JP7198367B2 - Switch device and manufacturing method - Google Patents

Description

The present invention relates to a switch device and manufacturing method.

Patent Literature 1 below discloses a receiving blade spring provided in an insertion connector, in which a pair of contact pieces facing each other are provided at the tip end of each of a pair of articulated portions. A receiving blade spring is disclosed between which a bayonet blade can be inserted.

JP-A-54-20667

However, in the technique of Patent Document 1, since the pair of contact pieces are provided facing each other in the direction perpendicular to the direction in which the pair of articulations extends, the distance between the pair of articulations, for example, If the gap widens due to an external force or the like, the gap between the pair of contact pieces also widens, so there is a risk that the force of holding the plug blade by the pair of contact pieces may be weakened.

A switch device according to one embodiment includes a metal terminal member and a resin member integrally formed with the metal terminal member by insert molding, wherein the metal terminal member extends from a side portion of the resin member. It comprises a first arm and a second arm extending alongside each other in a first outward direction, the first arm having a first contact portion facing the first direction. and the second arm has a second contact portion facing the first contact portion in a second direction opposite to the first direction, and the first contact portion and the second contact portion face each other. An external terminal can be inserted between the first contact portion and the second contact portion while elastically deforming each of the two contact portions.

According to one embodiment, even when the distance between the pair of arm portions is widened, the force of holding the external terminal by the pair of contact portions can be prevented from weakening.

1 is an external perspective view of a molded part according to one embodiment; FIG. 1 is a plan view of a molded part according to one embodiment; FIG. 1 is a side view of a molded part according to one embodiment; FIG. 3 is an external perspective view of three metal terminal members according to one embodiment; FIG. Exterior perspective view of molded part (lever, spring, and clip assembled) according to one embodiment 1 is an external perspective view of a switch device according to an embodiment; FIG. The external perspective view of the connection part which concerns on one Embodiment A plan view of a connection part according to one embodiment Side view of a connection part according to one embodiment FIG. 4 is a diagram showing a method of connecting external terminals to connection units according to an embodiment; Partially enlarged view of a side portion of a resin member in a molded component according to one embodiment 1 is a flow chart showing the procedure of a method for manufacturing a molded part and a switch device according to one embodiment; Three-sided view of a metal plate according to one embodiment Three-sided view of the metal plate (after the first bending process) according to one embodiment Three-sided view of the metal plate (after the second bending process) according to one embodiment Three-sided view of a metal plate (after insert molding) according to one embodiment Three-sided view of the metal plate (after the third bending process) according to one embodiment

An embodiment will be described below with reference to the drawings.

(Overview of Molded Part 100)
FIG. 1 is an external perspective view of a molded part 100 according to one embodiment. FIG. 2 is a plan view of molded part 100 according to one embodiment. FIG. 3 is a side view of molded part 100 according to one embodiment. FIG. 4 is an external perspective view of three metal terminal members 111, 112, 113 according to one embodiment.

The molded component 100 shown in FIGS. 1 to 3 has three metal terminal members 111, 112, 113 and a resin member 120. As shown in FIG. The resin member 120 is integrally formed with the three metal terminal members 111, 112, 113 by insert molding.

The three metal terminal members 111, 112, and 113 are all metal and thin plate members. As shown in FIG. 4, the three metal terminal members 111, 112, 113 are arranged side by side on the same plane (on the XY plane) without contacting each other. 1 to 3, in the molded component 100, each of the three metal terminal members 111, 112, 113 is partially embedded in the resin member 120 (intermediate portion).

The three metal terminal members 111, 112, 113 respectively have connecting portions 130A, 130B, 130C on one end side (X-axis negative side). The connecting portions 130A, 130B and 130C have a pair of arm portions 131 and 132, respectively. As shown in FIG. 2 , the pair of arms 131 and 132 extend linearly and parallel to each other outward (X-axis negative direction). The connection portions 130A, 130B, and 130C have a pair of contact portions 131D and 132E facing each other in the direction (X-axis direction) in which the pair of arm portions 131 and 132 extend. This is a portion to which the external terminal 30 (see FIG. 8) is connected by inserting the external terminal 30 between 131D and 132E. 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 Y-axis negative side).

Also, the three metal terminal members 111, 112, 113 respectively have sliding contact portions 111B, 112B, 113B on the other end side (Y-axis positive side). As shown in FIG. 2, in plan view from above, the sliding contact portions 111B, 112B, and 113B extend from the Y-axis positive side of the resin member 120 to the slide path of a clip 16 (see FIG. 5), which will be described later. It is a part that protrudes in a curved shape along the The sliding contact portions 111B, 112B, and 113B are portions where electrical connection and switching between terminals are performed by sliding the clip 16 thereon. The sliding contact portions 111B, 112B, and 113B are arranged side by side in the X-axis direction (in the order of the sliding contact portions 113B, 112B, and 111B from the negative side of the X-axis) at regular intervals.

The tip of the sliding contact portion 112B is cut shorter than that of the sliding contact portion 113B. , the tip of the sliding contact portion 111B is arranged to face the tip of the sliding contact portion 112B.

FIG. 5 is an external perspective view of molded part 100 (with lever 12, spring 14, and clip 16 assembled) according to one embodiment. Molded part 100 incorporates lever 12, spring 14, and clip 16, as shown in FIG. The lever 12 is a member made of resin that is rotatably supported by a resin member 120 about a rotation center axis AX extending in the Z-axis direction. The spring 14 is a so-called torsion spring, and biases the lever 12 in the return direction (counterclockwise when viewed from the Z-axis positive side) by an arm 14A provided at the end on the Z-axis positive side.

The clip 16 is held by the lever 12 and moves along the circumference around the rotation center axis AX as the lever 12 rotates. The clip 16 is made 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 surface and the lower surface of the sliding contact portion 113B of the metal terminal member 113, and in a state in which the sliding contact portion 113B of the metal terminal member 113 is sandwiched therebetween, the contact points move as the clip 16 moves. , slide on the upper and lower surfaces of the sliding contact portion 113B. As the clip 16 moves, the pair of second contacts slides on the upper and lower surfaces of the sliding contact portion 111B of the metal terminal member 111 while sandwiching the sliding contact portion 111B, or slides on the upper and lower surfaces of the metal terminal member. The upper surface and the lower surface of the sliding contact portion 112B are slid in a state where the sliding contact portion 112B of 112 is sandwiched. Thereby, the clip 16 can electrically connect the metal terminal member 113 with the metal terminal member 111 or the metal terminal member 112 as it moves.

FIG. 6 is an external perspective view of the switch device 10 according to one embodiment. As shown in FIG. 6, the molded part 100 is housed within the case 18 with the lever 12, spring 14 and clip 16 installed. The molded part 100 thus forms the switch device 10 together with the lever 12 , the spring 14 , the clip 16 and the case 18 .

In the switch device 10 configured as described above, the pair of first contacts of the clip 16 are in contact with the metal terminal member 113 and the pair of second contacts of the clip 16 are in contact with the metal terminal member 113 when the lever 12 is not pressed. By contacting the terminal member 111, the first state in which the metal terminal member 113 and the metal terminal member 111 are electrically connected to each other is established.

Also, in the switch device 10, when the lever 12 is pressed, the pair of first contacts of the clip 16 contacts the metal terminal member 112, and the pair of second contacts of the clip 16 contacts the metal terminal member 111. As a result, the metal terminal member 112 and the metal terminal member 111 are brought into a second state in which they are electrically connected to each other.

Further, in the switch device 10, when the pressing force of the lever 12 is released, the biasing force of the spring 14 causes the lever 12 to automatically return to the initial position. As a result, switch device 10 automatically returns to the first state in which metal terminal member 113 and metal terminal member 111 are electrically connected to each other.

For example, the switch device 10 can be used to detect the open/closed state of an automobile door.

In the switch device 10, on each of the upper surface 18A and the lower surface 18B of the case 18, at least the external terminals 30 are inserted at positions overlapping the connection portions 130A, 130B, and 130C in plan view from the Z-axis direction. An opening 18C is formed to allow Thus, in the switch device 10, each of the connection portions 130A, 130B, and 130C can be connected to the external terminal 30 from either the upper surface 18A side or the lower surface 18B side.

(Structure of connecting portion 130)
Next, detailed structures of the connection portions 130A, 130B, 130C of the metal terminal members 111, 112, 113 will be described with reference to FIGS. 7 to 9. FIG. In addition, the connection portions 130A, 130B, and 130C have structures similar to each other. Therefore, here, the connection portions 130A, 130B, and 130C will be collectively referred to as the "connection portion 130" without distinction.

FIG. 7 is an external perspective view of the connecting portion 130 according to one embodiment. FIG. 8 is a plan 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.

<Schematic configuration of connection unit 130>
As shown in FIGS. 7-9, the connecting portion 130 has a first arm portion 131, a second arm portion 132, and a branch portion 133. As shown in FIGS.

The first arm portion 131 is provided extending in the negative X-axis direction from the portion of the branch portion 133 on the positive side of the Y-axis. After resin member 120 is insert-molded, first arm portion 131 is a portion that extends outward (X-axis negative direction) from side portion 120A of resin member 120 on the X-axis negative side.

The second arm portion 132 is provided to extend in the negative X-axis direction from the portion of the branch portion 133 on the negative Y-axis side. After the resin member 120 is insert-molded, the second arm portion 132 extends in an outward direction (X-axis negative direction) from the side portion 120A on the X-axis negative side of the resin member 120, side by side with the first arm portion 131. and a portion extending longer than the first arm portion 131 .

As shown in FIG. 8 , in a plan view from above, a portion of the first arm 131 extending outward (X-axis negative direction) and a portion of the second arm 132 extending outward (X-axis negative direction) ) are parallel to each other and at regular intervals.

Further, as shown in FIG. 8 , the connecting portion 130 includes a portion extending in the outward direction (X-axis negative direction) of the first arm portion 131 and a portion extending in the outward direction (X-axis negative direction) of the second arm portion 132 . ) extending parallel to the X-axis, the first contact portion 131D and the second contact portion 131D and the second contact portion 131D and the second contact portion 132E.

The first contact portion 131D faces outward (the negative direction of the X-axis, an example of the “first direction”). The first contact portion 131D has an outwardly convex curved shape and a downward hanging shape. The first contact portion 131D is provided at the tip portion of the first arm portion 131, and the upper end portion thereof is supported by the first beam portion 131C of the first arm portion 131. As shown in FIG. In order to position the first contact portion 131D on the intermediate line L1, the first arm portion 131 has, in a plan view from above, a tip end portion of a portion extending outward (X-axis negative direction). It has a shape bent at right angles toward the intermediate line L1.

The second contact portion 132E faces inward (the positive direction of the X axis, an example of the “second direction”). The second contact portion 132E has an inwardly convex curved shape and a downward hanging shape. The second contact portion 132E is provided at the tip 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. As shown in FIG. In order to position the second contact portion 132E on the intermediate line L1, the second arm portion 132, in a plan view from above, extends outward (in the negative direction of the X-axis) at the distal end of the portion. It has a shape bent at right angles toward the intermediate line L1.

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 external terminal 30 can be inserted between them from above and below. be. By being inserted between the first contact portion 131D and the second contact portion 132E, the external terminal 30 is electrically connected to the connection portion 130 while being sandwiched between the pair of contact portions 131D and 132E. .

<Detailed Configuration of First Arm 131>
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.

The first horizontally extending portion 131A is a portion that extends linearly and horizontally in the negative direction of the X axis from the portion of the branch portion 133 on the positive side of the Y axis at the first height position H1 (see FIG. 9). is. As shown in FIG. 8 , the first horizontally extending portion 131A is parallel to the second horizontally extending portion 132B of the second arm portion 132 in plan view from above.

The first rising portion 131B is a portion that extends linearly 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. be. The first rising portion 131B is bent upward along the bending line L11 (see FIG. 7) at the boundary with the first horizontally extending portion 131A to form the front end portion of the first horizontally extending portion 131A. It will be in a state of being inclined upward from the Also, as shown in FIG. 9, the first rising portion 131B extends to a second height position H2 higher than the first height position H1. Thereby, the first rising portion 131B can position the upper end portion of the first contact portion 131D at the second height position H2.

The first beam portion 131C extends linearly in the direction of the intermediate line L1 (negative Y-axis direction) from the upper end portion (the end portion on the negative side of the X-axis) of the first rising portion 131B at the second height position H2. It is a vertical beam-like part that extends in a shape. The first beam portion 131C is bent upward along the bending line L12 (see FIG. 7) at the boundary with the first rising portion 131B, thereby being in a vertical state. The first beam portion 131C is connected to the upper end portion of the first contact portion 131D on the intermediate line L1. Thereby, the first beam portion 131C supports the upper end portion of the first contact portion 131D.

The upper portion of the first beam portion 131C is reinforced by being bent toward the X-axis positive side at the bending line L13 (see FIG. 7). As a result, the first beam portion 131C is arranged to prevent the first arm portion 131 from twisting and deforming when the external terminal 30 is inserted between the pair of contact portions 131D and 132E. The stiffness of 131 can be increased.

The first contact portion 131D is a portion extending downward from the first beam portion 131C on the intermediate line L1. The first contact portion 131D is bent toward the negative side of the X axis with the boundary line with the first beam portion 131C as a bending line L14 (see FIG. 7). Also, the first contact portion 131D has a convexly curved shape toward the negative side of the X axis. The top of the convex portion of the first contact portion 131D faces the top of the convex portion of the second contact portion 132E. When the flat external terminal 30 is inserted between the first contact portion 131D and the second contact portion 132E, the top portion of the convex portion of the first contact portion 131D is a flat surface of the external terminal 30. Contact with the surface on the positive side of the X-axis.

<Detailed Configuration of Second Arm 132>
The second arm portion 132 has a falling portion 132A, a second horizontally extending portion 132B, a second rising portion 132C, a second beam portion 132D, and a second contact portion 132E.

The falling portion 132A is a portion extending linearly 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 falling portion 132A is bent downward along the bending line L21 (see FIG. 7) at the boundary with the branching portion 133, thereby tilting downward from the Y-axis negative side of the branching portion 133. Become. As shown in FIG. 9, the falling portion 132A extends to a third height position H3 lower than the first height position H1. Thereby, the trailing portion 132A can position the following second horizontally extending portion 132B at the third height position H3.

The reason for providing the second arm portion 132 with the falling portion 132A is as follows. As shown in FIG. 13 and the like, in this embodiment, metal terminal members 111, 112, and 113 are formed from a single metal plate P. As shown in FIG. Here, as shown in FIG. 13 and the like, in the state where 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. ing. Thus, in this embodiment, the first contact portion 131D and the second contact portion 132E can be efficiently formed from a single metal plate P. As shown in FIG. For this purpose, 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. However, as shown in FIGS. , in order to reduce the terminal length difference and bring the second contact portion 132E closer to the first contact portion 131D when the first arm portion 131 and the second arm portion 132 are formed into a three-dimensional shape. , the second arm portion 132 is provided with a descending portion 132A.

The second horizontally extending portion 132B extends linearly and horizontally in the negative direction of the X axis from the lower end of the falling portion 132A (the end on the negative side of the X axis) at the third height position H3. part. The second horizontally extending portion 132B is brought into a horizontal state by being bent along the bending line L22 (see FIG. 7) along the boundary with the falling portion 132A. As shown in FIG. 8, the second horizontally extending portion 132B is parallel to the first horizontally extending portion 131A of the first arm portion 131 in a plan view from above. The second horizontally extending portion 132B passes through the Y-axis negative side of the pair of contact portions 131D and 132E and extends to a position aligned with the upper end portion of the second contact portion 132E.

The second rising portion 132C is a vertical portion that extends upward from the tip (the end on the negative side of the X axis) of the second horizontally extending portion 132B. The second rising portion 132C is bent upward at two bending lines L23 and L24 (see FIG. 7) provided between itself and the second horizontally extending portion 132B, thereby forming a vertical state. . Also, as shown in FIG. 9, the second rising portion 132C extends to the second height position H2. Thereby, the second rising portion 132C can position the upper end portion of the second contact portion 132E at the second height position H2. Note that the switch device 10 of the present embodiment has a configuration in which the second rising portion 132C is bent in two stages along the two bending lines L23 and L24, thereby allowing the height position and The position in the X-axis direction (that is, the height position and the position in the X-axis direction of the second contact portion 132E) can be adjusted with high accuracy.

The second beam portion 132D is a vertical beam linearly extending in the direction of the intermediate line L1 (the positive direction of the Y axis) from the upper end of the second rising portion 132C at the second height position H2. part of the shape. The second beam portion 132D is connected to the upper end portion of the second contact portion 132E on the intermediate line L1. Thereby, the second beam portion 132D supports the upper end portion of the second contact portion 132E.

The upper portion of the second beam portion 132D is reinforced by being bent toward the X-axis negative side at the bending line L25 (see FIG. 7). As a result, the second beam portion 132D is designed to prevent the second arm portion 132 from twisting and deforming when the external terminal 30 is inserted between the pair of contact portions 131D and 132E. The stiffness of 132 can be increased.

Here, as shown in FIG. 9, 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. Thereby, the strength of the second beam portion 132D is higher than that of the first beam portion 131C. This is because the second arm portion 132 has a longer terminal length in the negative direction of the X-axis than the first arm portion 131, and is more prone to torsional deformation than the first arm portion 131 when an external force is applied. It is from. Therefore, in the molded component 100 of the present embodiment, the bending angle of the upper portion of the second beam portion 132D is made larger than the bending angle of the upper portion of the first beam portion 131C, so that the second arm portion 132 and the second arm portion 132 The difficulty of torsional deformation is set to be the same as that of the arm portion 131 of No. 1.

The second contact portion 132E is a portion extending downward from the second beam portion 132D on the intermediate line L1. The second contact portion 132E is bent toward the positive side of the X axis with the boundary line with the second beam portion 132D as a bending line L26 (see FIG. 7). Also, the second contact portion 132E has a convexly curved shape toward the positive side of the X axis. The top of the convex portion of the second contact portion 132E faces the top of the convex portion of the first contact portion 131D. When the flat external terminal 30 is inserted between the first contact portion 131D and the second contact portion 132E, the top portion of the convex portion of the second contact portion 132E is a flat plate-like external terminal 30. Contact with the surface on the negative side of the X axis.

Here, the first contact portion 131D and the second contact portion 132E are provided so as to hang downward from the same height position H2, and have symmetrical shapes. Thereby, the spring constants of the first contact portion 131D and the second contact portion 132E are equal to each other. Therefore, the first contact portion 131D and the second contact portion 132E can apply an equal load to the external terminal 30 when the external terminal 30 is inserted between them.

(Method of connecting external terminal 30)
FIG. 10 is a diagram showing a method of connecting the external terminal 30 to the connection portion 130 according to one embodiment. As shown in FIG. 10, the flat external terminal 30 has one surface facing the first contact portion 131D and the other surface facing the second contact portion 132E. It is inserted between the pair of contact portions 131D and 132E from above or below 131D and 132E.

As a result, the external terminal 30 expands the distance between the pair of contact portions 131D and 132E by elastically deforming each of the pair of contact portions 131D and 132E. The external terminal 30 is sandwiched between the pair of contact portions 131D and 132E and electrically connected to the connection portion 130 by the elastic force of the pair of contact portions 131D and 132E.

At this time, as described above, the spring constant of the first contact portion 131D and the spring constant of the second contact portion 132E are substantially equal. Therefore, the external terminal 30 can evenly elastically deform the pair of contact portions 131D and 132E, and can receive an equal load from the pair of contact portions 131D and 132E. Accordingly, the connection portion 130 of the present embodiment can stably hold the external terminal 30 between the pair of contact portions 131D and 132E.

(Structure of side portion 120A of resin member 120)
FIG. 11 is a partially enlarged view of side portion 120A of resin member 120 in molded component 100 according to one embodiment. As shown in FIG. 11, the resin member 120 has a first holding portion 121 and a second holding portion 122, which both protrude in the X-axis negative direction, on the X-axis negative side portion 120A. The first holding portion 121 holds the base portion of the first arm portion 131 by embedding the base portion (first horizontally extending portion 131A) of the first arm portion 131 by insert molding. In the second holding portion 122, the root portion (the descending portion 132A and the second horizontally extending portion 132B) of the second arm portion 132 is embedded by insert molding. hold.

Here, as shown in FIG. 11, the amount of protrusion of the second holding portion 122 from the side portion 120A is larger than the amount of protrusion of the first holding portion 121 from the side portion 120A. This is because the second arm 132 has a longer terminal length in the negative direction of the X-axis than the first arm 131, and thus twists and deforms more than the first arm 131 when an external force is applied. Because it is easy. Therefore, in the molded component 100 of the present embodiment, the amount of protrusion of the second holding portion 122 from the side portion 120A is made larger than the amount of protrusion of the first holding portion 121 from the side portion 120A. The strength of the root portion of the arm portion 132 (the descending portion 132A and the second horizontally extending portion 132B) is increased. Accordingly, in the molded component 100 of the present embodiment, the second arm portion 132 and the first arm portion 131 are made to have the same degree of difficulty of torsional deformation.

It should be noted that the second holding portion 122 covers the root portion of the second arm portion 132, so that the second arm portion 132 is provided in close proximity to the second arm portion 132. It is possible to suppress a short circuit with the arm portion 131 of 1.

(Procedures of Manufacturing Method of Molded Component 100 and Switch Device 10)
Next, with reference to FIGS. 12 to 17, procedures of a method for manufacturing the molded component 100 and the switch device 10 will be described. FIG. 12 is a flow chart showing the steps of a method for manufacturing the molded component 100 and the switch device 10 according to one embodiment.

<Step S201: Metal Terminal Member Forming Step>
First, as shown in FIG. 13, metal terminal members 111, 112, 113 and a holding member 20 are formed from a single metal plate P. As shown in FIG. FIG. 13 is a trihedral view of the metal plate P according to one embodiment. A metal plate P shown in FIG. 13 is a base material for the metal terminal members 111 , 112 , and 113 .

As shown in FIG. 13, the metal plate P has a rectangular outer shape when viewed from above. The blank portions of the metal plate P are punched out using a die, thereby forming metal terminal members 111, 112, and 113 and holding members for holding the metal terminal members 111, 112, and 113, as shown in FIG. 20 are integrally formed.

As shown in FIG. 13 , the holding member 20 has an outer frame portion 22 , a pair of holding arms 24 and 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 .

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

The support portion 27 is a linear portion extending in the Y-axis negative direction from the frame portion on the Y-axis positive side of the outer frame portion 22 . The support portion 27 supports the metal terminal member 111 from the Y-axis positive side by being connected to the metal terminal member 111 .

The support portion 28 is a linear portion extending in the X-axis negative direction from the frame portion on the X-axis positive side of the outer frame portion 22 . The support portion 28 supports the metal terminal member 111 from the X-axis positive side by being connected to the metal terminal member 111 .

The support portion 29 is a linear portion extending in the positive Y-axis direction from the frame portion on the Y-axis negative side of the outer frame portion 22 between the pair of holding arms 24 and 26 . The support portion 29 supports the metal terminal member 111 from the Y-axis negative side by being connected to the metal terminal member 111 .

<Step S202: First Bending Step>
Next, as shown in FIG. 14, 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 is a trihedral view of the metal plate P (after the first bending process) according to one embodiment.

Specifically, the first contact portion 131D of the first arm portion 131 of each of the metal terminal members 111, 112, and 113 is curved downward along the bending line L14 (see FIG. 7). Also, the second contact portion 132E of the second arm portion 132 of each of the metal terminal members 111, 112, 113 is curved upward along the bending line L26 (see FIG. 7). The plurality of contact portions 131D and 132E can be bent collectively by, for example, press working using a mold.

<Step S203: Second Bending Step>
Next, as shown in FIG. 15, 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 is a trihedral view of the metal plate P (after the second bending process) according to one embodiment.

Specifically, the first arm portion 131 is bent into a valley fold along the bending line L11 (see FIG. 7) at the boundary between the first horizontally extending portion 131A and the first rising portion 131B. , the first rising portion 131B is tilted at a predetermined tilt angle. Further, the first arm portion 131 is bent into a valley fold along a bending line L12 (see FIG. 7) on the boundary between the first raised portion 131B and the first beam portion 131C, thereby forming the first beam. The portion 131C is placed in a vertical state. At the same time, the first beam portion 131C is reinforced by folding the first beam portion 131C into a valley fold at the folding line L13 (see FIG. 7).

In addition, the second arm portion 132 is folded in a mountain fold at the folding line L21 (see FIG. 7) at the boundary between the trailing portion 132A and the branch portion 133, so that the trailing portion 132A is inclined downward at a predetermined angle. Tilt at an angle. In addition, the second arm portion 132 is folded into a valley fold along the bending line L22 (see FIG. 7) at the boundary between the falling portion 132A and the second horizontally extending portion 132B, thereby forming the second horizontally extending arm portion 132. The holding portion 132B is placed in a horizontal state.

<Step S204: Insert molding step>
Next, as shown in FIG. 16, the resin member 120 is insert-molded to the metal terminal members 111 , 112 , 113 . FIG. 16 is a trihedral view of the metal plate P (after insert molding) according to one embodiment. In this insert molding process, first, the metal plate P in the state shown in FIG. 15 is set in the mold of the insert molding machine.

Then, the insert molding machine injects the resin into the mold. Thereby, the resin member 120 is insert-molded with respect to the metal terminal members 111, 112, 113, and the molded part 100 in which the metal terminal members 111, 112, 113 and the resin member 120 are integrated is formed. At this time, the tip portions of the pair of holding arms 24 and 26 are embedded in the resin member 120 by insert molding.

At this point, the molded part 100 is connected to the outer frame 22 by the pair of retaining arms 24, 26, the support 27, the support 28 and the support 29, i.e. retained by the retaining member 20. in a state.

<Step S205: Removal step>
Next, as shown in FIG. 17, unnecessary portions of the holding member 20 are removed so that the molded part 100 is cantilevered by the pair of holding arms 24 and 26 . FIG. 17 is a trihedral view of the metal plate P (after the third bending process) according to one embodiment. Here, the "unnecessary part" is a part that will be unnecessary in the later assembly process.

Specifically, by punching or the like, the holding member 20 is cut along the cutting line CL1 shown in FIG. Remove. Since the removal target portion 20A includes the support portion 27, the support portion 27 is also removed at the same time.

In addition, by punching or the like, the support portion 28 is cut along the cutting line CL2 (connected portion with the metal terminal member 111) and the cutting line CL3 (connected portion with the outer frame portion 22) shown in FIG. 28 is removed.

Further, by punching or the like, the support portion 29 is cut along the cutting line CL4 (connection portion with the metal terminal member 111) and the cutting line CL5 (connection portion with the outer frame portion 22) shown in FIG. 29 is removed.

As a result, as shown in FIG. 17, the molded component 100 is cantilevered from the Y-axis negative side by the pair of holding arms 24 and 26 . Moreover, the holding member 20 is in a state where the Y-axis positive side is opened by removing unnecessary portions. As a result, the molded component 100 can be easily assembled with other components and removed from the holding member 20 from the Y-axis positive side.

Note that the part to be removed 20A, the support part 28, and the support part 29 may be removed collectively by one punching process.

<Step S206: Third Bending Step>
Next, as shown in FIG. 17, the second arm portion 132 is bent at the bending lines L23 and L24 (see FIG. 7) on the boundary between the second horizontally extending portion 132B and the second rising portion 132C. By folding in the valley fold, the second rising portion 132C and the second beam portion 132D are brought into a vertical state. As a result, as shown in FIG. 17, the pair of contact portions 131D and 132E face each other in the X-axis direction. At the same time, the second beam portion 132D is reinforced by folding the second beam portion 132D into a mountain fold at the folding line L25 (see FIG. 7). In this way, after the insert molding, the base portion of the second arm portion 132 is reinforced by the second holding portion 122, and the second rising portion 132C and the second beam portion 132D are placed in a vertical state. By performing the bending process, the second contact portion 132E can be aligned with the first contact portion 131D with high accuracy. This is because if this 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. .

<Step S207: Assembly Process>
Next, while the molded part 100 is held by the pair of holding arms 24 and 26 as shown in FIG. 18) form the switching device 10 (see FIG. 6). Since the molded part 100 is cantilevered from the Y-axis negative side by the pair of holding arms 24, 26, other parts can be easily incorporated.

<Step S208: Removal process>
After that, the molded part 100 (that is, the switch device 10) in which the other parts are assembled is removed from the holding member 20 by being pulled out in the positive Y-axis direction (D1 direction shown in FIG. 17). Since the molded part 100 is cantilevered from the Y-axis negative side by the pair of holding arms 24 and 26, it can be easily pulled out in the Y-axis positive direction.

As described above, the switch device 10 according to one embodiment includes the metal terminal members 111, 112, and 113 and the resin member 120 integrally formed with the metal terminal members 111, 112, and 113 by insert molding. wherein the metal terminal members 111, 112, and 113 include a first arm portion 131 extending side by side from a side portion 120A of a resin member 120 in the X-axis negative direction (first direction) and A second arm portion 132 is provided, and the first arm portion 131 has a first contact portion 131D facing in the negative direction of the X axis. direction) and faces the first contact portion 131D. The external terminal 30 can be inserted between 131D and the second contact portion 132E.

As a result, in the switch device 10 according to the embodiment, even if the distance between the pair of arm portions 131 and 132 is widened due to an external force or the like, the pair of contact portions 131D and 132E can be kept in contact with each other in the Y-axis direction. However, the distance between the pair of contact portions 131D and 132E does not widen. Therefore, according to the switch device 10 according to one embodiment, even if the distance between the pair of arm portions 131 and 132 is widened, the force of holding the external terminal 30 by the pair of contact portions 131D and 132E is weak. You can keep it from getting stuck.

Further, in the switch device 10 according to one embodiment, the spring constant related to elastic deformation of the first contact portion 131D and the spring constant related to elastic deformation of the second contact portion 132E are substantially equal.

As a result, the switch device 10 according to one embodiment can substantially equalize the load that the external terminal 30 receives from the first contact portion 131D and the load that the external terminal 30 receives from the second contact portion 132E. . Therefore, according to the switch device 10 according to one embodiment, the external terminal 30 can be stably held between the first contact portion 131D and the second contact portion 132E.

Further, in the switch device 10 according to one embodiment, the first contact portion 131D and the second contact portion 132E have symmetrical shapes.

As a result, the switch device 10 according to one embodiment relatively easily equalizes the spring constant associated with elastic deformation of the first contact portion 131D and the spring constant associated with elastic deformation of the second contact portion 132E. be able to.

In addition, in the switch device 10 according to one embodiment, the resin member 120 has a second holding portion 122 that protrudes from the side portion 120A in the X-axis negative direction and holds a part of the root portion of the second arm portion 132. have.

As a result, the switch device 10 according to one embodiment can suppress torsional deformation of the second arm portion 132, which tends to undergo torsional deformation due to the terminal length being longer than that of the first arm portion 131. .

Further, in the switch device 10 according to one embodiment, the second arm portion 132 is reinforced by being partially bent.

As a result, the switch device 10 according to one embodiment can suppress torsional deformation of the second arm portion 132, which tends to undergo torsional deformation due to the terminal length being longer than that of the first arm portion 131. .

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

As a result, the switch device 10 according to one embodiment can increase the spring length of each of the first contact portion 131D and the second contact portion 132E, so that the external terminal 30 is inserted between them. At this time, each of the first contact portion 131D and the second contact portion 132E can be elastically deformed appropriately. In addition, in the switch device 10 according to one embodiment, since the first contact portion 131D and the second contact portion 132E hang down from the same height position, the spring associated with the elastic deformation of the first contact portion 131D It is relatively easy to equalize the constant and the spring constant associated with the elastic deformation of the second contact portion 132E.

In addition, the switch device 10 according to one embodiment allows the external terminal 30 to be inserted between the first contact portion 131D and the second contact portion 132E from above and below.

As a result, the switching device 10 according to the embodiment can be configured so that the switching device 10 does not invert the vertical direction of the switching device 10 regardless of whether the external terminal 30 is inserted from the upper side or the lower side. Since the terminal 30 can be inserted, the switch device 10 can be made versatile.

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. As shown in FIG.

As a result, 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 are opposed to each other in the X-axis direction, simply by bending the single metal plate P. can be formed.

In addition, in the switch device 10 according to one embodiment, all the bending lines L11 to L14 and L21 to L26 (see FIG. 7) in the bending process of the metal terminal members 111, 112, and 113 are aligned in the negative direction of the X axis (first direction) and the Y-axis direction (third direction) orthogonal to each of the X-axis positive direction (second direction).

As a result, the switch device 10 according to the embodiment can be bent along the bending lines L11 to L14 and L21 to L26 extending in the Y-axis direction. , the pair of contact portions 131D and 132E can relatively easily form a three-dimensional shape in which they face each other in the X-axis direction.

Although one embodiment of the present invention has been described in detail above, the present invention is not limited to these embodiments, and various modifications or Change is possible.

This international application claims priority based on Japanese Patent Application No. 2019-186855 filed on October 10, 2019, and the entire contents of this application are incorporated into this international application.

REFERENCE SIGNS LIST 10 switch device 12 lever 14 spring 16 clip 18 case 20 holding member 22 outer frame portion 24, 26 holding arm 27, 28, 29 support portion 30 external terminal 100 molded part 111, 112, 113 metal terminal member 111B, 112B, 113B slide contact portion 120 resin member 120A side portion 121 first holding portion 122 second holding portion 130, 130A, 130B, 130C connecting portion 131 first arm portion 131A first horizontally extending portion 131B first rising portion 131C first beam portion 131D first contact portion 132 second arm portion 132A falling portion 132B second horizontally extending portion 132C second rising portion 132D second beam portion 132E second contact portion 133 Branch portion H1, H2, H3 Height position L1 Intermediate line L11, L12, L13, L14 Bending line L21, L22, L23, L24, L25, L26 Bending line P Metal plate

Claims (10)

A switch device comprising a metal terminal member and a resin member integrally formed with the metal terminal member by insert molding,
The metal terminal member is
a first arm and a second arm extending side by side in a first direction outward from a side of the resin member;
The first arm has a first contact portion facing the first direction,
the second arm has a second contact portion facing the first contact portion in a second direction opposite to the first direction;
An external terminal can be inserted between the first contact portion and the second contact portion while elastically deforming each of the first contact portion and the second contact portion. switch device. The switch device according to claim 1, wherein a spring constant associated with the elastic deformation of the first contact portion and a spring constant associated with the elastic deformation of the second contact portion are approximately equal. The first contact portion and the second contact portion are
3. The switch device according to claim 2, having mutually symmetrical shapes. The resin member is
4. The switch device according to claim 2, further comprising a holding portion projecting in the first direction from the side portion and holding a part of the root portion of the second arm. The second arm is
The switch device according to any one of claims 2 to 4, wherein the switch device is reinforced by being partially bent. The first arm is
Having a first rising portion for raising the upper end portion of the first contact portion to a predetermined height position,
The second arm is
The switch device according to any one of claims 1 to 5, further comprising a second rising portion for rising an upper end portion of the second contact portion to the predetermined height position. 7. The external terminal can be inserted between the first contact portion and the second contact portion from above and below, respectively. switch device. The metal terminal member is
The switch device according to any one of claims 1 to 7, wherein the switch device is formed into a three-dimensional shape by bending a single metal plate. The metal terminal member is
9. The switch device according to claim 8, wherein all bending lines in said bending process extend in a third direction orthogonal to each of said first direction and said second direction. A method of manufacturing a switch device comprising a metal terminal member and a resin member integrally formed with the metal terminal member by insert molding, the method comprising:
a metal terminal member forming step of forming the metal terminal member in a developed state from one metal plate;
an insert molding step of integrally forming the resin member with the metal terminal member by the insert molding;
a step of bending the metal terminal member into a three-dimensional shape by bending the metal terminal member;
The metal terminal member, in the three-dimensional shape,
a first arm portion and a second arm portion extending side by side in a first direction outward from a side portion of the resin member;
a first contact portion provided on the first arm portion and facing the first direction;
a second contact portion provided on the second arm portion facing the first contact portion in a second direction opposite to the first direction;
An external terminal can be inserted between the first contact portion and the second contact portion while elastically deforming each of the first contact portion and the second contact portion. manufacturing method.

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