Switch device and manufacturing method

Abstract

A switch device is a switch device comprising a metal terminal component and a resin component, wherein the resin component is formed integrally with the metal terminal component by insert molding, and the metal terminal component comprises a first arm portion and a second arm portion extending side by side with each other from a side portion of the resin component to a first direction as an outer direction, the first arm portion having a first contact portion facing the first direction, and the second arm portion having a second contact portion facing a second direction opposite to the first direction and opposite to the first contact portion, and an external terminal can be inserted between the first contact portion and the second contact portion while elastically deforming the first contact portion and the second contact portion respectively.

Description

Technical Field

[0001] The invention relates to a switch device and a manufacturing method. Background Art

[0002] Patent Document 1 below discloses a blade spring provided on an inserting connector, wherein each of a pair of joint portions includes a pair of contact pieces facing each other at the front end thereof, and the insert piece can be inserted between the pair of contact pieces.

[0003] Prior art literature

[0004] Patent Literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 54-20667 Summary of the invention

[0006] Technical Problems to be Solved by the Invention

[0007] However, in the technology of the above-mentioned patent document 1, a pair of contact pieces are arranged opposite to each other in a direction orthogonal to the direction in which the pair of connecting parts extend. Therefore, when the interval between the pair of connecting parts is enlarged due to external force, for example, the interval between the pair of contact pieces is also enlarged, and thus the holding force of the pair of contact pieces on the inserted plug may be weakened.

[0008] Means for solving technical problems

[0009] A switch device in one embodiment is a switch device comprising a metal terminal component and a resin component formed integrally with the metal terminal component by insert molding, the metal terminal component comprising a first arm portion and a second arm portion extending side by side with each other from a side portion of the resin component toward a first direction as an outer direction, the first arm portion having a first contact portion facing the first direction, the second arm portion having a second contact portion facing a second direction opposite to the first direction and opposite to the first contact portion, and an external terminal can be inserted between the first contact portion and the second contact portion while elastically deforming the first contact portion and the second contact portion respectively.

[0010] Effects of the Invention

[0011] According to one embodiment, even when the distance between the pair of arm portions is increased, it is possible to avoid a reduction in the holding force of the pair of contact portions for the external terminal. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 This is a perspective view of the appearance of a molded component according to one embodiment.

[0013] Figure 2 is a top view of a formed part according to one embodiment.

[0014] Figure 3 is a side view of a formed part of one embodiment.

[0015] Figure 4 This is a perspective view of the appearance of three metal terminal components according to one embodiment.

[0016] Figure 5 This is a perspective view of the appearance of a molded component (in a state where a rod, a spring, and a clamp are assembled) according to one embodiment.

[0017] Figure 6 This is a perspective view of the appearance of a switch device according to one embodiment.

[0018] Figure 7 This is a perspective view of the appearance of a connecting portion according to one embodiment.

[0019] Figure 8 It is a top view of the connection part of one embodiment.

[0020] Fig. 9 is a side view of a connecting portion of one embodiment.

[0021] Fig.10 It is a diagram showing a method of connecting an external terminal to a connecting portion according to one embodiment.

[0022] Fig.11 This is a partially enlarged view of a side portion of a resin component in a molded component according to one embodiment.

[0023] Fig.12 This is a flowchart showing the procedure of a method for manufacturing a molded component and a switch device according to one embodiment.

[0024] Fig.13 1 is a three-dimensional view of a metal plate according to an embodiment.

[0025] Fig.14 This is a three-sided view of a metal plate (after the first bending process) according to one embodiment.

[0026] Fig.15 This is a three-sided view of a metal plate (after the second bending process) according to one embodiment.

[0027] Fig.16 This is a three-dimensional view of a metal plate (after insert molding) according to one embodiment.

[0028] Fig.17 It is a three-sided view of the metal plate (after the third bending process) according to one embodiment. DETAILED DESCRIPTION

[0029] Hereinafter, one embodiment will be described with reference to the drawings.

[0030] (Overview of Molded Component 100)

[0031] Figure 1 This is a perspective view of the appearance of a molded component 100 according to one embodiment. Figure 2 is a top view of a formed part 100 according to one embodiment. Figure 3 is a side view of a formed part 100 according to one embodiment. Figure 4 This is a perspective view of the appearance of three metal terminal components 111, 112, and 113 according to one embodiment.

[0032] Figure 1 to Figure 3 The molded component 100 shown has three metal terminal components 111, 112, 113 and a resin component 120. The resin component 120 is formed integrally with the three metal terminal components 111, 112, 113 by insert molding.

[0033] The three metal terminal parts 111, 112, and 113 are all metal and thin plate-shaped parts. Figure 4 As shown in FIG. 1 , the three metal terminal members 111, 112, and 113 are arranged on the same plane (XY plane) without contacting each other. Figure 1 to Figure 3 As shown, in the molded component 100 , a portion (middle portion) of each of the three metal terminal members 111 , 112 , and 113 is buried in the resin member 120 .

[0034] The three metal terminal members 111, 112, and 113 have connection portions 130A, 130B, and 130C at one end side (X-axis negative side), respectively. The connection portions 130A, 130B, and 130C have a pair of arm portions 131 and 132. Figure 2 As shown, when viewed from above, the pair of arm portions 131 and 132 extend linearly and parallel to each other in the outward direction (negative direction of the X-axis) from the side portion 120A on the negative side of the X-axis of the resin member 120. In addition, the connecting portions 130A, 130B, and 130C have a pair of contact portions 131D and 132E facing each other in the direction in which the pair of arm portions 131 and 132 extend (the X-axis direction), and the external terminal 30 (see FIG. 1 ) is inserted between the pair of contact portions 131D and 132E. Figure 8 ) thereby connecting the portion of the external terminal 30. The connection portions 130A, 130B, and 130C are arranged parallel to each other in the Y-axis direction (in the order of the connection portions 130A, 130B, and 130C from the negative side of the Y-axis).

[0035] In addition, the three metal terminal members 111, 112, and 113 have sliding contact portions 111B, 112B, and 113B on the other end side (positive side of the Y axis), respectively. Figure 2As shown, when viewed from above, the sliding contact portions 111B, 112B, and 113B are formed from the side portion of the resin member 120 on the positive side of the Y axis along the jig 16 (see Figure 5 ) is a portion of the sliding path that projects in a curved shape. In addition, the sliding contact portions 111B, 112B, and 113B are portions that electrically connect and switch the terminals to each other by sliding the clamp 16. The sliding contact portions 111B, 112B, and 113B are arranged at a certain interval in the X-axis direction (from the negative side of the X-axis in the order of the sliding contact portions 113B, 112B, and 111B).

[0036] In addition, the front end portion of the sliding contact portion 112B is cut shorter than that of the sliding contact portion 113B, and in the space on the extension line of the sliding contact portion 112B formed thereby, the front end portion of the sliding contact portion 111B having a shape bent toward the side of the sliding contact portion 112B is arranged opposite to the front end portion of the sliding contact portion 112B.

[0037] Figure 5 1 is a perspective view of the appearance of a molded component 100 (in a state where a rod 12, a spring 14, and a clamp 16 are assembled) according to an embodiment. Figure 5 As shown, a rod 12, a spring 14, and a clamp 16 are assembled in the molded component 100. The rod 12 is a resin component that is rotatably supported by the resin component 120 with the rotation center axis AX extending in the Z-axis direction as the rotation center. The spring 14 is a so-called torsion spring, and urges the rod 12 in the return direction (counterclockwise when viewed from the Z-axis positive side) through an arm 14A provided at the end on the Z-axis positive side.

[0038] The clamp 16 is held by the rod 12, and moves along a circle centered on the rotation center axis AX as the rod 12 rotates. The clamp 16 is formed of a metal material and has a pair of upper and lower first contacts (not shown) and a pair of upper and lower second contacts (not shown). The pair of first contacts are always in contact with the upper and lower surfaces of the sliding contact portion 113B of the metal terminal component 113, and slide on the upper and lower surfaces of the sliding contact portion 113B as the clamp 16 moves when the sliding contact portion 113B of the metal terminal component 113 is clamped. The pair of second contacts slide on the upper and lower surfaces of the sliding contact portion 111B when the sliding contact portion 111B of the metal terminal component 111 is clamped, or slide on the upper and lower surfaces of the sliding contact portion 112B when the sliding contact portion 112B of the metal terminal component 112 is clamped. Thus, the clamp 16 can bring the metal terminal member 113 into electrical conduction with the metal terminal member 111 or the metal terminal member 112 as the clamp 16 moves.

[0039] Figure 6FIG. 1 is a perspective view of the appearance of a switch device 10 of an embodiment. Figure 6 As shown, the molded component 100 is housed in the housing 18 in a state where the rod 12, the spring 14, and the clamp 16 are assembled. Thus, the molded component 100, the rod 12, the spring 14, the clamp 16, and the housing 18 together constitute the switch device 10.

[0040] In the switch device 10 constructed in this way, when the rod 12 is not pressed, a pair of first contacts of the clamp 16 contact the metal terminal part 113, and a pair of second contacts of the clamp 16 contact the metal terminal part 111, thereby forming a first state in which the metal terminal part 113 and the metal terminal part 111 are electrically connected to each other.

[0041] In addition, when the rod 12 of the switch device 10 is pressed, a pair of first contacts of the clamp 16 contact the metal terminal part 112, and a pair of second contacts of the clamp 16 contact the metal terminal part 111, thereby forming a second state in which the metal terminal part 112 and the metal terminal part 111 are electrically connected to each other.

[0042] Furthermore, in the switch device 10, when the pressing of the lever 12 is released, the lever 12 automatically returns to the initial position by the force of the spring 14. Thus, the switch device 10 automatically returns to the first state in which the metal terminal member 113 and the metal terminal member 111 are in conduction with each other.

[0043] For example, the switch device 10 can be used to detect the open / closed state of a door of a car.

[0044] In addition, in the switch device 10, an opening 18C through which at least the external terminal 30 can be inserted is formed on each of the upper surface 18A and the lower surface 18B of the housing 18 at each position overlapping with the connection parts 130A, 130B, and 130C when viewed from above in the Z-axis direction. Thus, each of the connection parts 130A, 130B, and 130C of the switch device 10 can be connected to the external terminal 30 from either the upper surface 18A side or the lower surface 18B side.

[0045] (Structure of the connecting portion 130)

[0046] Next, refer to Figure 7 to Figure 9 , the detailed structure of the connection parts 130A, 130B, and 130C of the metal terminal parts 111, 112, and 113 is described. In addition, the connection parts 130A, 130B, and 130C have the same structure. Therefore, here, the connection parts 130A, 130B, and 130C are not distinguished and are collectively referred to as "connection parts 130" for description.

[0047] Figure 7This is a perspective view of the appearance of the connection portion 130 according to one embodiment. Figure 8 FIG. 1 is a top view of the connection portion 130 according to one embodiment. Fig. 9 is a side view of the connection portion 130 according to one embodiment.

[0048] <Schematic Structure of Connecting Section 130>

[0049] like Figure 7 to Figure 9 As shown, the connecting portion 130 has a first arm portion 131 , a second arm portion 132 and a branch portion 133 .

[0050] The first arm portion 131 is provided to extend from the Y-axis positive side portion of the branch portion 133 toward the X-axis negative direction. The first arm portion 131 is a portion extending outward (X-axis negative direction) from the X-axis negative side portion 120A of the resin component 120 after the resin component 120 is insert molded.

[0051] The second arm portion 132 is provided to extend in the negative direction of the X axis from the portion on the negative side of the Y axis of the branch portion 133. The second arm portion 132 is a portion that extends from the side portion 120A on the negative side of the X axis of the resin component 120 to the outside direction (negative direction of the X axis) in parallel with the first arm portion 131 and extends a distance longer than the first arm portion 131 after the resin component 120 is insert molded.

[0052] like Figure 8 As shown, when viewed from above, the portion of the first arm 131 extending outward (the negative direction of the X-axis) and the portion of the second arm 132 extending outward (the negative direction of the X-axis) are parallel to each other and have a certain distance therebetween.

[0053] In addition, if Figure 8 As shown, the connection portion 130 includes a first contact portion 131D and a second contact portion 132E, and the first contact portion 131D and the second contact portion 132E are arranged opposite to each other in the X-axis direction on the middle line L1 (see Figure 8 ), the middle line L1 passes through the middle position of the portion of the first arm 131 extending in the outward direction (negative direction of the X-axis) and the portion of the second arm 132 extending in the outward direction (negative direction of the X-axis) and is parallel to the X-axis.

[0054] The first contact portion 131D faces the outward direction (the negative direction of the X-axis, an example of the “first direction”). The first contact portion 131D has a shape that is bent convexly toward the outward direction and has a shape that hangs downward. The first contact portion 131D is provided at the front end portion of the first arm portion 131, and the upper end portion is supported by the first beam portion 131C of the first arm portion 131. In order to position the first contact portion 131D on the middle line L1, the first arm portion 131 has a shape that is bent at a right angle toward the middle line L1 at the front end portion of the portion extending toward the outward direction (the negative direction of the X-axis) when viewed from above.

[0055] The second contact portion 132E faces the inner direction (the positive direction of the X-axis, an example of the "second direction"). The second contact portion 132E has a shape that is convexly bent in the inner direction and has a shape that hangs downward. The second contact portion 132E is provided at the front end portion of the second arm portion 132, and the upper end portion is supported by the second beam portion 132D of the second arm portion 132. In order to position the second contact portion 132E on the middle line L1, the second arm portion 132 has a shape that is bent at a right angle toward the middle line L1 at the front end portion of the portion extending in the outer direction (the negative direction of the X-axis) when viewed from above.

[0056] The top of the first contact portion 131D and the top of the second contact portion 132E are close to each other, and the flat plate-shaped external terminal 30 can be inserted between the two from either the upper side or the lower side. The external terminal 30 is inserted between the first contact portion 131D and the second contact portion 132E, and is sandwiched by the pair of contact portions 131D and 132E, and is electrically connected to the connection portion 130.

[0057] <Detailed Structure of the First Arm 131>

[0058] The first arm portion 131 has a first horizontally extending portion 131A, a first rising portion 131B, a first beam portion 131C, and a first contact portion 131D.

[0059] The first horizontal extension portion 131A is at a first height position H1 (see Fig. 9 ) is a portion extending linearly and horizontally from the portion on the positive side of the Y axis of the branch portion 133 toward the negative direction of the X axis. Figure 8 As shown, when viewed from above, the first horizontal extending portion 131A is parallel to the second horizontal extending portion 132B of the second arm portion 132 .

[0060] The first rising portion 131B is a portion that extends straightly forward (in the negative direction of the X-axis) and obliquely upward from the front end portion (the end portion on the negative side of the X-axis) of the first horizontally extending portion 131A. The first rising portion 131B is formed by setting the boundary line with the first horizontally extending portion 131A as the bending line L11 (see Figure 7) is bent upward, and becomes inclined upward from the front end of the first horizontal extension portion 131A. Fig. 9 As shown in FIG. 1 , the first rising portion 131B extends to a second height position H2 higher than the first height position H1 . Thus, the first rising portion 131B can position the upper end of the first contact portion 131D at the second height position H2 .

[0061] The first beam portion 131C is a vertical beam-shaped portion that extends linearly from the upper end portion (the end portion on the negative side of the X axis) of the first rising portion 131B in the direction of the middle line L1 (the negative direction of the Y axis) at the second height position H2. The first beam portion 131C is formed by taking the boundary line with the first rising portion 131B as the bending line L12 (see Figure 7 ) is bent upward to be in a vertical state. The first beam portion 131C is connected to the upper end portion of the first contact portion 131D on the middle line L1. Thus, the first beam portion 131C supports the upper end portion of the first contact portion 131D.

[0062] The upper portion of the first beam portion 131C passes through the bending line L13 (see Figure 7 ) is bent toward the positive side of the X-axis and reinforced. Thus, the first beam portion 131C can improve the rigidity of the first arm portion 131 so that the first arm portion 131 will not be twisted and deformed when the external terminal 30 is inserted between the pair of contact portions 131D and 132E.

[0063] The first contact portion 131D is a portion extending downward from the first beam portion 131C on the middle line L1. The first contact portion 131D has a boundary line with the first beam portion 131C as a bending line L14 (see Figure 7 ) is bent in the negative direction of the X-axis. In addition, the first contact portion 131D has a shape that is convexly curved in the negative direction of the X-axis. The top of the convex portion of the first contact portion 131D is opposite to the top of the convex portion of the second contact portion 132E. When the flat plate-shaped external terminal 30 is inserted between the first contact portion 131D and the second contact portion 132E, the top of the convex portion of the first contact portion 131D contacts the surface of the external terminal 30 on the positive side of the X-axis.

[0064] <Detailed Structure of Second Arm 132>

[0065] The second arm portion 132 has a hanging portion 132A, a second horizontally extending portion 132B, a second rising portion 132C, a second beam portion 132D, and a second contact portion 132E.

[0066] The hanging portion 132A is a portion extending straightly forward (in the negative direction of the X axis) and obliquely downward from the portion of the branch portion 133 on the negative side of the Y axis. The hanging portion 132A is formed by setting the boundary line with the branch portion 133 as the bending line L21 (see Figure 7) is bent downward to become a state in which the portion on the negative side of the Y axis of the branch portion 133 is tilted downward. Fig. 9 As shown, the hanging portion 132A extends to a third height position H3 that is lower than the first height position H1. Thus, the hanging portion 132A enables the subsequent second horizontally extending portion 132B to be located at the third height position H3.

[0067] The reason for providing the hanging portion 132A in the second arm portion 132 is as follows. Fig.13 As shown in FIG. 1 and FIG. 2 , in this embodiment, the metal terminal members 111, 112, and 113 are formed by a metal plate P. Fig.13 As shown in FIG. 1 , when the metal plate P is unfolded, the first contact portion 131D and the second contact portion 132E are arranged on the same straight line in the X-axis direction. Therefore, in this embodiment, the first contact portion 131D and the second contact portion 132E can be efficiently formed by a single metal plate P. Therefore, it is necessary to make the terminal length of the second arm portion 132 in the X-axis direction longer than the terminal length of the first arm portion 131, but as shown in FIG. Figure 7 to Figure 9 When first arm portion 131 and second arm portion 132 are formed into a three-dimensional shape as shown, second arm portion 132 is provided with hanging portion 132A in order to reduce the difference in terminal length and bring second contact portion 132E closer to first contact portion 131D.

[0068] The second horizontal extension portion 132B is a portion that extends linearly and horizontally from the lower end portion (the end portion on the negative side of the X-axis) of the hanging portion 132A in the negative direction of the X-axis at the third height position H3. Figure 7 ) bends to a horizontal state. Figure 8 As shown, when viewed from above, the second horizontal extension portion 132B is parallel to the first horizontal extension portion 131A of the first arm portion 131. In addition, the second horizontal extension portion 132B passes through the side of the pair of contact portions 131D and 132E on the negative side of the Y axis and extends to a position parallel to the upper end of the second contact portion 132E.

[0069] The second rising portion 132C is a vertical portion extending upward from the front end portion (the end portion on the negative side of the X-axis) of the second horizontally extending portion 132B. The second rising portion 132C is provided at two bending lines L23 and L24 (see FIG. 1 ) provided between the second rising portion 132C and the second horizontally extending portion 132B. Figure 7 ) is bent upward to become vertical. Fig. 9As shown, the second rising portion 132C extends to the second height position H2. Thus, the second rising portion 132C can position the upper end of the second contact portion 132E at the second height position H2. In addition, the switch device 10 of this embodiment has a structure in which the second rising portion 132C is bent in two stages along two bending lines L23 and L24, thereby being able to adjust the height position and the position in the X-axis direction of the second rising portion 132C (that is, the height position and the position in the X-axis direction of the second contact portion 132E) with high precision.

[0070] The second beam portion 132D is a vertical beam-shaped portion that extends linearly from the upper end of the second rising portion 132C in the direction of the middle line L1 (the positive direction of the Y axis) at the second height position H2. The second beam portion 132D is connected to the upper end of the second contact portion 132E on the middle line L1. Thus, the second beam portion 132D supports the upper end of the second contact portion 132E.

[0071] The upper portion of the second beam portion 132D passes through the bending line L25 (see Figure 7 ) is bent in the negative direction of the X-axis and reinforced. Thus, the second beam portion 132D can improve the rigidity of the second arm portion 132 so that the second arm portion 132 will not be twisted and deformed when the external terminal 30 is inserted between the pair of contact portions 131D and 132E.

[0072] Here, if Fig. 9 As shown, the bending angle of the upper portion of the second beam portion 132D is approximately 90°, which is larger than the bending angle of the upper portion of the first beam portion 131C. Therefore, the strength of the second beam portion 132D is higher than the strength of the first beam portion 131C. This is because the terminal length of the second arm portion 132 in the negative direction of the X-axis is longer than the terminal length of the first arm portion 131 in the negative direction of the X-axis, and when an external force is applied, it is easier to cause twisting deformation than the first arm portion 131. Therefore, in the molded component 100 of this embodiment, by making the bending angle of the upper portion of the second beam portion 132D larger than the bending angle of the upper portion of the first beam portion 131C, the difficulty of causing twisting deformation between the second arm portion 132 and the first arm portion 131 is made to be the same.

[0073] The second contact portion 132E is a portion extending downward from the second beam portion 132D on the middle line L1. The second contact portion 132E has a boundary line with the second beam portion 132D as a bending line L26 (see Figure 7) is bent toward the positive side of the X-axis. In addition, the second contact portion 132E has a shape that is bent into a convex shape toward the positive side of the X-axis. The top of the convex portion of the second contact portion 132E is opposite to the top of the convex portion of the first contact portion 131D. When the flat external terminal 3 is inserted between the first contact portion 131D and the second contact portion 132E, the top of the convex portion of the second contact portion 132E contacts the surface of the external terminal 30 on the negative side of the X-axis.

[0074] Here, the first contact portion 131D and the second contact portion 132E are provided downwardly from the same height position H2, and have mutually symmetrical shapes. Thus, the first contact portion 131D and the second contact portion 132E have the same spring constant. Therefore, when the external terminal 30 is inserted between the first contact portion 131D and the second contact portion 132E, an equal load can be applied to the external terminal 30.

[0075] (Connection method of external terminal 30)

[0076] Fig.10 1 is a diagram showing a method of connecting the external terminal 30 to the connecting portion 130 according to one embodiment. Fig.10 As shown, the flat external terminal 30 is inserted between the pair of contact portions 131D and 132E from above or below with one surface facing the first contact portion 131D and the other surface facing the second contact portion 132E.

[0077] Thus, the external terminal 30 expands the distance between the pair of contact portions 131D and 132E by elastically deforming the pair of contact portions 131D and 132E. The external terminal 30 is clamped between the pair of contact portions 131D and 132E by the elastic force of the pair of contact portions 131D and 132E and is electrically connected to the connection portion 130.

[0078] At this time, as described above, the spring constant of the first contact portion 131D is substantially equal to the spring constant of the second contact portion 132E. Therefore, the external terminal 30 can cause the pair of contact portions 131D and 132E to elastically deform uniformly, and can receive equal loads from the pair of contact portions 131D and 132E. Thus, the connection portion 130 of this embodiment can stably clamp the external terminal 30 through the pair of contact portions 131D and 132E.

[0079] (Structure of Side Portion 120A of Resin Member 120)

[0080] Fig.11 FIG. 1 is a partially enlarged view of a side portion 120A of a resin component 120 in a molded component 100 according to an embodiment. Fig.11As shown, the resin component 120 has a first holding portion 121 and a second holding portion 122, both of which protrude in the negative direction of the X-axis, at the side portion 120A on the negative side of the X-axis. The root portion (first horizontal extension portion 131A) of the first arm portion 131 of the first holding portion 121 is buried by insert molding, and the root portion of the first arm portion 131 is held. In the second holding portion 122, the root portion (hanging portion 132A and second horizontal extension portion 132B) of the second arm portion 132 is buried by insert molding, and the root portion of the second arm portion 132 is held.

[0081] Here, if Fig.11 As shown in FIG. 1 , the second holding portion 122 protrudes more from the side portion 120A than the first holding portion 121 protrudes from the side portion 120A. This is because the terminal length of the second arm portion 132 in the negative direction of the X axis is longer than the terminal length of the first arm portion 131 in the negative direction of the X axis, and therefore, when an external force is applied, it is easier to be twisted and deformed than the first arm portion 131. Therefore, in the molded component 100 of the present embodiment, the protrusion amount of the second holding portion 122 from the side portion 120A is made larger than the protrusion amount of the first holding portion 121 from the side portion 120A, thereby improving the strength of the root portion (hanging portion 132A and second horizontal extension portion 132B) of the second arm portion 132. As a result, the molded component 100 of the present embodiment makes it equally easy to be twisted and deformed between the second arm portion 132 and the first arm portion 131.

[0082] Furthermore, the second holding portion 122 covers the base portion of the second arm portion 132 , thereby preventing the second arm portion 132 from short-circuiting with the first arm portion 131 provided close to the second arm portion 132 .

[0083] (Procedure of Manufacturing Method of Molded Component 100 and Switch Device 10)

[0084] Next, refer to Figure 12 to Figure 17 , the procedure of the method for manufacturing the molded component 100 and the switch device 10 is described. Fig.12 This is a flowchart showing the procedure of a method for manufacturing a molded component 100 and a switch device 10 according to one embodiment.

[0085] <Step S201: Metal Terminal Member Forming Process>

[0086] First, if Fig.13 As shown, the metal terminal members 111 , 112 , 113 and the holding member 20 are formed from a single metal plate P. Fig.13 1 is a three-dimensional view of a metal plate P according to an embodiment. Fig.13 The metal plate P shown is a material that becomes a base of the metal terminal members 111 , 112 , and 113 .

[0087] like Fig.13 As shown in FIG. 1 , the metal plate P has a rectangular shape when viewed from above. Fig.13 As shown, the metal plate P is punched out at a blank portion by punching using a die, thereby integrally forming the metal terminal members 111 , 112 , 113 and the holding member 20 that holds the metal terminal members 111 , 112 , 113 .

[0088] like Fig.13 As shown, the holding member 20 includes an outer frame portion 22, a pair of holding arms 24, 26, a support portion 27, a support portion 28, and a support portion 29. The outer frame portion 22 is a portion having a rectangular outer shape surrounding the metal terminal members 111, 112, 113.

[0089] The pair of holding arms 24 and 26 are arm-shaped portions extending linearly and in parallel to each other from the frame portion on the Y-axis negative side of the outer frame portion 22 toward the Y-axis positive direction.

[0090] The support portion 27 is a linear portion extending from the frame portion on the Y axis positive side of the outer frame portion 22 toward the Y axis negative direction. The support portion 27 is connected to the metal terminal member 111 to support the metal terminal member 111 from the Y axis positive side.

[0091] The support portion 28 is a linear portion extending from the frame portion on the positive side of the X axis of the outer frame portion 22 toward the negative direction of the X axis. The support portion 28 is connected to the metal terminal member 111 to support the metal terminal member 111 from the positive side of the X axis.

[0092] The support portion 29 is a linear portion extending from the Y-axis negative side frame portion of the outer frame portion 22 between the pair of holding arms 24 and 26 in the Y-axis positive direction. The support portion 29 is connected to the metal terminal member 111, thereby supporting the metal terminal member 111 from the Y-axis negative side.

[0093] <Step S202: First Bending Process>

[0094] Then, if Fig.14 As shown, the first arm portion 131 and the second arm portion 132 of each of the metal terminal members 111 , 112 , and 113 are subjected to a first bending process. Fig.14 This is a three-view diagram of a metal plate P (after the first bending process) according to one embodiment.

[0095] Specifically, the first contact portion 131D of the first arm portion 131 of each of the metal terminal members 111, 112, and 113 is bent along the bending line L14 (see Figure 7 ) is bent downward into a convex shape. In addition, the second contact portion 132E of the second arm portion 132 of each of the metal terminal members 111, 112, and 113 is bent at the bending line L26 (see Figure 7) is bent upward into a convex shape. The bending of the plurality of contact portions 131D and 132E can be performed at once by, for example, a press process using a die.

[0096] <Step S203: Second Bending Process>

[0097] Then, if Fig.15 As shown, the first arm portion 131 and the second arm portion 132 of each of the metal terminal members 111 , 112 , and 113 are subjected to a second bending process. Fig.15 This is a three-view diagram of a metal plate P (after the second bending process) according to one embodiment.

[0098] Specifically, the first arm portion 131 is provided at a bending line L11 (see Figure 7 ) is bent in a valley-folded manner, thereby inclining the first upright portion 131B at a predetermined inclination angle. In addition, for the first arm portion 131, a bending line L12 (see Figure 7 ) is bent in a valley-folded manner, thereby making the first beam portion 131C vertical. At the same time, by bending the first beam portion 131C at the bending line L13 (refer to Figure 7 ) is bent in a valley fold manner to strengthen the first beam portion 131C.

[0099] In addition, the second arm portion 132 is provided at a bending line L21 (see Figure 7 ) is bent in a mountain fold manner, thereby making the hanging portion 132A tilt downward at a predetermined tilt angle. In addition, for the second arm portion 132, a bending line L22 (see Figure 7 ) is bent in a valley fold manner, thereby making the second horizontal extension portion 132B horizontal.

[0100] <Step S204: Insert molding process>

[0101] Then, if Fig.16 As shown, a resin component 120 is insert-molded into the metal terminal components 111 , 112 , and 113 . Fig.16 1 is a three-dimensional view of a metal plate P (after insert molding) according to an embodiment. In the insert molding process, first, Fig.15 The metal plate P in the shown state is set in a mold of an insert molding machine.

[0102] Then, resin is injected into the mold by an insert molding machine. Thus, the resin component 120 is insert-molded into the metal terminal components 111, 112, 113, forming a molded component 100 in which the metal terminal components 111, 112, 113 and the resin component 120 are integrated. At this time, the front end portions of the pair of retaining arms 24, 26 are respectively embedded in the resin component 120 by insert molding.

[0103] At this point in time, the molded component 100 is connected to the outer frame portion 22 via the pair of holding arms 24 and 26 , the support portion 27 , the support portion 28 , and the support portion 29 , that is, is in a state of being held by the holding member 20 .

[0104] <Step S205: Removal process>

[0105] Then, if Fig.17 As shown, by removing unnecessary portions of the holding member 20 , the molded member 100 is held in a cantilevered state by the pair of holding arms 24 , 26 . Fig.17 1 is a three-sided view of a metal plate P (after the third bending process) according to one embodiment. Here, the "unnecessary portion" refers to a portion that is not required in the subsequent assembly process.

[0106] Specifically, by punching and other processes, Fig.16 The holding member 20 is cut along the cutting line CL1 shown, thereby removing the removal target portion 20A, which is a portion of the holding member 20 on the positive side of the Y axis relative to the cutting line CL1. Since the removal target portion 20A includes the support portion 27, the support portion 27 is also removed at the same time.

[0107] In addition, by punching, etc. Fig.16 The support portion 28 is cut along the cutting line CL2 (the connection portion with the metal terminal member 111 ) and the cutting line CL3 (the connection portion with the outer frame portion 22 ), thereby removing the support portion 28 .

[0108] In addition, by punching, etc. Fig.16 The support portion 29 is cut along the cutting line CL4 (the connection portion with the metal terminal member 111 ) and the cutting line CL5 (the connection portion with the outer frame portion 22 ) shown, thereby removing the support portion 29 .

[0109] Therefore, if Fig.17 As shown, the molded component 100 is cantilevered and held by a pair of holding arms 24 and 26 from the negative side of the Y axis. In addition, the holding component 20 is removed from an unnecessary portion and is open on the positive side of the Y axis. As a result, the molded component 100 can be easily assembled with other components and removed from the holding component 20 from the positive side of the Y axis.

[0110] Alternatively, the removal target portion 20A, the support portion 28, and the support portion 29 may be removed collectively by a single punching process.

[0111] <Step S206: Third Bending Process>

[0112] Then, if Fig.17 As shown, for the second arm portion 132, the bending lines L23 and L24 (see Figure 7 ) is bent in a valley-fold manner, thereby making the second upright portion 132C and the second beam portion 132D vertical. Fig.17 As shown, the pair of contact portions 131D and 132E are in a state of being opposed to each other in the X-axis direction. Figure 7 ) is bent in a mountain fold manner to strengthen the second beam portion 132D. In this way, after insert molding, the second upright portion 132C and the second beam portion 132D are bent to a vertical state while the root portion of the second arm portion 132 is reinforced by the second holding portion 122, thereby enabling the second contact portion 132E to be aligned with the first contact portion 131D with high accuracy. This is because if the bending process is performed before insert molding, the reaction force of the second arm portion 132 may prevent the second contact portion 132E from being aligned with the first contact portion 131D with high accuracy.

[0113] <Step S207: Assembly process>

[0114] Then, if Fig.17 As shown, in a state where the molded component 100 is held by a pair of holding arms 24 and 26, other components (the rod 12, the spring 14, the clamp 16, and the housing 18) are assembled to the molded component 100, thereby forming the switch device 10 (see Figure 6 ). The molded component 100 is cantilevered and held by a pair of holding arms 24 and 26 from the negative side of the Y axis, so that other components can be easily assembled.

[0115] <Step S208: Disassembly process>

[0116] Then, the molded component 100 (i.e., the switch device 10) in a state of being assembled with other components is moved along the positive direction of the Y axis ( Fig.17 The molded component 100 is pulled out (in the D1 direction shown) and removed from the holding member 20. Since the molded component 100 is cantilevered and held by a pair of holding arms 24 and 26 from the negative side of the Y axis, it can be easily pulled out in the positive direction of the Y axis.

[0117] As described above, a switch device 10 according to an embodiment is a switch device including metal terminal components 111, 112, 113 and a resin component 120, wherein the resin component 120 is formed integrally with the metal terminal components 111, 112, 113 by insert molding, and the metal terminal components 111, 112, 113 include a first arm portion 131 and a second arm portion 132 extending side by side from a side portion 120A of the resin component 120 along the negative direction of the X axis (the first direction), the first arm portion 131 has a first contact portion 131D facing the negative direction of the X axis, and the second arm portion 132 has a second contact portion 132E facing the positive direction of the X axis (the second direction) and opposite to the first contact portion 131D, and the external terminal 30 can be inserted between the first contact portion 131D and the second contact portion 132E while elastically deforming the first contact portion 131D and the second contact portion 132E respectively.

[0118] Thus, in the switch device 10 of one embodiment, even when the distance between the pair of arm portions 131 and 132 is increased due to external force or the like, the pair of contact portions 131D and 132E are only relatively displaced in the Y-axis direction, and the distance between the pair of contact portions 131D and 132E does not increase. Therefore, according to the switch device 10 of one embodiment, even when the distance between the pair of arm portions 131 and 132 is increased, the holding force of the pair of contact portions 131D and 132E on the external terminal 30 can be made strong.

[0119] In the switch device 10 according to one embodiment, the spring constant associated with the elastic deformation of the first contact portion 131D and the spring constant associated with the elastic deformation of the second contact portion 132E are substantially equal.

[0120] Thus, the switch device 10 of one embodiment can make the load received by the external terminal 30 from the first contact portion 131D and the load received by the external terminal 30 from the second contact portion 132E substantially equal. Therefore, according to the switch device 10 of one embodiment, the external terminal 30 can be stably held between the first contact portion 131D and the second contact portion 132E.

[0121] In the switch device 10 according to one embodiment, the first contact portion 131D and the second contact portion 132E have shapes symmetrical to each other.

[0122] Thus, in the switch device 10 according to one embodiment, the spring constant related to the elastic deformation of the first contact portion 131D and the spring constant related to the elastic deformation of the second contact portion 132E can be made equal relatively easily.

[0123] In the switch device 10 according to one embodiment, the resin member 120 includes the second holding portion 122 that protrudes from the side portion 120A in the negative direction of the X axis and holds a part of the base portion of the second arm portion 132 .

[0124] Thus, the switch device 10 according to one embodiment can suppress the torsional deformation of the second arm portion 132 which is prone to torsional deformation due to the longer terminal length than the first arm portion 131 .

[0125] In addition, in the switch device 10 according to one embodiment, the second arm portion 132 is reinforced by being partially bent.

[0126] Thus, the switch device 10 according to one embodiment can suppress the torsional deformation of the second arm portion 132 which is prone to torsional deformation due to the longer terminal length than the first arm portion 131 .

[0127] In the switch device 10 according to one embodiment, the first arm 131 has a first rising portion 131B that raises the upper end of the first contact portion 131D to a predetermined height position, and the second arm 132 has a second rising portion 132C that raises the upper end of the second contact portion 132E to a predetermined height position.

[0128] Thus, the switch device 10 of one embodiment can obtain the spring length of each of the first contact portion 131D and the second contact portion 132E, and thus, when the external terminal 30 is inserted therebetween, the first contact portion 131D and the second contact portion 132E can each be elastically deformed appropriately. In addition, in the switch device 10 of one embodiment, since the first contact portion 131D and the second contact portion 132E are suspended from the same height position, the spring constant related to the elastic deformation of the first contact portion 131D and the spring constant related to the elastic deformation of the second contact portion 132E can be made equal relatively easily.

[0129] In addition, in the switch device 10 according to one embodiment, the external terminal 30 can be inserted between the first contact portion 131D and the second contact portion 132E from both the upper side and the lower side.

[0130] Thus, the switch device 10 of one embodiment can insert the external terminal 30 without reversing the vertical direction of the switch device 10 even when the external terminal 30 is inserted from either the top or the bottom, thereby achieving multi-purpose use of the switch device 10.

[0131] In addition, in the switch device 10 according to one embodiment, the metal terminal members 111 , 112 , and 113 are formed into a three-dimensional shape by bending a single metal plate P.

[0132] Thus, the switch device 10 according to one embodiment can relatively easily form a three-dimensional shape in which the pair of contact portions 131D and 132E face each other in the X-axis direction simply by bending one metal plate P.

[0133] In the switch device 10 of one embodiment, all the bending lines L11 to L14 and L21 to L26 (see Figure 7 ) extends in the Y-axis direction (third direction) which is orthogonal to the X-axis negative direction (first direction) and the X-axis positive direction (second direction).

[0134] Therefore, the switch device 10 of one embodiment only needs to perform all bending processing along the bending lines L11 to L14 and L21 to L26 extending in the Y-axis direction, so it is relatively easy to form a three-dimensional shape in which a pair of contact portions 131D and 132E are opposed to each other in the X-axis direction from a metal plate P.

[0135] As mentioned above, although one embodiment of the present invention has been described in detail, the present invention is not limited to these embodiments, and various modifications and changes can be made within the scope of the gist of the present invention described in the claims.

[0136] The present international application claims the benefit of priority based on Japanese Patent Application No. 2019-186855, filed on October 10, 2019, the entire contents of which are incorporated herein by reference.

[0137] Description of Reference Numerals

[0138] 10 Switchgear

[0139] 12 rods

[0140] 14 Spring

[0141] 16. Fixture

[0142] 18 Housing

[0143] 20. Retaining parts

[0144] 22 Outer frame

[0145] 24, 26 Holding arm

[0146] 27, 28, 29 Supporting parts

[0147] 30 external terminals

[0148] 100 Formed parts

[0149] 111, 112, 113 Metal terminal parts

[0150] 111B, 112B, 113B Sliding contact part

[0151] 120 Resin parts

[0152] 120A Side

[0153] 121 First holding unit

[0154] 122 Second holding unit

[0155] 130, 130A, 130B, 130C Connecting part

[0156] 131 First Arm

[0157] 131A First horizontal extension

[0158] 131B First rising part

[0159] 131C First beam

[0160] 131D First contact part

[0161] 132 Second Arm

[0162] 132A hanging part

[0163] 132B Second horizontal extension

[0164] 132C Second rising part

[0165] 132D Second beam

[0166] 132E Second contact part

[0167] 133 Branch

[0168] H1, H2, H3 height positions

[0169] L1 Middle Line

[0170] L11, L12, L13, L14 bending lines

[0171] L21, L22, L23, L24, L25, L26 bending lines

[0172] P Metal sheet.

Claims

1. A switch device comprising a metal terminal component and a resin component, wherein the resin component is formed integrally with the metal terminal component by insert molding, the switch device being characterized in that the metal terminal component includes a first arm portion and a second arm portion, the first arm portion and the second arm portion extending side by side with each other from respective root portions arranged on a side portion of the resin component in a first direction as an outer direction, the first arm portion having a first contact portion facing the first direction, the second arm portion having a second contact portion facing a second direction opposite to the first direction, the second contact portion being opposite to the first contact portion, and being capable of inserting an external terminal between the first contact portion and the second contact portion while elastically deforming the first contact portion and the second contact portion, respectively.

2. The switch device according to claim 1, characterized in that A spring constant of the first contact portion related to the elastic deformation is equal to a spring constant of the second contact portion related to the elastic deformation.

3. The switch device according to claim 2, characterized in that: The first contact portion and the second contact portion have shapes symmetrical to each other.

4. The switch device according to claim 2, characterized in that The resin member has a holding portion that protrudes from the side portion toward the first direction and holds a portion of a base portion of the second arm portion.

5. The switch device according to claim 3, characterized in that: The resin member has a holding portion that protrudes from the side portion toward the first direction and holds a portion of a base portion of the second arm portion.

6. The switch device according to any one of claims 2 to 5, characterized in that: The second arm portion is reinforced by being partially bent.

7. The switch device according to any one of claims 1 to 5, characterized in that: The first arm portion has a first rising portion formed by raising the upper end portion of the first contact portion to a predetermined height position, and the second arm portion has a second rising portion formed by raising the upper end portion of the second contact portion to the predetermined height position.

8. The switch device according to any one of claims 1 to 5, characterized in that: The external terminal can be inserted between the first contact portion and the second contact portion from above and below, respectively.

9. The switch device according to any one of claims 1 to 5, characterized in that: The metal terminal member is formed into a three-dimensional shape by bending a metal plate.

10. The switch device according to claim 9, characterized in that All bending lines of the metal terminal member in the bending process extend in a third direction that is orthogonal to the first direction and the second direction.

11. A manufacturing method, which is a manufacturing method of a switch device, the switch device having a metal terminal component and a resin component, the resin component being formed integrally with the metal terminal component by insert molding, the manufacturing method being characterized by comprising: A metal terminal component forming step, forming the metal terminal component in an unfolded state from a metal plate; an insert molding step, forming the resin component integrally with the metal terminal component by insert molding; and a bending step, bending the metal terminal component to make the metal terminal component into a three-dimensional shape, wherein the metal terminal component has: a first arm portion and a second arm portion, the first arm portion and the second arm portion extending side by side from respective root portions arranged on the side of the resin component toward a first direction as an outer direction; a first contact portion, which is provided on the first arm portion and faces the first direction; and a second contact portion, which is arranged on the second arm portion, faces a second direction opposite to the first direction and is opposite to the first contact portion, and can insert an external terminal between the first contact portion and the second contact portion while elastically deforming the first contact portion and the second contact portion respectively.

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