GB2149213A - Electrical switch - Google Patents

Abstract

Contacts 6,7,8 are partially embedded in a contact holding member 2 of electrically insulating material. The switch is manufactured by stamping a blank (Fig. 3) defining non-overlapping contacts lying in a single plane. The contact holding member 2 is then formed by injection in a mould assembled about the blank. The contacts 6,7,8 are subsequently cut from the remainder of the blank and bent to form the required contacting areas 6a,7a,8a. <IMAGE>

Description

SPECIFICATION Switch structure comprising embedded contacts This invention relates to a switch structure comprising a plurality of contacts or contact segments (hereinafter called "contacts" embedded into a contact holding member to be held therein, and performing a certain switching function on the putting of a plug in and out, individually or in combination with a jack or the like.

In a known switch structure, it is conventional that each contact is held in a contact holding member in such a manner as to be engagedly fixed to one or more grooves formed in said contact holding member which is of electrical insulating material, taking advantage of resiliency of the material.

Accordingly, it is difficult to carry out formation of each contact, formation of the contact holding member and incorporation of each contact into the contact holding member continuously on the same production line, and it seems almost impossible to realize the automation in manufacturing the contact holding member while holding the plurality of contacts therein. For that reason, it is general to effect manually the incorporation of each contact into the contact holding member. And in such manual incorporation, there inevitably arise such problems as irregularity in accuracy depending upon the experience or skill of the worker, tarnish on the plated surface of the contact due to stain applied thereto when handling the contact, imperfect contact or the like.

Furthermore, since the contacts are simply engaged with the contact holding member in the case of the prior art, there is a possibility of producing unexpected play or looseness in the contacts caused by error in the manufacturing or assembling process or by a long period of use, resulting in loss of quality of the product.

A believed possibility of this invention is to provide a switch structure in which a step of punching contacts as well as a step of incorporating the contacts into the contact holding member, i.e a process of molding the contact holding member while the contacts are inserted therein can be continuously carried out on the same production line, automation in manufacturing the switch structure thereby being feasible.

Another believed possibility of this invention is to provide a switch structure in which a manual process of manufacture is eliminated by the automation thereof, the switch structure being efficiently obtained thereby at reasonable cost.

A further believed possibility of this invention is to provide a switch structure in which each contact can be securely held in the contact holding member, and the accuracy thereof is higher in association with the feature of eliminating such problem as stain incidental to the manual process by introducing an automatic manufacturing method thereof.

A still further believed possibility of this invention is to provide a switch structure in which the necessary quantity of such costly plating material as silver required for securing high electro-conductivity of each contact is reduced to as iittle as possible with a view to cost saving.

A yet further believed possibility of this invention is to provide a switch structure in which the formation or manufacture of a jack into which the switch structure is incorporated are also easy and simplified.

According to one aspect of the invention there is provided a (claim 1 after "1.A ").

According to another aspect of the invention there is provided a (claim 1 4 after "1 4A ").

The invention will be described by way of examples with reference to the accompanying drawings, in which like parts are designated like reference numerals throughout the same, and in which: Fig. 1 is a longitudinal sectional view of a jack in which a plug is inserted illustrating a first embodiment; Fig. 2 is a longitudinal sectional view of a switch structure; Fig. 3 is a plan view of a contact group or collection plate; Fig. 4 is a transversal sectional view of a switch structure illustrating each contact in the developed state; Fig. 5 is a longitudinal sectional view of a jack in which a plug is inserted illustrating a second embodiment; Fig. 6 is a longitudinal section view of a switch structure; Fig. 7 is a longitudinal section view of a switch structure illustrating a third embodiment; Fig. 8 is an exploded perspective view of a jack illustrating a fourth embodiment;; Fig. 9 is a perspective view of a switch structure in the state before assembling; Fig. 10 is a transversal sectional view of a switch structure in which a contact group or collection plate is recessed; Fig. 11 is a perspective view of a jack illustrating a fifth embodiment; Fig. 1 2 is a perspective view of a jack in the state before assembling; Fig. 1 3 is a perspective view of a part taking a look from different angle from that of Fig. 12; Fig. 1 4 is a perspective view of a jack illustrating a sixth embodiment; Fig. 1 5 is a longitudinal sectional view of a connector illustrating a seventh embodiment; Fig. 1 6 is a transversal sectional view of a switch structure in which a contact group collection plate is recessed;; Fig. 1 7 is a partially cutaway view of a switch structure illustrating each contact in the developed state; Fig. 18 is a longitudinal sectional view of a switch structure in the same state as Fig. 17; Fig. 1 9 is a perspective view of a switch structure illustrating an eighth embodiment; Fig. 20 is a longitudinal sectional view of a switch structure; Fig. 21 is a plan view of a contact group or collection plate; Fig. 22 is a transversal sectional view of a switch structure illustrating each contact in the developed state; and Fig. 23 is a longitudinal sectional view of a switch structure in the same state as Fig. 22.

Referring now to the accompanying drawings, a first embodiment in accordance with this invention is illustrated in Figs. 1 to 4.

This embodiment comprises a switch structure incorporated in a jack.

The jack of Fig. 1 comprises a box-shaped jack body 1 with its upper side open, and a switch structure 2 engagediy fixed to the upper opening of the body 1. The switch structure 2 comprises two pairs of stationary contacts 4, 5 and movable contacts 6, 7 of which a contacting and separating operation (or connection and disconnection) is effected by putting of a plug 10 in and out, a movable contact 8 performing a contacting and separating operation directly with respect to the plug 10 upon putting the same in and out, and a contact holding member 3 in the form of a rectanguiar plate in which said contacts 4 to 8 are embedded to be held therein. Said jack body 1 and the contact holding member 3 are molded of electrical insulating resin material.A plug insertion sleeve cylinder 1a (or plug receiving sleeve or cylinder) is provided on the front wall of the jack body 1.

Said switch structure 2 is integrally formed by a below-described process while the first and second stationary contacts 4, 5 as well as the first, second and third movable contact 6, 7, 8 are inserted in the contact holding member 3.

In the first step, as illustrating in Fig. 3, a metal plate is punched to obtain a contact group or collection plate 9 in which said the contacts 4 to 8 are collectively placed, connected to each other and not overlapping each other, in the same plane. In this step, it is preferred that as the case may be, relatively slight bending or projecting parts are formed before hand to the extent not affecting the flatness or planeness of the contact group or collection plate 9. In the case of this first embodiment, such projecting parts or projections are formed on the ends of contact areas 6a, 7a of the first and second movable contacts 6, 7.

Then, in order to secure satisfactory electroconductivity of each contact 4 to 8, a highly electro-conductive film is formed on both sides of the contact group or collection plate 9. Namely, such electro-conductive material as silver is plated on both sides of the collection plate 9. Such plating, however, is not necessary when using plated material or clad material as said plate.

The contact holding member 3 is formed by injection molding in a cavity between a male mold and a corresponding female mold (not illustrated). In this step, the contact collection plate 9 is horizontally held while any parts to be embedded are placed in said cavity, said parts to be embedded including communicating portions 4c to 8c between contact areas 4a to 8a and terminals 4b to 8b of contacts 4 to 8 including portions 9a (to be cut off later) connecting ends of contact areas of the first contacts 4, 6 and ends of contact areas of the second contacts 5, 7.

In the next step, each unnecessary portion 9b (indicated by hatching portion in Fig. 3) of the contact group or collection plate 9 is removed, and portions 9c connecting other ends of contact areas of the first contacts 4, 6 and other ends of contact areas of the second contacts 5, 7 as well as said portions 9a are cut off respectively. Thus the contact holding member 3 is obtained while each contact 4 to 8 being embedded and held in the separate state (see Fig. 4). In this respect, as said portions 9a to be cut off are now embedded in the resin layer, cutting them off is conducted using vertical through-holes 3a, 3b provided in the resin above and below the portions 9a for introduction of a punching tool.

Then, parts not to be embedded of contacts 4 to 8 are bent to form contact areas for a jack circuit. Namely, each contact area 6a, 7a, 8a of each movable contact 6, 7, 8 is bent downward forming a (-shape, and contact areas 4a, 5a of stationary contacts 4, 5 are bent under the corresponding contact areas 6a, 7a of movable contacts 6, 7. Then the flexing portions of movable contacts 6, 7, 8 are projected or extended downward from the under-side of the contact holding plate 3 to a certain extent, and contact areas 6a, 7a of movable contacts 6, 7 are resiliently brought into contact witht he contact areas 4a, 5a of the respective contacts 4, 5.

Further, terminal portions 4b to 8b of contacts 4 to 8 are bent to depend or hang downward from the left and right sides of the contact holding member 3 respectively.

In this manner, the switch structure 2 in which each contact 4 to 8 is embedded in the contact holding member 3 to be held therein is satisfactorily obtained or manufactured as illustrated in Fig. 2.

The switch structure 2 thus obtained is engagedly fixed to the upper opening of the body 1 while the areas to be in contact with the plug 10, i.e the bent portions of each contact area 6a, 7a, 8a are made to project inside the plug insertion passage by engagement of the contact holding member 3 with engaging parts 1 b, 1 c formed on the upper part of the body 1 and by engagement of the embedded parts 4e to 8e formed on the terminals 4b to 8b of the respective contacts 4 to 8 with each engaging parts (not illustrated) formed on the left and right sides of the body 1, respectively. In this respect, each contact area 4a, 5a of the respective stationary contact 4, 5 is supported on the supporting parts id, 1 e formed on the body 1.

In the jack constructed as above-descrived, when the plug 10 is inserted therein through the plug insertion sleeve or cylinder 1 a, each contact area 6a, 7a, 8a of the first, second and third movable contacts 6, 7, 8 comes in contact with a tip 1 Oa, a ring 1 Ob and an earth device 1 Oc respectively so that each contact area 6a, 7a of the first and second contacts 6, 7 is separated upward from each corresponding contact area 4a, 5a of the first and second stationary contacts 4, 5 (see Fig.

1).

By employing the foregoing construction, the step of obtaining the contact collection plate 9 from a metal plate, the step of injectionally molding the contact holding member 3 while the contact collection plate 9 is inserted therein, and the step of obtaining each contact 4 to 8 separated from the contact collection plate 9 and bent to be a required shape can be continuously carried out on the same production line; thus the automation in manufacturing the switch structure 2 with each contact 4 to 8 embedded into the contact holding member 3 is feasible with ease.

Consequently, the manual work required in the known art is no more necessary and the manufacture of the switch structure, or eventually the manufacture of the whole jack can be efficiently carried out contributing much to the provision of the jack at reasonable cost.

Besides there is no problem incidental to the manual work as mentioned above.

Further, since each contact 4 to 8 is embedded in the contact holding member 3 to be held therein, each contact 4 to 8 is more securely held than the known art where each contact is simply fixed engagedly, and there is no such problem as producing unexpected play or loose in the contacts 4 to 8.

Also, by bending each contact 4 to 8 after being recessed in the contact holding member 3 as above-described, the accuracy in relative position of each contact 4 to 8 can be greatly improved.

Furthermore, it is not necessary to provide such portions with which each contact is to be engaged as is required in the known art, in other words, it becomes unnecessary to provide a rather thick resin layer for securing the engaging parts resulting in the realization of a small-sized and thin jack.

Moreover, the switch structure 2, particularly the contact holding member 3 serves as an upper wall of the jack body, the number of necessary components thereby being decreased.

Since each terminal 4b to 8b of each contact 4 to 8 is made to depend or hang down from the contact holding member 3 mounted on the upper side of the body 1, there also arises such advantage as sufficiently securing a spacing for avoiding the intrusion entrance or invasion of flux.

The manner of forming the switch structure 2 is not limited to said first embodiment. For example, the switch structure 2 can be formed in such manner as described in the following second to eighth embodiments.

In the second embodiment illustrated in Fig.

5 and Fig. 6, the contact areas 4a, 5a of stationary contacts 4, 5 are bent downward froming-shape, although such other features as formation of the contact group or collection plate 9 are the same as the preceding first embodiment.

By employing such construction, the contact surfaces between contact areas 4a, 5a of stationary contacts 4, 5 and the respective areas 6a, 7a of movable contacts 6, 7, as well as the contact surfaces between movable contacts 6, 7, 8 and the plug 10 are located on one and the same side, that is, the underside of the contact group or collection plate 9 illustrated in Fig. 3, and it is not necessary to provide said electro-conductive film on both sides of the contact collection plate 9 for securing good electro-conductivity, as is required in the case of the first embodiment.

Thus only plating one side of the collection plate 9 (or metal plate) is sufficient for securing the electro-conductivity, whereby the required quantity of such costly material as silver is reduced or decreased, resulting in considerable cost saving.

Although in the foregoing first and second embodiments, such unexpected trouble as dislocation downward of said each contact area 4a, 5a as a result of resilient contact with the corresponding contact areas 6a, 7a of the movable contacts 6, 7 is prevented by retaining or supporting contact areas 4a, 5a of the stationary contacts 4, 5 on the supporting parts id, 1e formed on the body 1, it is not always necessary to form such supporting parts id, 1 e particularly on the body 1. It is also possible to form the supporting parts (not illustrated), performing the same function as the parts id, le, on the contact holding member 3.

Further, in the third embodiment illustrated in Fig. 7, each contact area 4a, 5a of each stationary contact 4, 5 is bent downward, forming an L-shape, so as to be orthogonal to the contact area 6a, 7a of the respective movable contact 6, 7 (the second stationary contact is not illustrated). By employing such construction, the rigidity of the contact area 4a, 5a of each stationary contact 4, 5 can be greatly improved compared with the first and second embodiments, and said supporting parts 1 d, 1 e on the body 1 or the equivalent parts on the contact holding member 3 become not always necessary to be formed, the shape or configuration of the body 1 or the contact holding member 3 thereby being simplified.

Furthermore, in the fourth embodiment illustrated in Figs. 8 to 10, a contact holding member 1 3 of a switch structure 1 2 is formed into ]-shaped and comprises a first contact holding member 1 3a in which a first stationary contact 14 and a first movable contact 1 6 are embedded to be held therein, a second contact holding member 1 3b in which a second stationary contact 1 5 and a second movable contact 1 7 are embedded to be held therein, and a third contact holding member 1 3c connected with said two contact holding members 1 3a, 1 3b through connecting pieces 20, 20 and in which a third movable contact 18 is embedded to be held therein, said each contact holding member 1 3a, 1 3b, 1 3c being flat-faced.The switch structure 1 2 is incorporated into a box-shaped jack body 11 with its upper side open and equipped with a plug insertion sleeve or cylinder 11 a (plug receiving sleeve or cylinder) in such a manner that said first and second contact holding members 1 3a, 1 3b overlap or overlie each other and come in contact with the inner surfaces of side walls 1 1 b, 1 1c of the body 11. In this respect, said each connecting piece 20 is formed on a part of the contact. By employing such construction, since the side walls 11 b, 1 ic of the body 11 and the first and second contact holding members 1 3a, 1 3b overlap or overlie each other, the rigidity of the jack body 11 is much improved.The formation of the J-shaped contact holding member 1 3 is easily effected by bending each connecting piece 20 after molding the member 1 3 into a flat plate as illustrated in Fig. 9, whereby automation in manufacturing the switch structure 1 2 is also feasible in the same manner as each foregoing embodiment. Further, in this fourth embodiment a contact group or collection plate 1 9 is formed by punching to be such shape as illustrated in Fig. 10.After each contact holding member 1 3a, 1 3b, 1 3c has been formed by injection molding while a part or parts to be embedded of said contact group or collection plate 1 9 is placed in each cavity, every unnecessary portion 1 9b (hatching portion in Fig. 9) is removed, each portion 1 9a, 1 9c between the contacts is cut off, and each contact area 1 4a to 1 boa of each contact 14 to 18, as well as each terminal 14b to 1 bob, is bent to be formed into the required shape; thus the switch structure 12, of which the developed state is illustrated in Fig. 9, is obtained. In this case, although each connecting member 20 is formed of a part of each contact as above mentioned, it is also possible for the member 20 to be either a metallic piece or a resin film or coating separate from the contact as a matter of course.

In the foregoing fourth embodiment, the body 11 and the contact holding member 1 3 are manufactured separately. On the other hand, in the fifth embodiment illustrated in Figs. 11 to 13, the body and the contact holding member are integrally formed. More particularly, as illustrated in Fig. 1 2, the contact holding member 1 3 and a front wall member 21 are formed integrally by injection molding into a developed state together with each contact 14 to 18 already inserted/embedded therein, said front wall member 21, equipped with the plug insertion sleeve or cylinder 21 a, depending down from the front end of the third contact holding member 1 3c.

Then the first and second contact holding members 1 3a, 1 3b are turned downward through each connecting piece 20, and by engaging each pawl 1 3d formed on the second contact holding member 1 3a with each recessed portion 1 3e formed on the first contact holding member 1 3a, a switch structure 22 or a jack is obtained as illustrated in Fig.

11. The remaining formation is the same as the fourth embodiment. By employing such construction, not only the switch structure but also the whole jack including the switch structure can be easily manufactured by automation. In this respect, in each of the fourth and fifth embodiments, the first, second and third movable contacts 16, 17, 18 are brought into contact with the tip 1 0a, ring 1 Ob and earth device 1 Oc respectively.

In the foregoing fifth embodiment, it is also possible that the third contact holding member 1 3c and the front wall member 21 are separately made and then said holding member 1 3c and the front wall 21 are connected to each other through some connecting piece or other (not illustrated). By such formation, each member 13, 21 can be of suitable material satisfying the intended function or operation thereof. In view of preventing the plug 10 from abrasion due to its being put in and out repeatedly, the front wall can be made of an abrasion resisting material, whilst each contact holding member 1 3a, 1 3b 1 3c can be made of some heat resistig material.

In the case of the following sixth embodiment illustrated in Fig. 14, a front wall member 51 equipped with a plug insertion sleeve or cylinder 51a is integrally formed on the front end of the contact holding member 53 in which first, second and third movable contacts 56, 57, 58 are embedded to be held therein. Thus a switch structure 52 is constructed which is capable of performing as a jack itself. By employing such construction, the jack can be obtained in the finished state resulting in the provision of the jack at reason able cost. Concerning the formation of each contact 54 to 58 as well as the contact holding member 53 including the front wall member 51, the same method as the preceeding embodiments can be employed as a matter of course.

In each of the above-described first to sixth embodiments, the switch structure in accordance with this invention is incorporated in a jack or serves as a jack itself, but the switch structure is further applicable to a connector for use with a printed circuit board.

In the seventh embodiment illustrated in Figs. 1 5 to 18, a connector comprises a switch structure 32 having a contact holding member 33 of electrical insulating material in which several pairs of stationary contacts 34 and associated movable contacts 36 (each of which comes in contact with its associated contact 34 in the normal stated) are arranged in parallel to be embedded and held therein, and a connector body 31 of electrical insulating material having a printed circuit board insertion opening 31 a formed between or in association with said holding member 33.

Thus when inserting a printed circuit board 40 into the insertion opening 31 a, the contact area 36a of each movable contact 36 is separated (or disconnected) from the corresponding contact area 34a of the associated stationary contact 34, and said each contact area 36a is brought into electrical contact with a printed circuit portion 40a of the printed circuit board 40. Said contact holding member 33 is formed by injection molding of resin material in the same or similiar manner as each foregoing embodiment while each contact 34, 36 is inserted therein. More particularly, a metal plate is punched to be formed into a contact group or collection plate 39 of which the shape is illustrated in Fig. 16, and the contact holding member 33 is formed by injection molding while the part to be embedded of the contact group or collection plate 39 is placed in the cavity.Then the portions shown hatched in Fig. 16, i.e first portion 39a interconnecting the top ends of the contact areas 34a of the stationary contacts 34, second portion 39b interconnecting the bottom ends of the contact areas 36a of the movable contacts 36 and third portions 39c each interconnecting a respective pair of stationary contacts 34 and movable contacts 36, are cut off respectively to obtain separate pairs stationary contacts 34 and respective movable contacts 36 (Fig. 1 7 and Fig. 1 8), and the terminal 34b, 36b of each contact 34, 36 is bent as illustrated in Fig. 1 5. In this case, said portions 39c are each cut off using vertical through holes 33a, 33b provided in the resin on the upper and lower sides for introduction of a punching tool or tools.By employing such formation, advantages similar to the preceeding embodiments are performed in the aspect of manufacture and accuracy of the connector. Particularly, since the connec-tor usually has a large number of contacts.

such advantages are significant.

In the foregoing seventh embodiment, although the connector body 31 and the switch structure 32 are separately formed initially and assembled into one conector later, it is also possible to form said body 31 and the structure 32 initially connected together with each other in the developed state through a connecting piece formed of a part of the contact group or collection plate as in the case of the fourth or fifth embodiment, and then assembling them into a connector by bending said integrated body 31 and structure 32. In this case, each contact can be embedded not only in the contact holding member but also in the connector body 31, thus a printed circuit board having its pattern on both sides being applicable to the connector.It is further possible that by bending the contact area 34a of each stationary contact 34 under the contact holding member 33 inverting the state illustrated in Fig. 15, each movable contact 36 is brought into contact with each stationary contact 34 (or with the associated stationary contact 34) when inserting the printed circuit board 40.

Although the switch structure in accordance with this invention is applied to such other devices as connectors, jacks, etc. in each of the preceding first to seventh embodiments, it is further possible to form the switch structure 42 to be used as an individual switch itself, which is the eighth embodiment of this invention as illustrated in Figs 1 9 to 23.

The switch illustrated in Fig. 1 9 and Fig.

20 incorporates a switching mechanism comprising a movable contact 44 and first and second stationary contacts 45, 46 in a contact holding member 43, and by pressing down an operation member 47 of electrical insulating material fixed to said movable contact 44 the first contact area 44a of the movable contact 44 separates from the contact area 45a of the first stationary contact 45, and the second contact area 44b of the movable contact 44 comes into contact with the contact area 46a of the second stationary contact 46 so that change-over of the circuit is effected.

Said switch, i.e the switch structure 42 is manufactured in the same process as the foregoing embodiments.

In the first step a contact group or collection plate 49 is formed by punching a metal plate in such manner that the contacts 44, 45, 46 are all interconnected with one another as illustrated in Fig. 21.

Then, in the same manner as said second embodiment, an electro-conductive film is formed only on the upper face of said contact collection plate 49. This step is not necessary when using certain plated material or clad material.

The contact holding member 43 and the operation member 47 are then formed by injection molding of resin material while a certain part of the contact group or collection plate 49 is inserted in the mold. After that, every unnecessary portion 49a (hatched portions in Fig. 21) of the contact collection plate 49 as well as portions 49b interconnecting the ends of the movable contact 44 and the first stationary contact 45 are cut off or separated respectively. Thus there is obtained the contact holding member 43 in which a part of each separate contact 44, 45, 46 is embedded to be held therein, with the operation member 47 fixed to the position near the end of the movable contact 44 as illustrated in Fig. 22 and Fig. 23.

Further by bending the end of the movable contact 44 downward to be U-shaped the upper part and the lower part thereof form the first contact area 44a and the second contact area 44b respectively, and by bending the end of the first stationary contact 45 upward to be ]-shaped the upper end thereof forms the contact area 45a. Then by bending the end of the second stationary contact 46 downward to be S-shaped the lower end thereof forms the contact area 46a and by bending the movable contact 44 upward to be inclined the first contact area 44a thereof is resiliently brought into contact with the contact area 45a of the first stationary contact 45. Furthermore the terminals 44c, 45b, 46b of the respective contacts 44, 45, 46 are respectively bent to hang downward.In this manner, by bending the end portion of each contact 44, 45, 46 despite the fact that the electro-conductive film is formed only on one side of the contact collection plate 49, the electro-conductive film is coated over every contact face between the opposed two pairs of the contact areas 44a, 45a and 44b, 46a.

The switch structure thus obtained is suitably used as a switch for various kinds of electrical apparatus and appliances, and particularly a jack of simplified construction can be obtained by attaching the structure 42 to a plug receiving member 48 mounted on some cabinet of the appliance, as illustrated in Fig.

1 9. Thus the usefulness of the switch structure in accordance with this invention is extremely high. In this respect, by applying guide rails 43a, 43a formed on both sides of the contact holding member 43 into guide grooves 48a, 48a formed on both sides of the plug receiving member 48 and by engaging a projection 43b provided on each rail 43a with a hole 48b of the plug receiving member 48, the switch structure is engagedly secured into said receiving member 48 while the operation member 47 is projected inside the plug insertion passage 48c.

Concerning the number and location of each contact and such matter as whether the opposed movable contact and stationary contact are to be in contact with or separated from each other in the normal state, this invention is not restricted to the above-described illustrative embodiments and it is possible to arrange them at one's option as a matter of course, and all changes which come with the meaning and the rage of equivalency of the appended claims are therefore intended to be embraced therein.

Reference is directed to our co-pending application No. 8424550 (Serial No. 2 preference 230P48962 of even date herewith, entitled "Jack with Embedded Contacts".

Claims (16)

1. A switch structure wherein contacts are embedded to be held and comprising.

at least one metallic stationary contact, at least one metallic movable contact, and a contact holding member of electrical insulating material in which a part to be embedded of each contact is embedded to be held, a contact area being formed by bending a part not embedded of at least one of said contacts to face a contact area formed on a part not embedded of at least one of the other contacts for performing a relative contacting and separating operation, the contacts being arranged not to overlap or overlie one another when said each contact is developed on the same plane.

2. A switch structure as set forth in claim 1, wherein said each contact is formed by punching a metal plate into a developed state on the same plane while said each contact being held in said contact holding member.

3. A switch structure as set forth in claim 1, wherein each said contact is formed by cutting off at least one contact-interconnecting portion from a contact group or collection plate.

4. A switch structure as set forth in claim 3, wherein at least one opening to be used when cutting off the portion to be separated is formed at the position corresponding to the part embedded in the contact holding member of each portion to be separated by cutting off.

5. A switch structure as set forth in claim 4, wherein the part not embedded of each contact is bent to form the contact area in such manner that each face between said contact area and the corresponding contact area of the other contact facing the former contact area and performing the relative connecting and separating operation is located on the same side when developing each contact on the same plane.

6. A switch structure as set forth in claim 5, wherein said each contact is formed using a metal plate or the contact collection plate on one side of which an electo-conductive film is formed.

7. A switch structure as set forth in claim 1, wherein the contact area of at least one stationary contact is bent to be orthogonal to the contact area of the movable contact performing the contacting and separating operation with respect to the former contact area.

8. A switch structure as set forth in claim 1, wherein the contact area of said stationary contact is supported on a supporting member formed on said contact holding member.

9. A switch structure as set forth in claim 1, wherein said contact holding member is divided into a plurality of parts and each of said parts is connected through connecting piece possible to be bent.

10. A switch structure as set forth in claim 9, wherein said connecting piece is a part of the contact.

11. A method of making a switch structure as set forth in claim 1, wherein said each contact is formed by punching a metal plate into a developed state on the same plane while said each contact is held in said contact holding member.

1 2. A method as set forth in claim 11 wherein said each contact is formed by cutting off each portion to be separated from a contact collection plate connecting among each contact through said each portion to be cut off.

1 3. A method as set forth in claim 1 2 wherein at least one opening to be used when cutting off the portion to be separated is formed at the position corresponding to the part to be embedded in the contact holding member of each portion to be separated by cutting off.

1 4. A method of mounting a plurality of separate electrical contacts in a holder of insulating material, comprising the steps of providing the contacts integrally joined together in a member of electrically conductive material, molding the holder in a mold in which said member is inserted so that each contact is partly embedded in the holder and thereafter separating the contacts from each other.

1 5. A method as set forth in claim 14 wherein said member is of sheet or plate form with the contacts arranged at least initially so as not to overlap or overlie each other.

16. A method as set forth in claim 14 or 1 5 wherein the step of separating the contacts from each other includes removal of some of the electrically conductive material.

1 7. A method as set forth in claim 1 6 dependant from claim 1 5 wherein the removal is effected by a punch tool.

1 8. A method as set forth in claim 1 7 wherein holes are molded in the holder for the punch tool to remove the material.