CONED DISK SPRING

Abstract: This invention relates to a coned disk spring which is used as a diaphragm and a keytop returning spring of a keyboard switch, or the like. The coned disk spring (D) of the present invention has a structure whose corrugated section describes spiral ripples (P) around the center circle (10) of a blank sheet starting at its arbitary circumferential points. The spiral ripples (P) can start at at least two points of equidistant points on the circumference of the center circle and preferably, at odd-numbered equidistant points. The coned disk spring (D) of this invention does not exhibit eccentric stress and operating direction at the time of deflection but undergoes a uniform deflection in a circumferential direction, when it is used as a diaphragm. When it is used as a spring for returning the keytop (43) of a keyboard switch, the pressing force of the keytop (43) is transmitted to the entire region and the spring can undergo smooth deflection and can exhibit a reliable switch operation. It is advisable to support and fix the dish spring (D) of the present invention by applying a tension in a centrifugal direction to the entire circumference of its outer periphery. In this manner, deflection of the entire region of the dish spring can be made uniform.

Description: [Field of Art] The present invention relates to coned disc springs. Coned disc springs made mainly of steel plate, stainless plate, rubber plate or plastic plate and suitable for use as a diaphragm or a return spring for a key top of a keyboard switch are known. [Background Art] One prior art coned disc spring D for use as a diaphragm is shown in Fig. 19 which is made of a plate-shaped material and has a circular central portion 10 and its peripheral portion corrugated to form concentrical wave rings P (see Fig. 2). The wave rings P in the drawings indicate the troughs of corrugation (to be so understood hereinafter). However, since the spring D has its peripheral fixing portion subjected to brazing or the like, it has a high rigidity at this portion. Also it has a high rigidity at its central portion because the radius of curvature is small at this portion. Thus it is less liable to deflect at its peripheral and central portions. As a result, the deflecting force tends to concentrate on the intermediate portion thereof. This will increase the possibility of buckling and cracking owing to metal fatigue if the plate is made of a metal and also the characteristcs, specifically the restoring force, of the plate can change during long use. Typical keyboard switches are shown in Figs. 16 to 18. The one shown in Fig. 16 has a contact 42 on the inner bottom surface of a keyboard case 41. A disk-shaped spring D is provided to cover the contact 42. As a key top 43 is depressed, the spring D, which is connected to the key top 43 through a stem 44, will deflect downwards, thus actuating the contact 42. The key top 43 will return to its original position by the restoring force of the spring D. It is also known to form part of the contact 42 from the spring D if the spring D has conductivity. The one shown in Fig. 17 has a coil spring 46 interposed between the keytop 43 and the stem 44 to improve the depressibility. The one shown in Fig. 18 has a lever 45 interposed between the spring D and the stem 44. The abovementioned depressibility refers to the relationship between the depth of depression of the key and the depressing force exerted by a fingertip. Such conventional spring D used in the abovementioned switches have an ordinary flat pressure-receiving surface (contact surface with the stem 44). No modifications thereto have been proposed. Their deflectability and restorability after having been deflected depend largely on the properties of their material. But such an improvement-by-material approach is not only coming to its limit but also costly. Also, the keytop 43 is not always depressed at the center of its top surface. A skilled operation who can type at a high speed tends to press the keytop at its corner portion. This is for the following reason. By depressing the keytop at its corner, the depressing force is divided into a vertical component and a horizontal component, thus deflecting the spring D with both component forces. This improves the operability. But if the spring D has a flat pressure-receiving surface, it will offer resistance to the horizontal component but will not deflect. Thus the operability is not good. If the coned disc spring is used as a diaphragm, it is a common practice to use two annular flanges (cases) 22 to grip it therebetween from both sides along it edge, as shown in Fig. 8(a) and (b). The flanges 22 are bonded to the edge of the coned disc spring D by means of an epoxy or silicone adhesive or by soldering at low temperature (190 to 210 C). But with such conventional bonding means, it is necessary to keep the coned disc spring D and the flanges 22 fixed in position until the adhesive or the solder hardens. Thus the productivity is bad. Further since adhesives and solders have poor heat resistance, they cannot keep their characteristics for a long period of time but tend to degrade with time. Further it requires high technique to secure such conventional support means to the coned disc spring D so that a uniform outward (centrifugal) tension will act on the spring D over the entire area. If the tension is not imparted uniformly, its properties will be badly affected. Figs. 14 and 15 show an ordinary pressure detector with a diaphragm. It has a casing 31 formed with a pressure detecting chamber 33 partitioned by a diaphragm D. One compartment 33a in the pressure detecting chamber 33 is filled with a pressure detecting fluid a . In another compartment 33b, there is provided a switch adapted to be activated when the diaphragm D deflects by a predetermined amount. Among such conventional pressure detectors, there is one having a diaphragm (coned disc spring) D as shown in Fig. 19. But as described above, this diaphragm D has a problem that it tends to degrade with time. If it degrades, the detected value of pressure will change. This will lower its reliability. It is therefore an object of the present invention to provide a coned disc spring which deflects uniformly in a circumferential direction so that uniform stress will act thereon over the entire area. A coned disc spring according to the present invention comprises a central circular portion and a peripheral portion which is corrugated, charaterised in that the peripheral portion is corrugated in such a manner as to form spirals each extending from a predetermined point on the perimeter of the circular portion. With this arrangement, if pressure is applied to any given point on the surface of the coned disc spring, deflection owing to the pressure will be transmitted to the entire area of the spring through the spiral waves. Thus the spring is subjected to a uniform stress and can deflect uniformly with respect to a circumferential direction. The spirals may be formed so as to extend from at least two predetermined points on the perimeter of the circular portion. This will serve to equalize the rigidity of the spring at the peripheral portion thereof and thus allow the spring to deflect equally in a circumferential direction. Further by providing the spirals in an odd number, the radii of curvature of the spirals over the entire area will get close to one another. This serves to further equalize the rigidity and allow the spring to deflect more uniformly in a circumferential direction. If the spirals are formed so that their crests and troughs are continuous with each other, the spring can deflect more smoothly. By providing inner and outer wave rings concentric with the circular central portion, a stress which acts on the central portion in such a manner as to cause an upheaval of the spring will be absorbed and dispersed in the inner concentrical wave ring, whereas a wrinkle-forming stress produced along the outer peripheral portion will be absorbed and dispersed in the outer wave ring. This effect will further strengthen the spirals are joined together at their starting and terminal ends. Therefore, a diaphragm or a diaphragm assembly made by use of the above-described coned disc spring, which has the above-described characteristics, can keep a certain property (restoring force) for a prolonged period of time and thus its reliability increases. If the above-described coned disc spring is used as a return spring for a keytop of a keyboard switch, a depressing force applied to the coned disc spring can be transmitted over the entire area through the wave pattern. The spring will deflect not only with a vertical component of the depressing force but with its horizontal component. Thus the operability improves. The invention provides a method for fixing a coned disc spring according to the present invention for use as a diaphragm, comprising the step of pressing contact surfaces of a pair of packings against the outer edge of said spring over the entire perimeter thereof from both sides so that said outer edge of said spring will be pushed outwardly, said contact surfaces being tapered outwardly toward said outer edge, said packings being fitted in annular opposed surfaces of support members. Since the outer edge of the spring is pushed outwardly by the packings, the spring can be supported so that a radial tensile force will act on its entire area. The invention also provides a method for fixing a coned disc spring according to the present invention for use as a diaphragm by fixing the outer peripheral edge of the spring to an inner surface of an annular flange having a sectional shape of the letter L, said method comprising: the first step of pressing the outer peripheral edge of said spring downwardly by mean of a punch having a bottom surface or a pressure application surface curved outwardly and downwardly, so as to insert the peripheral edge into a downwardly extending groove formed in the inner surface of the flange along a fold line; the second step of placing the flange on a female die so that a bottom surface and an inner surface of a horizontal portion of the flange comes into close contact with the female die, and pressing the outer peripheral edge at the top surface of an upright portion of the flange by means of a punch having a bottom surface or a pressure application surface curved outwardly and downwardly to push said upright portion inward; and the third step of pressing downwardly the thus inwardly pushed upright portion of the flange by means of a punch having a bottom surface or a pressure application surface tapered outwardly and upwardly, with the flange placed on the female die. If the spring is made of a metal, the flange should be made of a material similar to that for the spring and preferably of an annealed material. With this arrangement, the outer peripheral edge of the spring is inserted in the groove in the first step and the upright portion of the flange is pressed down inwardly in the second step. This will collapse the groove, thus fixing the outer edge of the spring to the flange. In this state, the upright portion of the flange is further pressed (caulked) to firmly grip the outer edge of the spring in the flange. A radially outwardly directed tensile force will be given to the outer edge of the spring through the contact surfaces tapered outwardly and upwardly. In order that the invention may be well understood, some embodiments thereof, which are given by way of example only, will now be described with reference to the accompanying drawings, in which: Fig. 1 is a schematic front view of a preferred embodiment of the coned disc spring according to the present invention, Fig. 2 is a sectional view of the same, Figs. 3 and 4 are views showing how the same is manufactured, Fig. 5 is a schematic front view of another embodiment, Fig. 6 is a sectional view of the same, Fig. 7 is a partial sectional view of still another embodiment, Fig. 8a is a perspective view showing how it is used, Fig. 8b is a sectional view of Fig. 8a, Fig. 9 is a view showing the result of measurement of pressure variation, Figs. 10a to 10d are views showing one example of the manner of fixing the diaphragm, Figs. 11a to 11b are views showing another example of the manner of fixing the same, Figs. 12 and 14 are sectional front views of the embodiments of a pressure detecting device, Figs. 13 and 15 are sectional side views of the embodiments of the same, Figs. 16 to 18 are sectional views of the embodiments of the keyboard switch, and Fig. 19 is a schematic front view of a prior art coned disc spring. (Embodiment I) In this embodiment, a coned disc spring D is used as a diaphragm. It is made by finishing a hoop of stainless foil having a thickness of 0.015 mm and a width of 34 mm so that its diameter will be 25.4 mm. Figs. 1 and 2 show embodiments made of the above-described foil. In these figures, the distance d between adjacent waves P₁, P₂ and P₃ (generally represented P), i.e. the distance between adjacent troughs except their junction areas, is 1.8 mm, the diameter of the inner wave ring (trough) P₁ is 5.9 mm and the diameter of the outer wave ring P₂ is 16.7 mm. The spirals P₃ shown in Fig. 2 have radii of curvature r and r' of 1.5 mm and 1.0 mm at its trough and crest portions, respectively, and extend outwardly from three points on the inner wave ring P1 spaced apart from one another at equal angular intervals. The height of wave t is 0.3 mm, the difference of height T between the peripheral portion and the central portion is 1.5 mm, and the radius of curvature R of the diaphragm B is 100 mm. In the embodiment, each spiral P₂ makes one turn. But its structure is not limited thereto. Also the abovementioned dimension are not limited to the abovementioned figures but should be determined through experiments or the like taking into consideration the mounting position and the material of the spring, or diaphragm, D. Instead of a stainless foil, it may be made of a copper alloy foil such as phosphor bronze and beryllium copper, rubber, plastic or any other known material. The diaphragm D is made by press molding a material put in a mold designed based on the predetermined dimensions (shape) and then by punching the press-molded product. The mold is made in principle by electrical discharge machining and put to use after making a suitable adjustment. Since the diaphragm is press-molded in such a way that both ends of the spirals P₃ will continue with the inner and outer wave rings P₁ and P₂, the stress acting on the spirals P₃ during press-molding is absorbed by the wave rings P₁ and P₂. Thus no wrinkles were formed on the diaphragm during press-molding. The mold is made by an electrode S for electrical discharge machining. The electrode may be made by use of a milling machine capable of three-dimensional numerical control. More specifically, after inputting the specifications of the diaphragm D in the milling machine, the wave pattern P₃ shown in Fig. 3 is formed on a plate as a material for the electrode by an end mill of the milling machine. As shown in Fig. 4, a rod 14 for supporting electrode is put on the thus made electrodes S through a boss 13 and the electrode is mounted on an electric discharge machine to produce one of the molds W (male and female molds). The mold thus made is then used as an electrode to produce the other mold by electrical discharge machining. (Embodiment 2) As shown in Figs. 5 and 6, the concentric inner and outer wave rings P₁ and P₂ of the first embodiment are omitted in this embodiment. Three spirals P extend in juxtaposition with one another from three points on an inner circle 10 spaced apart from one another at equal angular intervals. Specimens 1 - 4 according to this embodiment were prepared by use of the manufacturing means used in the embodiment 1. Their dimensions (the values of t, T, etc.) are shown in Table 1. They are all made of a stainless foil (hoop) and have the same dimensions, that is, 0.015 mm thick, 100 mm in the radius of curvature and 25.4 mm in diameter. Fig. 7 shows the sectional shape or the wave pattern P of the specimen 1 while Fig. 6 shows those of the others. The number of turns of the spirals P₃ is determined by the distance d between the adjacent troughs thereof. Those of the specimens 1 and 2 and the specimens 3 and 4 were one and a half and two, respectively. Annular flanges 22 were secured to the diaphragms D thus made to support them, as shown in Fig. 8. Displacement under pressure was measured for each specimen. The results are shown in Fig. 9. As is apparant from Fig. 9, the curves for the specimens 3 and 4 have a portion sloping at a steep angle (200 - 500 mm H₂0). Thus the digital output can be changed over between ON and OFF at this portion. The results show that any of the specimens can be satisfactorily used for the purposes required. To mount the spring for use as a diaphragm in a fixed position, an annular flange 22 (made of SUS 304 or 316 steel under JIS) having a sectional shape of the letter L is fixed in position, as shown in Fig. 10a, the diaphragm is put on a horizontal portion 22a of the flange 22 as shown by chain line, and then a punch 24 having its bottom surface 24a as a pressure application surface curved outwardly and downwardly is pressed against the outer edge of the diaphragm D to deflect its edge downwardly into a flat shape, thus pushing it into a downwardly extending groove 22c formed in the inner surface of the flange 22 along its fold line. In this state, the edge of the diaphragm D, which is urged to return to its original position, will abut the top surface of the groove 22c so as to be kept in this position. Then, as shown in Fig. 10b, the flange 22 is placed on a female die 25 so that its bottom and inner sides will be brought into close contact with the female die 25 and a punch 26 having its bottom surface 26a as a pressure application surface curved outwardly and downwardly is pressed against the outer top edge of an upright portion 22b of the flange 22 to push down the upright portion inwards. Thus the groove 22c will disappear and the outer edge of the diaphragm D will be held by the flange 22 (see Fig. 10c). Further, as shown in Fig. 10c, after removing the punch 26, a punch 27 having its bottom surface 27a as a pressure application surface curved outwardly and upwardly is pressed against the thus bent upright portion of the flange 22 to caulk the flange and thus to tightly hold the edge of the diaphragm D in the flange 22. In this state, an outward (centrifugal) tensile force is applied uniformly to the entire peripheral portion of the diaphragm D. This will allow the diaphragm to deflect uniformly over the entire area thereof and thus serve to stabilize its characteristics. Figs. 11a and 11b show another means for supporting the diaphragm D. It comprises support members 20 each formed with a dovetail groove 20a and packings 28 received in the dovetail grooves 20a and having contact surfaces 28a tapered outwardly toward the abutting surfaces with the diaphragm D. The diaphragm D has its outer edge inserted in between the packings 28 and secured firmly by means of bolts 29. As the bolts 29 are tightened, the packings 28 will deflect outwardly, thus biasing the outer edge of the diaphragm D in a centrifugal direction. The diaphragm D will undergo a tensile force in the radial direction over the entire area thereof. In the embodiments 1 and 2, the diaphragm D is made of a foil. But if the diaphragm has a larger diameter, or if the object being measured has a higher pressure, it may be made of a thicker material. (Embodiment 3) In this embodiment, the aforementioned diaphragm D is used as a pressure detector. As shown in Figs. 12 and 13, a casing 31 comprises three members 31a, 31b and 31c. A pressure detecting chamber 33 is defined between the members 31a and 31b. The diaphragm D is held between the members 31a and 31b through a packing 32. The diaphragm D partitions the pressure detecting chamber 33 into two compartments 33a and 33b. A pressure detecting fluid a is adapted to be introduced into the compartment 33a. The diaphragm D deflects as the pressure of the fluid fluctuates. The bonded surface between the members 31a and 31b are hermetically sealed by means of a seal ring 36. The member 31c of the casing 31 is secured to the member 31b by screws 37. A switch 34 is provided in the member 31c. The switch 34 comprises a contact 34a, a lever 34b, a ram 34c and the like. The ram 34c extends through the member 31b so that its top end will get into and out of contact with the diaphragm D. Its bottom end is abutting the lever 34b pivotally supported by a support lever 34d. A hydraulic pressure adjusting element 38 is screwed through the member 31c and is in abutment with the bottom surface of the support lever 34d through a spring 39. The lever 34b and the ram 34c can be located in a desired position by adjusting the length of engagement of the adjusting element 38. The adjusting element 38 is adjusted so that the ram 34c will be pushed by the diaphragm D when it returns to its original position after having been deflected, thus actuating (turning ON or OFF) the contact 34a. In the embodiment shown in Figs. 14 and 15, the sensor for detecting the deflection of diaphragm D is composed of a differential transformer 34e, a lever 34 for moving its iron core, a ram 34c and the like, in place of the switch 34. As with the previous embodiments, the lever 34b and the ram 34c can be located in a desired position by adjusting the length of engagement of the adjusting element 38. The adjusting element 38 is adjusted so that the diaphragm D will push the ram 34c to move the iron core of the differential transformer 34e when the diaphragm is deflected into its straight state. The detected value should be compensated for by taking into account the biasing force of the spring 39. The pressure detecting device of the diaphragm type of this embodiment can be used as a detecting unit for the monitoring and control of the level of water in a water tank by mounting it on its bottom so that the water pressure will be applied to the detecting chamber 33a. For example, this device can be used to monitor and control the level of water in a full-automatic washing machine. This device can also detect the fluctuation of back pressure in a fluid feed line by introducing the detecting fluid through this feed line and thus can be used as a detecting unit for controlling valves provided in the fluid feed line. For example, this device may be provided in the supply and discharge lines of a hot water supply device, in the fuel supply line of an engine, or the air intake line of an air-conditioner to detect the clogging of lines and filters. Also the device of this embodiment can be used as an instrument for monitoring and controlling the fluctuation of heat or one for measuring temperature by sealing a thermal expansion gas in the pressure detecting chamber 33a. For example, this device can be used as a detecting unit in a fire alarm system. (Embodiment 4) In this embodiment, as shown in Figs. 16 to 18, the coned disc spring of the embodiments 1 or 2 (which is in the form of the diaphragm D) is used as a return spring for a key top 43 of a keyboard switch. The keyboard has a construction as described in the "back ground art" chapter. By pressing the key top 43, the coned disc spring D will deflect smoothly, turning on the contact 42. By releasing the key top, the coned disc spring D will return to its original position smoothly, thus turning off the contact 42. Thus the key top can be operated smoothly. The coned disc spring according to the present invention can be used not only as a diaphragm or a return spring for a key top but also for other purposes. (Industrial application) The coned disc spring according to the present invention can be used as a return spring for a key top of the keyboard switch of a word processor for a personal computer and is suitable for use in other devices which is required to deflect smoothly and reliably.

Claims: A coned disc spring D comprising a central circular portion (10) and a peripheral portion which is corrugated, characterised in that the peripheral portion is corrugated in such a manner as to form spirals (P3) each extending from a predetermined point on the perimeter of said circular portion (10). A coned disc spring as claimed in claim 1, wherein said respective spirals (P3) extend from at least two predetermined points on the perimeter of said circular portion (10), said predetermined points being arranged at equal angular intervals from each other. A coned disc spring as claimed in claim 1 or 2, wherein said spirals (P3) are provided in an odd number. A coned disc spring as claimed in any one of claims 1 to 3, wherein said spirals (P3) are formed so that their crests and troughs are continuous with each other. A coned disc spring as claimed in any one of claims 1 to 4, wherein said peripheral portion is formed around and adjacent to said circular portion (10) with a wave ring (P1) concentric with said circular portion (10) and with another wave ring (P2) outside of and spaced apart by a predetermined distance from as said wave ring (P1) so as to be concentrical with said wave ring (P1), said spirals (P3) being formed between said wave rings (P1, P2). A coned disc spring as claimed in claim 5, wherein said each spiral (P3) has its respective ends joined to said inner ring (P1) and said outer ring (P2). A coned disk spring (D) as claimed in any one of claims 1 to 6, characterised in that the said spring (D) is used as a diaphragm. A coned disc spring (D) as claimed in claim 7, the edge portion of which is gripped from both sides by a pair of annular flanges (22) having integrally joined together outer peripheral portions such that a uniform radial tensile force is imparted to said diaphragm over the entire area thereof. A pressure detecting means having a casing (31) formed with pressure detecting chambers (33) separated from each other by a diaphragm (D), comprising a coned disc spring as claimed in claim 7, one of said pressure detecting chambers (33) being filled with a pressure detecting fluid ( a ), the other chamber containing a switch means adapted to be actuated by said diaphragm (D) when it deflects by a predetermined amount. A pressure detecting means as claimed in claim 9, wherein said switch means (34) is a sensor for continuously detecting the amount of deflection of said diaphragm (D). A coned disc spring (D) as claimed in any one of claims 1 to 6, characterised in that said spring (D) is used as a return spring for a key top (43) of a keyboard switch. A method for fixing a coned disc spring as claimed in any one of claims 1 to 6 for use as a diaphragm, comprising the step of pressing contact surfaces (28a) of a pair of packings (28) against the outer edge of said spring (D) over the entire perimeter thereof from both sides so that said outer edge of said spring will be pushed outwardly, said contact surfaces (28a) being tapered outwardly toward said outer edge, said packings (28) being fitted in annular opposed surfaces of support members (20). A method for fixing a coned disc spring as claimed in any one of claims 1 to 6 for use as a diaphragm, by fixing the outer peripheral edge of the spring (D) to an inner surface of an annular flange (22) having a sectional shape of the letter L, said method comprising: the first step of pressing the outer peripheral edge of said spring (D) downwardly by means of a punch (24) having a bottom surface (24a) or a pressure application surface curved outwardly and downwardly, so as to insert said peripheral edge into a downwardly extending groove (22c) formed in the inner surface of said flange along a fold line; the second step of placing said flange (22) on a female die (25) so that a bottom surface and an inner surface of a horizontal portion (22a) of said flange (22) comes into close contact with said female die (25), and pressing the outer peripheral edge at the top surface of an upright portion (22b) of said flange (22) by means of a punch (26) having a bottom surface (26a) a pressure application surface curved outwardly and downwardly to push said upright portion (22b) inwards; and the third step of pressing downwardly the thus inwardly pushed upright portion (22b) of the flange by means of a punch (27) having a bottom surface (27a) or a pressure application surface tapered outwardly and upwardly, with said flange (22) placed on said female die (25).

Inventors: MOTOKAWA, SHIGEAKI TATSUTA ELECTRIC WIRE & CABLE, OHGASHI, SHINICHI TATSUTA ELECTRIC WIRE & CABLE, ONISHI, KIHACHI TATSUTA ELECTRIC WIRE & CABLE, SHIMADA, TOSHINORI TATSUTA ELECTRIC WIRE & CABLE, MOTOKAWA, Shigeaki Tatsuta Electric Wire &amp; Cable, OHGASHI, Shinichi Tatsuta Electric Wire &amp; Cable, ONISHI, Kihachi Tatsuta Electric Wire &amp; Cable, SHIMADA, Toshinori Tatsuta Electric Wire &amp; Cable
Applicants: TATSUTA ELECTRIC WIRE & CABLE CO., LTD
Application year: 1989
Main classification: F16F1
IPC codes: G01L9, H01H5, G01L7, F16J3, F16F1