Relay

Abstract

The present invention relates to a relay, comprising: an electromagnet; a plurality of springs, having contacts and terminals that are opened and closed according to the action of the electromagnet; and a base that supports the springs, at least one of the plurality of springs having a locked portion that is locked to the base by utilizing the spring characteristics of the spring, and the base having a locking portion that locks the locked portion.

Description

Technical Field

[0001] The present disclosure relates to a relay (electromagnetic relay). Background Art

[0002] In a small relay with a rated load capacity of about 8 to 10A, when inserting a spring having contacts and terminals into a base, it is difficult to ensure a sufficient amount of press-in due to the small size, and there are problems such as insufficient press-in strength or various trade-offs for obtaining the press-in strength. Therefore, in relays, countermeasures such as those described below are adopted, and in many cases, products are produced with burdens on the manufacturing process, product costs, etc.

[0003] If the spring thickness is kept small, the spring characteristics can be maintained, but there is a risk of deformation during the press-fitting process. Therefore, the spring thickness is increased and the spring is firmly pressed in with a short press-fit distance.

[0004] It is assumed that only the terminal portion of the spring has a large thickness, and the spring portion is welded to the terminal portion with a small thickness. However, in this case, the processing cost increases.

[0005] When the press-in strength cannot be ensured, the spring is temporarily bonded after the spring is inserted. However, in this case, the manufacturing cost increases, and there is also a risk that when a load is applied to the spring terminal from the insertion of the spring into the base to the temporary bonding, the spring is temporarily bonded in a state where it is moved from the correct position.

[0006] Therefore, a relay is sought that prevents the spring from falling off.

[0007] In addition, it is known that the contacts of the relays have one point contact, sliding contact friction, rolling contact rolling, etc. In the case of contact sliding, the oxide film on the contact surface is destroyed, the wear powder is scraped off, and the contact cleaning effect is improved. In addition, when the contact resistance is low, the heat generation can be suppressed. On the other hand, in the case of rolling, the cleaning effect of the contact is reduced, but a large change in the contact point of the contact can be expected, and the resistance to welding when the contact is in contact is improved.

[0008] In the case of a sliding type, when a large bump is generated on the contact due to contact wear, additional force is required to make the contact go over the bump when sliding. When this force exceeds the attraction of the electromagnet used to press the spring, the card may not be able to completely press the spring. In order to suppress this situation, there is a method of reducing the stiffness of the spring so that the attraction of the electromagnet has a margin, but in this case, it is necessary to also consider the design of the current carrying capacity of the spring.

[0009] Japanese Utility Model Publication No. 2-145752 discloses a relay in which a movable contact spring and a fixed contact terminal plate are supported by a fixed block formed of an insulator, and the fixed blocks are pressed against each other and inserted and fixed to an opening of an insulating base. In this way, the movable contact spring and the fixed contact terminal plate can be fixed vertically to the insulating base, and a stable contact pressure and contact gap can be achieved.

[0010] Japanese Patent Application Laid-Open No. 2020-21594 discloses a relay having a protrusion formed on at least one of a side portion of a housing or an inner surface of a cover, and states that even if the cover is warped, the adhesive will flow into the gap between the housing and the cover.

[0011] Japanese Patent Application Laid-Open No. 2006-59702 discloses that a movable contact and a fixed contact are brought into contact by rolling, thereby increasing the contact life of the movable contact and the fixed contact. Summary of the invention

[0012] An object of the present invention is to provide an improved electromagnetic relay in view of various problems in the related art.

[0013] One scheme of the present disclosure provides a relay, comprising: an electromagnet; a plurality of springs having contacts and terminals that are opened and closed according to the action of the electromagnet; and a base that supports the springs, at least one of the plurality of springs having a locking portion that is locked to the base by utilizing the spring characteristics of the spring, and the base having a locking portion that locks the locked portion.

[0014] Other schemes of the present disclosure provide a relay, comprising: an electromagnet; a plurality of springs having contacts and terminals that are opened and closed according to the action of the electromagnet; a base that supports the springs; and a cover that covers the base, wherein a step is formed on the outer side surface of the base opposite to the inner side surface of the cover or on the inner side surface of the cover opposite to the outer side surface of the base to ensure a bonding layer between the base and the cover.

[0015] Another scheme of the present disclosure provides a relay, comprising: an electromagnet; a plurality of springs having contacts and terminals that are opened and closed according to the action of the electromagnet; and a base that supports the springs, the base having a reference surface that specifies a reference position of the springs and a through hole for inserting the terminals, the inner side surface of the through hole being flush with the reference surface, and the base having a notch on the reference surface side near the terminal outlet of the through hole.

[0016] Another embodiment of the present disclosure provides a relay, comprising: a base; an electromagnet mounted on the base; a moving member that moves as the electromagnet operates; and a movable spring, comprising a base supported on the base and a main spring portion extending from the base and having a movable contact at the top end side, the moving member comprising a first protrusion and a second protrusion that respectively press both side portions of the movable contact in the movable spring, the movable spring comprising an extension portion and a branch portion, the extension portion being formed to extend from a portion of the main spring portion where the movable contact is provided toward a portion pressed by the first protrusion, the branch portion branching from a portion between a portion of the main spring portion where the movable contact is provided and the base on a side opposite to a side having the extension portion with respect to the movable contact, and extending to a portion pressed by the second protrusion.

[0017] Another embodiment of the present disclosure provides a relay comprising: an electromagnet; a plurality of springs having contacts and terminals that are opened and closed according to the action of the electromagnet; and a base that supports the plurality of springs, wherein the base is formed with an insertion hole for inserting at least one terminal of the plurality of springs, the insertion hole being formed in a recessed portion that is formed in the base in the internal space of the relay and having a spatial dimension that is larger than an opening portion on the internal space side of the insertion hole.

[0018] Another embodiment of the present disclosure provides a relay, comprising: a base; an electromagnet mounted on the base; a movable spring provided with a movable contact; and a fixed spring, comprising a base supported by the base and a spring portion extending from the base and provided with a fixed contact, wherein the base has a position limiting portion, the position limiting portion being formed to stand upright from the bottom surface of the base on the movable spring side relative to the fixed spring, and having a surface that contacts an area from a connection position with the base in the spring portion to a predetermined height when the fixed spring falls toward the movable spring side due to a reaction effect of pressure applied by the movable spring.

[0019] According to one scheme of the present disclosure, an improved spring fall-off prevention technology can be provided. That is, the spring's press-in strength can be reduced, and the spring can be prevented from falling off regardless of the thickness of the spring. This is particularly useful for small electromagnetic relays. In addition, the spring is inserted using the spring characteristics, thereby reducing mold scratches during press-in, reducing wear powder, etc. Moreover, temporary bonding becomes unnecessary, so the temporary bonding and drying processes can be abolished, resulting in a reduction in equipment costs, product costs, etc.

[0020] According to another aspect of the present disclosure, even if the cover is warped inwardly, a sufficient adhesive layer can be obtained between the inner side surface of the cover and the outer side surface of the base.

[0021] According to another aspect of the present disclosure, the adhesive flows into the notch on the reference surface side near the terminal outlet of the insertion hole, and a sufficient adhesive layer can be ensured between the base and the terminal.

[0022] According to another embodiment of the present disclosure, the contacting action between the contacts can include rolling motion in addition to sliding. Thus, the advantages of the contact cleaning effect achieved by sliding can be enjoyed, and the influence of the unevenness on the sliding path can be dispersed, and the improvement of the resistance to welding when the contacts contact can be achieved, which is an advantage of rolling.

[0023] According to still another aspect of the present disclosure, the adhesive that has flowed into the insertion hole from the outside of the electromagnetic relay can be retained near the insertion hole by surface tension, thereby preventing the adhesive from flowing into the internal space.

[0024] According to still another aspect of the present disclosure, the movement of the fixed spring to fall toward the movable spring due to the reaction of being pressed in by the movable spring can be restricted. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is an exploded perspective view showing an example of a relay.

[0026] Figure 2 This is an exploded side view showing an example of a relay.

[0027] Figure 3 It is a top view showing a part of the relay.

[0028] Figure 4 It is a perspective view showing an example of a movable spring.

[0029] Figure 5A It is a VV cross-sectional view which shows an example of a spring structure.

[0030] Figure 5B It is a VV cross-sectional view which shows an example of a spring structure.

[0031] Figure 6 It is a perspective view showing an example of the second fixing spring.

[0032] Figure 7 It is a VII-VII cross-sectional perspective view showing another example of the spring structure.

[0033] Fig. 8A It is a partial perspective view showing a modified example of the locked portion.

[0034] Figure 8B It is a partial cross-sectional view showing a modified example of the spring structure.

[0035] Fig.9A It is a partial perspective view showing another modified example of the locked portion.

[0036] Fig. 9B It is a cross-sectional view showing another modified example of the spring structure.

[0037] Fig. 10A It is a cross-sectional view showing the stress range when the raised portion is formed as a protrusion.

[0038] Fig. 10B It is a cross-sectional view showing the stress range when the raised portion is formed as a cut-and-raised piece.

[0039] Fig.11 It is a figure which shows the influence of the warpage in a cover.

[0040] Fig.12 It is a perspective view of a base showing an example of a step.

[0041] Fig.13 It is a schematic cross-sectional view taken along the line XIII-XIII showing an example of the structural ratio of the base and the cover.

[0042] Fig.14 It is a perspective view of a base showing a modified example of a step.

[0043] Fig.15 This is a schematic cross-sectional view showing the adhesive layer between the terminal and the base.

[0044] Fig.16A This is a bottom perspective view of an example of a base for securing an adhesive layer.

[0045] Fig. 16B This is a cross-sectional view of an example of a base for securing an adhesive layer.

[0046] Fig.17 This is a perspective view of the relay with the cover removed.

[0047] Fig.18 This is an exploded perspective view of a relay.

[0048] Fig.19 It is a three-dimensional diagram of the movable spring.

[0049] Fig. 20 It is the front view of the movable spring.

[0050] Fig.21A This is a side view showing a state where the movable spring and the second fixed spring begin to contact each other.

[0051] Fig. 21B This is a side view showing a state where the movable spring is completely pressed by the card.

[0052] Fig. 21C Observed from above Fig. 21B .

[0053] Fig. 22 The figure shows an example of a contact path on a movable contact point due to rolling.

[0054] Fig.23This is a perspective view of a relay with a movable spring mounted on a base.

[0055] Fig.24 It is a perspective view of the portion of the base where the first fixed spring, the movable spring, and the second fixed spring are installed.

[0056] Fig.25 It is a partial stereoscopic view of a base with a first fixing spring installed.

[0057] Fig.26 yes Fig.25 XXVI-XXVI section view in the figure.

[0058] Fig. 27 yes Fig.24 XXVII-XXVII section view.

[0059] Fig.28 It is a perspective view showing the initial state of the first fixed spring, the movable spring, and the second fixed spring.

[0060] Fig.29 It is the front view of the second fixing spring. DETAILED DESCRIPTION

[0061] Hereinafter, the embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In each of the drawings, the same or similar elements are marked with the same or similar reference numerals. In addition, the embodiments described below do not limit the technical scope of the invention described in the scope of the patent claim and the meaning of the term.

[0062] Figure 1 and Figure 2 1 is an exploded perspective view and an exploded side view of an example of a relay 1. Figure 3 1 is a top view of a part of the relay 1. The relay 1 comprises: a base 2, on which components are assembled; and a box-shaped cover 3, which covers the base 2. For example, the base 2 and the cover 3 may be made of resin molds. The components assembled to the base 2 include an electromagnet 8, a hinge spring 9, an armature 10, a card 11, and a spring 4, each of which has a contact, and the contact opens and closes with another contact.

[0063] The spring 4 is formed of various metals and includes a first fixed spring 5, a movable spring 6, and a second fixed spring 7. The first fixed spring 5 has a first fixed contact 12, the movable spring 6 has a movable contact 13, and the second fixed spring 7 has a second fixed contact 14. In addition, the spring 4 has a spring portion 15 and a terminal 16. For example, the spring portion 15 is formed as a leaf spring. The spring portion 15 and the terminal 16 can be welded together or formed from a thin plate.

[0064] The electromagnet 8 includes a coil assembly 21 , an iron core 22 , and a yoke 23 . The coil assembly 21 includes two terminals 24 , a bobbin 26 , and a coil 25 wound around the bobbin and connected to the terminal 24 .

[0065] In the relay 1, the electromagnet 8 is excited by applying a voltage between the terminals 24. The armature 10 is swung by the excitation of the electromagnet 8 and is attracted to the iron core 22. The card 11 is mounted on the armature 10, and as the armature 10 swings, the movable spring 6 is pressed, so that the movable contact 13 contacts the second fixed contact 14 from the first fixed contact 12. The hinge spring 9 mounted on the armature 10 and the yoke 23 elastically applies force to one end of the armature 10 in a direction away from the iron core 22.

[0066] When the voltage application to the terminal 24 stops, the armature 10 returns to the initial position away from the iron core 22 by the biasing force of the hinge spring 9. When the armature 10 returns to the initial position, the pressing force from the card 11 to the movable spring 6 is released, and the movable contact 13 is separated from the second fixed contact 14.

[0067] With the above configuration, the relay 1 opens and closes the first fixed contact 12 and the movable contact 13, and the movable contact 13 and the second fixed contact 14. The above configuration is an example, and any components and principles may be adopted.

[0068] Figure 4 is a perspective view of an example of the movable spring 6. Figure 5A and Figure 5B 2 is a cross-sectional view taken along a line VV of an example of a spring structure. The movable spring 6 includes a protrusion 28 for pressing the movable spring 6 against the reference surface 27 and a locked portion 29 locked to the base 2. Figure 4 In the embodiment, the end of the U-shaped piece formed on the spring portion 15 is set as the locked portion 29. The end of the U-shaped piece is formed to face rearward in the insertion direction I of the movable spring 6. When the locked portion 29 receives the external force F, it is elastically deformed due to the spring characteristics, and when the external force F is released, it returns to its original shape.

[0069] The base 2 has a reference surface 27 for defining a reference position of the movable spring 6 when the movable spring 6 is assembled to the base 2, a press-fit surface 30 opposite to the reference surface 27, and a locking portion 31 for locking the movable spring 6. For example, a claw-shaped protrusion formed on the reference surface 27 is provided as the locking portion 31, and the protrusion is preferably provided to protrude in a direction different from the insertion direction I. The different directions may be any direction as long as they can lock the locked portion 29, and may be a direction orthogonal to the insertion direction I, a direction inclined forward toward the insertion direction I, and the like. In addition, the protrusion may be formed on a surface orthogonal to the reference surface 27 instead of on the reference surface 27. In Figure 5AIn the initial stage of insertion of the movable spring 6 shown in the figure into the base 2, the protrusion 28 contacts the press-fit surface 30, and the locked portion 29 contacts the locking portion 31. The locked portion 29 in contact with the locking portion 31 is elastically deformed. Figure 5B In the later stage of the insertion of the movable spring 6 shown, the raised portion 28 contacting the pressing surface 30 presses the movable spring 6 against the reference surface 27, and the locked portion 29 dives under the locking portion 31 by its restoring force and is locked with the lower part of the locking portion 31. The movable spring 6 is thus self-locked during the insertion process to prevent the movable spring 6 from falling off. The locking portion 31 restricts the movement of the locked portion 29 in the direction opposite to the insertion direction I, thereby preventing the movable spring 6 from falling off.

[0070] The relay 1 described here is of a type in which the movable spring 6 is inserted vertically into the base 2. However, the relay 1 may be of a type in which the movable spring is inserted horizontally.

[0071] As described above, the spring's press-in strength can be reduced, and the spring can be prevented from falling off even for thin springs. Therefore, the spring structure of this example is useful for small relays in particular. The movable spring 6 is inserted by utilizing the spring characteristics of the locked portion 29, thereby reducing mold scratches and wear powder during press-in. In addition, the temporary bonding and drying process of the movable spring can be abolished, resulting in a reduction in equipment costs, product costs, etc. In addition, the potential risk of the spring falling off during the process from spring insertion to bonding can be eliminated.

[0072] The self-locking structure of this example can also be applied to the first fixing spring 5 and the second fixing spring 7 . Figure 6 is a perspective view of an example of the second fixing spring 7, Figure 7 VII-VII is a cross-sectional stereoscopic view of another example of a spring structure. The second fixing spring 7 has a raised portion 28 for pressing the second fixing spring 7 against the reference surface 27 and a locked portion 29 that is locked to the base 2. For example, the inclined end of the root 32 of the inclined and raised terminal 16 is set as the locked portion 29, and the end is formed to face backward in the insertion direction I. When the locked portion 29 is subjected to an external force F, the locked portion 29 is elastically deformed due to the spring characteristics, and returns to its original shape when the external force F is released.

[0073] The base 2 has a reference surface 27 for defining a reference position of the second fixing spring 7, a press-fit surface 30 opposite to the reference surface 27, and a locking portion 31 for locking the second fixing spring 7. For example, a recessed edge portion formed on the press-fit surface 30 side is set as the locking portion 31. The edge portion extends in a direction different from the insertion direction I. The edge portion refers to not only the side wall portion of the recess but also the press-fit surface 30 portion. At the initial stage of inserting the second fixing spring 7 into the base 2, the raised portion 28 ( Figure 7The second fixing spring 7 is inserted into the base 2 by the protrusion 28 contacting the pressing surface 30, and the locked portion 29 contacts the pressing surface 30 and undergoes elastic deformation (not shown). In the later stage of the insertion of the second fixing spring 7 into the base 2, the protrusion 28 contacting the pressing surface 30 presses the second fixing spring 7 against the reference surface 27, and the locked portion 29 is embedded in the locking portion 31 by the restoring force and is locked with the locking portion 31. The second fixing spring 7 is thus self-locked during the insertion process. The locking portion 31 limits the movement of the locked portion 29 in the direction opposite to the insertion direction I, thereby preventing the second fixing spring 7 from falling off.

[0074] Fig. 8A 2 is a partial perspective view showing a modified example of the locked portion 29 of the movable spring 6. Figure 8B It is a partial cross-sectional view showing a modified example of the self-locking structure.

[0075] exist Fig. 8A In the embodiment, the end of the V-shaped piece formed near the root of the terminal 16 is set as the locked portion 29. The end is formed to face backward in the insertion direction I. When the locked portion 29 is subjected to an external force F, the locked portion 29 is elastically deformed due to the spring characteristics, and when the external force F is released, it returns to its original shape. Figure 8B The edge portion of the depression formed on the press-in surface 30 is set as the locking portion 31. The edge portion is extended in a direction different from the insertion direction I. In the initial stage of the insertion of the movable spring 6 into the base 2, the locked portion 29 contacts the press-in surface 30 and is elastically deformed by the force from the press-in surface 30. In the later stage of the insertion of the movable spring 6 into the base 2, the locked portion 29 sneaks into the locking portion 31 by the restoring force and engages with the locking portion 31. The movable spring 6 is self-locked in this way during the insertion process. The locking portion 31 limits the movement of the locked portion 29 in the direction opposite to the insertion direction I, thereby preventing the movable spring 6 from falling off.

[0076] Fig.9A 2 is a partial perspective view showing another modified example of the locked portion 29. Fig. 9B It is a cross-sectional view showing another modified example of the self-locking structure. Fig.9A The locked portion 29 is a protrusion protruding laterally from the terminal 16, and the protrusion is formed to face laterally in the insertion direction I. When the locked portion 29 is subjected to an external force F, the locked portion 29 is elastically deformed by the spring characteristics, and when the external force F is released, it returns to its original shape. Fig. 9B The locking portion 31 is a claw-shaped protrusion that protrudes from the reference surface 27 in a direction different from the insertion direction I.

[0077] The raised portion 28 may also be Figure 4 However, when any of the various spring fall-off prevention structures described above is adopted, it is preferred to Figure 4As shown on the left side, a portion of the movable spring 6 is cut and raised to form a raised portion 28 .

[0078] Fig. 10A is a cross-sectional view showing a range A of spring stress when the protrusion is set as a convex portion, Fig. 10B It is a XX cross-sectional view showing a range B of the spring stress when the raised portion is formed as a raised piece. Fig. 10A and Fig. 10B Both show the state where the movable spring 6 passes over the locking portion 31. From the perspective of the contact state between the locked portion 29 and the locking portion 31, Fig. 10A and Figure 10b corresponds to Figure 5A and Figure 5B states between the states shown.

[0079] When the movable spring 6 is assembled to the base 2, when the locked portion 29 passes over the locking portion 31, the movable spring 6, especially the portion above the protrusion 29, is deformed due to the height of the locking portion 31. In this case, it is necessary to use the elasticity of the movable spring 6 to absorb the height of the locking portion 31. At the same time, when the protrusion 29 contacts the press-fit surface 30, a portion of the movable spring 6 provided with the protrusion 29 is pressed toward the reference surface 27.

[0080] When the protrusion 28 is a convex portion, depending on the distance between the locking portion 31 and the protrusion 28, stress may be concentrated in a relatively narrow range A of the movable spring 6 between the locking portion 31 and the protrusion 28. In this case, the spring may be plastically deformed, resulting in a reduction in self-locking performance.

[0081] In order to relieve stress when the protrusion 28 is in a convex shape, the stress can be dispersed by increasing the spring width or arranging the locking portion 31 at a higher position of the base 2. However, if this structure is applied to a small relay, the insulation distance and the coil width of the spring will be affected.

[0082] From the viewpoint of suppressing the plastic deformation of the spring, stress dispersion can be achieved by forming the protrusion 28 as a cut-and-raised piece instead of a convex portion.

[0083] In the case where the raised portion 28 is formed as a cut-and-raised piece, when the movable spring 28 is assembled to the base 2, the raised portion 28 is deformed. The deformed raised portion 28 absorbs the stress generated when the locked portion 29 passes over the locking portion 31 and overlaps with the locking portion 31, and the movable spring 6 is elastically deformed at the height of the locking portion 31. In addition, the distance between the locking portion 31 and the root 28a of the cut-and-raised piece is relatively far. Therefore, the stress is dispersed in a relatively wide range B of the movable spring 6 including the portion where the raised portion 28 is formed, and the plastic deformation of the spring can be suppressed. The cut-and-raised piece can be used for the first fixed spring 5 and the second fixed spring 7.

[0084] The cover 3 has a small thickness, and the cover 3 may be warped inward during molding. Fig.11 : is a diagram showing the influence of the inner warping of the cover 3. The base 2 has an outer side surface 41 that is opposite to the inner side surface 40 of the cover. If the outer side surface 41 is a flat surface, when the cover 3 that has warped inward is covered with the base 2, the gap between the base 2 and the cover 3 provided as the adhesive layer 42 for bonding the base 2 and the cover 3 becomes narrower. In this case, the gap as designed cannot be ensured, and there may be a place C where the adhesive layer 42 becomes thin. When the adhesive layer 42 becomes thin, the cover and the base cannot be fully sealed, which may cause poor airtightness.

[0085] Therefore, a step for securing the adhesive layer 42 is formed on the outer side surface 41 . Fig.12 FIG. 4 is a perspective view of a base 2 having an example step 43 formed thereon. For example, the step 43 is a depression 46 that is one level lower than the outer side surface 41. Fig.11 As shown, the inner warping of the cover 3 becomes the largest near the middle of the opening of the cover 3. Therefore, by forming a step 43 (see FIG. 4 ) at a position near the middle 45 of the side surface of the cover 3 on the outer side surface 41 facing the cover edge 44 Figure 1 and Figure 2 ), even if the cover 3 is warped inwardly, an adhesive layer that ensures a sufficient gap between the inner side surface 40 and the outer side surface 41 can be obtained.

[0086] The most preferred structural ratio of the thickness of the adhesive layer 42 and the height and depth of the step 43 may be determined based on the relationship between the warping shape and amount of the cover 3, the properties of the adhesive, the bonding strength of the resin material (base, cover), and the like.

[0087] Fig.13 : is a schematic cross-sectional view XIII-XIII showing an example of the structural ratio of the base-cover. The reference numeral "3" shows a cover without warping, the reference numeral "3'" shows a cover with warping, and the reference numeral "3' '" shows a cover with warping restricted by the step 43 formed on the outer side surface 41. For example, when the design gap z between the base 2 and the cover 3 is set to 0.05 mm, the target thickness y1 of the adhesive layer at the position of the cover edge 44 is set to 0.04 mm or more, the depth y2 of the step 43 is set to 1.5 mm, the height a of the step 43 is set to 0.1 mm, the length L of the cover with warping is set to 12.7 mm, and the cover warping amount d at the position of the cover edge 44 is set to 0.1 mm, the cover warping amount x (= 0.057 mm) after restriction at the position of the cover edge 44 can be calculated according to the following formula.

[0088]

[0089] The thickness of the adhesive layer at the position of the assembled cover edge 44 can be calculated by the following formula (= 0.093 mm). In the case of the above ratio, the minimum adhesive thickness is 0.093 mm, the adhesive inflow depth corresponding to the depth of the step 43 is 1.5 mm, and the target thickness y1 is 0.04 mm or more.

[0090] y1=(z+a)-x

[0091] If the target thickness y1 of 0.04 mm or more is not obtained based on the above calculation formula, the target thickness can be obtained by re-adjusting at least one of the height a or the depth y2 of the step 43. The height and depth of the step 43 may be set in this manner.

[0092] The step 43 may be a protrusion 47 protruding from the outer side surface 41 instead of the recess 46 . Fig.14 4 is a perspective view of the base 2 showing a modified example of the step 43. The protrusion 47 corrects the inward warping of the cover 3 from the inside, thereby ensuring a clearance between the cover and the base as designed. Fig.14 In the example, the protrusion 47 is formed on the outer side 41 on the side of the edge 44 of the cover and is approximately equally spaced from the middle 45 of the side. The height of the protrusion 47 is preferably the designed gap between the base and the cover during assembly. Through the above step 43, even if the cover is warped inward, an adhesive layer with sufficient gap can be ensured, and the adhesive can flow from the cover edge 44 to ensure the sealing performance of the relay 1. The step 43 can also be formed on the inner side 40 instead of the outer side 41.

[0093] In small relays, spring terminals are often thin and have height restrictions, so the size and area of ​​the adhesive layer obtained between the terminal and the base may also be restricted. Fig.15 1 is a schematic cross-sectional view showing the adhesive layer 50 between the terminal and the base. When a load is applied to the terminal 16, stress is generated in the adhesive around the terminal 16. Therefore, there is a risk that the adhesive layer 50 will peel off, cracks will occur in the adhesive layer around the terminal 16, and the airtightness will be poor, especially when the area of ​​the adhesive is restricted. In addition, when the inner side surface 52 of the insertion hole 51 for the terminal 16 to be inserted is the same surface as the reference surface 27, the terminal 16 is in contact with the reference surface 27, and the adhesive is not easy to enter the inner side surface 52. Therefore, a thin place D where the adhesive layer becomes thinner will be formed on the reference surface 27 side of the adhesive layer 50. It is also possible to lower the base 2 around the terminal 16 by one level as a whole to prevent the thin place from occurring, but due to the above-mentioned restrictions, this solution has its limits.

[0094] Fig.16A This is a bottom perspective view of an example of a base 2 for securing an adhesive layer. Fig. 16BIt is a cross-sectional view XVI-XVI of the base 2. In Figure 16, the adhesive layer 50 can be ensured on the side of the reference plane 27 below the insertion hole 51. The base 2 has a notch 54 on the reference plane 27 near the terminal outlet of the insertion hole 51. For example, the notch 54 has an inclined surface inclined relative to the reference plane 27. By forming the inclined surface, the adhesive becomes easy to flow into the notch 54. The notch 54 may also be a depression descending from the reference plane 27 instead of an inclined surface. The notch 54 can increase the area of ​​the adhesive layer between the terminal and the base on the reference plane side, and the airtightness of the relay can be improved. In addition, the crack resistance of the adhesive layer when a load is applied to the terminal 16 is improved. In addition to the notch 54, the insertion hole 51 around the terminal can also be lowered as a whole, which can also improve the terminal strength.

[0095] The slit and other structures of the movable spring are described. Fig.17 It is a perspective view of relay 200 with the cover removed. Fig.18 2 is an exploded perspective view of the relay 200. Fig.17 and Fig.18 As shown, the relay 200 includes: a base 204, on which components are assembled; and a cover 206, which covers the base 204. The base 204 and the cover 206 are, for example, molded from resin. The base 204 and the cover 206 form a housing. The components assembled to the base 204 include: a spring including a first fixed spring 260, a movable spring 270, and a second fixed spring 280, an electromagnet 207, an armature 208, and a card 209 as a moving member. The springs are respectively metal plate-shaped spring members. The card 209 is, for example, molded from resin.

[0096] The first fixed spring 260 has a terminal 261 and a first fixed contact 262 (see Fig.26 ). The movable spring 270 has a terminal 271 and a movable contact 272. The second fixed spring 280 has a terminal 281 and a second fixed contact 282. The electromagnet 207 includes a coil assembly 227, an iron core 228, a yoke 229, and terminals 207a, 207b.

[0097] In the relay 200, a voltage is applied to the terminal 207a and the terminal 207b to excite the electromagnet 207, so that the armature 208 swings and is attracted to the iron core 228. Two protrusions 208a and 208b are formed at the upper end of the armature 208. The protrusions 208a and 208b are respectively locked with the engaging claws 209a and 209b of the card 209. Two protrusions 209c and 209d are formed at the top of the card 209, and are inserted through the holes 270a and 270b formed on both sides of the movable contact 272 of the movable spring. As the armature 208 swings, the protrusions 209c and 209d press the holes 270a and 270b formed in the movable spring 270 toward the second fixed spring 280. As a result, the movable contact 272 separates from the first fixed contact 262 and contacts the second fixed contact 282. It should be noted that a hinge spring (not shown) is attached to the armature 208 and the yoke 229 , and elastically urges the armature 208 in a direction away from the core 228 .

[0098] When the voltage applied to the coil stops, the armature 208 is reset by the biasing force of the hinge spring in a manner away from the iron core 228. As the armature 208 returns, the pressing force applied by the card 209 to the movable spring 270 is released, and the movable contact 272 separates from the second fixed contact 282 and contacts the first fixed contact 262.

[0099] According to the above configuration, the relay 200 opens and closes the first fixed contact 262 and the movable contact 272 as disconnection contacts, and opens and closes the second fixed contact 282 and the movable contact 272 as connection contacts. The above configuration of the relay 200 is exemplary, and other types of moving mechanisms or moving members that press the movable spring 270 as the electromagnet 207 works may also be used. The number of springs installed in the relay 200 is also exemplary, and for example, the number of springs may be two, namely, a movable spring and a fixed spring.

[0100] Fig.19 and Fig. 20 They are a three-dimensional view and a front view of the movable spring 270. Fig.19 and Fig. 20As shown, the movable spring 270 includes a flat base 273 supported on the base 204, a terminal 271 extending downward from one lateral end of the base 273, and a main spring 274 bent into a U-shape so as to protrude downward from the center of the lower end of the base 273 and extending upward. The main spring 274 has a movable contact 272 at the upper end. An extension 275 is formed at the upper end of the main spring 274 where the movable contact 272 is mounted. The extension 275 extends straight toward the position pressed by the protrusion 209c, and a hole 270a is formed at the top. A branch 276 is formed between the movable contact 272 and the base 273 of the main spring 274 on the side opposite to the extension 275 with respect to the movable contact 272 as a reference. The branch 276 branches from the main spring 274 and extends to a height substantially the same as the upper end of the main spring 274, and a hole 270b is formed at the top end. A slit 278 is formed between the branch portion 276 and a portion of the main spring 274 where the movable contact 272 is mounted.

[0101] As described above, by forming the slit 278 on one side of the movable contact 272 at the upper end of the movable spring 270, when the upper end of the movable spring 270 is pressed into the second fixed spring 280 by the card 209, a lateral movement can be added to the contact path between the movable contact 272 and the second fixed contact 282 in addition to the sliding in the up-and-down direction. Thus, a rolling motion can be added to the contact motion of the contact. Fig.21A -21C and Fig. 22 The effect of forming the slit 278 will be described.

[0102] Fig.21A This is a side view showing a state in which the movable spring 270 is pressed toward the second fixed spring 280 by the card 209 and the movable contact 272 and the second fixed contact 282 begin to contact each other. Fig. 21B The movable spring 270 is shown as Fig.21A The state from which the card 209 is fully pressed in. Fig. 21C Observed from above Fig. 21B Figure. Fig. 21C In the embodiment, the portion of the main spring 274 provided with the movable contact 272 receives a pressing force from the second fixed contact 282 toward the first fixed spring 260. At this time, a slit 278 is formed at the upper end of the movable spring 270 where the hole 207b is formed, so the portion of the main spring 274 provided with the movable contact 272 is twisted in such a way that the side of the main spring 274 provided with the slit 278 slightly tilts toward the first fixed spring 260. As a result, Fig. 21C As shown, the portion of the main spring 274 where the movable contact 272 is provided is inclined toward the card 209 at an angle θ relative to a direction perpendicular to the moving direction of the card 209 .

[0103] Thus, when the movable contact 272 contacts the second fixed contact 282, a lateral motion perpendicular to the moving direction and up-down direction of the card 209 can be added between the movable contact 272 and the second fixed contact 282. This lateral motion can add a rolling motion to the movable contact 272. Fig. 22 An example of a contact path C1 of the second fixed contact 282 on the movable contact 272 in a case where a rolling motion is added to the movable contact 272 is shown.

[0104] In this embodiment, the rigidity of the movable spring 270 can be reduced by forming a slit 278 at the upper end of the movable spring 270, without adopting a design that is strict on the current carrying capacity, such as reducing the spring width and setting the spring thickness small. In this embodiment, by providing the slit 278 only on one side of the movable contact 272 of the movable spring 270, a lateral rolling motion can be added to the contact contact action in addition to the sliding in the up and down directions. As a result, in addition to the contact cleaning effect such as removing the oxide film on the contact surface and scraping off the wear powder, it is also expected that the resistance to welding when the contact contacts can be improved. In the case where the movable spring does not have a slit, the contacts can slide in the up and down directions, but when unevenness occurs on the contact, the contact is 100% affected by it. On the other hand, in the case where the slit 278 is provided only on one side of the movable contact 272 in the movable spring 270 as in this embodiment, the upper end portion of the movable spring 270 twists in the direction of the slit 278 when the contacts contact each other. Therefore, the torsional motion of the movable spring 270 can disperse and avoid the influence of the unevenness generated on the contact point when the contact point slides.

[0105] Fig.23 2 is a perspective view showing a state where the movable spring 270 is mounted on the base 204 with the front portion cut away. The movable spring 270 is supported on the base 204 in a state where the position is restricted by the base 273. The movable spring 270 is inserted into the insertion hole 244 ( Fig.24 ) is bonded to the terminal 271. The main spring 274 is formed to be bent into a U-shape from the lower end of the base 273 and extend upward.

[0106] pass Fig.23 By forming the main spring 274 into a U-shape, it becomes easy to attach the movable spring 270 to the base 204 from the longitudinal direction. In addition, by setting the deformation area of ​​the movable spring 270 as the main spring 274 bent into a U-shape, the gap between the base 273 and the base 204 can be enlarged. Therefore, it is possible to prevent the adhesive from flowing from the insertion hole 244 to the rigid point of the main spring 274 and causing uneven rigidity. In addition, compared with the case where the main spring is set to an L-shape, the length of the part of the main spring 274 that functions as a spring can be ensured to be longer, and the spring characteristics of the main spring 274 can be improved.

[0107] Fig.24It is a perspective view of a portion of the base 204 where the first fixed spring 260 , the movable spring 270 , and the second fixed spring 280 are mounted. Fig.25 It is a perspective view of the base 204 in a state where the first fixing spring 260 is mounted. Fig.26 yes Fig.25 The first fixed spring 260 includes a terminal 261, a base 263 supported by the base 204, and a spring portion 264 extending from the base 263 and having a first fixed contact 262 at the tip end side.

[0108] like Fig.24 As shown, a first support portion 241 and a second support portion 242 supporting the base 263 are formed on the bottom surface of the base 204. The first support portion 241 has reference surfaces 241a and 241b for defining the position of the base 263 in the moving direction of the card 209. The second support portion 242 has reference surfaces 242a and 242b for defining the position of the base 263 in the moving direction of the card 209. An insertion hole 243 for inserting the terminal 261 of the first fixing spring 260 is formed on the bottom wall of the base 204. Fig.25 As shown, the base 263 is supported by the first support portion 241 and the second support portion 242, and the first fixing spring 260 is mounted on the base 204 from above in such a manner that the terminal 261 passes through the insertion hole 243. When the first fixing spring 260 is assembled to the base 204, the adhesive flows from the outside of the insertion hole 243, thereby fixing the terminal 261 to the base 204.

[0109] like Fig.24 As shown, a recess R1 is formed in the area of ​​the base 204 where the terminal 261 is arranged. The recess R1 is formed by the outer surface 351 on the insertion hole 243 side of the second support part 242, the side wall surface 352, the wall surface 353 on the movable spring 270 side, and the wall surface 354 on the electromagnet 207 side, and the insertion hole 243 is formed at the bottom of the recess R1. The recess R1 suppresses the inflow of adhesive from the outside into the terminal insertion area by surface tension.

[0110] like Fig.26 As shown, the terminal 261 has a shape bent into a crank shape. The terminal 261 has a first portion 261a extending downward from the base 263, a second portion 261b bent from the lower end of the first portion 261a and extending obliquely downward, and a third portion 261c bent downward from the top end of the second portion 261b. The gap G between the surface 261f on the bottom surface 204a side of the second portion 261b and the bottom surface 204a is a shape that expands from the opening end 243a on the inner side of the insertion hole 243 toward the internal space of the relay 200. Fig.26 In the example of FIG. 1 , the gap G is formed into a tapered shape in a cross-sectional view.

[0111] In this way, by gradually expanding from the opening end of the insertion hole 243 toward the internal space, the gap G is formed, so that the adhesive flowing into the insertion hole 243 from the outside can be retained near the insertion hole 243 due to surface tension, thereby preventing the adhesive from flowing into the internal space.

[0112] like Fig.24 As shown, an insertion hole 244 for inserting the terminal 271 is formed on the bottom wall of the base 204 . Fig. 27 The base 204 is equipped with a movable spring 270. Fig.24 XXVII-XXVII section view of the Fig. 27 As shown in FIG. 2 , a recess R2 is provided in the portion of the insertion hole 244 where the terminal 271 is disposed. The recess R2 is composed of wall surfaces 361, 362, and 363 located on both sides of the terminal 271 in the moving direction of the card 209. Fig.24 The front wall surface 363 and the peripheral surface of the protrusion 364 define a recess R2. The recess R2 has a width W2 greater than the width W1 of the opening end of the insertion hole 244. By forming the recess R2 having a size greater than the opening end of the insertion hole 244 in the portion having the insertion hole 244, the adhesive flowing into the insertion hole 244 from the outside can be retained inside the insertion hole 244 by surface tension, thereby preventing the adhesive from flowing into the internal space.

[0113] like Fig.24 As shown in FIG. 2 , a recess R3 is provided in the region of the insertion hole 245 of the base 24. The recess R3 has a larger spatial dimension than the width WX in the short side direction and the width WY in the long side direction of the rectangular insertion hole 245. The recess R3 is defined by the inner surfaces 371 and 372 of the base 204 and the side surface 311b of the restriction portion 311 on the insertion hole 245 side. By forming such a recess R3, the adhesive that flows into the insertion hole 245 from the outside can be retained inside the insertion hole 245 by surface tension, and the adhesive that flows into the internal space can be suppressed.

[0114] Fig.28 It is a perspective view showing an initial state of the first fixed spring 260 , the movable spring 270 , and the second fixed spring 280 mounted on the base 204 when no pressing force is applied from the card 209 . Fig.29 is from Fig.28 Observe the front view of the second fixing spring 280 from the right side.

[0115] The second fixing spring 280 includes a terminal 281 inserted into an insertion hole 245 formed in the base 204, a base 283 supported by the base 204, and a spring portion 284. Fig.28In the initial state, the limiting portion 311 having a reference surface 311a in contact with the surface of the spring portion 284 on the card 209 side is formed to be erected from the inner side of the bottom wall. When the excitation of the electromagnet becomes off and the card 209 is reset to the initial position, from the state in which the electromagnet 207 is working and the second fixed spring 280 is pressed by the movable spring 270, the card 209 loses the force of pressing the second fixed spring 280. Due to its reaction, the second fixed spring 280 quickly returns to the card 209 side and tilts toward the movable contact 272 side from the initial position. The limiting portion 311 limits the action of the second fixed spring 280 tilting toward the card 209 side due to the reaction when returning to the initial state from the state in which the second fixed contact 282 is pressed by the movable contact 272 and the second fixed spring 280 is warped in the direction opposite to the card 209 side.

[0116] The base 204 has restriction portions 321 and 322 formed on the opposite side of the restriction portion 311 with respect to the base 283. The restriction portions 321 and 322 abut against the protrusions 283a and 283b of the base 283, respectively, to restrict the position of the base 283 ( Fig.24 With this configuration, when the second fixed spring 280 is pressed into the movable spring 270, the second fixed spring 280 is moved to the boundary P0 ( Fig.29 ) as a swing fulcrum, the spring portion 284 is elastically deformed in a manner that it falls toward the side opposite to the card 209 as a whole.

[0117] The reference surface 311a contacts the spring portion 284 at a position P1 higher than the boundary position P0 in the height direction. The height of the restricting portion 311 on the movable spring 270 side relative to the second fixed spring 280 becomes higher than the height on the opposite side. Fig.29 The dotted oblique line in the figure shows the contact area 280s where the second fixed spring 280 contacts the limiting portion 311. With this structure, when the second fixed spring 280 tilts toward the card 209 side due to the reaction of the pressure applied by the movable spring 270, the swing fulcrum rises from position P0 to position P1. Therefore, the deformation area in the spring portion 284 becomes shorter, and the rigidity of the second fixed spring 280 is increased. As a result, the second fixed spring 280 can be prevented from tilting toward the movable contact 272 side to a greater extent than the initial position, and the influence of the arc caused by the instantaneous blockage of the gap between the movable contact 272 and the second fixed contact 282 can be reduced.

[0118] Although various embodiments have been described in this specification, the present invention is not limited to the aforementioned embodiments, and various modifications can be made within the scope described in the claims.

Claims

1. A relay having: Electromagnet; A plurality of springs, each comprising a contact and a terminal, wherein the contact opens and closes with another contact according to the action of the electromagnet; and a base supporting the spring, At least one of the plurality of springs has a locked portion that is locked to the base by utilizing the spring characteristics of the spring. The base has a locking portion for locking the locked portion. The base includes a reference surface for defining a reference position of the spring and a press-fit surface facing the reference surface. At least one of the springs has a raised portion formed by cutting out a portion of the spring for pressing the spring against the reference surface. The press-fit surface is provided with a recessed portion that engages with the raised portion when the spring is inserted. In the initial stage of insertion of the spring into the base, the raised portion contacts the pressed surface, and the locked portion contacts the locking portion and undergoes elastic deformation. In the later stage of insertion of the spring, the locked portion engages with the locking portion through its restoring force, and the locking portion restricts the movement of the locked portion in a direction opposite to the insertion direction of the spring.

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