Switch device and method for manufacturing switch device

Patent metadata

Field	Value
Publication number	US-9959987-B2
Application number	US-201715651375-A
Country	US
Kind code	B2
Filing date	Jul 17, 2017
Priority date	Jul 22, 2016
Publication date	May 1, 2018
Grant date	May 1, 2018

Abstract

A switch device includes a housing having a case and a holding member, a moving member, a biasing member, a movable contact, a common fixed contact, a first switching fixed contact, a second switching fixed contact, extending portions, at least two terminal members, and resistors for obtaining the resistance value between two terminal members, and fixing portions to which the resistors are soldered. The holding member includes a bottom wall portion that covers the bottom of the case, and a holding wall portion holding the fixing portions. The holding wall portion is formed of a first synthetic resin material having heat resistance, and the bottom wall portion is made of a second synthetic resin material having a heat distortion temperature lower than that of the first synthetic resin material. A method for manufacturing a switch device includes a first molding step, a resistor mounting step, and a second molding step.

First claim

What is claimed is:

1. A switch device comprising:
a housing having a through portion;
a moving member provided with an operation portion exposed from the through portion;
a biasing member that returns the moving member to an initial state before operation;
a movable contact that moves with the movement of the moving member;
a common fixed contact that is always in contact with the movable contact;
a first switching fixed contact, the first switching fixed contact being in contact with the movable contact in the initial state where the operation portion is not operated, the first switching fixed contact coming out of contact with the movable contact with the operation of the operation portion;
a second switching fixed contact, the second switching fixed contact being out of contact with the movable contact in the initial state where the operation portion is not operated, the second switching fixed contact coming into contact with the movable contact with the operation of the operation portion;
a plurality of extending portions that extend from at least two of the common fixed contact, the first switching fixed contact, and the second switching fixed contact;
at least two terminal members that extend from the housing to an outside of the housing; and
two resistors for obtaining the resistance value between the at least two terminal members,
the housing including a box-shaped case that has the through portion and has an open bottom, and a holding member in which the terminal members are embedded and that covers the bottom of the case, some of the extending portions and the terminal members having fixing portions to which the resistors are soldered,
wherein the holding member includes a bottom wall portion that covers the bottom of the case, and a holding wall portion provided above the bottom wall portion and holding the fixing portions, and
wherein the holding wall portion comprises a first synthetic resin material having heat resistance, and the bottom wall portion is comprises a second synthetic resin material having a heat distortion temperature lower than that of the first synthetic resin material.

2. The switch device according to claim 1 , wherein the terminal members extend from the bottom wall portion to the outside of the housing, and wherein a part of each terminal member is surrounded, throughout its circumference, by the second synthetic resin material of the bottom wall portion.

3. The switch device according to claim 1 , wherein the holding wall portion is disposed in a sealed housing space formed by the case and the bottom wall portion.

4. The switch device according to claim 1 ,
wherein the holding wall portion has, in a lower part thereof, embedded portions embedded in the bottom wall portion, and
wherein the embedded portions are each provided with an engaging portion formed such that the lower part thereof is larger than an upper part thereof.

5. The switch device according to claim 1 , wherein the case comprises a third synthetic resin material having a heat distortion temperature lower than that of the first synthetic resin material.

6. The switch device according to claim 5 , wherein the second synthetic resin material and the third synthetic resin material are the same type of material.

7. A method for manufacturing a switch device including
a housing having a through portion,
a moving member provided with an operation portion exposed from the through portion,
a biasing member that returns the moving member to an initial state before operation,
a movable contact that moves with the movement of the moving member,
a common fixed contact that is always in contact with the movable contact,
a first switching fixed contact, the first switching fixed contact being in contact with the movable contact in the initial state where the operation portion is not operated, the first switching fixed contact coming out of contact with the movable contact with the operation of the operation portion,
a second switching fixed contact, the second switching fixed contact being out of contact with the movable contact in the initial state where the operation portion is not operated, the second switching fixed contact coming into contact with the movable contact with the operation of the operation portion,
extending portions that extend from at least two of the common fixed contact, the first switching fixed contact, and the second switching fixed contact,
at least two terminal members that extend from the housing to an outside of the housing, and
two resistors for obtaining the resistance value between the at least two terminal members,
the housing including a box-shaped case that has the through portion and has an open bottom, and a holding member in which the terminal members are embedded and that covers the bottom of the case, some of the extending portions and the terminal members having fixing portions to which the resistors can be soldered,
wherein the holding member includes a bottom wall portion that covers the bottom of the case, and a holding wall portion provided above the bottom wall portion and holding the fixing portions, and
wherein the holding wall portion is formed of a first synthetic resin material having heat resistance, and the bottom wall portion is made of a second synthetic resin material having a heat distortion temperature lower than that of the first synthetic resin material,
the method comprising a first molding step in which the holding wall portion is formed, with the fixing portions exposed, by insert-molding a metal member having the fixing portions using the first synthetic resin material, a resistor mounting step in which the resistors are soldered to the fixing portions, and a second molding step in which the bottom wall portion is formed by insert-molding the terminal members located on the lower side of the holding wall portion using the second synthetic resin material.

8. The method according to claim 7 , wherein the resistor mounting step includes a reflow step in which solder paste provided between the fixing portions and electrode portions of the resistors is heated.

9. The method according to claim 7 , wherein, in the second molding step, the bottom wall portion is formed such that a part of each terminal member is surrounded, by the second synthetic resin material, and such that the terminal members extend from the bottom wall portion to the outside of the housing.

10. The method according to claim 7 , wherein, in the second molding step, the bottom wall portion is formed such that a lower part of the holding wall portion is embedded in the bottom wall portion, and such that the holding wall portion is not exposed on a lower side of the bottom wall portion.

11. The method according to claim 10 , wherein, in the first molding step, an engaging portion having a shape such that the lower part thereof is larger than an upper part thereof is formed in each of embedded portions of the holding wall portion that are embedded in the bottom wall portion.

12. The method according to claim 7 , further comprising,
before the first molding step, a frame body preparation step in which a frame body is prepared to which at least a part of each of the common fixed contact, the first switching fixed contact, the second switching fixed contact, the extending portions, and the terminal members is connected by a connecting portion, and
after the second molding step, a cutting step in which the connecting portions are cut.

13. The method according to claim 7 ,
wherein the case is formed of a third synthetic resin material having a heat distortion temperature lower than that of the first synthetic resin mat

Assignees

• Alps Electric Co Ltd

Inventors

• Tanaka Takaki

Classifications

• H01H11/0056

  comprising a successive blank-stamping, insert-moulding and severing operation · CPC title

• H01H9/0271

  structurally combining a switch and an electronic component (for relays H01H50/021) · CPC title

• H01H2229/04

  Solder problems · CPC title

• H01H13/10 Primary

  Bases; Stationary contacts mounted thereon · CPC title

• H01H2229/048

  Insertion moulding · CPC title