Switch structure and method of manufacturing a switch

Abstract

A switch structure and a method of manufacturing a switch are disclosed. The switch structure includes a light emitting portion configured to receive power from a vehicle and radiate light, a moving block positioned to surround the light emitting portion, a light transmitting portion configured to allow the light radiated from the light emitting portion to pass through an opening in the moving block, and a film print layer on a top surface of the light transmitting portion and including a symbol.

Description

Technical Field

[0001] This disclosure relates to a switch structure and a method of manufacturing the same, and more specifically, to a switch structure and method of manufacturing which provides improved processability and exhibits enhanced durability by providing symbols on the surface of the handle, the handle being injection molded using a film printing method. Background Technology

[0002] Typically, vehicles are equipped with an emergency light switch, which, when operated by the driver, simultaneously flashes the left and right turn signals (i.e., hazard lights) to notify surrounding vehicles of an emergency or to warn following vehicles of an emergency stop.

[0003] For drivers, it is important to be able to quickly operate the hazard light switch in an emergency. Therefore, the hazard light switch needs to be highly visible so that the driver can accurately identify its location and operate it rapidly.

[0004] Normally, there is no issue with the visibility of emergency light switches during the day. However, when the emergency light switch is turned on at night, light from the light source passes through the red and white parts of the emergency light switch symbol, causing the symbol to become blurred and reducing its visibility.

[0005] To manufacture an emergency light switch, the process involves injection molding, three painting processes (red, black, and high-gloss painting), laser cutting, and symbol printing. Here, when light from the light source passes through the red-painted area, it is required that the light not pass through the symbol-printed area. However, the light from the light source also passes through the white area of ​​the symbol-printed area, thus reducing the visibility of the emergency light switch symbol.

[0006] In many vehicles, not only emergency light switches but also other switches located inside the vehicle are configured to include light sources. Therefore, research has been conducted on switch structures and manufacturing methods to provide improved nighttime visibility.

[0007] The information disclosed in this background section is intended only to enhance the understanding of the background of this disclosure, and therefore may contain information that does not constitute related technology known to a person skilled in the art in this country. Summary of the Invention

[0008] This disclosure provides a switch structure consisting of a single part.

[0009] Another object of this disclosure is to provide a switch structure for use in a vehicle interior and a method for manufacturing the same, wherein a handle is disposed on the top surface of a movable block by means of a film printing method.

[0010] Another object of this disclosure is to provide a process that enables the simultaneous manufacture of moving blocks and handles using a single mold.

[0011] The purpose of this disclosure is not limited to the objectives described above, and other objectives not mentioned herein will be clearly understood by those skilled in the art from the following description, and will become apparent from the embodiments of this disclosure. Furthermore, the objectives of this disclosure can be achieved through the components and combinations thereof described in the technical solutions.

[0012] The switch structure and its manufacturing method for achieving the above-described objectives of this disclosure have the following configuration.

[0013] In one aspect, this disclosure provides a switch structure comprising: a light-emitting portion configured to receive power from a vehicle and radiate light; a movable block positioned around the light-emitting portion; a light-transmitting portion configured to allow light radiated from the light-emitting portion to pass through an opening in the movable block; and a film-printed layer located on the top surface of the light-transmitting portion and including symbols.

[0014] In a preferred embodiment, the film-printed layer may be formed to have a thickness ranging from 20 micrometers to 50 micrometers.

[0015] In another preferred embodiment, each of the opposite ends of the film-printed layers may be positioned inwardly by 0.1 to 0.3 micrometers from the end of the movable block.

[0016] In yet another preferred embodiment, the film-printed layer may be configured to form a symbol at a position corresponding to an opening in the moving block, so that light radiated from the light-emitting portion passes through the symbol.

[0017] In yet another preferred embodiment, the top surface of the moving block where the light-transmitting part is located may be tapered in the height direction of the moving block.

[0018] In another aspect, this disclosure provides a method for manufacturing a switch, the method comprising the steps of: injection molding a movable block using an upper mold; injection molding a handle by engaging the upper mold, in which the movable block has been injection molded, with a lower mold; and removing the injection-molded product.

[0019] In a preferred embodiment, the injection molding step may include: printing a symbol on a film-printed layer; placing the film-printed layer on the upper end of the lower mold forming the handle; and pre-forming the film according to the shape of the lower mold forming the handle.

[0020] In another preferred embodiment, the preforming step may include inserting a film-printed layer into a recessed portion of the lower mold forming the handle.

[0021] In yet another preferred embodiment, the injection molding step may include: rotating the upper mold when the movable block is fully injection molded at one end of the upper mold; and after the upper mold has been rotated, injection molding the movable block at the opposite end of the upper mold.

[0022] In yet another preferred embodiment, the step of injection molding the movable block at the opposite end of the upper mold after the upper mold is rotated can be performed simultaneously with the step of injection molding the handle at one end of the upper mold.

[0023] In yet another preferred embodiment, the method may further include, after removing the product having the already injection-molded handle, rotating the opposite end of the upper mold to injection mold the handle in the opposite end.

[0024] Other aspects and preferred embodiments of this disclosure are discussed below. Attached Figure Description

[0025] The above and other features of this disclosure will now be described in detail with reference to certain exemplary embodiments thereof shown in the accompanying drawings, which are given by way of example only and are not intended to limit the disclosure, and wherein:

[0026] Figure 1 This is a cross-sectional view of a switch structure manufactured integrally according to an embodiment of the present disclosure;

[0027] Figure 2 This is an enlarged view of the side of an integrally manufactured switch structure according to an embodiment of the present disclosure;

[0028] Figure 3 This is a diagram illustrating the manufacturing process of a switch using a film printing method according to an embodiment of the present disclosure; and

[0029] Figure 4 This is a diagram illustrating the manufacturing process of a switch using a film printing method according to another embodiment of the present disclosure.

[0030] It should be understood that the accompanying drawings are not necessarily drawn to scale and present a simplified representation to some extent of the various preferred features illustrating the basic principles of this disclosure. Specific design features of this disclosure, including, for example, specific dimensions, orientations, positions, and shapes, will be determined in part by the specific intended application and environment of use.

[0031] In the accompanying drawings, reference numerals throughout the drawings refer to the same or equivalent parts of this disclosure. Detailed Implementation

[0032] It should be understood that the term "vehicle" or "of a vehicle" or other similar terms as used herein generally include motor vehicles, such as passenger cars including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, water vehicles including various vessels, aircraft, etc., and includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other vehicles powered by alternative fuels (e.g., fuels derived from resources other than petroleum). As referred to herein, a hybrid vehicle is a vehicle having two or more power sources, such as a gasoline-powered vehicle and an electric-powered vehicle.

[0033] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit this disclosure. As used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It will be further understood that, when used in this specification, the terms “comprising” and / or “including” specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items. Throughout this specification, unless explicitly stated to the contrary, the word “comprising” and variations such as “including” or “containing” will be understood to imply the inclusion of the stated elements, but do not exclude any other elements. Additionally, the terms “unit,” “device,” “man-made,” and “module” described in the specification refer to a unit for performing at least one function and operation and may be implemented by hardware components or software components and combinations thereof.

[0034] Furthermore, the control logic of this disclosure can be implemented as a non-transitory computer-readable medium containing executable program instructions that can be executed by a processor, controller, etc. Examples of computer-readable media include, but are not limited to, ROM, RAM, optical disc (CD)-ROM, magnetic tape, floppy disk, flash memory drive, smart card, and optical data storage device. The computer-readable medium can also be distributed across a network-coupled computer system, such that it is stored and executed in a distributed manner, for example, by a telematics server or a controller area network (CAN).

[0035] In the following, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. However, the present disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that the present disclosure will be thorough and complete, and will more fully convey the scope of the disclosure to those skilled in the art.

[0036] The terms “section,” “block,” and “layer” used in this specification refer to a unit used to process at least one function or operation, and can be implemented using hardware components, software components, or a combination thereof.

[0037] Furthermore, the terms “first” and “second” used in the description of the constituent elements mentioned below are intended only to distinguish one element from another and are not related to the order of the constituent elements.

[0038] Furthermore, the term "knob" used in the specification can refer to components including "film printing layer" and "light transmission part".

[0039] Conventionally, to manufacture the switch, the white emergency light switch body is first injection molded. Then, it undergoes red spraying, black spraying, and high-gloss spraying in sequence, followed by laser cutting and symbol printing to complete the final product.

[0040] However, when manufacturing the final product using these conventional methods, the time spent producing the product increases due to repeated spraying and drying, thereby increasing manufacturing costs and defect rates.

[0041] Therefore, this disclosure relates to a switch structure and a method for manufacturing the same, wherein the switch is manufactured using two injection molding processes of a film printing method.

[0042] Figure 1 and Figure 2 This is a side cross-sectional view of the structure of the switch 100 according to the present disclosure. The structure of the switch 100 includes: a light-emitting part 150 configured to receive power from a vehicle and radiate light; a movable block 110 arranged around the light-emitting part 150 and having an opening 111 therein through which light radiated from the light-emitting part 150 passes; and a light-transmitting part 120 disposed on the top surface of the movable block 110 and configured to allow light radiated from the light-emitting part 150 to pass through.

[0043] The moving block 110 can be configured to move along the height direction or a set direction in response to user input, or it can be configured to send user input to the controller via a printed circuit board (PCB) located below it.

[0044] More preferably, the movable block 110 can be configured to prevent light radiated from the light-emitting part 150 from passing through the area outside the symbol 131, and can be formed to have a dark color.

[0045] The movable block 110 may include an opening 111 formed therein, having the same shape as the symbol 131 of the handle 140 located at the top, and may be configured to allow light radiated from the light-emitting part to pass through the opening 111.

[0046] The handle 140 includes a light-transmitting portion 120, which is formed in the opening 111 of the moving block 110 and has a predetermined height on the top surface of the moving block 110, and includes a film-printed layer 130 disposed on the top surface of the light-transmitting portion 120.

[0047] The film-printed layer 130 is formed by stacking a film and a printing layer, and a coating is applied between the film and the printed surface of the symbol 131. Preferably, the film-printed layer 130 is configured such that the release material is printed on a polyethylene terephthalate (PET) film. Furthermore, a coating is applied to prevent peeling or discoloration of the switch 100 surface, and a primer is applied to ensure adhesion between the printed surface of the symbol 131 on which the printing ink is printed and the coating, thereby completing the film-printed layer 130 on which the symbol 131 is printed.

[0048] The light-transmitting section 120 is configured to allow light radiated from the light-emitting section 150 to pass through. The light-transmitting section 120 may be formed of a transparent material to transmit light passing through the opening 111 in the moving block 110 to the film-printed layer 130.

[0049] The film printing layer 130 may include a symbol 131 having any of various shapes. The symbol 131 may be determined according to the function and usage conditions of the switch 100.

[0050] The symbol 131 located in the film printing layer 130 is configured to correspond substantially to the opening 111 located in the moving block 110, and is configured such that light passing through the light transmission section 120 is radiated according to the shape of the symbol 131.

[0051] The movable block 110 may be configured such that its width gradually decreases in the height direction. More preferably, the movable block 110 may be configured such that its upper end tapers in the height direction. Furthermore, the movable block 110 may be configured in a multi-level shape, wherein the lower end and the upper end of the taper portion have surfaces parallel to each other.

[0052] The top surface of the movable block 110 can be formed into a multi-level shape, thereby forming two parallel surfaces in a side cross-sectional view. The outermost plane of the movable block 110 forming the bottom surface of the multi-level portion can be formed to have a thickness of 0.5 to 0.7 micrometers.

[0053] Therefore, the light-transmitting portion 120 can be arranged around the moving block 110. More preferably, the light-transmitting portion 120 can be formed around the entire upper end of the moving block 110, including the tapered portion.

[0054] The handle 140 may be formed at a position further inward toward the center of the moving block 110 than the outermost surface of the opposite end of the moving block 110. The side surface of the moving block 110 may be formed to protrude further than the side surface of the handle 140 to form a stepped portion 121 therebetween, the size of which ranges from 0.1 micrometer to 0.3 micrometer.

[0055] More preferably, the outermost surface of the side surface of the handle 140 can be formed by a predetermined stepped portion 121 to be located further in the width direction than the outermost surface of the moving block 110 with a multi-level structure.

[0056] According to the embodiments of this disclosure, since the side surface of the movable block 110 protrudes further than the side surface of the light-transmitting portion 120 facing the movable block 110, the movable block 110 serves to completely block the leakage of light emitted from the light-emitting portion 150.

[0057] As described above, the switch structure according to this disclosure has a structure that prevents light radiated from the light-emitting part 150 from leaking into areas other than the opening 111 in the moving block 110 due to the structure of the light-transmitting part 120 having a stepped portion 121 therebetween and the outermost shape of the moving block 110 and the top surface of the moving block 110 having a tapered shape.

[0058] The light-transmitting portion 120 can be configured such that, in a side cross-sectional view, at least one distal end of the light-transmitting portion 120 is formed as a curved portion 122. The space between the moving block 110 and the curved portion 122 of the light-transmitting portion 120 may be narrower than the space between the moving block 110 and the flat portion of the light-transmitting portion 120.

[0059] In this way, the switch 100 can be configured such that the thickness of the light-transmitting portion 120 gradually decreases towards the region closer to the curved portion 122 of the light-transmitting portion 120. As the thickness of the light-transmitting portion 120 gradually decreases, the amount of light leaking from the light-emitting portion 150 to the outside can be reduced.

[0060] In embodiments of this disclosure, the film-printed layer 130 may be formed to have a thickness ranging from 20 micrometers to 50 micrometers, and the thickness from the top surface of the moving block 110 to the top surface of the film-printed layer 130 may be 1.3t. Additionally, the thickness of the side surface of the moving block 110 may be 1.2t.

[0061] Figure 3 A method for manufacturing a switch 100 using a film printing method and an insert injection molding method according to embodiments of the present disclosure in chronological order is shown.

[0062] like Figure 3As shown, a film-printed layer 130 with the symbol 131 printed on it is fixed to the lower mold 300, and a process of pre-forming the film-printed layer 130 according to the shape of the lower mold 300 is performed. In addition, the lower mold 300 is configured to injection mold the light-transmitting part 120, and the upper mold 200 is configured to injection mold the moving block 110.

[0063] The method includes the following processes: bringing the movable block 110, which is injection molded by the upper mold 200, into close contact with the lower mold 300, which has been pre-formed, and performing injection molding to form a light-transmitting portion 120 according to the shape of the top surface of the movable block 110 and the shape of the lower mold 300.

[0064] More preferably, in order to allow the movable block 110 to be injection molded from the upper mold 200 via the intermediate partition wall 400, molten resin for forming the movable block 110 is introduced into the partition wall 400. After the movable block 110 is injection molded, the upper mold 200 is brought into contact with the lower mold 300 so that the light-transmitting portion 120 is located on the top surface of the movable block 110.

[0065] Remove the product, in which the film-printed layer 130 is located on the top surface of the light-transmitting portion 120, which is injection-molded in this manner, and the moving block 110 is located on the bottom surface of the light-transmitting portion 120.

[0066] More preferably, when the light-transmitting portion 120 is injection molded, a portion of the light-transmitting portion 120 is introduced and fixed in the opening 111 formed in the movable block 110.

[0067] Furthermore, since the movable block 110 is injection molded from the upper mold 200 due to the inclusion of the intermediate partition wall 400, the method includes the process of placing the intermediate partition wall 400 facing the upper mold 200 and the process of injecting molten resin for forming the movable block 110 through the intermediate partition wall 400. After the movable block 110 is injection molded, the upper mold 200 and the lower mold 300 are placed facing each other, and molten resin for forming the light-transmitting portion 120 is injected along the upper mold 200.

[0068] As a result, a switch 100 is provided, which includes a movable block 110, a light-transmitting portion 120, and a film-printed layer 130 integrally formed together by the above-described manufacturing process.

[0069] Figure 4 A method for manufacturing a switch 100 according to another embodiment of the present disclosure is shown.

[0070] Specifically, a method for manufacturing a switch 100 using a film printing method and an insert injection molding method according to another embodiment of the present disclosure is shown in chronological order.

[0071] A lower mold 300 is placed such that a film covers the lower mold 300 to form a film printing layer 130. The lower mold 300 includes a recess formed therein for injection molding the light-transmitting portion 120.

[0072] The upper mold 200 includes one end facing the lower mold 300 and an opposite end disposed away from the lower mold 300. The upper mold 200 may include recesses symmetrically formed at one end and the opposite end for injection molding the movable block 110.

[0073] More preferably, the upper mold 200 may include a first upper mold 210 and a second upper mold 220, the first upper mold 210 having a recess formed therein for injection molding the movable block 110, and the second upper mold 220 being located near the opposite end of the upper mold 200.

[0074] The first upper mold 210 is configured such that molten resin for forming the movable block 110 is introduced therein. The first movable block 110a is injection molded through contact between the first upper mold 210 and the second upper mold 220.

[0075] After the first movable block 110a is injection molded, the second upper mold 220 is removed from the first upper mold 210, and the end of the first upper mold 210 that has been injection molded with the first movable block 110a moves to a position close to the lower mold 300.

[0076] More preferably, the first upper mold 210 is located between the second upper mold 220 and the lower mold 300, and is configured to rotate about an axis of the first upper mold 210. The first movable block 110a, which has been injection molded between the first upper mold 210 and the second upper mold 220, rotates integrally with the first upper mold 210 and is positioned facing the lower mold 300.

[0077] The first upper mold 210 can be rotated about one of its axes by a drive unit (not shown), so that the injection molding surface of the first upper mold 210 faces the lower mold 300 or the second upper mold 220.

[0078] The first moving block 110a for injection molding is located at the end of the first upper mold 210, which has been rotated to face the lower mold 300, and the light-transmitting part 120 is injection molded in a state where the first upper mold 210 and the lower mold 300 face each other.

[0079] like Figure 4 As shown, when the light-transmitting part 120 is injection molded, the film-printed layer 130 with the symbol 131 printed on it is fixed to the lower mold 300 and pre-formed according to the shape of the lower mold 300.

[0080] Furthermore, while the light-transmitting part 120 is being injection molded between the first upper mold 210 and the lower mold 300, the opposite end face of the first upper mold 210 faces the second upper mold 220, thereby injection molding the second moving block 110b.

[0081] When the injection molding process between the first upper mold 210 and the second upper mold 220 and between the first upper mold 210 and the lower mold 300 is completed, the switch 100 between the first upper mold 210 and the lower mold 300 is removed, and the first upper mold 210 is rotated so that the end of the first upper mold 210 on which the second moving block 110b has been injection molded faces the lower mold 300.

[0082] That is, the light-transmitting portion 120, including the film-printed layer 130, is injection molded between the first upper mold 210 and the lower mold 300, and at the same time, the moving block 110 is injection molded between the first upper mold 210 and the second upper mold 220.

[0083] It is evident from the above description that the switch structure and manufacturing method of the present disclosure have the following effects.

[0084] This disclosure provides a switch consisting of a single component, thereby reducing manufacturing costs and time.

[0085] In addition, this disclosure allows for the injection molding of moving blocks and handles using a single mold, thereby increasing manufacturing convenience.

[0086] In addition, this disclosure can improve usability by removing harmful substances and odor factors instead of chrome plating technology.

[0087] The foregoing detailed description of this disclosure is merely illustrative. The foregoing is intended to illustrate and describe exemplary embodiments of this disclosure, and this disclosure can be used in various other combinations, modifications, and environments. That is, this disclosure can be modified or changed within the scope of the concepts disclosed herein, the scope equivalent to the foregoing, and / or the scope of technology or knowledge known in the art. The above embodiments are intended to describe the best mode for implementing the technical ideas of this disclosure, and various modifications are possible as required for the specific application and use of this disclosure. Therefore, the foregoing detailed description is not intended to limit this disclosure to the disclosed mode. The technical solutions should be interpreted as including other modes as well.

Claims

1. A switch structure comprising: a light emitting portion configured to receive power from a vehicle and radiate light; a moving block positioned to surround the light emitting portion; a light transmitting portion configured to allow light radiated from the light emitting portion to pass through an opening in the moving block; and a film print layer located on a top surface of the light transmitting portion, the film print layer including a symbol, wherein a top surface of the moving block is tapered in a height direction of the moving block, and wherein the light transmitting portion is formed to surround an upper end of the moving block including a tapered portion; wherein a side surface of the moving block adjacent to the top surface of the moving block is formed to protrude more than a corresponding side surface of a handle, thereby forming a stepped portion between the side surface of the moving block and the side surface of the handle; the handle is a constituent element including the light transmitting portion and the film print layer; and wherein each of opposite ends of the film print layer is positioned inwardly from an end of the moving block by 0.1 to 0.3 micrometers. The film print layer is formed to have a thickness ranging from 20 to 50 micrometers.

2. The switch fabric of claim 1, wherein, The film print layer is configured to form a symbol at a position corresponding to the opening in the moving block to allow light radiated from the light emitting portion to pass through the symbol.

3. The switch fabric of claim 1, wherein, 4.A method of manufacturing a switch, the method comprising the steps of: injection molding a moving block using an upper mold; injection molding a handle by engaging the upper mold in which the moving block has been injection molded with a lower mold; and removing an injection molded product from the upper mold and the lower mold, wherein the switch comprises: a light emitting portion configured to receive power from a vehicle and radiate light; a moving block positioned to surround the light emitting portion; a light transmitting portion configured to allow light radiated from the light emitting portion to pass through an opening in the moving block; and a film print layer located on a top surface of the light transmitting portion, the film print layer including a symbol, wherein a top surface of the moving block is tapered in a height direction of the moving block, and wherein the light transmitting portion is formed to surround an upper end of the moving block including a tapered portion; wherein a side surface of the moving block adjacent to the top surface of the moving block is formed to protrude more than a corresponding side surface of a handle, thereby forming a stepped portion between the side surface of the moving block and the side surface of the handle; the handle is a constituent element including the light transmitting portion and the film print layer; and wherein each of opposite ends of the film print layer is positioned inwardly from an end of the moving block by 0.1 to 0.3 micrometers. The injection molding step includes: printing a symbol on a film print layer; 5. The method of claim 4, wherein, placing the film print layer on an upper end of the lower mold forming the handle; and pre-forming a film according to a shape of the lower mold forming the handle. The pre-forming step includes: inserting the film print layer into a recessed portion in the lower mold forming the handle.

6. The method of claim 5, wherein, The injection molding step includes: rotating the upper mold when the moving block is completely injection molded at one end of the upper mold; and 7. The method of claim 4, wherein, injection molding the moving block at an opposite end of the upper mold after the upper mold is rotated. ​ ​ 8. The method of claim 7, wherein, The step of injection molding the moving block in the opposite end of the upper mold after the upper mold has been rotated is performed simultaneously with the step of injection molding the handle in one end of the upper mold.

9. The method of claim 8, further comprising, after the product with the handle already injection molded is removed, rotating the opposite end of the upper mold to injection mold the handle in the opposite end.

Images