JPH0247810B2 - KAKUGATADENKISETSUTENNOSEIHO - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a rectangular electrical contact, and is particularly suitable for mass production of a rectangular contact having a rectangular contact at the tip of a base whose width is equal to the width of the base.

The inventor is a developer of square pressure contacts. At the time of development, it was difficult to change from round contacts to square contacts due to conventional customs and standards. However, as the many characteristics of rectangular pressure contacts such as mounting strength, reliability, dimensional accuracy, high productivity with a continuous press machine, and cost reduction due to rational savings in silver were recognized, the conventional round pressure contacts At present, shaped contacts and welded contacts are becoming a thing of the past.

The above-mentioned square pressure contact was made by drilling a square hole in the base material, cutting a band-shaped contact material with the same width as one side of the square hole, or its cladding material into the square hole to the same size, fitting it, and caulking it ( Japanese Patent Publication No. 54-150678, No. 56
-50010).

According to the above invention, the base material must be one size larger than the contact point and must extend outward.

The purpose of this invention was to develop a method for manufacturing rectangular pressure contacts that does not require any base material protruding around the contact, which does not waste contact material (silver, etc.) and is the most efficient.

A possible method for manufacturing such a rectangular contact will be described first. There is a method shown in FIGS. 3 and 4 which applies the concept of conventional welded contacts. This is the first
Several protrusions P for projection welding are extruded at the contact mounting positions of the base material 2 of the electric contact shown in FIG. 2, and the rectangular contact 1' is welded onto these protrusions P.
However, the number of welded joints in welded contacts is one in tens of thousands, and the occurrence of defective welds is unavoidable, resulting in a lack of reliability.

The one in Figure 5 uses a ready-made clad material with contact material pasted to the entire length of the copper alloy base, and the excess contact material was removed so that it could be punched out in the shapes shown in Figures 1 and 2 using a press. It is something. The problem with this is that expensive contact materials are scraped away.

Now, to first describe the outline of this invention, the above width is equal to one side of the intended rectangular contact,
The leg strips of a cladding material are made of a copper or copper alloy strip having a short T-shaped cross section with leg strips protruding from the entire length of the center of the lower surface, and a thin plate of contact material covering the upper surface of the strip. A strip-shaped contact material is made by removing a certain length at the same pitch from the other side and turning it into pillars lined up at the same pitch.The strip for the contact base material is sent to a continuous press machine, and the above pillars are fitted one after another. The strip-shaped contact material is also sent to the same continuous press machine and divided by the pillars, each pillar is inserted into the square hole and caulked, and then each contact is punched from the base material strip. This is a method for manufacturing square electrical contacts characterized by separating the base material.

When making the electrical contacts shown in FIGS. 1 and 2, the strip plate 4 for the contact base material is sent to a continuous press machine, and the outer shape of the base material 2 and the mounting hole 3 are punched and formed one after another in the conventional manner. As shown in FIG. 6, the base material strip 4 moves between the left and right connecting bars 4a and 4b with the base material 2 connected at the interstices. Now, punch out a square hole 6 that is slightly smaller than the size of the square contact 1 as a caulking hole.

Then, in this example, a strip-shaped contact material 5 is fed into the base material strip 4 from a perpendicular direction as shown in FIG. This strip contact material 5 is shown in FIG.
By sequentially cutting this from the tip, a clad contact material 10 with crimping pillars 7 as shown in FIGS. 10 and 11 is obtained.

A slightly enlarged elevational view of the state in which the band-shaped contact material 5 shown in FIG. 6 is fed into the square hole 6 of the base material 2 is shown in FIG. 7. Although the shearing and pressing equipment has been omitted, this is the state immediately before the top clad contact material 10 is sheared and its pedestal 7 is pushed into the square hole 6 of the base material 2. FIG. 8 shows the appearance of the pedestal 7 inserted into the square hole 6 and the clad contact material 10 fixed to the base 2 by caulking. The leading clad contact material 10 of the strip contact material 5 in FIG. 6 may be sheared and caulked at the same time, but it may also be caulked after moving to the right side in FIG. 6 without being disturbed by the shearing blade. . Table material strip 4
Needless to say, they move one after another to the processing position on the right as shown by the arrows and undergo processing at each location.

Now, the purpose of this invention was to achieve its original purpose, that is, as a method of making electrical contacts in which the base material does not protrude around the contacts. It consists of both an idea of using the contact material 5 and a mass production method as shown in FIGS. 6 and 7, and a method of manufacturing the material 5 as shown in FIG. 9 in order to embody that idea. The method for manufacturing the latter strip-shaped contact material 5 will be described below.

The idea for the contact material 5 shown in FIG. 9 comes from the fact that a cladding material with a relatively free cross-sectional shape can be manufactured by drawing a die at a cladding material manufacturing factory.
Therefore, a cross-section like that shown in Figure 12, made of copper or copper alloy, with the upper width equal to one side of the intended square contact 1 and with leg strips 8 protruding from the entire length of the center of the lower surface to form a short T-shaped cross section, is used. It was decided to use a cladding material A consisting of a strip 9 and a thin contact material plate 9a covering the top surface of the strip 9. By removing the legs 8 by a certain length at the same pitch as the other side of the square contact 1, it can be changed to the legs 7 lined up at the same pitch.

Of course, the dimensions of the pillar 7 should be suitable for caulking into the square hole 6 of the base material. If the lower edge of the square hole is chamfered as shown in Figures 7 and 8, and the crushed end of the pillar 7 fills the chamfer when caulking, the lower edge of the base material 2 It can be finished so that it is smooth or slightly concave.

Although the removal method for converting the leg strips 8 into rows of pillars 7 is arbitrary, FIG. 13 shows an apparatus for removing the legs by press working. It uses a broaching punch 11 equal to the width to be deleted, 12 is a punch plate, 13 is a punch holder, 14 is a spacer, 15
1 is a back plate, 16 is a die holder, 17 is a die plate, 18 is a stripper, 19 is a support member having a guide groove for the cladding material A, 20 is a waste suction hole, 2
1 is a punch guide hole liner.

In this case, the broaching punch 11 has three blades that successively cut through the leg strips 8 of the cladding material A and remove them flatly.
Alternatively, three shaping punches may be arranged one after another at the pressing position and the leg strips 8 may be removed one after another. Of course, a cutting machine such as a milling cutter or a shaper may be used.

Although one embodiment has been described above, it goes without saying that the present invention can be modified and applied as appropriate depending on the implementation conditions. The shape of the rectangular contact is not limited to a square. You are free to add roundness to the surface.
The strip contact material 5 is not limited to the shape in which the clad contact materials 10 are arranged in one row, but may be arranged in two or three rows,
In accordance with this, the base material 2 may also be caulked two or three at a time. Further, the direction in which the strip contact material 5 is fed into the press machine may be in a direction other than that shown in FIG. 6, and the shape and orientation of the pillar 7 are not limited to those in the above embodiment.

This invention enables pressure welding using a continuous press machine even when the contact and the base material are of the same size, which was considered impossible with the conventional square pressure contact method in which the strip contact material is divided one after another and caulked to the base material. paved the way for applying the method. By simply thinning out the leg strips of the clad material into dice at a fixed pitch, we have installed a row of leg columns that have the same function as the material cut from the conventional band-shaped contact material. This made it possible to use a mass-produced caulking method.

This invention has a great effect in that electrical contacts in which the base material does not protrude beyond the contact point can be produced at high speed using a highly reliable pressure welding method.

[Brief explanation of drawings]

1 and 2 are a plan view and an elevation view of an example of a rectangular electrical contact made according to the present invention; FIGS. 3 and 4 are plan and cross-sectional explanatory views of a similar electrical contact made by welding; Fig. 5 is a punching and forming material made by cutting clad material, Fig. 6 is a plan view of the main part of an embodiment of this invention, Fig. 7 is an elevational view of the main part, and Fig. 8 is the finished electric wire. 9 is an elevational view of the contact, and FIG. 9 is a perspective view of the strip-shaped contact material used in this invention.
Figures 0 and 11 are elevational views and bottom views of the clad contact material separated from the above material, Figure 12 is a perspective view of the clad contact material before it is made into a strip-shaped contact material, and Figure 13 is the clad contact material separated from the material.
FIG. 3 is an explanatory diagram of a broaching punch for processing the clad material shown in the figure. 5... Strip contact material, 6... Caulking hole, 7...
pedestal.

Claims (1)

[Claims] 1. A short T with an upper width equal to one side of the intended rectangular contact and a leg protruding from the entire length of the center of the lower surface.
A clad material consisting of a copper or copper alloy strip with a shaped cross section and a thin plate of contact material covering the top surface of the strip.
A strip-shaped contact material is made by removing only the leg strips by a certain amount at the same pitch as the other sides of the square contact, turning them into leg columns lined up at the same pitch, and sending the strips for the contact base material one after another to a continuous press machine. Then, a caulking hole is punched out into which the pedestal fits, and the strip-shaped contact material is also sent to the same continuous press machine to be divided between the pedestals, and each pedestal is inserted into the crimped hole and caulked, and then, A method for manufacturing a rectangular electrical contact characterized by separating each contact base material from a base material strip.