Magnetic reed switch and preparation method thereof

Abstract

The invention provides a magnetic reed switch and a preparation method thereof, and the preparation method comprises the steps: carrying out the grooving of a nickel-iron wire or a nickel-iron sheet, and obtaining a static reed with one end provided with a first positioning groove; grooving the nickel-iron wire material and welding a hollow pipe to obtain a movable contact spring with a second positioning groove at one end; plating layers are plated on the surfaces of the movable reed and the static reed; metal pieces are welded to the first positioning groove of the static reed and the second positioning groove of the movable reed, and a static reed assembly and a movable reed assembly are obtained respectively; the ends, provided with the metal pieces, of the movable reed assembly and the static reed assembly are packaged in a glass tube, the metal pieces in the movable reed assembly and the static reed assembly are arranged in a non-contact crisscross mode, and finally the magnetic reed switch is manufactured. By additionally arranging the high-melting-point metal pieces which are distributed in the crisscross manner at the end parts of the movable magnetic reed and the static magnetic reed, the magnetic contact area is effectively reduced, the rebounding time of the magnetic reed is shortened, and the ablation of a switching arc to the magnetic reed is reduced.

Description

Technical Field

[0001] This application relates to the field of electronic switch technology, specifically to a reed switch and its manufacturing method. Background Technology

[0002] A reed switch, also known as a reed switch, is a core component of a magnetically controlled proximity switch and reed relay. It consists of two magnetizable reeds with overlapping ends and a small gap, sealed within a glass tube. When an external magnetic field is present, the two reeds generate polarity, attract each other, and make contact, thus completing the circuit. When the magnetic field disappears or moves away from the switch, the reeds return to their initial positions under their own elastic reaction force, reforming the gap and disconnecting the circuit.

[0003] Because reed switches generate an electric arc when opening or closing, the contact surfaces of the reeds are typically plated or sputtered with a layer of high-hardness, high-melting-point precious metal to resist arc erosion. However, the elastic reaction force of the reeds is limited by the adhesive force between them, which is proportional to the magnetic contact area. In existing reed switches, such as those described in patent DE1112161B, the reeds often have end-to-end contact, resulting in a large magnetic contact area. This leads to high adhesive force, affecting the reed's springback and causing a longer opening time. This increases the arc erosion of the reeds and severely impacts the lifespan of the reed switch.

[0004] To address these issues, domestic and international experts have conducted research on reed-related products. Patent CN 113035639A improves the magnetic contact area and springback of the reed by riveting a spherical silver alloy rivet with a precious metal-plated surface to the armature and a copper alloy stationary reed, and installing a planar silver alloy stationary contact with a precious metal-plated surface on the copper alloy moving reed. When an external magnetic field is applied, only the armature is polarized, driving the stationary reed with the spherical rivet to move, while the moving reed remains unpolarized, thus achieving the opening and closing action. However, in this patent, the spherical silver alloy rivet simultaneously rivets both the armature and the stationary reed. Since there are dimensional tolerance differences between the two, it is difficult for the spherical rivet to fit tightly and seamlessly with both simultaneously. With repeated opening and closing actions of the reed switch, the rivet is prone to loosening, affecting the opening and closing action of the reed switch and increasing the risk of reed switch failure.

[0005] Therefore, there is an urgent need to develop a reed switch and its manufacturing method to solve at least one of the following problems in existing reed switches: large magnetic contact area of ​​reeds, strong adhesion, slow rebound, short service life, and easy loosening and failure of spherical electrical contact riveted reeds. Summary of the Invention

[0006] In view of the deficiencies in the prior art, the purpose of this application is to provide a reed switch and a method for manufacturing the same.

[0007] According to one aspect of this application, a method for manufacturing a reed switch is provided, comprising: Grooving is performed on nickel-iron wire or nickel-iron sheet to obtain a stationary spring with a first positioning groove at one end; The nickel-iron wire is grooved and welded with a hollow tube to obtain a moving spring with a second positioning groove at one end; A coating is applied to the surfaces of the moving spring and the stationary spring; A first metal part is welded to the first positioning groove of the stationary spring to obtain a stationary spring assembly; a second metal part is welded to the second positioning groove of the movable spring to obtain a movable spring assembly. One end of the stationary reed assembly containing the first metal component and one end of the moving reed assembly containing the second metal component are encapsulated in a glass tube, such that the second metal component and the first metal component are arranged in a non-contact cross shape; the other end of the stationary reed assembly and the hollow tube are respectively sealed and connected to the two ends of the glass tube, thus obtaining a magnetic reed switch.

[0008] Optionally, the step of grooving the nickel-iron wire or nickel-iron sheet to obtain a stationary spring with a first positioning groove at one end includes: The nickel-iron wire is die-cut, or the nickel-iron sheet is punched to obtain a static spring semi-finished product with a flat end. At least one first positioning groove is machined on the planar end surface of the stationary spring semi-finished product to obtain a stationary spring with the first positioning groove at the end. The length direction of the first positioning groove is parallel to the length direction of the stationary spring.

[0009] Optionally, the grooving process of the nickel-iron wire to obtain a movable spring with a second positioning groove at one end includes: Nickel-iron wire is die-cut to obtain a semi-finished moving spring with a stepped overall shape and flat ends; A hollow tube is welded to one end of the semi-finished moving spring. A second positioning groove is machined at the other end of the semi-finished moving spring to obtain a moving spring with a second positioning groove at the end. The length direction of the semi-finished moving spring is parallel to the central axis of the hollow tube, and the length direction of the second positioning groove is perpendicular to the length direction of the moving spring.

[0010] Optionally, the nickel-iron wire, nickel-iron sheet, and hollow tube are made of nickel-iron alloy or a conductive magnetic material with a coefficient of thermal expansion matching that of the glass tube.

[0011] Optionally, the coating thickness on the surfaces of the moving spring and the stationary spring is 10μm~30μm, and the coating material is any one of Cu, Ni, Sn, copper alloy, nickel alloy or silver-copper-titanium alloy.

[0012] Optionally, welding a first metal part to the first positioning groove of the stationary spring to obtain a stationary spring assembly; and welding a second metal part to the second positioning groove of the movable spring to obtain a movable spring assembly, comprising: At least one first metal part is horizontally placed in the first positioning groove of the stationary spring, the first metal part and the stationary spring are welded together, and then cleaned to obtain the stationary spring assembly. A second metal part is placed horizontally in the second positioning groove of the moving spring, the second metal part and the moving spring are welded together, and then cleaned to obtain the moving spring assembly.

[0013] Optionally, the step of encapsulating one end of the stationary reed assembly with the first metal component and one end of the moving reed assembly with the second metal component inside a glass tube, such that the second metal component and the first metal component are arranged in a non-contact cross-shaped configuration; and sealing the other ends of the moving reed assembly and the other ends of the stationary reed assembly to the two ends of the glass tube respectively, thus finally producing a magnetic reed switch, includes: One end of the stationary reed assembly with the first metal part is encapsulated in a glass tube, and one end of the moving reed assembly with the second metal part is encapsulated in a glass tube. The positions of the moving reed assembly and the stationary reed assembly are adjusted so that the second metal part and the first metal part are arranged in a non-contact cross shape, wherein the distance between the first metal part and the second metal part is 0.1mm~2mm. The magnetic reed switch is finally produced by welding one end of a glass tube and the static reed assembly, as well as the other end of the glass tube and the hollow tube, using thermal radiation or laser processing methods in a protective atmosphere or vacuum environment.

[0014] Optionally, the materials of the first metal part and the second metal part are any one of W, Rh, Mo or Ta; the central axis direction of the first metal part is parallel to the length direction of the first positioning groove, and the central axis direction of the second metal part is parallel to the length direction of the second positioning groove.

[0015] Optionally, the protective atmosphere is a nitrogen-hydrogen mixture, nitrogen, or argon atmosphere.

[0016] According to another aspect of this application, a reed switch is provided, which is prepared using the above-described method for preparing a reed switch, the reed switch comprising: The stationary reed has at least one first positioning groove at one end along its own length direction; The moving spring is parallel to the stationary spring, with at least one second positioning groove along its own width at one end and a hollow tube at the other end; The first metal component is connected to the first positioning groove; The second metal part is connected to the second positioning groove, and the second metal part and the first metal part are arranged in a non-contact cross shape. A glass tube, parallel to the length direction of the stationary spring, has a hollow cavity. One end of the stationary spring with a first metal component and one end of the moving spring with a second metal component are both located in the hollow cavity. The other ends of the moving spring and the stationary spring are respectively sealed and connected to the two ends of the glass tube.

[0017] This application provides a method for manufacturing a reed switch. By adding metal parts to the contact ends of the moving and stationary reeds, the magnetic contact method is changed from the original surface-to-surface contact to a multi-point contact or point-to-surface contact in a cross-shaped manner. This significantly reduces the magnetic contact area, lowers the adhesion force between the reeds during switch breaking, shortens the reed recovery time, and effectively reduces the erosion of the reeds by the breaking arc, thereby improving the service life of the reed switch. Furthermore, when current flows through the reeds, the metal parts of the stationary reed contact the metal parts of the moving reed in parallel, acting as a current shunt, thus reducing the risk of the reed ends being burned by large currents. Other technical effects resulting from the additional features will be further illustrated in the corresponding embodiments. Attached Figure Description

[0018] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 This is a flowchart illustrating the fabrication process of the reed switch in this application embodiment; Figure 2 This is a schematic diagram of the outer contour structure of the reed switch in Embodiment 1 of this application; Figure 3 This is a cross-sectional view of the reed switch in Embodiment 1 of this application; Figure 4 This is a partial structural diagram of the static and dynamic reed ends within the glass tube cavity of the reed switch in Embodiment 1 of this application; Figure 5 This is a partial structural diagram of the ends of the stationary and moving reeds inside the glass tube cavity of the reed switch in Embodiment 2 of this application; Figure 6 This is a partial structural diagram of the ends of the stationary and moving reeds inside the glass tube cavity of the reed switch in Embodiment 3 of this application; Figure 7This is a schematic diagram of the static and dynamic reed structure inside the glass tube cavity of the reed switch in Embodiment 3 of this application.

[0019] In the diagram: 1. Glass tube; 2. Stationary spring; 3. Moving spring; 4. First positioning groove; 5. Second positioning groove; 6. First metal part; 7. Second metal part; 8. Hollow tube. Detailed Implementation

[0020] The present application will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present application, and these all fall within the protection scope of the present application. Parts not described in detail in the following embodiments can be implemented using existing technology.

[0021] It should be noted that all information (including but not limited to user device information, user personal information, etc.) and data (including but not limited to data used for analysis, data stored, data displayed, etc.) involved in this application are information and data authorized by the user or fully authorized by all parties, and the collection, use and processing of related data must comply with relevant regulations.

[0022] In the description of the embodiments of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature.

[0024] In the description of the embodiments in this application, "multiple" means two or more, unless otherwise explicitly specified. In this application, unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," "fixed," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0025] The terms "comprising" and "having," and any variations thereof, in the embodiments of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such processes, methods, products, or devices.

[0026] Because reed switches generate an electric arc when opening or closing, the contact surface of the reed is usually plated or sputtered with a layer of high-hardness, high-melting-point precious metal to resist arc erosion. However, the elastic reaction force of the reed is limited by the adhesive force between the reeds, which is proportional to the magnetic contact area. In existing reed switches, most are end-to-end contact, resulting in a large magnetic contact area. This leads to a large adhesive force, affecting the reed's springback and causing the reed to take a long time to open, increasing the arc erosion of the reed and severely affecting the service life of the reed switch. Based on the above problems, this application provides a method for manufacturing a reed switch to solve the aforementioned issues.

[0027] Reference Figures 1-5 As shown in the figure, this application provides a method for manufacturing a reed switch, including the following steps: S1. Grooving is performed on nickel-iron wire or nickel-iron sheet to obtain a stationary spring 2 with a first positioning groove 4 at one end. S2. Grooving is performed on the nickel-iron wire and hollow tube 8 is welded to obtain a moving spring 3 with a second positioning groove 5 at one end; S3. A coating is applied to the surfaces of the stationary reed 2 and the moving reed 3; S4. Weld the first metal part 6 at the first positioning groove 4 of the stationary spring 2 to obtain the stationary spring assembly; weld the second metal part 7 at the second positioning groove 5 of the moving spring 3 to obtain the moving spring assembly. S5. The end of the stationary reed assembly with the first metal part 6 and the end of the moving reed assembly with the second metal part 7 are encapsulated in the glass tube 1, so that the second metal part 7 and the first metal part 6 are arranged in a non-contact cross shape; the other end of the stationary reed assembly and the hollow tube 8 are respectively sealed and connected to the two ends of the glass tube 1 to finally obtain the magnetic reed switch.

[0028] For example, in this embodiment of the application, nickel-iron wire or nickel-iron sheet is machined to obtain a stationary spring 2 with a double positioning groove structure at the flat end; then, the nickel-iron wire is die-cut and then welded to a hollow tube 8, and then grooved to obtain a stepped moving spring 3 with a single positioning groove structure at the flat end; a layer of metal or alloy is plated on the surfaces of the moving spring and the stationary spring; at least one or more parallel high-melting-point metal parts are welded at the positioning groove of the stationary spring to obtain a stationary spring assembly; a single high-melting-point metal part is welded at the positioning groove of the moving spring to obtain a moving spring assembly; finally, the moving spring assembly and the stationary spring assembly containing the metal parts are welded and sealed in a glass tube to obtain a reed switch with at least one high-melting-point metal part welded to the end of the stationary spring, a single high-melting-point metal part welded to the end of the moving spring, and the moving spring metal parts and the stationary spring metal parts are arranged in a cross shape. The first metal part 6 and the second metal part 7 are both made of high melting point metal materials with a melting point greater than 1500℃. The first metal part 6 and the second metal part 7 can be made of metal wire or metal sheet.

[0029] In the embodiments described above, by adding high-melting-point metal components to the contact ends of the moving and stationary reeds, the magnetic contact method is changed from the original surface-to-surface contact to a cross-shaped point-to-point or point-to-surface contact. This significantly reduces the magnetic contact area, lowers the adhesion force between the reeds during switch breaking, shortens the reed recovery time, and effectively reduces the erosion of the reeds by the breaking arc, thereby improving the service life of the reed switch. Furthermore, when current flows through the reeds, multiple high-melting-point metal components of the stationary reed contact the high-melting-point metal component of the moving reed in parallel, acting as a current shunt and reducing the risk of the reed ends being burned by high current. This application also improves the dimensional consistency of the reed products by creating positioning grooves at the welding positions, thereby increasing the yield rate and significantly reducing the production cost of the reed switch.

[0030] In some specific embodiments of this application, grooving is performed on nickel-iron wire or nickel-iron sheet to obtain a stationary spring 2 with a first positioning groove 4 at one end, which may further include: S11. Perform die-cutting on nickel-iron wire or punching on nickel-iron sheet to obtain a semi-finished static spring with a flat end. S12. At least one first positioning groove 4 is machined on the planar end surface of the stationary spring sheet semi-finished product to obtain a stationary spring sheet 2 with the first positioning groove 4 at the end. The length direction of the first positioning groove 4 is parallel to the length direction of the stationary spring 2.

[0031] In the above embodiments of this application, the molding and cutting process specifically involves: after the nickel-iron wire is molded, it is then cut to obtain a semi-finished workpiece with a preset size and structure. One, two, or more parallel first positioning grooves 4 are machined at the end of the semi-finished stationary spring sheet to obtain a stationary spring sheet 2 with one or more positioning grooves on its flat end. The shape of the first positioning groove 4 is a recess or pit, and the groove depth of the first positioning groove 4 is 0mm-0.2mm, including two boundary values ​​of 0mm and 0.2mm, to prevent positional shifts and deflections during subsequent welding of high-melting-point metal parts and the stationary spring sheet 2, thereby improving product quality consistency. Through the wire molding and cutting method, the portion of the stationary spring sheet 2 exposed outside the glass tube 1 and the portion located inside the glass tube 1 can be integrally formed, reducing the number of parts and process steps, and improving production efficiency.

[0032] In some specific embodiments of this application, the grooving process of the nickel-iron wire to obtain a movable spring 3 with a second positioning groove 5 at one end may further include: S21. The nickel-iron wire is die-cut to obtain a semi-finished moving spring with a stepped shape and flat ends. S22. Weld a hollow tube 8 to one end of the semi-finished moving spring; S23. A second positioning groove 5 is machined at the other end of the semi-finished moving spring to obtain a moving spring 3 with a second positioning groove 5 at the end. The length direction of the semi-finished moving spring is parallel to the central axis of the hollow tube 8, and the length direction of the second positioning groove 5 is perpendicular to the length direction of the moving spring 3.

[0033] For example, one end of the semi-finished moving spring is welded to the end of the hollow tube 8, thereby achieving a good connection between the stepped structure area of ​​the moving spring 3 located inside the glass tube 1 and the hollow tube 8 exposed outside the glass tube 1. A second positioning groove 5 is machined into the surface of the other end of the semi-finished moving spring, resulting in a stepped moving spring 3 with a single positioning groove structure at its flat end. The shape of the second positioning groove 5 is a groove or pit, and the groove depth of the second positioning groove 5 is 0mm-0.3mm, including two boundary values ​​of 0mm and 0.3mm, which facilitates precise control of the welding position during subsequent welding.

[0034] In the embodiments described above, the moving spring is prepared by replacing the existing strip cutting method with a wire molding and cutting method. This results in a stepped structure for the moving spring, allowing the step height of the moving spring 3 to be adjusted according to customer product requirements. This also changes the distance between the stationary spring 2 and the moving spring 3, thereby improving the sensitivity of the reed switch to the magnetic field strength and meeting the ampere-turns (AT) value (i.e., the product of the number of coil turns and the current) of different specifications of reed switches, thus satisfying the performance requirements of different specifications of reed switch products.

[0035] In some specific embodiments of this application, the nickel-iron wire, nickel-iron sheet and hollow tube 8 are made of nickel-iron alloy or conductive soft magnetic material with a coefficient of thermal expansion matching that of glass tube 1.

[0036] In the above embodiments of this application, the nickel-iron wire, nickel-iron sheet, and hollow tube 8 can be made of nickel-iron alloy, or any other conductive soft magnetic material with a coefficient of thermal expansion close to or matching that of the glass tube. This enables the stationary spring 2 and the moving spring 3 to polarize and attract each other under the presence of an external magnetic field, thus conducting the circuit and preventing the glass tube 1 from cracking due to inconsistent thermal expansion between the magnetic spring and the glass tube 1. "Coefficient of thermal expansion matching" means that the difference between the conductive soft magnetic material and the glass tube 1's coefficient of thermal expansion does not exceed 5%. The conductive soft magnetic material refers to a material that conducts electricity and is magnetized under a magnetic field and demagnetized under a non-magnetic field.

[0037] In some specific embodiments of this application, the coating thickness on the surfaces of the stationary spring 2 and the moving spring 3 is 10μm~30μm, and the coating material is any one of Cu, Ni, Sn, copper alloy, nickel alloy or silver-copper-titanium alloy.

[0038] In the above embodiments of this application, in order to improve the solderability and corrosion resistance of the magnetic reed, when the stationary reed 2 and the moving reed 3 are surface-plated, the stationary reed 2 and the moving reed 3 are first pre-treated to remove surface oxides, grease and impurities, and then a layer of metal or alloy is plated on the surface of the stationary reed 2 and the moving reed 3 by electroplating or chemical plating.

[0039] In some specific embodiments of this application, a first metal part 6 is welded to the first positioning groove 4 of the stationary spring 2 to obtain a stationary spring assembly; a second metal part 7 is welded to the second positioning groove 5 of the movable spring 3 to obtain a movable spring assembly, which may further include: S41. Place the first metal part 6 horizontally in the first positioning groove 4 of the stationary spring 2, weld the first metal part 6 and the stationary spring 2, and clean them to obtain the stationary spring assembly. S42. Place the second metal part 7 horizontally in the second positioning groove 5 of the moving spring 3, weld the second metal part 7 and the moving spring 3, and clean them to obtain the moving spring assembly.

[0040] In the embodiments described above, to obtain a moving spring assembly and a stationary spring assembly with a special arrangement of high-melting-point metal parts, at least one high-melting-point metal part is horizontally placed in one or more parallel first positioning grooves 4 of the stationary spring 2, and then the high-melting-point metal part and the stationary spring 2 are welded together. After cleaning, shaping, heat treatment, and other post-processing, a stationary spring assembly with at least one high-melting-point metal part welded to its flat end is obtained. Similarly, a high-melting-point metal part is horizontally placed in the second positioning groove 5 of the moving spring 3, and then the high-melting-point metal part and the moving spring 3 are welded together. After cleaning, shaping, heat treatment, and other post-processing, a moving spring assembly with a single high-melting-point metal part welded to its flat end is obtained. Through the above welding process, a stationary spring assembly with high-melting-point metal parts arranged along the length direction and a moving spring assembly with high-melting-point metal parts arranged along the width direction are obtained.

[0041] In some specific embodiments of this application, one end of the stationary reed assembly containing the first metal member 6 and one end of the moving reed assembly containing the second metal member 7 are encapsulated within a glass tube 1, such that the second metal member 7 and the first metal member 6 are arranged in a non-contact cross configuration; the other ends of the moving reed assembly and the other ends of the stationary reed assembly are respectively sealed and connected to the two ends of the glass tube 1, thus finally producing a magnetic reed switch, which may further include: S51. One end of the stationary reed assembly with the first metal part 6 is encapsulated in the glass tube 1, and one end of the moving reed assembly with the second metal part 7 is encapsulated in the glass tube 1. The positions of the moving reed assembly and the stationary reed assembly are adjusted so that the second metal part 7 and the first metal part 6 are arranged in a non-contact cross shape, wherein the distance between the first metal part 6 and the second metal part 7 is 0.1mm~2mm. S52. Using thermal radiation or laser processing, weld one end of the glass tube and the static reed assembly, as well as the other end of the glass tube and the hollow tube 8, in a protective atmosphere or vacuum environment to finally produce a magnetic reed switch.

[0042] In the above embodiments of this application, the processing method of the magnetic reed switch is as follows: the end of the moving reed assembly containing the high melting point metal part is placed from one end of the glass tube into the hollow glass tube, and the end of the stationary reed assembly containing the high melting point metal part is placed from the other end of the glass tube into the hollow glass tube, so that the high melting point metal parts on the moving reed and the high melting point metal parts on the stationary reed are arranged with a small gap and in a cross shape. Then, using thermal radiation or laser processing methods, and in a protective atmosphere or vacuum environment, the glass tube end and the moving reed assembly, and the glass tube end and the stationary reed assembly are welded together respectively, so that the end of the moving reed assembly and the stationary reed assembly with metal parts is sealed inside the glass tube, resulting in a magnetic reed switch with at least one high melting point metal part welded to the end of the stationary reed, a single high melting point metal part welded to the end of the moving reed, and the moving reed metal parts and the stationary reed metal parts are arranged in a cross shape with a small gap between them.

[0043] In some specific embodiments of this application, the first metal part 6 and the second metal part 7 are made of any one of W, Rh, Mo, or Ta. The central axis of the first metal part 6 is parallel to the length direction of the first positioning groove 4, and the central axis of the second metal part 7 is parallel to the length direction of the second positioning groove 5. For example, if the first metal part 6 and the second metal part 7 are made of metal sheets, the planar shape of the first metal part 6 is consistent with the groove shape of the first positioning groove 4, and the planar shape of the second metal part 7 is consistent with the groove shape of the second positioning groove 5.

[0044] In the above embodiments of this application, the high-melting-point metal component is any one of tungsten (W), rhodium (Rh), molybdenum (Mo), or tantalum (Ta) to reduce material sputtering and transfer during the arc breaking process of the reed switch, thereby improving the reed switch's resistance to arc erosion.

[0045] In some specific embodiments of this application, the protective atmosphere is a nitrogen-hydrogen mixture, nitrogen, or argon atmosphere.

[0046] In the embodiments described above, to prevent the high-melting-point metal component at the end of the reed assembly from oxidizing in air and affecting the circuit conduction of the reed switch, the ends of the moving and stationary reed assemblies containing the high-melting-point metal component are welded and sealed within a glass tube 1. The end of the glass tube 1 is heated and melted through thermal radiation or other methods, sealing one end of the glass tube 1 to the moving reed assembly and the other end of the glass tube 1 to the stationary reed assembly. This completely seals the high-melting-point metal component at the end of the reed assembly within the cavity of the glass tube 1, preventing contact with external air and avoiding high-temperature oxidation of the reed assembly when the reed switch closes or opens the circuit. The protective atmosphere is a nitrogen-hydrogen mixture, nitrogen, or argon atmosphere to prevent oxidation and blackening of the reed assembly during sealing welding.

[0047] In the above embodiments of this application, a stepped moving spring is obtained by wire molding and cutting. A positioning groove is formed at the contact end of the stationary spring 2 and the moving spring 3, and a high-melting-point metal part is added to the positioning groove to obtain the finished product. Compared with existing manufacturing methods, this process is simpler, easier to mass-produce, and has a higher product yield, meeting the performance requirements of reed switches of different specifications.

[0048] The reed switch prepared using the above-described method of this application allows for customized design of the spacing between the moving and stationary reeds, significantly reducing the magnetic contact area and making the reed switch easier to break. Furthermore, replacing the existing high-melting-point metal plating with a high-melting-point metal component greatly increases the thickness of the material layer resistant to arc erosion, thereby improving the voltage resistance and service life of the reed switch. This application also adjusts the electrical contact between the stationary reed 2 and the moving reed 3 from the existing surface-to-surface contact to a double-point contact or point-to-surface contact by setting at least one longitudinal high-melting-point metal component at the contact end of the stationary reed 2 and a single transverse high-melting-point metal component at the contact end of the moving reed 3. This causes current shunting in the reed assembly, reducing the erosion of the reed ends. Therefore, the reed switch prepared using this process exhibits significantly improved arc erosion resistance, voltage resistance, and breaking performance, with more controllable dimensional consistency and a higher product yield.

[0049] Based on the same inventive concept, another embodiment of this application provides a reed switch, including: The stationary spring 2 has at least one first positioning groove 4 along its own length direction at one end; The moving spring 3 is parallel to the stationary spring 2, with at least one second positioning groove 5 along its own width direction at one end and a hollow tube 8 at the other end; The first metal part 6 is connected to the first positioning groove 4; The second metal part 7 is connected to the second positioning groove 5, and the second metal part 7 and the first metal part 6 are arranged in a non-contact cross shape. The glass tube 1 is parallel to the length direction of the stationary spring 2 and has a hollow cavity. One end of the stationary spring 2 with the first metal part 6 and the other end of the moving spring 3 with the second metal part 7 are both located in the hollow cavity. The other ends of the stationary spring 2 and the moving spring 3 are respectively sealed and connected to the two ends of the glass tube 1.

[0050] For example, the stationary spring 2 has at least one first positioning groove 4, and the movable spring 3 has at least one second positioning groove 5. The first positioning groove 4 and the second positioning groove 5 are arranged perpendicularly. A first metal part 6 is horizontally welded to the first positioning groove 4 along the length direction of the stationary spring 2, and a second metal part 7 is horizontally welded to the second positioning groove 5 along the width direction of the movable spring 3. The central axis of the hollow tube 8 is parallel to the length direction of the movable spring 3. The stationary spring 2 and the first metal part 6 form a stationary spring assembly, and the movable spring 3, the second metal part 7, and the hollow tube 8 form a movable spring assembly.

[0051] The glass tube 1 has a hollow cavity, and its two ends are respectively sealed and connected to the metal-free end of the stationary reed assembly and the outer wall of the hollow tube 8 of the moving reed assembly. Specifically, the end of the stationary reed assembly containing the first metal part 6 and the end of the moving reed assembly containing the second metal part 7 are both located in the hollow cavity of the glass tube 1. The other end of the moving reed assembly is sealed and connected to one end of the glass tube, and the other end of the stationary reed assembly is sealed and connected to the other end of the glass tube.

[0052] Both the stationary reed 2 and the moving reed 3 are magnetizable reeds, and their surfaces are plated with copper, but not limited to copper; other metals or alloys may also be plated. The first metal component 6 and the second metal component 7 are both high-melting-point metals with a melting point greater than 1500℃. The end of the moving reed assembly with the high-melting-point metal component overlaps with the end of the stationary reed assembly with the high-melting-point metal component; the high-melting-point metal components on the moving reed assembly and the stationary reed assembly are arranged in a non-contact, cross-shaped distribution. The distance between the first metal component 6 and the second metal component 7 in the vertical direction (i.e., the height direction perpendicular to the length and width directions) of the stationary reed 2 is 0.1mm to 2mm.

[0053] The embodiments described above in this application replace the existing method of plating with high-melting-point metal by adding cross-shaped high-melting-point metal parts to the ends of the moving and stationary magnetic reeds. This effectively reduces the magnetic contact area, shortens the springback time of the magnetic reeds, and reduces the erosion of the magnetic reeds by the switching arc. The embodiments of this application also obtain stepped magnetic reeds by molding and cutting, which improves the gap between the moving and stationary magnetic reeds and thus improves the magnetic performance of the magnetic reed switch. In addition, the embodiments of this application also add positioning grooves to improve the quality consistency of the magnetic reed switch products.

[0054] The present application's solution will be explained below with reference to specific embodiments and comparative examples. Those skilled in the art will understand that the following embodiments are for illustrative purposes only and should not be construed as limiting the scope of the application. Where specific techniques or conditions are not specified in the embodiments, they are performed in accordance with the techniques or conditions described in the literature in the art or according to the product instructions. Reagents or instruments used, unless otherwise specified, are all conventional products that can be obtained through commercial channels.

[0055] Example 1 This embodiment prepares as follows: Figures 2-4 The NiFe52 reed switch shown includes the following steps: S1: NiFe52 nickel-iron wire is die-cut to obtain a stationary spring semi-finished product with a flat end; subsequently, two parallel elongated grooves with a groove depth of 0.1mm are machined on the flat end surface of the stationary spring semi-finished product to obtain a stationary spring with a double positioning groove structure at its flat end; wherein, the length direction of the first positioning groove is parallel to the length direction of the stationary spring. S2: NiFe52 nickel-iron wire is die-cut to obtain a stepped, flat-ended movable spring. One end of the NiFe52 movable spring is then welded to the end of a NiFe52 hollow tube. A long, narrow groove with a depth of 0.2mm is machined onto the other end of the movable spring, resulting in a stepped movable spring with a single second positioning groove at its flat end. The length of the movable spring is parallel to the axis of symmetry of the hollow tube. The length of the second positioning groove is perpendicular to the length of the movable spring. S3: First, the moving and stationary springs obtained in step S2 are degreased and activated to remove surface oxides, grease and impurities. Then, a Cu metal coating with a thickness of 20μm is electroplated on the surface of the moving and stationary springs. S4: Place two W-wires horizontally in the two parallel first positioning slots of the copper-plated stationary spring, then weld the W-wires and the copper-plated stationary spring together. After cleaning, a stationary spring assembly with two W-wires welded to its flat end is obtained. Place one W-wire horizontally in the second positioning slot of the copper-plated moving spring, then weld the W-wire and the copper-plated moving spring together. After cleaning, a moving spring assembly with a single W-wire welded to its flat end is obtained. The axis of symmetry of the W-wires is parallel to the length direction of the corresponding positioning slot.

[0056] S5: Place the end of the moving reed assembly containing the W wire into the cavity of the glass tube from one end, and place the end of the stationary reed assembly containing the W wire into the cavity of the glass tube from the other end, so that the W wires on the moving reed and the stationary reed are face-to-face, cross-shaped, and spaced by a small gap; then, soften the two ends of the glass tube by thermal radiation under a nitrogen-hydrogen mixed gas atmosphere, so that the ends of the moving reed assembly and the stationary reed assembly with the W wire are sealed in the cavity of the glass tube, resulting in a magnetic reed switch with two W wires welded to the end of the stationary reed, a single W wire welded to the end of the moving reed, and the W wires of the moving reed and the stationary reed being face-to-face, cross-shaped, and with an end gap of 0.2mm.

[0057] Example 2 This embodiment prepares as follows: Figure 5 The NiFe36 reed switch shown includes the following steps: S1: The NiFe36 nickel-iron material is punched to obtain a stationary spring semi-finished product with a flat end; then, two parallel long strip grooves with a groove depth of 0mm are machined on the flat end surface of the stationary spring semi-finished product to obtain a stationary spring with a double positioning groove structure at its flat end; wherein, the length direction of the first positioning groove is parallel to the length direction of the stationary spring. S2: NiFe36 nickel-iron wire is die-cut to obtain a stepped, flat-ended movable spring. One end of the NiFe36 movable spring is then welded to the end of a NiFe36 hollow tube. A long, narrow groove with a depth of 0mm is machined onto the other end of the movable spring, resulting in a stepped movable spring with a single second positioning groove at its flat end. The length of the movable spring is parallel to the axis of symmetry of the hollow tube. The length of the second positioning groove is perpendicular to the length of the movable spring. S3: First, the moving and stationary springs obtained in step S2 are degreased and activated to remove surface oxides, grease and impurities. Then, a layer of Ni metal with a thickness of 10μm is electroplated on the surface of the moving and stationary springs. S4: Place two Rh wires horizontally in the two parallel first positioning grooves of the nickel-plated stationary spring, then weld the Rh wires and the nickel-plated stationary spring together. After cleaning, a stationary spring assembly with two Rh wires welded to its flat end is obtained. Place one Rh wire horizontally in the second positioning groove of the nickel-plated moving spring, then weld the Rh wire and the nickel-plated moving spring together. After cleaning, a moving spring assembly with a single Rh wire welded to its flat end is obtained. The axis of symmetry of the Rh wire is parallel to the length direction of the corresponding positioning groove.

[0058] S5: Place the end of the moving reed assembly containing the Rh wire into the cavity of the glass tube from one end, and place the end of the stationary reed assembly containing the Rh wire into the cavity of the glass tube from the other end, so that the Rh wires on the moving reed and the stationary reed are face-to-face, cross-shaped, and separated by a small gap; then, soften the two ends of the glass tube by thermal radiation under a nitrogen-hydrogen mixed gas atmosphere, so that the ends of the moving reed assembly and the stationary reed assembly with Rh wires are sealed in the cavity of the glass tube, resulting in a magnetic reed switch with two Rh wires welded to the end of the stationary reed, a single Rh wire welded to the end of the moving reed, and the Rh wires of the moving reed and the stationary reed being face-to-face, cross-shaped, and with an end gap of 0.15mm.

[0059] Example 3 This embodiment prepares as follows: Figures 6-7 The NiFe46 reed switch shown includes the following steps: S1: Molding and cutting NiFe46 nickel-iron wire to obtain a stationary spring semi-finished product with a flat end; then, machining a long strip-shaped groove structure with a groove depth of 0mm on the flat end surface of the stationary spring semi-finished product to obtain a stationary spring with a single first positioning groove structure on its flat end; wherein, the length direction of the first positioning groove is parallel to the length direction of the stationary spring. S2: Molding and cutting NiFe46 nickel-iron wire to obtain a planar movable spring semi-finished product; then, welding one end of the NiFe46 movable spring semi-finished product to the end of the NiFe46 hollow tube; then machining a long strip-shaped groove with a groove depth of 0.2mm on the surface of the other end of the movable spring semi-finished product to obtain a planar movable spring with a single second positioning groove at the end; wherein, the length direction of the movable spring semi-finished product is parallel to the symmetry axis direction of the hollow tube; the length direction of the second positioning groove is perpendicular to the length direction of the movable spring. S3: First, the moving and stationary springs obtained in step S2 are degreased and activated to remove surface oxides, grease and impurities. Then, a Cu metal coating with a thickness of 15μm is electroplated on the surface of the moving and stationary springs. S4: Place a Mo sheet horizontally in the first positioning groove of the copper-plated stationary spring, then weld the Mo sheet and the copper-plated stationary spring together. After cleaning, a stationary spring assembly with a single Mo sheet welded to its flat end is obtained. Place a Mo wire horizontally in the second positioning groove of the copper-plated moving spring, then weld the Mo wire and the copper-plated moving spring together. After cleaning, a moving spring assembly with a single Mo wire welded to its flat end is obtained. The axis of symmetry of the Mo wire is parallel to the length direction of the corresponding positioning groove.

[0060] S5: Place the end of the moving reed assembly containing the Mo wire into the cavity of the glass tube from one end, and place the end of the stationary reed assembly containing the Mo sheet into the cavity of the glass tube from the other end, so that the Mo wire on the moving reed and the Mo sheet on the stationary reed are arranged in a cross shape and are spaced 0.3 mm apart, with the Mo sheet located on the outer side of the end of the stationary reed; then, soften the two ends of the glass tube by thermal radiation under a nitrogen-hydrogen mixed gas atmosphere, so that the ends of the moving reed assembly and the stationary reed assembly containing Mo material are sealed in the cavity of the glass tube, resulting in a magnetic reed switch with one Mo sheet welded to the end of the stationary reed, the Mo sheet located on the outer side of the stationary reed, and a single Mo wire welded to the end of the moving reed, with the moving reed Mo wire and the stationary reed Mo sheet arranged in a cross shape and the two ends spaced 0.3 mm apart.

[0061] Comparative Example 1 Comparative Example 1 provides a conventional reed switch, specifically a NiFe52 reed switch made by plating a high-melting-point metal onto the end of a reed. This NiFe52 reed switch is made by sputtering a layer of high-melting-point metal W onto the end of the reed, and does not have any metal parts or positioning grooves. The two reeds are in direct contact.

[0062] The NiFe52 reed switch sample with W wire at the planar end prepared in Example 1 was compared with the NiFe52 reed switch prepared by the conventional plating method in Comparative Example 1. Electrical life test, AT value and yield evaluation were carried out. The detailed results are shown in Table 1 below. The characterization results of the sample in Example 2 are close to those of Example 1.

[0063] Table 1. Electrical life test, AT value, and yield results As can be seen from Table 1, the reed switch for reed relays with high pressure resistance, high sensitivity and higher yield was prepared by the method in the embodiments of this application.

[0064] The embodiments described above in this application use only molding and heat radiation welding to obtain magnetic reeds with customizable gaps, which can effectively improve the product's AT value and BDV, extend the service life of electrical appliances such as relays, and are suitable for mass production with high yield, thus resulting in lower costs.

[0065] The preferred features in the above embodiments can be used individually in any embodiment, or in any combination thereof, provided they do not conflict with each other. Furthermore, parts not described in detail in the embodiments can be implemented using existing technologies.

[0066] The foregoing has described some specific embodiments of this application. It should be understood that this application is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the substantive content of this application. The above-described preferred features can be used in any combination without conflict.

Claims

1. A method for manufacturing a reed switch, characterized in that, include: Grooving is performed on nickel-iron wire or nickel-iron sheet to obtain a stationary spring with a first positioning groove at one end; The nickel-iron wire is grooved and welded with a hollow tube to obtain a moving spring with a second positioning groove at one end; A coating is applied to the surfaces of the stationary spring and the moving spring; A first metal part is welded to the first positioning groove of the stationary spring to obtain a stationary spring assembly; a second metal part is welded to the second positioning groove of the movable spring to obtain a movable spring assembly. One end of the stationary reed assembly containing the first metal component and one end of the moving reed assembly containing the second metal component are encapsulated in a glass tube, such that the second metal component and the first metal component are arranged in a non-contact cross shape; the other end of the stationary reed assembly and the hollow tube are respectively sealed and connected to the two ends of the glass tube, thus obtaining a magnetic reed switch.

2. The method for manufacturing a reed switch according to claim 1, characterized in that, The process of grooving nickel-iron wire or nickel-iron sheet to obtain a stationary spring with a first positioning groove at one end includes: The nickel-iron wire is die-cut, or the nickel-iron sheet is punched to obtain a static spring semi-finished product with a flat end. At least one first positioning groove is machined on the planar end surface of the stationary spring semi-finished product to obtain a stationary spring with the first positioning groove at the end. The length direction of the first positioning groove is parallel to the length direction of the stationary spring.

3. The method for manufacturing a reed switch according to claim 1, characterized in that, The process of grooving nickel-iron wire to obtain a movable spring with a second positioning groove at one end includes: Nickel-iron wire is die-cut to obtain a semi-finished moving spring with a stepped overall shape and flat ends; A hollow tube is welded to one end of the semi-finished moving spring. A second positioning groove is machined at the other end of the semi-finished moving spring to obtain a moving spring with a second positioning groove at the end. The length direction of the semi-finished moving spring is parallel to the central axis of the hollow tube, and the length direction of the second positioning groove is perpendicular to the length direction of the moving spring.

4. A method for manufacturing a reed switch according to any one of claims 1-3, characterized in that, The nickel-iron wire, nickel-iron sheet, and hollow tube are made of nickel-iron alloy or a conductive magnetic material with a coefficient of thermal expansion matching that of the glass tube.

5. The method for manufacturing a reed switch according to claim 1, characterized in that, The coating thickness on the surfaces of the stationary and moving springs is 10μm to 30μm, and the coating material is any one of Cu, Ni, Sn, copper alloy, nickel alloy or silver-copper-titanium alloy.

6. The method for manufacturing a reed switch according to claim 1, characterized in that, The first metal part is welded at the first positioning groove of the stationary spring to obtain the stationary spring assembly; A second metal part is welded to the second positioning groove of the movable spring to obtain a movable spring assembly, comprising: The first metal part is placed horizontally in the first positioning groove of the stationary spring, the first metal part and the stationary spring are welded together, and then cleaned to obtain the stationary spring assembly. The second metal part is placed horizontally in the second positioning groove of the moving spring, the second metal part and the moving spring are welded together, and then cleaned to obtain the moving spring assembly.

7. The method for manufacturing a reed switch according to claim 1, characterized in that, The static reed assembly with a first metal component at one end and the dynamic reed assembly with a second metal component at one end are encapsulated in a glass tube, such that the second metal component and the first metal component are arranged in a non-contact cross-shaped arrangement. The other end of the stationary reed assembly and the other end of the moving reed assembly are respectively sealed and connected to the two ends of the glass tube to finally produce a magnetic reed switch, comprising: One end of the stationary reed assembly with the first metal part is encapsulated in a glass tube, and one end of the moving reed assembly with the second metal part is encapsulated in a glass tube. The positions of the stationary reed assembly and the moving reed assembly are adjusted so that the second metal part and the first metal part are arranged in a non-contact cross shape, wherein the distance between the first metal part and the second metal part is 0.1mm~2mm. The magnetic reed switch is finally produced by welding one end of a glass tube and the static reed assembly, as well as the other end of the glass tube and the hollow tube, using thermal radiation or laser processing methods in a protective atmosphere or vacuum environment.

8. A method for manufacturing a reed switch according to any one of claims 1, 6, and 7, characterized in that, The materials of the first metal part and the second metal part are any one of W, Rh, Mo or Ta; the central axis of the first metal part is parallel to the length direction of the first positioning groove, and the central axis of the second metal part is parallel to the length direction of the second positioning groove.

9. A method for manufacturing a reed switch according to claim 7, characterized in that, The protective atmosphere is a nitrogen-hydrogen mixture, nitrogen, or argon atmosphere.

10. A reed switch, characterized in that, The reed switch is prepared using the method for preparing the reed switch according to any one of claims 1-9, wherein the reed switch comprises: The stationary reed has at least one first positioning groove at one end along its own length direction; The moving spring is parallel to the stationary spring, with at least one second positioning groove along its own width at one end and a hollow tube at the other end; The first metal component is connected to the first positioning groove; The second metal part is connected to the second positioning groove, and the second metal part and the first metal part are arranged in a non-contact cross shape. A glass tube, parallel to the length direction of the stationary spring, has a hollow cavity. One end of the stationary spring with a first metal component and one end of the movable spring with a second metal component are both located in the hollow cavity. The other ends of the stationary spring and the movable spring are respectively sealed and connected to the two ends of the glass tube.

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