Abstract:
The present invention relates to a gasket, a magnetic switch of a starter including the same, and a starter including the magnetic switch, the gasket including: a membrane which carries out a sealing function and is made of a resin material having flexibility; and a membrane washer provided along the edge of the membrane in order to prevent bending of the membrane, wherein the membrane and the membrane washer are insert injected. Unlike prior art, the present invention can enhance the durability of the membrane by insert injection molding a hard membrane washer into the membrane having flexibility, can enhance a waterproofing performance by enabling the membrane to be firmly fixed to a plunger, and can enhance an assembly performance by enabling assembly through an automatic production line.

Description:
[0001]    This application is the U.S. National Phase of International Application No. PCT/KR2014/010958 filed on Nov. 14, 2014, and claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0154454, filed on Dec. 12, 2013, which are hereby expressly incorporated by reference in their entirety for all purposes. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention relates to a starter for a vehicle, and more particularly, to a gasket that can enhance the durability of a membrane by insert injection molding a hard membrane washer into the membrane having flexibility, can enhance a waterproofing performance by enabling the membrane to be firmly fixed to a plunger, and can enhance an assembly performance by enabling assembly through an automatic production line, to a magnetic switch of a starter including the gasket, and to a starter including the magnetic switch. 
       BACKGROUND OF THE DISCLOSURE 
       [0003]    In general, since a car engine cannot start on its own, a crankshaft has to be turned by an external force to rotate the engine by causing an initial explosive combustion in a cylinder. A starting device is used to turn the crankshaft of the engine. Such a starting device includes a starter that generates a torque for cranking of the engine and a battery used to supply driving power to the starter. The starter includes a magnetic switch unit, an armature assembly, an overrunning clutch (ORC) for transferring a driving force of the armature assembly to the crankshaft of the engine and an armature assembly, a gear assembly for torque conversion by reductions of speeds of the revolution per minute (RPM) of a rotating armature and an ORC that is gear-coupled to ring gears of the engine and transfers power to the starter. 
         [0004]    The above-described technical configuration is a background art for helping understanding of the present invention and does not indicate a well-known conventional art in the art to which the present invention belongs. The starter is disclosed in Korean Patent Registration No. 10-1111546. 
         [0005]    In a conventional starter, a problem is that a gap may be formed due to a deformation of a membrane provided to seal a gap between a case and a plunger that makes reciprocating motions relative to the case. Thus, an improvement is needed for the problem. 
         [0006]    The present invention is directed to providing a gasket that can enhance the durability of a membrane by insert injection molding a hard membrane washer into the membrane having flexibility, to a magnetic switch of a starter including the gasket, and to a starter including the magnetic switch. 
         [0007]    The present invention is also directed to providing a gasket that can enhance a sealing ability and a waterproofing performance by enabling a bellows of a membrane to be firmly fixed to a plunger by inserting the bellows of the membrane into the plunger and can enhance an assembly performance by enabling assembly through an automatic production line, to a magnetic switch of a starter including the gasket, and to a starter including the magnetic switch. 
         [0008]    One aspect of the present invention provides a gasket of a starter for starting an engine of a vehicle, the gasket including: a membrane which carries out a sealing function and is made of a resin material having flexibility; and a membrane washer provided along an edge of the membrane in order to prevent bending of the membrane, wherein the membrane and the membrane washer may be insert injected. Thus, the number of components of the gasket is reduced, and the membrane is hardened so that durability is enhanced. 
         [0009]    The membrane may include: a rim member supported at the membrane washer; and a bellows provided inside of the rim member and formed to be wrinkled. Thus, the membrane may harden only the rim member so that a soft state of the bellows may be maintained. The membrane may be formed to expose the membrane washer at one side and may form support ribs to prevent separation of the membrane washer at one side. 
         [0010]    Thus, the membrane washer is exposed at one side of the membrane so that an increase in the thickness of the rim member of the membrane may be minimized, and the position of exposure of the membrane washer may be fixed using support ribs. The membrane washer may form bent ribs so as to prevent from being separated from the membrane. The membrane washer forms the bent ribs so that the injected membrane is united with the bent ribs and is prevented from being arbitrarily separated from the membrane washer. 
         [0011]    The membrane washer may form accommodation hole portions that accommodate a part of the membrane to prevent being separated from the membrane. The membrane washer forms the accommodation hole portions so that the injected membrane is filled in the accommodation hole portions and is united therewith and thus is prevented from being arbitrarily separated from the membrane washer. 
         [0012]    Another aspect of the present invention provides a magnetic switch of a starter for starting an engine of a vehicle, the magnetic switch including: a case; a plunger provided to make reciprocating motions along an axial direction of the case; a gasket that seals a gap between the case and the plunger; and a fixing unit that prevents the gasket supported at the case from escaping in an axial direction of the plunger. Thus, the gasket may be easily assembled to be fixed to the plunger by the fixing unit. 
         [0013]    The gasket may include: a membrane which carries out a sealing function for sealing a gap between the case and the plunger, is made of a resin material having flexibility, and forms an insertion hole for inserting the plunger; and a membrane washer provided along the edge of the membrane to prevent bending of the membrane, and the membrane and the membrane washer may be insert injected. Thus, the number of components of the gasket is reduced, and the membrane is hardened so that durability is enhanced. 
         [0014]    The fixing unit may include: a fit groove portion formed on a perimeter surface of the plunger; and a fit protrusion protruding along inside of the membrane and inserted into the fit groove portion. As the fixing unit includes the fit groove portion and the fit protrusion, the membrane is simply inserted into the plunger and is naturally fixed and mounted. 
         [0015]    Another aspect of the present invention provides a starter for starting an engine of a vehicle, the starter including: a front bracket; and a magnetic switch in which a case enables the front bracket for accommodating the gasket to be separably coupled, wherein a deformation of the gasket may be prevented by a deformation prevention unit. When the front bracket is assembled with the case, a deformation of the gasket is prevented by a deformation prevention unit. 
         [0016]    The deformation prevention unit may include: a position setting protrusion extending from an edge of the gasket; and a position setting groove portion formed in the front bracket to accommodate the position setting protrusion. While the position setting groove portion accommodates the position setting protrusion, the front bracket is assembled with the case so that a deformation of the gasket is prevented. 
         [0017]    As described above, a gasket, a magnetic switch of a starter including the gasket, and a starter including the magnetic switch can enhance the durability of a membrane by insert injection molding a hard membrane washer into the membrane having flexibility, unlike in the conventional art. 
         [0018]    Furthermore, the present invention can enhance a sealing ability and a waterproofing performance by enabling a bellows of the membrane to be firmly fixed to a plunger by inserting the bellows of the membrane into the plunger and can enhance an assembly performance through an automatic production line. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    The present disclosure is described in conjunction with the appended figures: 
           [0020]      FIG. 1  is a perspective view of a principal portion of a magnetic switch of a starter according to an embodiment of the present invention. 
           [0021]      FIG. 2  is an exploded perspective view of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention. 
           [0022]      FIG. 3  is an exploded perspective view of the rear of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention. 
           [0023]      FIG. 4  is an enlarged perspective view of a gasket according to an embodiment of the present invention. 
           [0024]      FIG. 5  is an exploded perspective view of a membrane and a membrane washer that constitute the gasket according to an embodiment of the present invention. 
           [0025]      FIG. 6  is an exploded perspective view of the rear of the membrane and the membrane washer that constitute the gasket according to an embodiment of the present invention. 
           [0026]      FIG. 7  is a cross-sectional view of the gasket according to an embodiment of the present invention. 
           [0027]      FIG. 8  is a cross-sectional view of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    Hereinafter, a gasket, a magnetic switch of a starter including the gasket, and a starter including the magnetic switch according to exemplary embodiments of the present invention will be described with reference to the attached drawings. In this process, thicknesses of lines or sizes of elements shown in the drawings may be exaggerated for clarity and convenience of explanation. Also, as the terms that will be described later have been defined with considerations given to functions in the present invention, they may be changed according to a user, an operator&#39;s intention, or practice. Therefore, definitions of the terms should be made based on the content of the present specification throughout. 
         [0029]      FIG. 1  is a perspective view of a principal portion of a magnetic switch of a starter according to an embodiment of the present invention,  FIG. 2  is an exploded perspective view of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention, and  FIG. 3  is an exploded perspective view of the rear of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention. 
         [0030]      FIG. 4  is an enlarged perspective view of a gasket according to an embodiment of the present invention,  FIG. 5  is an exploded perspective view of a membrane and a membrane washer that constitute the gasket according to an embodiment of the present invention,  FIG. 6  is an exploded perspective view of the rear of the membrane and the membrane washer that constitute the gasket according to an embodiment of the present invention, and  FIG. 7  is a cross-sectional view of the gasket according to an embodiment of the present invention. 
         [0031]      FIG. 8  is a cross-sectional view of a principal portion of the magnetic switch of the starter according to an embodiment of the present invention. 
         [0032]    As illustrated in  FIGS. 1 through 3 , a magnetic switch  100  of a starter for starting a vehicle according to an embodiment of the present invention includes a case  110 , a plunger  120 , a gasket  130 , a fixing unit  200 , a front bracket  140 , and a deformation prevention unit  300 . The case  110  is coupled to the front bracket  140  using a coupling method utilizing a mechanical coupling element and includes a plunger  120  capable of reciprocating motions in an axial direction. Of course, the form of the case  110  may be changed to various other shapes. In particular, the front bracket  140  is coupled to the other side of the case  110 . Thus, the other side of the case  110  is sealed by the front bracket  140 . 
         [0033]    As the plunger  120  is accommodated in the case  110  to make a rectilinear reciprocating motion, a gap into which foreign substances such as external moisture may be introduced is formed in a coupling portion of the case  110  and the front bracket  140  and between the case  110  and the plunger  120 . Thus, the gap formed in the coupling portion of the case  110  and the front bracket  140  and the gap formed between the case  110  and the plunger  120  may be sealed. Thus, the gasket  130  is provided. 
         [0034]    The gasket  130  is located at an inner portion of the front bracket  140  and provided on the other side of the case  110 . Thus, the gasket  130  is used to seal the gap in the coupling portion of the case  110  and the front bracket  140  and the gap between the case  110  and the plunger  120 . In this case, the gasket  130  may be formed of a rubber material to enhance a sealing ability. In particular, the gasket  130  has to be deformed when the plunger  120  makes reciprocation motions. In this case, the sealing ability of the gasket  130  may be deteriorated. Thus, the gasket  130  includes a membrane  132  and a membrane washer  134 . 
         [0035]    The membrane  132  is formed of a resin material having a sealing function and is formed of a soft material to be deformable to correspond to the plunger  120  that makes reciprocating motions. The membrane washer  134  is provided along an edge of the membrane  132  to prevent bending or deforming of the soft membrane  132 . In particular, the membrane washer  134  is formed of a hard material. Also, the membrane  132  and the membrane washer  134  are insert injection molded to improve an assembly performance. In this case, the membrane washer  134  may be formed of a steel material or a hard resin material. 
         [0036]    Meanwhile, the membrane  132  includes a rim member  131  and a bellows  133 . The rim member  131  is supported in contact with the other side of the case  110 . Also, the rim member  131  is provided to closely contact the case  110  in a direction of the other side of the case  110  by the front bracket  140  coupled to the other side of the case  110 . Here, the rim member  131  is firmly coupled and fixed to the other side of the case  110  by bolting, etc. Furthermore, the rim member  131  is formed in the form of a ring including a circle, an oval, etc. Here, the rim member  131  includes the membrane washer  134  formed integrally therewith. That is, the membrane washer  134  is insert injection molded into the rim member  131 . 
         [0037]    The bellows  133  is provided inside of the rim member  131 . Also, the bellows  133  forms an insertion hole  135  for inserting the plunger  120 . In particular, the bellows  133  may be formed capable of contracting or expanding depending on a flow direction of air when the bellows  133  makes a rectilinear reciprocating motion together with the plunger  120  in the case  110 . Thus, the bellows  133  is formed to be wrinkled. Of course, the bellows  133  may be formed in various shapes. Thus, the gasket  130  may be firmly assembled and enhance a waterproofing performance. 
         [0038]    Meanwhile, when the membrane washer  134  is insert injected to be completely encompassed by the membrane  132 , in particular, the rim member  131 , the rim member  131  becomes thicker than the necessary. Thus, the membrane  132  may be formed so that the membrane washer  134  is exposed to one side. That is, the membrane washer  134  is insert injected into the rim member  131  to be exposed at one side of the rim member  131 . Thus, the membrane washer  134  may arbitrarily escape from the membrane  132 , i.e., the rim member  131 . Thus, as illustrated in  FIGS. 4 through 7 , the membrane  132  forms support ribs  137  to prevent separation of the membrane washer  134  on one side. In other words, the rim member  131  forms the support ribs  137  when insert injection molding is performed to firmly confine the membrane washer  134 . The support ribs  137  are formed discontinuously along an edge of the rim member  131  of the membrane  132  and thus surround the membrane washer  134 . 
         [0039]    In particular, as the support ribs  137  extend to one side of the rim member  131 , grooves are formed by the rim member  131  and the support ribs  137 . The membrane washer  134  is formed to be inserted into the grooves formed by the rim member  131  and the support ribs  137 . The shape and the number of support ribs  137  are not limited. Here, preferably a minimum number of support ribs  137  may be formed. Of course, the support ribs  137  are naturally formed at the rim member  131  when insert injection molding is performed from a mold (not shown). 
         [0040]    Also, the membrane washer  134  may preferably form bent ribs  138  to prevent being arbitrarily separated from the membrane  132 . 
         [0041]    The bent ribs  138  are formed to extend bent inward or outward from the membrane washer  134 . For convenience, the bent ribs  138  are formed to be bent inward from both sides of the membrane washer  134  facing each other. Thus, when the membrane washer  134  is insert injection molded into the rim member  131 , the bent ribs  138  increase a cohesive force between the rim member  131  and the membrane washer  134 . Of course, the bent ribs  138  may be formed in various shapes. In addition, the membrane washer  134  forms accommodation hole portions  139  that accommodate a part of the membrane  132  to prevent being arbitrarily separated from the membrane  132 . 
         [0042]    As a result, when the membrane washer  134  is insert injection molded into the rim member  131 , the rim member  131  is formed with the accommodation hole portions  139  of the membrane washer  134  filled with an injection solution. Thus, the membrane washer  134  and the rim member  131  are firmly coupled to each other. Meanwhile, the gasket  130  may be fixed to the plunger  120  that makes a rectilinear reciprocating motion by being supported at the other side of the case  110  to be contracted and expanded. This is to maintain the gasket  130  in a sealed state. Thus, as illustrated in  FIGS. 1 through 3  and  FIG. 8 , the fixing unit  200  is provided. The fixing unit  200  prevents the gasket  130  supported at the case  110  from escaping in an axial direction of the plunger  120 . 
         [0043]    Here, the fixing unit  200  includes a fit groove portion  210  and a fit protrusion  220 . The fit groove portion  210  is dented on a perimeter surface of the plunger  120  in a circumferential direction. 
         [0044]    The fit protrusion  220  is formed to protrude along the membrane  132 , in particular, along inside of the bellows  133 . That is, the fit protrusion  220  is formed to protrude along inside of the insertion hole  135 . Thus, the fit protrusion  220  is inserted into the fit groove portion  210 . The fit protrusion  220  may be formed in various shapes. As a result, the bellows  133  moves together with the plunger  120 . 
         [0045]    Furthermore, the plunger  120  may receive the force that enables the plunger  120  to be restored to its initial state after being inserted into the case  110 . Thus, the plunger  120  forms a flange  122 . A large elastic restoration force is applied to the plunger  120  by an elastic member  124  for restoration to an initial state. In this case, one side of the elastic member  124  is elastically supported at the other side of the case  110 , and one other side of the elastic member  124  is elastically supported at the flange  122 . A coil spring may be used as the elastic member  124 . Also, after the gasket  130  having the soft bellows  133  is assembled with the plunger  120 , the front bracket  140  is assembled with the case  110  while covering the gasket  130 . In this case, when the front bracket  140  is incorrectly assembled, a deformation of the gasket  130  occurs. Due to this, a sealing ability is deteriorated. Thus, the deformation prevention unit  300  is provided to set an assembling position of the front bracket  140  and the gasket  130  to prevent a deformation of the gasket  130  due to the front bracket  140 . 
         [0046]    The deformation prevention unit  300  includes a position setting protrusion  310  and a position setting groove portion  320 . The position setting protrusion  310  extends outward from the edge of the gasket  130 . In this case, the position setting protrusion  310  may be formed to extend from the hard rim member  131  by insert injecting the membrane washer  134 . Of course, the shape and the number of position setting protrusions  310  are not limited. 
         [0047]    In addition, the position setting groove portion  320  is formed at the front bracket  140  to accommodate the position setting protrusion  310 . In this case, the position setting groove portion  320  is formed so that there is a one-to-one correspondence between the position setting groove portion  320  and the position setting protrusion  310 . While the position setting groove portion  320  accommodates the position setting protrusion  310 , the front bracket  140  is assembled with the case  110  so that a deformation of the gasket  130  can be prevented. 
         [0048]    Consequently, the gasket  130  may be easily assembled with the plunger  120  through an automatic facility (not shown), and an assembly performance can be enhanced. While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.