Method of manufacturing a synthetic resin part integrally formed with metal members

• US 5,609,652 A
• Filed: 04/07/1995
• Issued: 03/11/1997
• Est. Priority Date: 04/13/1994
• Status: Expired due to Fees

• Current Assignee: Koito Manufacturing Company Limited
• Original Assignee: Koito Manufacturing Company Limited
• Inventors: Yoshida, Yoshihide, Yamada, Atsushi, Hagiwara, Masaki, Okuda, Tadayuki
• Primary Examiner(s): THURLOW, JEFFERY
• Application Number:
  US08/418,410
• Time in Patent Office: 704 Days
• Field of Search: 264/157, 264/104, 264/272.16, 264/272.11, 264/271.1, 264/328.8, 264/328.12, 29/827, 29/856, 29/883-4
• US Class Current: 29/882
• CPC Class Codes: B29C 45/14639 for obtaining an insulating effect, e.g. for electrical components
• CPC Class Codes: B29K 2995/0005 Conductive
• CPC Class Codes: B60Q 3/252 Sun visors
• CPC Class Codes: B60Q 3/74 for overall compartment lighting; for overall compartment lighting in combination with specific lighting, e.g. room lamps with reading lamps general lighting mounted on specific fittings B60Q3/20; general lighting for mass transit vehicles B60Q3/43
• CPC Class Codes: Y10T 29/49172 by molding of insulating material
• CPC Class Codes: Y10T 29/49218 with deforming
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/49787 Obtaining plural composite product pieces from preassembled workpieces
• CPC Class Codes: Y10T 29/4998 Combined manufacture including applying or shaping of fluent material

Abstract

Disclosed are a method of manufacturing a synthetic resin part integrally formed with metal members, including the steps of: integrally forming a plurality of metal member sets through coupling portions, each of the metal member sets including a plurality of coupled together metal members; inserting the metal member sets into the molding dies of a forming machine; injecting synthetic resin for molding into the molding die, and forming a synthetic resin part integrally formed with metal members in sequence to form a synthetic resin part continuum where a plurality of synthetic resin parts are connected; and cutting off the coupling portions to manufacture the plurality of synthetic resin parts, and a synthetic resin part manufactured according to the above-mentioned manufacturing method. With this manufacturing method, the assembling accuracy of the synthetic resin part to metal members is enhanced, there is no danger of unnecessary contact between metal members, and the time for assembling metal members is saved to contribute to cost reduction.

Claims

1. A method of manufacturing a synthetic resin part integrally formed with metal members, comprising the steps of:

integrally forming a plurality of flat metal member sets which are coupled together through coupling portions, each of the flat metal member sets comprising a plurality of metal members coupled together;

bending said plurality of coupled together metal members to form a set of coupled together contacts;

inserting said metal member sets after bending into molding dies of a forming machine;

injecting a synthetic resin for molding into said molding die, and forming a synthetic resin part integrally formed with each of the metal member sets in sequence to form an integral synthetic resin part where a plurality of synthetic resin parts are connected by said coupling portions; and

cutting off said coupling portions to manufacture said plurality of synthetic resin parts.

2. The method according to claim 1, wherein groove portions are formed in adjacent side surfaces of each of said synthetic resin parts, part of each of said coupling portions is positioned within a corresponding groove portion, and said part positioned within the groove portion is cut to cut off the synthetic resin part.

3. The method according to claim 1, wherein at least two of metal members which are to be in non-contact state are connected by a connection portion, and said connection portion of said at least two of metal members is also cut off when said coupling portions are cut off.

4. The method according to claim 2, wherein at least two of metal members which are to be in non-contact state are connected by a connection portion, and said connection portion of said at least two of metal members is also cut off when said coupling portions are cut off.

5. The method according to claim 1, wherein before said synthetic resin is injected into said molding dies, at least one kind of metal members is pressed against one of said molding dies through the other by a press pin.

6. The method according to claim 2, wherein before said synthetic resin is injected into said molding dies, at least one kind of metal members is pressed against one of said molding dies through the other by a press pin.

7. The method according to claim 3, wherein before said synthetic resin is injected into said molding dies, at least one kind of metal members is pressed against one of said molding dies through the other by a press pin.

8. The method according to claim 1, wherein said synthetic resin is ABS resin.

9. The method according to claim 1, wherein said metal members are formed of a metal material having conductivity and elasticity.