Sensor switch and method of assembly thereof

A method of assembly of a sensor switch which includes an insulated housing, a first conductive terminal, a second conductive terminal, and at least one conductive member, the insulated housing defining an axis and having first and second end faces opposite to each other along the axis, and an inner wall surface defining a through hole that extends from the first end face to the second end face, the through hole including a first diameter hole section proximate to the second end face, a second diameter hole section proximate to the first end face and having a hole diameter smaller than that of the first diameter hole section, and a shoulder interconnecting the first and second diameter hole sections, the first conductive terminal including a head portion, and a stem portion having a width measured in a direction transverse to the axis smaller than that of the head portion, the head portion having an abutment surface, and a first contact surface opposite to the abutment surface, the stem portion having a stem peripheral surface, and at least one annular barb formed on the stem peripheral surface, the second conductive terminal including a plug portion, and an end cap connected to the plug portion, the plug portion having a second contact surface, a plug peripheral surface connected to the second contact surface, and at least one annular barb formed on the plug peripheral surface, the end cap having a cap stop surface and a cap end face opposite to the cap stop surface, an assembly direction being defined as a direction parallel to the axis and extending from the second end face toward the first end face, said method of assembly comprising:

• (A) inserting the first conductive terminal into the first diameter hole section along the assembly direction with the stem portion thereof being inserted first into the first diameter hole section;
• (B) pushing the first conductive terminal into the through hole until the abutment surface thereof abuts against the shoulder, during this time, the stem portion is embedded in the second diameter hole section, and a portion of the inner wall surface of the insulated housing that defines the second diameter hole section is deformed by the at least one annular barb of the stem portion to form at least one annular groove, the at least one annular barb of the stem portion and the at least one annular groove being engaged to each other, the direction of the at least one annular barb of the stem portion being opposite to the assembly direction so as to prevent the first conductive terminal from loosening from the insulated housing;
• (C) inserting the conductive member into the first diameter hole section along the assembly direction;
• and
• (D) inserting the plug portion of the second conductive terminal into the first diameter hole section along the assembly direction, and pushing the cap end face until the cap stop surface abuts against the second end face of the insulated housing, during this time, another portion of the inner wall surface of the insulated housing that defines the first diameter hole section is deformed by the at least one annular barb of the plug portion to form at least another one annular groove, the at least one annular barb of the plug portion and the at least another one annular groove being engaged to each other, the direction of the at least one annular barb of the plug portion being opposite to the assembly direction so as to prevent the second conductive terminal from loosening from the insulated housing, wherein the inner wall surface and the first and second contact surfaces cooperatively define a sensing chamber, and the at least one conductive member is rollably accommodated in the sensing chamber.