The production of plastic switches is a complex process that requires precision and attention to detail. The process begins with the selection of the appropriate raw materials, typically a blend of thermoplastic polymers. These materials must be capable of withstanding the stresses and temperatures associated with the manufacturing process, while also maintaining their electrical insulation properties.
Once the raw materials are chosen, they are conveyed to the extruder, where they are heated and mixed before being pushed through a die to form the desired shape of the switch. In the extrusion process, the molten plastic is forced through a small opening, creating a continuous sheet or film. This sheet is then cooled and reheated in the orientation stage, where it is stretched in one direction to enhance its mechanical properties.
After the orientation stage, the sheet proceeds to the cutting and punching stations, where it is cut into individual switch blanks and punched with holes or slots for the various components. These components typically include electrical contacts, springs, and insulating disks. The punched parts are then transferred to the assembly station, where they are inserted into the switch housings. During assembly, the plastic switch housings are filled with an insulating compound to ensure electrical insulation between the various components. The filled switch is then cured in an oven or autoclave to bond the components together and ensure the integrity of the electrical insulation.
