Method of making a switch

Details Method of making a switch Method of making a switch

1975-11-17

1978-09-12

Hall, Carl E.

Metal working

Method of mechanical manufacture

Electrical device making

29622, 29630B, 264264, 264272, 264276, 264277, H01H 1106

Patent

active

041125762

ABSTRACT:
A solenoid and electric terminal heads are embedded in plastic by injection molding. Die faces accurately position and orient contact surfaces on the heads relative to the solenoid and contacts on the solenoid plunger, eliminating subsequent machining. The solenoid windings and lead wires are encapsulated by plastic injected in the molding process through openings in the coil casing. Portions of the lead wires outside of the casing and contact posts connected thereto are also embedded in the plastic. Injection molded walls guide axial movement of a rectangular contact member with the plunger and prevent its rotation out of alignment with the terminal heads. A fibrous washer compresses axially under the die force to compensate for cumulative axial tolerances of the solenoid and terminal heads for accurately positioning the bottom of the plunger opening relative to the contact surfaces on the terminal heads. Engagement of the plastic with the terminals and contact posts provides moisture-proof seals which cooperate with a plastic cap welded to the molded plastic to provide a moisture-proof housing.

REFERENCES:
patent: 3210453 (1965-10-01), Smith
patent: 3263306 (1966-08-01), Chapin et al.
patent: 3361997 (1968-01-01), Freeman, Jr.
patent: 3387076 (1968-06-01), Murooka
patent: 3798763 (1974-03-01), Deltoer
patent: 3978439 (1976-08-01), Thomson

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