JP3062686B2 - Ground child and its forming method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for securing safety for a train operating on a fixed route such as a track.
For example, the present invention relates to a grounding element used for grounding equipment such as an automatic train stop device, and a forming method thereof.

[0002]

2. Description of the Related Art The grounding element is installed as ground equipment such as an in-car alarm device, an automatic train stop device (ATS), an automatic train control device (ATC), and an automatic train operation device (ATO). Therefore, there is a demand for a manufacturing method that facilitates production adjustment because the number of production units varies.

[0003] For these reasons, at the time of the development of the grounding element (at the time of 1965), molding was possible one by one, and a molding method advantageous in terms of cost was examined.
The combination of the ground coil and capacitor, which are the functional parts, is set in a mold or resin mold for the number of units to be produced, and the synthetic resin is placed in the mold or resin mold in which the ground child functional parts are set.
A method of producing an epoxy resin by potting (normal pressure) casting has been mainly used.

In the above method, after the resin is solidified,
By removing the molded body from the mold and the resin mold, it is possible to obtain a ground child in which the ground child functional component is molded in the outer shell of the resin. Conventionally, the molding method of the ground piece has been slightly improved after that (for example, Japanese Patent Publication No. Sho 60-4).
No. 6901, Japanese Patent Publication No. Sho 60-46902), and the production method has been basically improved over 25 years following the above method as it is.

[0005]

However, epoxy resins are toxic, and there is a concern that they may affect human bodies. Also, regarding the workability, if the epoxy resin is poured into the mold and resin mold at one time, the electrical characteristics of the functional parts on the ground will be degraded by the curing heat generated by the resin. However, molding required a long time.

[0006] In this method, although molding can be performed one by one, when a certain number is manufactured together,
For example, to manufacture 50 ground pieces, 50 molds (or resin molds) are prepared, these molds are arranged on a workbench, and resin is sequentially poured into each mold. In addition, molding must be performed while casting several times.

[0007] When the epoxy resin is cast into 50 molds in four separate steps, the time required for the casting operation is about 7 hours. Moreover, every time the resin is cast,
Since a synthetic resin layer is formed, it is necessary to molecularly bond the previous resin layer and the next resin layer, and when the synthetic resin is cast for forming the next layer, the previous resin is not adhered. There is a timing constraint that it must be before losing the properties, it is difficult to set the casting timing, and there is a risk that the product will vary, and the molding process is a work that requires skill. It has been.

An object of the present invention is to provide a grounding element capable of improving product quality, increasing production efficiency and reducing manufacturing costs, and a method of forming and processing the same.

[0009]

In order to achieve the above-mentioned object, a ground piece according to the present invention is a ground piece in which an outer shell and a ground piece functional part are integrated , and the outer shell has a shape of the ground piece. And a lid for covering the container. The ground functional element includes a ground coil and other electric components and is housed in the container. Is covered with the opening of the container that holds the container, and the outer shell is sealed by adhering to the container.The gap formed between the outer shell and the ground functional component is filled with the casting agent. The casting agent is silicone rubber.
And press-fit into the sealed outer shell containing the functional parts
And cured.

[0010] The container has an injection hole and an outlet hole.
The injection hole presses the casting agent into the container covered with the lid.
The outlet hole is used when the casting agent is pressed into the outer shell.
In a hole for degassing the air in the outer shell, casting agent in the shell
After press-fitting, the injection hole and outlet are sealed.
is there.

In the method of forming a ground piece according to the present invention, there is provided a method of forming a ground piece having an assembling process, a welding process, and an injection and solidification process.
Assemble the ground child functional parts including the ground child coil and other electric parts in the fixed container of the outer shell that imitates the shape of the ground child, electrically connect these, cover the container, and cover the ground child functional part The welding process is a process of welding the joint between the container and the lid, and the injection solidification process is to inject a casting agent into the outer shell, and hold the casting agent. It solidified fill the gap between the outer shell and the ground coil functional components, a shell, a process to integrate the balise functional parts, casting agent, silicone rubber
It is.

In the welding process, a vibration welding method is used.
This is a process of applying relative vibration to the outer shell container and the lid for covering the opening of the container, welding the lid to the container, and sealing the outer shell.

[0013]

The ground piece according to the present invention is formed by sequentially performing an assembling process, a welding process, and an injection solidification process, and the above-mentioned functional part housed in the outer shell is filled with a casting agent. A ground child in which the shell and the ground child functional parts are integrated can be obtained.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below with reference to the drawings. The present invention uses a synthetic resin outer shell 1 to sequentially perform an assembling process, a welding process, and an injection solidification process, thereby manufacturing a ground piece.

(1) Outer shell The outer shell 1 of the above-mentioned ground child is a combination of a fixed container 2 in the shape of a ground child as shown in FIG. 1 and a lid 3 for covering the opening of the container 2. is there. The container 2 is a synthetic resin molded body having a substantially rectangular planar shape, and has a coil housing portion 4 formed on the molded body and an electric component housing portion 5.

The coil housing portion 4 is a substantially rectangular groove having three rectangular sides of the outer shell 1 and one side formed across the outer shell 1, and a portion surrounded by the coil housing portion 4 is as follows. The pedestal 6 is provided. The electric component storage unit 5 includes the coil storage unit 4.
And a recess formed at one end in the longitudinal direction of the outer shell 1. The coil housing portion 4 and the electronic component housing portion 5 are separated from each other by a partition wall 7, and a cutout 8 is formed in a part of an upper edge of the partition wall 7.

The notch 8 forms a gap that allows the coil housing 4 and the electronic component housing 5 to communicate with each other when the outer shell 1 is covered. An injection hole 10 for casting agent is opened through the outer wall 9 of the groove of the coil housing portion 4 facing the outer surface on the short side of the outer shell 1 through the outer wall 9. A fitting seat 14 for seating the mounting fixture 13 is formed so as to protrude toward the pedestal 6, and ground mounting holes 15 are opened in the seating surface of the pedestal 6 and the plate surfaces on both sides of the electronic component storage unit 5. .

Further, in the recess of the electronic component storage section 5, a recess serving as a cable storage space 16 is further formed, and a connector mounting hole 17 is provided on an inner surface of the cable storage space 16, and a bottom surface thereof is provided. An outlet hole 18 for the casting agent is opened. The lid 3 is a plate-like body that is overlaid on the container 2 and closes the upper opening of the coil storage unit 4 and the electric component storage unit 5. A window 19 for exposing the pedestal 6 of the container 2 is opened on the plate surface of the lid 3.

For the outer shell 1, for example, a combination of a container 2 and a lid 3 obtained by directly molding a mixture of polypropylene and glass fiber by an injection molding method is used. With direct injection molding, dry blending of resin with reinforcing agents and fillers,
This is a molding method that integrates material mixing and molding processing in the process of molding as it is.

The material used for the outer shell is a well-balanced molding material having excellent mechanical strength by adding glass fiber based on the impact resistance of polypropylene. Moreover, since it is a thermoplastic resin, it can be recycled. Furthermore, it generally has excellent electrical properties (low dielectric constant) and excellent water resistance and oil resistance.

It is generally said that the weather resistance of polypropylene is not good, but with proper incorporation of stabilizers, the weather resistance is considerably improved and it can be used for more than 10 years. When the change in appearance exceeds the allowable limit, it has a feature that the life can be further extended by coating with a weather-resistant paint.

(2) Incorporation process In the incorporation process, the ground child functional component 20 is set in the container 2 of the outer shell 1, the components are electrically connected to each other, the container 2 is covered, and the ground child functional component 20 is attached. This is a process of storing the inside of the outer shell 1. In FIG. 1, a ground terminal functional component 20 is a printed board 22 on which an electric component 21 including a ground coil 12 and a capacitor, a resistor, a relay, and a resonance coil is mounted. The ground functional element 20 is attached to a cable 23, which is held by a cable connector 24 and pulled out of the container 2.

The ground coil 12 is formed by winding a covered electric wire 12a around a coil frame 12b.
Is provided with a fitting 13 projecting from the inner peripheral edge thereof, and the fitting 13 is seated on the fitting seat 14 of the container 2 to house the ground coil 12 in the coil housing portion 4, and the electric component 21 is provided. The mounted printed board 22 is housed in the electrical component housing 5.

Further, a cable connector 24 is fixed in the connector mounting hole 17, a cable 23 is inserted into the connector 24, and the ground coil 12 is connected to the printed boards 22 and 22 and the cable 23 is connected thereto. 14 seats
And the printed board 22 is mounted on the electrical component storage 5.
Then, an electric circuit shown in FIG. 2, for example, is configured, and at this stage, the electric characteristics of the grounded electric circuit are adjusted as adjustment processing. If the grounding circuit is properly adjusted,
Then, the lid 3 is placed on the container 2 to cover the coil storage section 4 and the electronic component storage section 5, and the pedestal 6 is exposed.

(3) Welding process The welding process is a process for welding the joint between the container 2 and the lid 3. In the welding treatment, a solvent and an adhesive can be used for bonding, but it is preferable to use a vibration welding method.
The vibration welding method is a method of applying pressure between two parts to be welded and simultaneously applying vibration to a welding surface to generate frictional heat necessary for the synthetic resin to melt.

Using such a vibration welding method, as shown in FIG. 4, the container 2 is held on a table 25, the lid 3 is set on a vibration head 26, and the container 2 is placed on the opening of the container 2. Vibration is applied to the surface to be welded to the lid 3, and the lid 3 is welded to the container 2 to seal the outer shell 1.

According to the vibration welding method, large components can be welded, and a strong adhesive strength can be obtained without using a solvent or an adhesive. In addition, an ultrasonic welding method can be used as the welding process. Ultrasonic welding is a method in which ultrasonic energy generated from a vibrator is applied to a synthetic resin to utilize heat generated at a boundary surface to weld both parts.

(4) Injection-solidification treatment In the injection-solidification treatment, a casting agent is injected into the outer shell 1 to fill a gap between the sealed outer shell 1 and the above-mentioned child functional component 20, and the casting agent is cured. This is a process of integrating the outer shell 1 and the above-mentioned functional child component 20 with the solidified casting agent. As the casting agent, a silicone rubber widely used as an excellent electric insulating potting agent is used. Silicone rubber is heat resistant,
Good cold resistance and water resistance, and excellent workability compared to epoxy resin. Table 1 shows the RTV silicone rubber,
The performance comparison of the electrical properties with the epoxy resin is shown.

[0030]

[Table 1] ◎: Excellent, ○: Good, △: Acceptable, ×: Not acceptable

The silicone rubber has the following characteristics. That is, (1) the dielectric constant and the dielectric loss tangent are good and the temperature dependence is small. (2) Deterioration hardly occurs in an environment of 60 ° C. or lower. (3) The water resistance is good, although the water resistance is good. (4) Adhesion to the outer shell is not possible due to lack of adhesiveness. (5) The compounding ratio is 1: 1, and the curing time is 60 ° C./90 minutes, or 24 hours at room temperature.
In addition, heat generation during curing is small.

At the time of the injection and solidification treatment, as shown in FIG. 5, the outer shell 1 is kept face down with the lid 3 on the lower side and the container 2 on the upper side, and the casting agent injection hole 10 and the outlet hole. A plug P is attached to the outlet 18, a vacuum pump 27 is connected to the outlet hole 18, and while the inside of the outer shell 1 is evacuated, the casting agent 29 is passed through the injection hole 10 from the hose 28 into the outer shell 1. Press in at high pressure.

The casting agent press-fitted into the outer shell 1 fills the gap between the outer shell 1 and the above-described functional child component 20 and cures. However, when the above silicone rubber is used for the casting agent,
Since the silicone rubber does not have an adhesive property, it cannot be bonded to the outer shell 1 and the above-mentioned ground functional element 20. However, by closing the plug P and closing the injection hole 10 and the outlet hole 18, moisture in the outer shell 1 can be reduced. Can be prevented from entering.

The outlet shell 18 is filled in the outer shell 1 while evacuating the outlet hole 18 opened at the bottom of the storage space of the cable 23 in an upward posture and overflowing the casting agent from the outlet hole 18. Therefore, it is difficult to form a cavity in the vicinity of the exit hole 18. Even if a cavity is formed in the vicinity of the exit hole 18, the cavity is located in the cable storage space 16, and the exit hole 18 is located at the bottom when the ground wire is installed. And cable storage space 16
Is located at the lowest position of the bottom of the ground piece at the time of installation, so there is no risk of intrusion of rainwater or the like. However, the injection hole 10 and the outlet hole 18 can be sealed to prevent rainwater from entering.

By sequentially performing the above series of processing,
As shown in FIG. 6, the ground child functional component 20 is stored in the outer shell 1, and a gap between the outer shell 1 and the ground child functional component 20 is filled with the casting agent 29, The grounding element in which the grounding element functional component 20 is integrated is obtained.

In the present invention, since the functional component 20 of the grounding element is incorporated in the fixed outer shell 1, the material such as strength, weight, and material of the outer shell can be freely set. For example, by selecting and using a polypropylene resin mixed with glass fiber, a ground piece that is lightweight and has excellent mechanical strength can be obtained.

Further, according to the present invention, as the adjustment processing,
After the assembling process, prior to the welding process, it is possible to stably perform the inspection of the electrical characteristics of the ground functional component assembled and connected in the outer shell. Furthermore, by using silicone rubber as a casting agent for the injection solidification treatment, curing at normal temperature becomes possible, and there is no toxicity, and electrical characteristics superior to epoxy resins can be obtained.

[0038]

As described above, according to the present invention,
An outer shell is prepared in advance, and an assembling process for incorporating the above-mentioned child functional component into the outer shell, a welding process for joining a lid to the outer shell container incorporating the above-mentioned child functional component, and a casting agent inside the outer shell. By sequentially performing a series of processes including the injection solidification process of injecting and curing, it is possible to perform the assembling work of the ground child on the assembly line, without requiring special skills, uniform, and with conventional products It is possible to obtain a lightweight and highly reliable product. Further, after the end of the useful life, the outer shell, the above-mentioned functional child component, and the silicone rubber can be separated, so that the material can be recycled.

[Brief description of the drawings]

FIG. 1 is a view showing a combination of an outer shell used for forming a ground member according to the present invention and a ground member functional component.

FIG. 2 is a diagram illustrating an example of an electric circuit of a ground terminal.

FIG. 3 is a view showing a state where a container is covered.

FIG. 4 is a view showing a situation where a container and a lid are welded by vibration.

FIG. 5 is a diagram showing an example of injecting a casting agent into an outer shell.

FIGS. 6A and 6B show a ground piece formed by the method of the present invention, wherein FIG. 6A is a partial cross-sectional plan view and FIG. 6B is a cross-sectional side view of the same part.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Outer shell 2 Container 3 Lid 4 Coil storage part 5 Electronic part storage part 6 Pedestal 7 Partition wall 8 Notch 9 Outer wall 10 Injection hole of casting agent 11 Inner wall 12 Ground coil 12a Coated wire 12b Coil frame 13 Fitting 14 Fitting Seat 15 Ground mounting hole 16 Cable storage space 17 Connector mounting hole 18 Outlet hole 19 Window hole 20 Ground wiring functional component 21 Electrical component 22 Printed board 23 Cable 24 Cable connector 25 Table 26 Vibration head 28 Hose 29 Casting agent

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-3-48411 (JP, A) JP-A-6-188130 (JP, A) JP-B-60-46901 (JP, B2) 4614 (JP, Y2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B61L 1/00-23/34

Claims (4)

(57) [Claims] An earth shell in which an outer shell and an above-ground child functional part are integrated , wherein the outer shell covers a fixed container in the shape of an above-ground child and covers the container. The cover is a cover, and the ground functional component includes a ground coil and other electric components,
The container is housed in the container, and the lid covers the opening of the container that houses the ground child functional component, and adheres to the container to seal the outer shell. The gap formed in the space is filled with a casting agent , and the casting agent is made of silicone rubber.
Pressurized into the sealed outer shell and cured.
Ground element, characterized in that that. 2. The container has an injection hole and an outlet hole, The injection hole is a hole for press-fitting the casting agent into a container covered with a lid.
And The outlet hole is used to press the casting agent into the shell,
It is a hole that degass After the casting agent has been pressed into the shell, the injection and exit holes are:
2. The plug according to claim 1, wherein the plug is sealed.
Ground child. 3. A method of forming a ground piece having an assembling process, a welding process, and a pouring and solidifying process, wherein the assembling process is performed by placing the ground piece in a fixed container having an outer shell modeled on the shape of the ground piece. This is the process of assembling the ground child functional components including coils and other electrical components, electrically connecting them, covering the container and storing the ground child functional components in the outer shell. It is a process of welding the joint part with the lid.Injection solidification process is to inject a casting agent into the outer shell, fill the gap between the outer shell and the functional parts on the ground with the casting agent, and solidify it.
A method of forming a ground piece, wherein the outer shell and the ground piece functional part are integrated, and the casting agent is silicone rubber . 4. The welding process uses a vibration welding method, and relatively vibrates the outer shell container and a lid for covering the opening of the container, and welds the lid to the container to seal the outer shell. The method according to claim 3, wherein the stopping is performed.