰＴＣサーミスター６を支持する支持部２３が形成されている。ＰＴＣサーミスター６は、固定片２の支持部２３に３箇所形成された凸状の突起（ダボ）２４の上に載置されて、突起２４に支持される。固定片２が階段状に曲げられることにより、固定接点２１と支持部２３とが段違いに配置され、ＰＴＣサーミスター６を収納する空間が容易に確保される。 The fixed piece 2 is formed by, for example, pressing a metal plate containing copper or the like as a main component (in addition, a metal plate such as a copper-titanium alloy, nickel silver, brass, etc.), and is formed by insert molding into the case body 7. It is embedded. A terminal 22 electrically connected to an external circuit is formed on one end side of the fixed piece 2, and a support portion 23 for supporting the PTC thermistor 6 is formed on the other end side. The PTC thermistor 6 is placed on a convex protrusion (dowel) 24 formed at three positions on the support portion 23 of the fixed piece 2 and supported by the protrusion 24. By bending the fixed piece 2 in a stepped manner, the fixed contact 21 and the support portion 23 are arranged in a stepped manner, and a space for accommodating the PTC thermistor 6 is easily secured.
　固定接点２１は、銀、ニッケル、ニッケル－銀合金の他、銅－銀合金、金－銀合金などの導電性の良い材料のクラッド、メッキ又は塗布等により可動接点４１に対向する位置に形成され、ケース本体７の内部に形成されている開口７３ａの一部から露出されている。端子２２はケース本体７の端縁から外側に突き出されている。支持部２３は、ケース本体７の内部に形成されている開口７３ｄから露出されている。 The fixed contact 21 is formed at a position facing the movable contact 41 by clad, plating or coating of a highly conductive material such as a copper-silver alloy or a gold-silver alloy in addition to silver, nickel and nickel-silver alloy. , It is exposed from a part of the opening 73a formed inside the case body 7. The terminal 22 protrudes outward from the edge of the case body 7. The support portion 23 is exposed from the opening 73d formed inside the case body 7.
　本出願においては、特に断りのない限り、固定片２において、固定接点２１が形成されている側の面（すなわち図１において上側の面）をＡ面、その反対側の面をＢ面として説明している。固定接点２１から可動接点４１に向く方向を第１方向と、第１方向とは反対の方向を第２方向とそれぞれ定義した場合、Ａ面は第１方向を向き、Ｂ面は第２方向を向く。他の部品、例えば、端子片３、可動片４及び熱応動素子５、ＰＴＣサーミスター６等についても同様である。 In the present application, unless otherwise specified, the surface on the side where the fixed contact 21 is formed (that is, the upper surface in FIG. 1) is referred to as the A surface, and the surface on the opposite side is referred to as the B surface in the fixed piece 2. doing. When the direction from the fixed contact 21 to the movable contact 41 is defined as the first direction and the direction opposite to the first direction is defined as the second direction, the A side faces the first direction and the B side faces the second direction. Turn to. The same applies to other parts such as the terminal piece 3, the movable piece 4, the heat responding element 5, the PTC thermistor 6, and the like.
　端子片３は、固定片２と同様に、銅等を主成分とする金属板により形成されている。端子片３の一端側には外部回路と電気的に接続される端子３２が形成され、他端側には、可動片４と電気的に接続される接続部３３が形成されている。端子３２はケース本体７の端縁から外側に突き出されている。接続部３３は、可動片４と電気的に接続される。 Like the fixed piece 2, the terminal piece 3 is formed of a metal plate containing copper or the like as a main component. A terminal 32 electrically connected to an external circuit is formed on one end side of the terminal piece 3, and a connecting portion 33 electrically connected to the movable piece 4 is formed on the other end side. The terminal 32 protrudes outward from the edge of the case body 7. The connecting portion 33 is electrically connected to the movable piece 4.
　可動片４は、銅等を主成分とする板状の金属材料をプレス加工することにより、長手方向の中心線に対して対称なアーム状に形成されている。 The movable piece 4 is formed in an arm shape symmetrical with respect to the center line in the longitudinal direction by pressing a plate-shaped metal material containing copper or the like as a main component.
　可動片４の長手方向の一端部には、可動接点４１が形成されている。可動接点４１は、例えば、固定接点２１と同等の材料によって形成され、溶接の他、クラッド、かしめ（crimping）等の手法によって可動片４の一端部に接合されている。 A movable contact 41 is formed at one end of the movable piece 4 in the longitudinal direction. The movable contact 41 is formed of, for example, a material equivalent to that of the fixed contact 21, and is joined to one end of the movable piece 4 by a method such as welding, clad, or crimping.
　可動片４の他端部には、端子片３の接続部３３と電気的に接続される接続部４２が形成されている。端子片３の接続部３３のＡ面と可動片４の接続部４２のＢ面とは、例えば、溶接によって固着されている。接続部３３のＢ面は、ケース本体７と接触し、接続部４２のＡ面は、蓋部材８と接触している。これにより、可動片４及び端子片３は、ケース本体７と蓋部材８とによって挟み込まれて固定される。 A connecting portion 42 that is electrically connected to the connecting portion 33 of the terminal piece 3 is formed at the other end of the movable piece 4. The A surface of the connection portion 33 of the terminal piece 3 and the B surface of the connection portion 42 of the movable piece 4 are fixed by welding, for example. The B surface of the connecting portion 33 is in contact with the case body 7, and the A surface of the connecting portion 42 is in contact with the lid member 8. As a result, the movable piece 4 and the terminal piece 3 are sandwiched and fixed by the case body 7 and the lid member 8.
　可動片４は、可動接点４１と接続部４２との間に、弾性部４３を有している。弾性部４３は、接続部４２から可動接点４１の側に延出されている。可動片４は、弾性部４３の基端側の接続部４２で、ケース１０及び端子片３によって片持ち支持され、その状態で弾性部４３が弾性変形することにより、弾性部４３の先端部に形成されている可動接点４１が固定接点２１の側に押圧されて接触し、固定片２と可動片４とが通電可能となる。可動片４と端子片３とは、電気的に接続されているので、固定片２と端子片３とが通電可能となる。 The movable piece 4 has an elastic portion 43 between the movable contact 41 and the connecting portion 42. The elastic portion 43 extends from the connecting portion 42 to the side of the movable contact 41. The movable piece 4 is a connecting portion 42 on the base end side of the elastic portion 43, and is cantilevered by the case 10 and the terminal piece 3, and in that state, the elastic portion 43 elastically deforms to the tip portion of the elastic portion 43. The formed movable contact 41 is pressed against the fixed contact 21 and comes into contact with each other, so that the fixed piece 2 and the movable piece 4 can be energized. Since the movable piece 4 and the terminal piece 3 are electrically connected to each other, the fixed piece 2 and the terminal piece 3 can be energized.
　可動片４は、弾性部４３において、プレス加工により湾曲又は屈曲されているのが望ましい。湾曲又は屈曲の度合いは、熱応動素子５を収納できる限り特に限定はなく、動作温度及び復帰温度における弾性力、接点の押圧力などを考慮して適宜設定すればよい。また、弾性部４３のＢ面には、熱応動素子５に対向して一対の突起（接触部）４４ａ，４４ｂが形成されている。突起４４ａ，４４ｂと熱応動素子５とは接触して、突起４４ａ，４４ｂを介して熱応動素子５の変形が弾性部４３に伝達される（図１、図２及び図３参照）。 It is desirable that the movable piece 4 is curved or bent by press working in the elastic portion 43. The degree of bending or bending is not particularly limited as long as the heat-responsive element 5 can be accommodated, and may be appropriately set in consideration of the elastic force at the operating temperature and the return temperature, the pressing force of the contact, and the like. Further, a pair of protrusions (contact portions) 44a and 44b are formed on the B surface of the elastic portion 43 so as to face the heat-responsive element 5. The protrusions 44a and 44b come into contact with the heat-responsive element 5, and the deformation of the heat-responsive element 5 is transmitted to the elastic portion 43 via the protrusions 44a and 44b (see FIGS. 1, 2 and 3).
　熱応動素子５は、可動片４の状態を可動接点４１が固定接点２１に接触する導通状態から可動接点４１が固定接点２１から離隔する遮断状態に移行させる。熱応動素子５は、熱膨張率の異なる薄板材を積層することにより板状に形成され、断面が円弧状に湾曲した初期形状をなしている。過熱により反転動作温度に達すると、熱応動素子５の湾曲形状は、スナップモーションを伴って逆反りし、冷却により正転復帰温度を下回ると復元する。熱応動素子５の初期形状は、プレス加工により形成することができる。所期の温度で熱応動素子５の逆反り変形により可動片４の弾性部４３が押し上げられ、かつ弾性部４３の弾性力により元に戻る限り、熱応動素子５の材料及び形状は特に限定されるものでないが、生産性及び逆反り変形の効率性の観点から矩形状が望ましい。 The heat-responsive element 5 shifts the state of the movable piece 4 from the conductive state in which the movable contact 41 contacts the fixed contact 21 to the cutoff state in which the movable contact 41 is separated from the fixed contact 21. The heat-responsive element 5 is formed in a plate shape by laminating thin plate materials having different coefficients of thermal expansion, and has an initial shape with a curved cross section in an arc shape. When the reversing operating temperature is reached due to overheating, the curved shape of the heat responding element 5 reversely warps with a snap motion, and is restored when it falls below the normal rotation return temperature due to cooling. The initial shape of the heat-responsive element 5 can be formed by press working. The material and shape of the heat-responsive element 5 are particularly limited as long as the elastic portion 43 of the movable piece 4 is pushed up by the reverse warp deformation of the heat-responsive element 5 at the desired temperature and is restored by the elastic force of the elastic portion 43. Although it is not, a rectangular shape is desirable from the viewpoint of productivity and efficiency of reverse warp deformation.
　熱応動素子５の材料としては、洋白、黄銅、ステンレス鋼等の各種の合金からなる熱膨張率の異なる２種類の材料を積層したものが、所要条件に応じて組み合わせて使用される。例えば、安定した反転動作温度及び正転復帰温度が得られる熱応動素子５の材料としては、高膨脹側に銅－ニッケル－マンガン合金、低膨脹側に鉄－ニッケル合金を組み合わせたものが望ましい。また、化学的安定性の観点からさらに望ましい材料として、高膨脹側に鉄－ニッケル－クロム合金、低膨脹側に鉄－ニッケル合金を組み合わせたものが挙げられる。さらにまた、化学的安定性及び加工性の観点からさらに望ましい材料として、高膨脹側に鉄－ニッケル－クロム合金、低膨脹側に鉄－ニッケル－コバルト合金を組み合わせたものが挙げられる。 As the material of the heat-responsive element 5, two kinds of materials having different coefficients of thermal expansion, which are made of various alloys such as nickel silver, brass, and stainless steel, are used in combination according to the required conditions. For example, as a material of the heat-responsive element 5 capable of obtaining a stable reversing operation temperature and a normal reversing temperature, a combination of a copper-nickel-manganese alloy on the high expansion side and an iron-nickel alloy on the low expansion side is desirable. Further, as a more desirable material from the viewpoint of chemical stability, a combination of an iron-nickel-chromium alloy on the high expansion side and an iron-nickel alloy on the low expansion side can be mentioned. Furthermore, as a more desirable material from the viewpoint of chemical stability and processability, a combination of an iron-nickel-chromium alloy on the high expansion side and an iron-nickel-cobalt alloy on the low expansion side can be mentioned.
　ＰＴＣサーミスター６は、可動片４が遮断状態にあるとき、固定片２と可動片４とを導通させる。ＰＴＣサーミスター６は、固定片２と熱応動素子５との間に配設されている。すなわち、ＰＴＣサーミスター６を挟んで、固定片２の支持部２３は熱応動素子５の直下に位置している。熱応動素子５の逆反り変形により固定片２と可動片４との通電が遮断されたとき、ＰＴＣサーミスター６に流れる電流が増大する。ＰＴＣサーミスター６は、温度上昇と共に抵抗値が増大して電流を制限する正特性サーミスターであれば、作動電流、作動電圧、作動温度、復帰温度などの必要に応じて種類を選択でき、その材料及び形状はこれらの諸特性を損なわない限り特に限定されるものではない。本実施形態では、チタニウム酸バリウム、チタニウム酸ストロンチウム又はチタニウム酸カルシウムを含むセラミック焼結体が用いられる。セラミック焼結体の他、ポリマーにカーボン等の導電性粒子を含有させたいわゆるポリマーＰＴＣを用いてもよい。 The PTC thermistor 6 conducts the fixed piece 2 and the movable piece 4 when the movable piece 4 is in the cutoff state. The PTC thermistor 6 is arranged between the fixed piece 2 and the heat-responsive element 5. That is, the support portion 23 of the fixing piece 2 is located directly below the heat-responsive element 5 with the PTC thermistor 6 interposed therebetween. When the energization between the fixed piece 2 and the movable piece 4 is cut off due to the reverse warp deformation of the heat-responsive element 5, the current flowing through the PTC thermistor 6 increases. If the PTC thermistor 6 is a positive characteristic thermistor whose resistance value increases as the temperature rises and limits the current, the type can be selected according to the needs such as operating current, operating voltage, operating temperature, and recovery temperature. The material and shape are not particularly limited as long as these properties are not impaired. In this embodiment, a ceramic sintered body containing barium titanate, strontium titanate, or calcium titanate is used. In addition to the ceramic sintered body, a so-called polymer PTC in which conductive particles such as carbon are contained in the polymer may be used.
　ケース１０を構成するケース本体７及び蓋部材８は、難燃性のポリアミド、耐熱性に優れたポリフェニレンサルファイド（ＰＰＳ）、液晶ポリマー（ＬＣＰ）、ポリブチレンテレフタレート（ＰＢＴ）などの熱可塑性樹脂により成形されている。上述した樹脂と同等以上の特性が得られるのであれば、樹脂以外の材料を適用してもよい。 The case body 7 and the lid member 8 constituting the case 10 are molded from a thermoplastic resin such as flame-retardant polyamide, polyphenylene sulfide (PPS) having excellent heat resistance, a liquid crystal polymer (LCP), and polybutylene terephthalate (PBT). Has been done. A material other than the resin may be applied as long as the characteristics equal to or higher than those of the above-mentioned resin can be obtained.
　ケース本体７には、可動片４、熱応動素子５及びＰＴＣサーミスター６などを収容するための内部空間である凹部７３が形成されている。凹部７３は、可動片４を収容するための開口７３ａ，７３ｂ、可動片４及び熱応動素子５を収容するための開口７３ｃ、並びに、ＰＴＣサーミスター６を収容するための開口７３ｄ等を有している。なお、ケース本体７に組み込まれた可動片４、熱応動素子５の端縁は、凹部７３を構成する枠によってそれぞれ当接され、熱応動素子５の逆反り変形時に案内される。 The case body 7 is formed with a recess 73, which is an internal space for accommodating a movable piece 4, a heat-responsive element 5, a PTC thermistor 6, and the like. The recess 73 has openings 73a and 73b for accommodating the movable piece 4, an opening 73c for accommodating the movable piece 4 and the heat-responsive element 5, an opening 73d for accommodating the PTC thermistor 6, and the like. ing. The movable piece 4 and the edge of the heat-responsive element 5 incorporated in the case body 7 are brought into contact with each other by the frame forming the recess 73, and are guided when the heat-responsive element 5 is deformed in the reverse direction.
　蓋部材８は、凹部７３を覆うように構成されている。蓋部材８は、凹部７３の少なくとも一部を覆う形態であってもよい。蓋部材８には、銅等を主成分とする金属板又はステンレス鋼等のカバー片８１がインサート成形によって埋め込まれていてもよい。カバー片８１は、可動片４のＡ面と適宜当接し、可動片４の動きを規制すると共に、蓋部材８のひいては筐体としてのケース１０の剛性・強度を高めつつブレーカー１の小型化に貢献する。 The lid member 8 is configured to cover the recess 73. The lid member 8 may be in a form that covers at least a part of the recess 73. A cover piece 81 made of a metal plate or stainless steel containing copper or the like as a main component may be embedded in the lid member 8 by insert molding. The cover piece 81 appropriately contacts the A surface of the movable piece 4, regulates the movement of the movable piece 4, and increases the rigidity and strength of the lid member 8 and thus the case 10 as a housing to reduce the size of the breaker 1. To contribute.
　図１が示すように、固定片２、端子片３、可動片４、熱応動素子５及びＰＴＣサーミスター６等を収容したケース本体７の開口７３ａ、７３ｂ、７３ｃ等を塞ぐように、蓋部材８が、ケース本体７に装着される。ケース本体７と蓋部材８とは、例えば超音波溶着によって接合される。 As shown in FIG. 1, the lid member closes the openings 73a, 73b, 73c, etc. of the case body 7 accommodating the fixed piece 2, the terminal piece 3, the movable piece 4, the heat responding element 5, the PTC thermistor 6, and the like. 8 is attached to the case body 7. The case body 7 and the lid member 8 are joined by, for example, ultrasonic welding.
　図２及び図３は、ブレーカー１の動作の概略を示している。図２は、通常の充電又は放電状態におけるブレーカー１の動作を示している。通常の充電又は放電状態においては、熱応動素子５は逆反り前の初期形状を維持している。弾性部４３によって可動接点４１が固定接点２１の側に押圧されることにより、可動接点４１と固定接点２１とが接触し、可動片４の弾性部４３を介してブレーカー１の固定片２と端子片３とが導通可能な状態とされる。 2 and 3 show an outline of the operation of the breaker 1. FIG. 2 shows the operation of the breaker 1 in a normal charging or discharging state. In a normal charging or discharging state, the heat-responsive element 5 maintains the initial shape before the reverse warp. When the movable contact 41 is pressed toward the fixed contact 21 by the elastic portion 43, the movable contact 41 and the fixed contact 21 come into contact with each other, and the fixed piece 2 and the terminal of the breaker 1 are brought into contact with each other via the elastic portion 43 of the movable piece 4. The piece 3 and the piece 3 are made conductive.
　図２に示される導通状態では、熱応動素子５は、導通状態の可動片４の突起４４ａ及び突起４４ｂと離隔している。これにより、可動接点４１と固定接点２１との接触圧力が高められ、両者間の接触抵抗が低減される。 In the conductive state shown in FIG. 2, the heat-responsive element 5 is separated from the protrusions 44a and 44b of the movable piece 4 in the conductive state. As a result, the contact pressure between the movable contact 41 and the fixed contact 21 is increased, and the contact resistance between the two is reduced.
　可動片４の弾性部４３と熱応動素子５とは接触していてもよい。この場合、端子片３、可動片４、熱応動素子５、ＰＴＣサーミスター６及び固定片２は、回路として導通している。しかし、ＰＴＣサーミスター６の抵抗は、可動片４の抵抗に比べて圧倒的に大きいため、ＰＴＣサーミスター６を流れる電流は、固定接点２１及び可動接点４１を流れる量に比して実質的に無視できる程度である。 The elastic portion 43 of the movable piece 4 and the heat-responsive element 5 may be in contact with each other. In this case, the terminal piece 3, the movable piece 4, the heat-responsive element 5, the PTC thermistor 6 and the fixed piece 2 are conducting as a circuit. However, since the resistance of the PTC thermistor 6 is overwhelmingly larger than the resistance of the movable piece 4, the current flowing through the PTC thermistor 6 is substantially larger than the amount flowing through the fixed contact 21 and the movable contact 41. It can be ignored.
　図３は、過充電状態又は異常時などにおけるブレーカー１の動作を示している。過充電又は異常により高温状態となると、反転動作温度に達した熱応動素子５は逆反り変形して可動片４の弾性部４３と接触し、弾性部４３が押し上げられて固定接点２１と可動接点４１とが離隔する。このとき、固定接点２１と可動接点４１の間を流れていた電流は遮断される。一方、熱応動素子５は、可動片４と接触して、僅かな漏れ電流が熱応動素子５及びＰＴＣサーミスター６を通して流れることとなる。すなわち、ＰＴＣサーミスター６は、可動片４を遮断状態に移行させている熱応動素子５を介して、固定片２と可動片４とを導通させる。ＰＴＣサーミスター６は、このような漏れ電流の流れる限り発熱を続け、熱応動素子５を逆反り状態に維持させつつ抵抗値を激増させるので、電流は固定接点２１と可動接点４１の間の経路を流れず、上述の僅かな漏れ電流のみが存在する（自己保持回路を構成する）。この漏れ電流は安全装置の他の機能に充てることができる。 FIG. 3 shows the operation of the breaker 1 in an overcharged state or an abnormal state. When the temperature becomes high due to overcharging or abnormality, the heat-responsive element 5 that has reached the reversing operating temperature deforms in the reverse direction and comes into contact with the elastic portion 43 of the movable piece 4, and the elastic portion 43 is pushed up to reach the fixed contact 21 and the movable contact. It is separated from 41. At this time, the current flowing between the fixed contact 21 and the movable contact 41 is cut off. On the other hand, the heat-responsive element 5 comes into contact with the movable piece 4, and a small leakage current flows through the heat-responsive element 5 and the PTC thermistor 6. That is, the PTC thermistor 6 conducts the fixed piece 2 and the movable piece 4 via the heat-responsive element 5 that shifts the movable piece 4 to the cutoff state. The PTC thermistor 6 continues to generate heat as long as such a leakage current flows, and the resistance value is drastically increased while maintaining the heat responding element 5 in a reverse warp state. Therefore, the current is a path between the fixed contact 21 and the movable contact 41. There is only a small amount of leakage current as described above (which constitutes a self-holding circuit). This leakage current can be used for other functions of the safety device.
　過充電状態を解除し、又は異常状態を解消すると、ＰＴＣサーミスター６の発熱も収まり、熱応動素子５は正転復帰温度に戻り、元の初期形状に復元する。そして、可動片４の弾性部４３の弾性力によって可動接点４１と固定接点２１とは再び接触し、回路は遮断状態を解かれ、図２に示す導通状態に復帰する。 When the overcharged state is released or the abnormal state is resolved, the heat generated by the PTC thermistor 6 also subsides, and the heat responding element 5 returns to the normal rotation return temperature and returns to the original initial shape. Then, the elastic contact force of the elastic portion 43 of the movable piece 4 causes the movable contact 41 and the fixed contact 21 to come into contact with each other again, the circuit is released from the cutoff state, and returns to the conductive state shown in FIG.
　図４～図７は、本発明のブレーカー１の製造方法を時系列で示している。本製造方法は、第１工程ないし第４工程を含んでいる。 4 to 7 show the manufacturing method of the breaker 1 of the present invention in chronological order. This manufacturing method includes a first step to a fourth step.
　図４は、第１工程を示している。第１工程では、固定接点２１、ＰＴＣサーミスター６及び熱応動素子５がケース本体７内に配置される。本実施形態の第１工程は、固定片２に固定接点２１を形成する工程と、当該固定片２を金型内にインサートする工程と、キャビティ空間に樹脂材料を射出して、ケース本体７を形成する工程とを含んでいる。上記ケース本体７を形成する工程では、ケース本体７に、開口７３ｃ、７３ｄが形成される。そして、ＰＴＣサーミスター６は開口７３ｄから、熱応動素子５は開口７３ｃから、それぞれケース本体７内に配置されて凹部７３に収容される。 FIG. 4 shows the first step. In the first step, the fixed contact 21, the PTC thermistor 6, and the heat-responsive element 5 are arranged in the case body 7. The first step of the present embodiment includes a step of forming a fixed contact 21 on the fixed piece 2, a step of inserting the fixed piece 2 into the mold, and a step of injecting a resin material into the cavity space to form the case body 7. It includes a step of forming. In the step of forming the case body 7, openings 73c and 73d are formed in the case body 7. The PTC thermistor 6 is arranged in the case body 7 from the opening 73d and the heat-responsive element 5 is arranged in the recess 73 from the opening 73c.
　図５は、第２工程を示している。第２工程では、可動片４と端子片３とが一体化され、複合片９が形成される。複合片９を構成する可動片４及び端子片３は、それぞれ別々の前工程にて準備される。そして、端子片３は、ケース本体７内に配置される前に、可動片４と一体化され、複合片９が構成される。可動片４と端子片３との一体化の際には、可動片４及び端子片３を位置決めし、固定するための治具等が適宜用いられる。 FIG. 5 shows the second step. In the second step, the movable piece 4 and the terminal piece 3 are integrated to form the composite piece 9. The movable piece 4 and the terminal piece 3 constituting the composite piece 9 are prepared in separate pre-processes. Then, the terminal piece 3 is integrated with the movable piece 4 before being arranged in the case main body 7, and the composite piece 9 is formed. When the movable piece 4 and the terminal piece 3 are integrated, a jig or the like for positioning and fixing the movable piece 4 and the terminal piece 3 is appropriately used.
　図６は、第３工程を示している。第３工程では、複合片９がケース本体７内に配置される。複合片９は、第１工程においてケース本体７に形成されている開口７３ａ、７３ｂ、７３ｃから、ケース本体７内に配置されて凹部７３に収容される。本発明の可動片４と端子片３とが一体化されて成る複合片９は、例えば、ＷＯ２０１１／１０５１７５号公報等に開始されている可動片と同様にケース本体７に配置することができる。 FIG. 6 shows the third step. In the third step, the composite piece 9 is arranged in the case body 7. The composite piece 9 is arranged in the case main body 7 from the openings 73a, 73b, 73c formed in the case main body 7 in the first step, and is housed in the recess 73. The composite piece 9 in which the movable piece 4 and the terminal piece 3 of the present invention are integrated can be arranged in the case body 7 in the same manner as the movable piece started in WO2011 / 105175, for example.
　図７は、第４工程を示している。第４工程では、ケース本体７に蓋部材８が装着される。このとき、複合片９は、ケース本体７と蓋部材８とによって挟み込まれる。そして、ケース本体７と蓋部材８とが超音波溶着等によって固着されると、複合片９は、ケース本体７と蓋部材８とによって固定される。 FIG. 7 shows the fourth step. In the fourth step, the lid member 8 is attached to the case body 7. At this time, the composite piece 9 is sandwiched between the case body 7 and the lid member 8. Then, when the case body 7 and the lid member 8 are fixed by ultrasonic welding or the like, the composite piece 9 is fixed by the case body 7 and the lid member 8.
　本発明の製造方法では、可動片４と端子片３とを一体化して複合片９を形成する第２工程を含む。第２工程は、複合片９をケース本体７内に配置する第３工程に先だって実行される。すなわち、端子片３は、ケース本体７内に配置される前に、可動片４と一体化され、複合片９が構成される。従って、ケース本体７の存在に煩わされることなく、容易かつ確実に可動片４と端子片３とを一体化することが可能となる。これにより、ブレーカー１の小型化に伴い、端子片３、可動片４及びケース本体７が小型になる場合であっても、端子片３と可動片４とを良好に接続することが可能となる。 The manufacturing method of the present invention includes a second step of integrating the movable piece 4 and the terminal piece 3 to form the composite piece 9. The second step is executed prior to the third step of arranging the composite piece 9 in the case body 7. That is, the terminal piece 3 is integrated with the movable piece 4 before being arranged in the case main body 7, and the composite piece 9 is formed. Therefore, the movable piece 4 and the terminal piece 3 can be easily and surely integrated without being bothered by the existence of the case body 7. As a result, even when the terminal piece 3, the movable piece 4, and the case body 7 become smaller due to the miniaturization of the breaker 1, the terminal piece 3 and the movable piece 4 can be satisfactorily connected. ..
　第２工程は、ケース本体７に各部品を配置する第１工程及び第３工程とは独立する別のラインにて実行可能となる。すなわち、端子片３及び可動片４の一体化は、第１工程及び第３工程とは独立したラインで、両者の一体化に適した治具等の設備を用いて、実施されうる。これにより、ブレーカー１の小型化に伴い、端子片３、可動片４及びケース本体７が小型になる場合であっても、端子片３と可動片４とを良好に接続することが可能となる。 The second step can be executed on a separate line independent of the first step and the third step in which each part is arranged on the case body 7. That is, the integration of the terminal piece 3 and the movable piece 4 can be carried out on a line independent of the first step and the third step by using equipment such as a jig suitable for integrating the two. As a result, even when the terminal piece 3, the movable piece 4, and the case body 7 become smaller due to the miniaturization of the breaker 1, the terminal piece 3 and the movable piece 4 can be satisfactorily connected. ..
　また、第１工程と第２工程とは、同時にすなわち並行して実行することができる。例えば、第１工程、第３工程及び第４工程は、一連のラインにて実行され、第２工程は、別レーンのラインにて、同時に実行されてもよい。従って、ブレーカー１の生産性に及ぶ影響は少ない。 Further, the first step and the second step can be executed at the same time, that is, in parallel. For example, the first step, the third step, and the fourth step may be executed on a series of lines, and the second step may be executed simultaneously on lines in different lanes. Therefore, the effect on the productivity of the breaker 1 is small.
　本製造方法では、可動片４と端子片３とを、互いに別の材料にて構成することが可能である。例えば、可動片４は、導電性に優れた材料にて構成され、端子片３は、外部回路を構成するタブリード等との接続や腐食等を考慮した材料にて構成されうる。なお、可動片４に導電性に劣る材料が用いられることにより、異常時の熱応動素子５の作動を早めることも可能である。 In this manufacturing method, the movable piece 4 and the terminal piece 3 can be made of different materials from each other. For example, the movable piece 4 may be made of a material having excellent conductivity, and the terminal piece 3 may be made of a material in consideration of connection with a tab lead or the like constituting an external circuit, corrosion, or the like. By using a material having inferior conductivity for the movable piece 4, it is possible to accelerate the operation of the heat-responsive element 5 at the time of abnormality.
　また、可動片４と端子片３とを、互いに厚さが異なる板材にて構成することも可能である。例えば、端子片３の厚さが可動片４の厚さよりも大きい形態の複合片９又は端子片３の厚さが可動片４の厚さよりも小さい形態の複合片９が容易に形成される。端子片３の厚さを大きく設定することにより、端子片３の抵抗値が減少し、電圧降下が抑制される。可動片４の厚さを大きく設定することにより、固定接点２１と可動接点４１との接触圧力が容易に高められ、両者間での接触抵抗が抑制される。可動片４の厚さを小さく設定することにより、押し上げ力の小さい熱応動素子５が適用可能となり、熱応動素子５の温度特性を容易に高めることが可能となる。 It is also possible to configure the movable piece 4 and the terminal piece 3 with plate materials having different thicknesses from each other. For example, a composite piece 9 having a thickness of the terminal piece 3 larger than the thickness of the movable piece 4 or a composite piece 9 having a thickness of the terminal piece 3 smaller than the thickness of the movable piece 4 can be easily formed. By setting a large thickness of the terminal piece 3, the resistance value of the terminal piece 3 is reduced and the voltage drop is suppressed. By setting a large thickness of the movable piece 4, the contact pressure between the fixed contact 21 and the movable contact 41 is easily increased, and the contact resistance between the two is suppressed. By setting the thickness of the movable piece 4 to be small, the heat-responsive element 5 having a small pushing force can be applied, and the temperature characteristics of the heat-responsive element 5 can be easily improved.
　本実施形態の第２工程において、可動片４と端子片３とは、溶接の手法によって一体化される。溶接の種類としては、例えば、レーザー溶接、抵抗溶接又は超音波溶接等が挙げられる。第２工程における可動片４と端子片３との一体化に溶接の手法が用いられることにより、短時間で可動片４と端子片３とが強固に一体化される。本発明では、可動片４と端子片３とは、他の部品から独立した状態で一体化される。従って、可動片４と端子片３とをレーザー溶接によって一体化する場合、レーザー光は、可動片４のＡ面又は端子片３のＢ面のいずれの側からも照射可能である。 In the second step of the present embodiment, the movable piece 4 and the terminal piece 3 are integrated by a welding method. Examples of the type of welding include laser welding, resistance welding, ultrasonic welding and the like. By using the welding method for integrating the movable piece 4 and the terminal piece 3 in the second step, the movable piece 4 and the terminal piece 3 are firmly integrated in a short time. In the present invention, the movable piece 4 and the terminal piece 3 are integrated in a state independent of other parts. Therefore, when the movable piece 4 and the terminal piece 3 are integrated by laser welding, the laser beam can be irradiated from either the A side of the movable piece 4 or the B side of the terminal piece 3.
　第２工程において、可動片４と端子片３とは、複数箇所にて溶接される、のが望ましい。これにより、可動片４と端子片３とがより一層強固に一体化される。本製造方法では、可動片４と端子片３とがケース本体７が独立した状態で溶接されるので、溶接箇所の自由度が高く、複数の溶接箇所が容易に設定できる。 In the second step, it is desirable that the movable piece 4 and the terminal piece 3 are welded at a plurality of places. As a result, the movable piece 4 and the terminal piece 3 are more firmly integrated. In this manufacturing method, since the movable piece 4 and the terminal piece 3 are welded in a state where the case body 7 is independent, the degree of freedom of the welded portion is high, and a plurality of welded portions can be easily set.
　なお、第２工程における一体化の手法は、溶接に限られない。例えば、可動片４と端子片３とは、蝋付け、かしめ又はねじによって一体化されていてもよい。 The method of integration in the second process is not limited to welding. For example, the movable piece 4 and the terminal piece 3 may be integrated by brazing, caulking, or screwing.
　図７に示されるように、本ブレーカー１において、接続部３３、４２は、ケース１０に収容されている。接続部３３、４２は、端子３２の側に延出され、端子３２と共にケース１０の外側に突出するように構成されていてもよい。このような構成により、可動片４と端子片３とがより一層強固に一体化される。 As shown in FIG. 7, in the breaker 1, the connection portions 33 and 42 are housed in the case 10. The connecting portions 33 and 42 may be configured to extend toward the terminal 32 and project to the outside of the case 10 together with the terminal 32. With such a configuration, the movable piece 4 and the terminal piece 3 are more firmly integrated.
　図８は、本製造方法の第２工程で形成される複合片９の変形例である複合片９Ａを示している。複合片９Ａのうち、以下で説明されてない部分については、上述した複合片９の構成が採用されうる。 FIG. 8 shows a composite piece 9A which is a modified example of the composite piece 9 formed in the second step of the present manufacturing method. The above-described configuration of the composite piece 9 may be adopted for a portion of the composite piece 9A that is not described below.
　複合片９Ａでは、端子３２と接続部３３との間に、階段状に曲げられた段曲げ部３５を有する端子片３Ａが適用される点で、上記複合片９とは相違している。段曲げ部３５は、例えば、プレス加工等によって形成される。端子片３Ａに段曲げ部３５が形成された後、可動片４と端子片３Ａとが一体化される。可動片４と端子片３Ａとが一体化された後、端子片３Ａに段曲げ部３５が形成されてもよい。 The composite piece 9A is different from the composite piece 9 in that the terminal piece 3A having the step-bent portion 35 bent in a stepped manner is applied between the terminal 32 and the connection portion 33. The step bent portion 35 is formed by, for example, press working. After the step bending portion 35 is formed on the terminal piece 3A, the movable piece 4 and the terminal piece 3A are integrated. After the movable piece 4 and the terminal piece 3A are integrated, the step bending portion 35 may be formed on the terminal piece 3A.
　図９は、本製造方法の第２工程で形成される複合片９の別の変形例である複合片９Ｂを示している。複合片９Ｂのうち、以下で説明されてない部分については、上述した複合片９、９Ａの構成が採用されうる。 FIG. 9 shows a composite piece 9B which is another modification of the composite piece 9 formed in the second step of the present manufacturing method. The configuration of the composite pieces 9 and 9A described above can be adopted for the portion of the composite piece 9B that is not described below.
　複合片９Ｂでは、可動片４Ｂと接続される接続部３３が段曲げ部３５を超えて端子３２の側に延出されている点で、上記複合片９Ａとは異なっている。すなわち、段曲げ部３５は、接続部３３に形成されている。これに伴い、可動片４Ｂの接続部４２も端子３２の側に延出され、段曲げ部４５は、接続部４２に形成されている。 The composite piece 9B is different from the composite piece 9A in that the connecting portion 33 connected to the movable piece 4B extends beyond the step bending portion 35 toward the terminal 32. That is, the step bending portion 35 is formed in the connecting portion 33. Along with this, the connecting portion 42 of the movable piece 4B also extends toward the terminal 32, and the step bending portion 45 is formed in the connecting portion 42.
　段曲げ部３５、４５は、例えば、プレス加工等によって形成される。端子片３Ｂに段曲げ部３５が、可動片４Ｂに段曲げ部４５がそれぞれ形成された後、可動片４Ｂと端子片３Ｂとが一体化されるのが望ましい。可動片４Ｂと端子片３Ｂとが一体化された後、複合片９Ｂに段曲げ部３５、４５が形成されてもよい。 The step bent portions 35 and 45 are formed by, for example, press working. It is desirable that the movable piece 4B and the terminal piece 3B are integrated after the step bending portion 35 is formed on the terminal piece 3B and the step bending portion 45 is formed on the movable piece 4B. After the movable piece 4B and the terminal piece 3B are integrated, the step bending portions 35 and 45 may be formed on the composite piece 9B.
　可動片４Ｂの接続部４２は、ケース１０の端縁から突出する領域まで延出されるのが望ましい。これにより、可動片４Ｂと端子片３Ｂとがより一層強固に一体化される。段曲げ部３５、４５は、第３工程でケース本体７上に配置される形態の他、端子３２と共にケース本体７の外側に突出するように配置される形態であってもよい。 It is desirable that the connecting portion 42 of the movable piece 4B extends from the edge of the case 10 to a protruding region. As a result, the movable piece 4B and the terminal piece 3B are more firmly integrated. The step bending portions 35 and 45 may be arranged on the case main body 7 in the third step, or may be arranged so as to project to the outside of the case main body 7 together with the terminals 32.
　図１０は、本製造方法の第２工程で形成される複合片９のさらに別の変形例である複合片９Ｃを示している。複合片９Ｃのうち、以下で説明されてない部分については、上述した複合片９、９Ａ、９Ｂの構成が採用されうる。 FIG. 10 shows a composite piece 9C which is still another modification of the composite piece 9 formed in the second step of the present manufacturing method. The configuration of the composite pieces 9, 9A, and 9B described above may be adopted for the portion of the composite piece 9C that is not described below.
　複合片９Ｃでは、その厚さ方向で、可動片４Ｃが端子片３Ｃよりも熱応動素子５の側に位置している点で、上記複合片９等とは異なっている。すなわち、端子片３Ｃの接続部３３のＢ面と可動片４Ｃの接続部４２のＡ面とは、溶接等によって固着されている。これに伴い、接続部３３のＡ面は、蓋部材８と接触し、接続部４２のＢ面は、ケース本体７と接触している。 The composite piece 9C is different from the composite piece 9 and the like in that the movable piece 4C is located closer to the heat-responsive element 5 than the terminal piece 3C in the thickness direction. That is, the B surface of the connecting portion 33 of the terminal piece 3C and the A surface of the connecting portion 42 of the movable piece 4C are fixed by welding or the like. Along with this, the A surface of the connecting portion 33 is in contact with the lid member 8, and the B surface of the connecting portion 42 is in contact with the case body 7.
　複合片９Ｃは、第２工程において、可動片４Ｃ及び端子片３Ｃの配置を入れ替えて、両者を一体化することにより、形成される。上記複合片９Ｃが第３工程でケース本体７内に配置されることにより、ブレーカー１の内部で可動片４Ｃを低位置に搭載し、容易にブレーカー１の低背化を図ることが可能となる。 The composite piece 9C is formed by exchanging the arrangement of the movable piece 4C and the terminal piece 3C in the second step and integrating the two. By arranging the composite piece 9C in the case body 7 in the third step, the movable piece 4C can be mounted at a low position inside the breaker 1, and the breaker 1 can be easily lowered in height. ..
　図１１、１２は、本製造方法の第２工程で形成される複合片９のさらに別の変形例である複合片９Ｄ、９Ｅを示している。複合片９Ｄ、９Ｅのうち、以下で説明されてない部分については、上述した複合片９、９Ａの構成が採用されうる。 FIGS. 11 and 12 show composite pieces 9D and 9E, which are still another modification of the composite piece 9 formed in the second step of the present manufacturing method. Of the composite pieces 9D and 9E, the above-described configuration of the composite pieces 9 and 9A can be adopted for a portion not described below.
　複合片９Ｄでは、可動片４Ｄの接続部４２と弾性部４３との間には、可動片４ＤのＢ面が内側に位置するように曲げられた曲部４６が形成されている。これに伴い、接続部４２は、弾性部４３に対してケース本体７の側（図１１中、下方）に突出している。一方、端子片３Ｄの接続部３３と端子３２との間には、端子片３ＤのＢ面が内側に位置するように曲げられた曲部３６が形成されている。これに伴い、接続部３３は、端子３２からケース本体７の側に突出している。複合片９Ｄが組み込まれるケース本体７には、例えば、接続部４２及び接続部３３との干渉を回避するための凹部が形成される。 In the composite piece 9D, a curved portion 46 bent so that the B surface of the movable piece 4D is located inside is formed between the connecting portion 42 of the movable piece 4D and the elastic portion 43. Along with this, the connecting portion 42 projects toward the case body 7 (lower side in FIG. 11) with respect to the elastic portion 43. On the other hand, between the connection portion 33 of the terminal piece 3D and the terminal 32, a curved portion 36 bent so that the B surface of the terminal piece 3D is located inside is formed. Along with this, the connection portion 33 projects from the terminal 32 toward the case body 7. The case body 7 into which the composite piece 9D is incorporated is formed with, for example, a recess for avoiding interference with the connecting portion 42 and the connecting portion 33.
　接続部４２と接続部３３とは、互いに向かい合う面（すなわち、両者の折り曲げ後のＡ面）で接続されている。可動片４Ｄ及び端子片３Ｄの折り曲げは、上記第２工程の前に実施される。そして、第２工程では、弾性部４３のＡ面と端子３２のＡ面の高さを揃えて、可動片４Ｄと端子片３Ｄとが一体化される。これにより、平面視での可動片４Ｄと端子片３Ｄとの重複が回避されるので、ブレーカー１の内部で可動片４Ｄを低位置に搭載し、容易にブレーカー１の低背化を図ることが可能となる。 The connecting portion 42 and the connecting portion 33 are connected by facing each other (that is, the A surface after both are bent). Bending of the movable piece 4D and the terminal piece 3D is performed before the second step. Then, in the second step, the heights of the A surface of the elastic portion 43 and the A surface of the terminal 32 are made uniform, and the movable piece 4D and the terminal piece 3D are integrated. As a result, the overlapping of the movable piece 4D and the terminal piece 3D in a plan view is avoided, so that the movable piece 4D can be mounted at a low position inside the breaker 1 to easily reduce the height of the breaker 1. It will be possible.
　複合片９Ｅでは、可動片４Ｅの接続部４２と弾性部４３との間には、可動片４ＥのＡ面が内側に位置するように曲げられた曲部４６が形成されている。これに伴い、接続部４２は、弾性部４３に対して蓋部材８の側（図１２中、上方）に突出している。一方、端子片３Ｅの接続部３３と端子３２との間には、端子片３ＥのＡ面が内側に位置するように曲げられた曲部３６が形成されている。これに伴い、接続部３３は、端子３２から蓋部材８の側に突出している。複合片９Ｅが用いられる蓋部材８には、例えば、接続部４２及び接続部３３との干渉を回避するための凹部が形成される。 In the composite piece 9E, a curved portion 46 bent so that the A surface of the movable piece 4E is located inside is formed between the connecting portion 42 of the movable piece 4E and the elastic portion 43. Along with this, the connecting portion 42 projects toward the lid member 8 (upward in FIG. 12) with respect to the elastic portion 43. On the other hand, between the connection portion 33 of the terminal piece 3E and the terminal 32, a curved portion 36 bent so that the A surface of the terminal piece 3E is located inside is formed. Along with this, the connecting portion 33 projects from the terminal 32 toward the lid member 8. The lid member 8 in which the composite piece 9E is used is formed with, for example, a recess for avoiding interference with the connecting portion 42 and the connecting portion 33.
　接続部４２と接続部３３とは、互いに向かい合う面（すなわち、両者の折り曲げ後のＢ面）で接続されている。可動片４Ｅ及び端子片３Ｅの折り曲げは、上記第２工程の前に実施される。そして、第２工程では、弾性部４３のＡ面と端子３２のＡ面の高さを揃えて、可動片４Ｅと端子片３Ｅとが一体化される。これにより、平面視での可動片４Ｅと端子片３Ｅとの重複が回避されるので、ブレーカー１の内部で可動片４Ｅを低位置に搭載し、容易にブレーカー１の低背化を図ることが可能となる。 The connecting portion 42 and the connecting portion 33 are connected by facing each other (that is, the B surface after both are bent). Bending of the movable piece 4E and the terminal piece 3E is performed before the second step. Then, in the second step, the movable piece 4E and the terminal piece 3E are integrated by aligning the heights of the A surface of the elastic portion 43 and the A surface of the terminal 32. As a result, the overlapping of the movable piece 4E and the terminal piece 3E in a plan view is avoided, so that the movable piece 4E can be mounted at a low position inside the breaker 1 to easily reduce the height of the breaker 1. It will be possible.
　以上、本発明のブレーカー１の製造方法が詳細に説明されたが、本発明は上記の具体的な実施形態に限定されることなく種々の態様に変更して実施される。すなわち、本発明は、少なくとも、固定接点２１と、弾性部４３及び弾性部４３の一端部に可動接点４１を有し、可動接点４１を固定接点２１に押圧して接触させる可動片４と、可動片４と接続される端子片３と、温度変化に伴って変形することにより、可動片４の状態を可動接点４１が固定接点２１に接触する導通状態から可動接点４１が固定接点２１から離隔する遮断状態に移行させる熱応動素子５と、固定接点２１、可動片４、端子片３及び熱応動素子５を収容するための開口７３ａ、７３ｂ、７３ｃ、７３ｄを有するケース本体７と、開口７３ａ、７３ｂ、７３ｃ、７３ｄを閉鎖するためにケース本体７に装着される蓋部材８とを備えたブレーカー１の製造方法であって、固定接点２１、及び熱応動素子５をケース本体７内に配置する第１工程と、可動片４と端子片３とを一体化して複合片９を形成する第２工程と、複合片９をケース本体７内に配置する第３工程と、ケース本体７と蓋部材８とによって、複合片９を挟み込んで固定する第４工程とを含んでいればよい。 Although the method for producing the breaker 1 of the present invention has been described in detail above, the present invention is not limited to the above specific embodiment, but is modified to various embodiments. That is, the present invention is movable with at least a fixed contact 21, a movable piece 4 having a movable contact 41 at one end of the elastic portion 43 and the elastic portion 43, and pressing the movable contact 41 against the fixed contact 21 to bring them into contact with each other. By deforming the terminal piece 3 connected to the piece 4 with a change in temperature, the movable contact 41 is separated from the fixed contact 21 from the conductive state in which the movable contact 41 contacts the fixed contact 21. A case body 7 having openings 73a, 73b, 73c, 73d for accommodating a heat-responsive element 5 that shifts to a cutoff state, a fixed contact 21, a movable piece 4, a terminal piece 3, and a heat-responsive element 5, and an opening 73a, A method of manufacturing a breaker 1 including a lid member 8 attached to a case body 7 to close 73b, 73c, 73d, in which a fixed contact 21 and a heat-responsive element 5 are arranged in the case body 7. The first step, the second step of integrating the movable piece 4 and the terminal piece 3 to form the composite piece 9, the third step of arranging the composite piece 9 in the case main body 7, the case main body 7 and the lid member. It suffices to include a fourth step of sandwiching and fixing the composite piece 9 by the method 8.
　例えば、本発明の製造方法は、ＰＴＣサーミスター６が省かれた形態のブレーカーにも適用可能である。この場合、図４に示される第１工程において、ＰＴＣサーミスター６の配置は省略される。また、本発明の製造方法は、可動片４と熱応動素子５とが一体的に形成された形態（例えば、バイメタルにより可動片４が構成された形態）のブレーカーにも適用可能である。この場合、図４に示される第１工程において、熱応動素子５の配置は省略される。 For example, the manufacturing method of the present invention can be applied to a breaker in which the PTC thermistor 6 is omitted. In this case, the arrangement of the PTC thermistor 6 is omitted in the first step shown in FIG. The manufacturing method of the present invention can also be applied to a breaker in which the movable piece 4 and the heat-responsive element 5 are integrally formed (for example, the movable piece 4 is formed of bimetal). In this case, in the first step shown in FIG. 4, the arrangement of the heat-responsive element 5 is omitted.
１　　　ブレーカー
３　　　端子片
４　　　可動片
５　　　熱応動素子
７　　　ケース本体（第１ケース）
８　　　蓋部材（第２ケース）
９　　　複合片
１０　　ケース
２１　　固定接点
３３　　接続部
４１　　可動接点
７３ａ　開口
７３ｂ　開口
７３ｃ　開口
７３ｄ　開口 1 Breaker 3 Terminal piece 4 Movable piece 5 Heat-responsive element 7 Case body (first case)
8 Lid member (second case)
9 Composite piece 10 Case 21 Fixed contact 33 Connection 41 Movable contact 73a Opening 73b Opening 73c Opening 73d Opening

Claims (7)

  1. 　固定接点と、弾性部及び前記弾性部の一端部に可動接点を有し、前記可動接点を前記固定接点に押圧して接触させる可動片と、前記可動片と接続される端子片と、温度変化に伴って変形することにより、前記可動片の状態を前記可動接点が前記固定接点に接触する導通状態から前記可動接点が前記固定接点から離隔する遮断状態に移行させる熱応動素子と、前記固定接点、前記可動片、前記端子片及び前記熱応動素子を収容するための開口を有する第１ケースと、前記開口を閉鎖するために前記第１ケースに装着される第２ケースとを備えたブレーカーの製造方法であって、
    　前記固定接点、及び前記熱応動素子を前記第１ケース内に配置する第１工程と、
    　前記可動片と前記端子片とを一体化して複合片を形成する第２工程と、
    　前記複合片を前記第１ケース内に配置する第３工程と、
    　前記第１ケースと前記第２ケースとによって、前記複合片を挟み込んで固定する第４工程とを含む、
    　ブレーカーの製造方法。     A temperature change between a fixed contact, a movable piece having a movable contact at an elastic portion and one end of the elastic portion, and pressing the movable contact against the fixed contact to bring the movable contact into contact, and a terminal piece connected to the movable piece. A heat-responsive element that shifts the state of the movable piece from a conductive state in which the movable contact contacts the fixed contact to a blocking state in which the movable contact separates from the fixed contact, and the fixed contact. A breaker comprising a first case having an opening for accommodating the movable piece, the terminal piece, and the heat-responsive element, and a second case attached to the first case to close the opening. It ’s a manufacturing method,
    The first step of arranging the fixed contact and the heat-responsive element in the first case, and
    The second step of integrating the movable piece and the terminal piece to form a composite piece,
    A third step of arranging the composite piece in the first case, and
    The first case and the second case include a fourth step of sandwiching and fixing the composite piece.
    How to make a breaker.
  2. 　前記可動片と前記端子片とは、互いに別の材料からなる、請求項１記載のブレーカーの製造方法。 The method for manufacturing a breaker according to claim 1, wherein the movable piece and the terminal piece are made of different materials from each other.
  3. 　前記可動片と前記端子片とは、互いに厚さが異なる、請求項１又は２に記載のブレーカーの製造方法。 The method for manufacturing a breaker according to claim 1 or 2, wherein the movable piece and the terminal piece have different thicknesses from each other.
  4. 　前記第２工程において、前記可動片と前記端子片とは、レーザー溶接、抵抗溶接又は超音波溶接によって一体化される、請求項１ないし３のいずれかに記載のブレーカーの製造方法。 The method for manufacturing a breaker according to any one of claims 1 to 3, wherein in the second step, the movable piece and the terminal piece are integrated by laser welding, resistance welding or ultrasonic welding.
  5. 　前記第２工程において、前記可動片と前記端子片とは、複数箇所にて溶接される、請求項１記載のブレーカーの製造方法。 The method for manufacturing a breaker according to claim 1, wherein in the second step, the movable piece and the terminal piece are welded at a plurality of places.
  6. 　前記第２工程において、前記可動片と前記端子片とは、蝋付け、かしめ又はねじによって一体化される、請求項１ないし３のいずれかに記載のブレーカーの製造方法。 The method for manufacturing a breaker according to any one of claims 1 to 3, wherein in the second step, the movable piece and the terminal piece are integrated by brazing, caulking, or screwing.
  7. 　前記第３工程で、前記複合片の厚さ方向で、前記可動片が前記端子片よりも前記熱応動素子の側に位置するように、前記第２工程において、前記可動片と前記端子片とが一体化される、請求項１ないし６のいずれかに記載のブレーカーの製造方法。 In the second step, the movable piece and the terminal piece are arranged so that the movable piece is located closer to the heat-responsive element than the terminal piece in the thickness direction of the composite piece in the third step. The method for manufacturing a breaker according to any one of claims 1 to 6, wherein the breaker is integrated.
PCT/JP2020/008924 2019-03-13 2020-03-03 Method for manufacturing breaker WO2020184298A1 (en)

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WO2022091434A1 (en) * 2020-10-29 2022-05-05 大塚テクノ株式会社 Non-conductive type breaker
JP6916498B1 (en) * 2020-10-29 2021-08-11 大塚テクノ株式会社 Non-energized type breaker
CN115295970A (en) * 2022-10-09 2022-11-04 宁德新能源科技有限公司 Electrochemical device and electric equipment

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