Electromagnetic relay and manufacturing process

Abstract

Electromagnetic relay, characterized by: a basic element (2); an electromagnet unit (3) with an electromagnet (31) arranged on the base element (2); an armature unit (4) which is movably connected to the electromagnet (31) and has a magnetically appealing element (41) which is magnetically attracted by the electromagnet (31); A connection unit (5) movably mounted on the armature unit (4), comprising a first terminal element (51) and a first contact (52) arranged on the first terminal element (51), wherein the first terminal element (51) is designed in two parts and consists of a spring plate (511) and a leg (512) which is fixedly connected to the spring plate (511) and extends through the base element (2), wherein the spring plate (511) has an operating section (513) connected to the armature unit (4) and an arc section (514) which is bent away from the operating section (513) towards the electromagnet (3), and a connecting section (515) which is bent away from the arc section (514) and attached to the first leg (512), wherein the operating section (513) and the arc section (514) have a first opening angle (θ1) between 75 degrees and 85 degrees between them. train,wherein the arc section (514) and the connecting section (515) form a second opening angle (θ2) between 80 degrees and 95 degrees, wherein the first leg (512) has a thickness (t1) that is greater than the thickness (t2) of the spring plate (511), wherein the ratio of the thickness (t1) of the first leg (512) to the thickness (t2) of the spring plate (511) is between 2 and 4; and , wherein a fixed terminal element (6) is attached to the base element (2) and extends partially through the base element (2), wherein the fixed terminal element (6) has a second contact (62) opposite the first contact (52) which it can contact; wherein, when the electromagnet (31) is energized and actuates the armature unit (4) to press the spring plate (511), the spring plate (511) moves elastically towards the stationary clamping element (6) and the first contact (52) contacts the second contact (62); and where, when the electromagnet (31) is de-energized, the first contact (52) moves away from the second contact (62).

Description

[0001] The disclosure relates to a relay, and more particularly to an electromagnetic relay and a method of manufacturing it.

[0002] Now we turn to the Fig. 1 to 3, an existing electromagnetic relay 100 uses a weak current to control a strong current. The electromagnetic relay 100 includes a base member 10, an electromagnet 11 mounted on the base member 10, a magnetically responsive member 12 magnetically attracted to the electromagnet 11, an operating member 13 actuated by the magnetically responsive member 12, a movable terminal member 14 connected to the operating member 13 and extending through the base member 10, and a fixed terminal member 15 mounted on the base member 10 and spaced from the movable terminal member 14.When the electromagnet 11 is energized, the magnetically responsive element 12 is magnetically attracted by the electromagnet 11 and actuates the operating element 13 to press the movable clamping element 14 into contact with the fixed element 15 so that they are electrically connected to each other.

[0003] However, since the movable terminal element 14 is composed of a plate body 141 and a contact 142 fixed to the plate body 141, and the plate body 141 is integral and has a uniform thickness and a spring plate 143 and a leg 144, the thickness of the plate body 141 cannot be increased to maintain the elasticity of the movable terminal element 14. Therefore, the allowable current of the electromagnetic relay 100 is limited by the thickness of the movable terminal element 14 and cannot be increased.

[0004] Such electromagnetic relays are also disclosed, for example, in US 2008 / 0238591 A1 and US 2016 / 0027602 A1.

[0005] Therefore, it is an object of the present disclosure to provide an electromagnetic relay that can increase the allowable current.

[0006] Accordingly, an electromagnetic relay of the present disclosure includes a base member, an electromagnet unit, an armature unit, a movable terminal unit, and a fixed terminal member.

[0007] The electromagnet unit has an electromagnet arranged on the base element. The armature unit is movably connected to the electromagnet and includes a magnetically responsive element that is magnetically attracted to the electromagnet unit. The movable connection unit is attached to the armature unit and includes a first terminal element and a first contact arranged on the first terminal element. The first terminal element is designed in two pieces and consists of a spring plate and a first leg that is fixedly connected to the spring plate and extends through the base element. The spring plate has an operating section connected to the armature unit, an arc section that is bent away from the operating section toward the electromagnet, and a connecting section that is bent away from the arc section and is attached to the first leg.The operating section and the curved section form a first opening angle between 75 degrees and 85 degrees. The curved section and the connecting section form a second opening angle between 80 degrees and 95 degrees. The first leg has a thickness that is greater than the thickness of the spring plate. The ratio of the thickness of the first leg to the thickness of the spring plate is between 2 and 4. The fixed clamping element is mounted on the base element and extends partially through the base element. The fixed clamping element has a second contact that is opposite the first contact and can contact it.

[0008] When the electromagnet is energized and the armature unit is actuated to press on the spring plate, the spring plate moves elastically toward the fixed terminal element, and the first contact contacts the second contact. When the electromagnet is de-energized, the first contact moves away from the second contact.

[0009] Another object of the present disclosure is to provide a method of manufacturing the electromagnetic relay that can increase the allowable current.

[0010] Accordingly, the method for manufacturing the electromagnetic relay of the present disclosure comprises the step of providing a mold assembly comprising a mold and a punch movable relative to the mold, the punch having at least one punching head; providing and positioning the first leg on the mold; providing the spring retainer having the connecting portion; arranging the spring retainer on the mold such that the connecting portion of the spring retainer rests on the first leg; actuating the punch such that the punching head moves toward the mold and pressing the spring retainer against the first leg, thereby connecting the spring retainer to the first leg and forming the first terminal member; attaching the first contact to the first terminal member to form a movable terminal unit; providing the base member, the electromagnet, the armature unit, and the fixed terminal member;and assembling the base element, the electromagnet, the armature unit, the first connection unit and a fixed terminal element;

[0011] Further features and advantages of the disclosure will become apparent from the following detailed description of the embodiment with reference to the accompanying drawings, which show the following: Fig. 1 is a perspective view of an existing electromagnetic relay; Fig. 2 is an exploded perspective view of the existing electromagnetic relay; Fig. 3 is a perspective view of a movable terminal member of the existing electromagnetic relay; Fig. 4 is a perspective view of an electromagnetic relay according to an embodiment of the present disclosure; Fig. 5 is an exploded perspective view of the embodiment; Fig. 6 is a side view of a movable terminal unit of the embodiment; Fig. 7 is a sectional view corresponding to Fig. 6; Fig. 8 is an exploded perspective view of the movable terminal unit of the embodiment; Fig. 9 is a side view of the embodiment showing that the movable terminal unit is spaced from a fixed terminal member when the electromagnetic relay is de-energized; Fig. 10 is a similar view to Fig. 9, but shows the movable terminal unit in contact with the fixed terminal element when the electromagnetic relay is energized; Fig. 11 is a flowchart showing the steps of the method for manufacturing the electromagnetic relay of the present disclosure; Fig. 12 is a perspective view of a mold assembly used in the method of manufacturing the electromagnetic relay of the present disclosure; Fig. 13 is an enlarged partial perspective view of a punch of the die assembly; Fig. 14 is a partial perspective view of the mold assembly showing a spring plate and a first leg to be disposed on a mold of the mold assembly; and Fig. 15 is a view similar to Fig. 14, however, shows how the spring plate and the first leg are arranged on the mold of the mold assembly.

[0012] Now we turn to the Fig. 4 and Fig. 5, wherein an electromagnetic relay according to an embodiment of the present disclosure includes a base member 2, an electromagnet unit 3, an armature unit 4, a movable terminal unit 5, and a fixed terminal member 6.

[0013] The electromagnet unit 3 comprises an electromagnet 31 arranged on the base element 2 for generating an electromagnetic force when energized.

[0014] The armature unit 4 is movably connected to the electromagnet 31 and comprises a magnetically responsive element 41, an operating element 42, and an elastic element 43. The magnetically responsive element 41 is magnetically attracted by the electromagnet 31 and has an insertion portion 411. The operating element 42 is connected to the magnetically responsive element 41 and spaced from the electromagnet 31. The elastic element 43 is elastically arranged on the magnetically responsive element 41 and extends through the base element 2. The operating element 42 has an insertion slot 421 on one side for inserting the insertion portion 411, as well as two spaced-apart positioning bolts 423 that protrude from its other side and opposite the insertion slot 421. The elastic element 43 is an elastic metal sheet that biases the magnetically responsive element 41 away from the electromagnet 31.

[0015] Now we turn to the Fig. 6 to 8 in combination with Fig. 4, wherein the movable terminal unit 5 is attached to the armature unit 4 and has a first terminal element 51 and a first contact 52. The first terminal element 51 is designed in two pieces and consists of a spring plate 511 and a first leg 512, which is fixedly connected to the spring plate 511 and extends through the base element 2. The spring plate 511 has an operating portion 513, an arc portion 514, and a connecting portion 515. The first contact 52 is fastened to the operating portion 513. The operating portion 513 has two receiving grooves 5130 formed on two opposite sides of the spring plate 511 and engage with the respective positioning pin 423. The arc portion 514 is bent away from the operating portion 513 toward the electromagnet 3. The connecting portion 515 is bent away from the arc portion 514 and is attached to the first leg 512.The connecting portion 515 has at least one engagement hole 5150. As shown in . Fig. 8, this embodiment has only one engagement hole 5150, but other embodiments may provide two, three, or more than three. The operating portion 513 and the arc portion 514 form a first opening angle (θ1) between 75 degrees and 85 degrees between them. The arc portion 514 and the connecting portion 515 form a second opening angle (θ2) between 80 degrees and 95 degrees between them. In this embodiment, the first opening angle (θ1) is 85 degrees, while the second opening angle (θ2) is 90 degrees. In this way, the spring plate 511 is elastic and can be elastically pressed.

[0016] The first leg 512 has a connecting portion 516 and a leg portion 517 extending downward from one end of the connecting portion 516 and protruding from the base member 2. The connecting portion 516 has an engaging projection 518 formed as a rivet for fixedly connecting to the engaging hole 5150 of the connecting portion 515, and a recess 519 formed on the rear side opposite the engaging projection 518 and aligned with the engaging projection 518 in a line perpendicular to the rear side. In this embodiment, one engaging projection 518 and one recess 519 are provided, but in other embodiments, two, three, or more than three may be provided. As long as the number of projections 518 corresponds to the number of engaging holes 5150 and can be riveted thereto, any number is acceptable.The first leg 512 has a thickness (t1) that is greater than the thickness (t2) of the spring plate 511. The thickness (t1) of the first leg 512 is between 0.3 mm and 0.5 mm. The thickness (t2) of the spring plate 511 is between 0.1 mm and 0.15 mm. The ratio of the thickness (t1) of the first leg 512 to the thickness (t2) of the spring plate 511 is between 2 and 4. In this embodiment, the ratio of the thickness (t1) of the first leg 512 to the thickness (t2) of the spring plate (511) is 3. Since the thickness (t1) of the first leg 512 is greater than the thickness of the leg 144 of the plate body 141 (cf. Fig. 3) in the prior art, the allowable current of the electromagnetic relay of the present disclosure can be increased from the allowable current of 10 A to 25 A. Furthermore, the spring plate 511 is also wider than the spring plate 143 (see FIG. Fig. 3) in the prior art, and it is also more elastic than in the prior art.

[0017] The fixed terminal element 6 is attached to the base element 2, close to the movable connection unit 5, and extends partially through the base element 2. The fixed terminal element 6 has a second contact 62 which is opposite the first contact 52, can contact it and be electrically connected thereto.

[0018] Now we turn to the Fig. 9 and Fig. 10, in which, when the electromagnet 31 is energized (cf. Fig. 10) the magnetically responsive element 41 is magnetically attracted by the electromagnet 31, and the operating element 42 is actuated by the magnetically responsive element 41 to elastically move the spring plate 511 toward the fixed terminal element 6, so that the first contact 52 contacts the second contact 62. When the electromagnet 31 is de-energized (cf. Fig. 9), the elastic member 43 biases the magnetically responsive member 41 to move away from the electromagnet 31, and the operating member 42 is actuated by the magnetically responsive member 41 to move and elastically pull the spring plate 511 away from the fixed terminal member 6, thereby moving the first contact 52 away from the second contact 62. Thus, the electromagnetic relay of the present disclosure can allow a large current to flow.

[0019] Since the first clamp element 51 is composed of the spring plate 511 and the first leg 512, which are connected and formed in two pieces, the thickness of the first leg 512 can be increased without changing the thickness (t2) of the spring plate 511. This allows the spring plate 511 to have good elasticity, and the allowable tension can be increased. Furthermore, the first opening angle (θ1) can be adjusted to achieve the desired elasticity, thereby improving the sensitivity of the electromagnetic relay of the present disclosure.

[0020] Now Fig. 11 in combination with the Fig. 12 to 15, wherein a method of manufacturing the electromagnetic relay of the present disclosure is shown including steps 91 to 98.

[0021] In step 91, a mold assembly 7 is provided. The mold assembly 7 comprises a mold 71 and a punch 72 movable relative to the mold 71. The mold 71 comprises two positioning cams 711 and a stepped portion 712 spaced from the positioning cams 711. The stepped portion 712 has a height in the direction of movement of the punch 72 that is greater than that of the positioning cams 711. The punch 72 has a frustoconical base element 721 and two punch heads 722. The frustoconical base element 721 has a conical end 720 that extends toward the mold 71.The conical end 720 has two lateral flat sections 723 opposite the die 71, a central section 725 projecting between the lateral flat sections 723 toward the die 71, a central flat end surface 7251 opposite the die 71, and two inclined surfaces 724, each sloping upward from the lateral flat sections 723 to the central flat end surface 7251. The punch heads 722 extend downward from the central flat end surface 7251 and are spaced apart from each other.

[0022] In step 92, the first leg 512 is provided with two engaging projections 518 and two recesses 519 formed in their rear sides opposite the engaging projections 518, as shown in Fig. 14, and is positioned on the mold 71 such that the recesses 519 each receive a positioning cam 711 of the first leg 512. In other embodiments, engagement of a pin in a hole is conceivable to effect the positioning of the first leg 512 on the mold 71.

[0023] In step 93, the spring plate 511 is provided with two engagement holes 5150 and the connecting portion 515. The spring plate 511 is manufactured by punching a metal sheet (not shown).

[0024] In step 94, the spring plate 511 is arranged on the mold 71 such that the operating portion 513 is held by the step portion 712, and the engaging holes 5150 each receive the engaging projections 518 of the first leg 512. That is, the connecting portion 515 of the spring plate 511 rests on the first leg 512.

[0025] In step 95, the punch 72 is actuated to move the punch heads 722 toward the mold 71, as shown in Fig. 15, and punching the spring seat 511 onto the first leg 512, thereby connecting the spring seat 511 to the first leg 512 to form the first clamp member 51. More specifically, the step of operating the punch to move the punch heads 722 toward the die 71 includes punching the engaging projections 518 to form each engaging projection 518 as a rivet, so that the spring seat 511 is riveted to the first leg 512. By having the frustoconical base member 721 with the side flat portions 723 and the inclined surfaces 724, the first and second opening angles (θ1, θ2) of the spring seat 511 are prevented from being damaged during the punching process.

[0026] In step 96, the first contact 52 is attached to the first terminal element 51 to form the movable terminal unit 5.

[0027] In step 97, the base element 2, the electromagnet 31, the armature unit 4 and the fixed clamp element 6 are provided.

[0028] In step 98, the base member 2, the electromagnet 31, the armature unit 4, the movable terminal unit 5, and the fixed terminal member 6 are assembled to form the electromagnetic relay of the present disclosure.

[0029] In particular, the method for manufacturing the electromagnetic relay of the present disclosure includes riveting the spring plate 511 to the first leg 512 to integrally form the first terminal element 51. In another embodiment, the spring plate 511 and the first leg 512 may be joined by other joining methods, such as welding or soldering.

[0030] Overall, since in the electromagnetic relay manufactured by the method of the present disclosure, the first terminal member 51 is formed in two pieces, only by increasing the thickness (t1) of the first leg 512, the allowable current of the electromagnetic relay of the present disclosure can be increased, and the elasticity of the spring plate 511 can be maintained.

[0031] Although the present disclosure has been described in connection with the embodiment, it is to be understood that the present disclosure is not limited to the disclosed embodiment, but is intended to include various arrangements that are within the spirit and scope of the broadest interpretation so as to encompass all modifications and equivalent arrangements.

Claims

[1] Electromagnetic relay, characterized by : a basic element (2); an electromagnet unit (3) with an electromagnet (31) arranged on the base element (2); an armature unit (4) movably connected to the electromagnet (31) and having a magnetically responsive element (41) magnetically attracted by the electromagnet (31); a connection unit (5) movably mounted on the armature unit (4), comprising a first terminal element (51) and a first contact (52) arranged on the first terminal element (51), wherein the first terminal element (51) is designed in two pieces and consists of a spring plate (511) and a leg (512) which is firmly connected to the spring plate (511) and extends through the base element (2), wherein the spring plate (511) has an operating section (513) connected to the armature unit (4) and a curved section (514) which is bent away from the operating section (513) towards the electromagnet (3), and a connecting section (515) which is bent away from the curved section (514) and is fastened to the first leg (512), wherein the operating section (513) and the curved section (514) have a first opening angle (θ1) between 75 degrees and 85 degrees,wherein the arcuate portion (514) and the connecting portion (515) form a second opening angle (θ2) between 80 degrees and 95 degrees, wherein the first leg (512) has a thickness (t1) that is greater than the thickness (t2) of the spring plate (511), wherein the ratio of the thickness (t1) of the first leg (512) to the thickness (t2) of the spring plate (511) is between 2 and 4; and, wherein a fixed terminal element (6) is attached to the base element (2) and extends partially through the base element (2), the fixed terminal element (6) having a second contact (62) opposite the first contact (52) with which it can contact; wherein, when the electromagnet (31) is energized and actuates the armature unit (4) to press the spring plate (511), the spring plate (511) moves elastically toward the fixed terminal element (6) and the first contact (52) contacts the second contact (62); and wherein when the electromagnet (31) is de-energized, the first contact (52) moves away from the second contact (62). [2] Electromagnetic relay according to claim 1, wherein the armature unit (4) further comprises an operating element (42) connected to the magnetically responsive element (41) and spaced from the electromagnet (31), the operating element (42) having two positioning bolts (423) engaging the operating portion (513) of the spring plate (511). [3] Electromagnetic relay according to claim 1, characterized by that the connecting portion (515) of the spring plate (511) has at least one engagement hole (5150), wherein the first leg (512) has at least one engagement projection (518) which is fixedly connected to the at least one engagement hole (5150). [4] Electromagnetic relay according to claim 3, characterized bythat the at least one engagement projection (518) is formed as a rivet which is firmly connected to the at least one engagement hole (5150). [5] Electromagnetic relay according to claim 3, characterized by that the first leg (512) further comprises a recess (519) formed on the rear side opposite the at least one engagement projection (518) and aligned on the at least one engagement projection (518) in a line perpendicular to the rear side. [6] A method of manufacturing the electromagnetic relay according to claim 1, characterized by : Providing a mold assembly (7) comprising a mold (71) and a punch (72) movable relative to the mold (71), the punch (72) having at least one punching head (722); Providing and positioning the first leg (512) on the mold (71); Providing the spring plate (511) having the connecting portion (515); Arranging the spring plate (511) on the mold (71) such that the connecting portion (515) of the spring plate (511) rests on the first leg (512); Actuating the punch (72) to move the punch head (722) toward the mold (71) and punch the spring plate (511) onto the first leg (512), thereby connecting the spring plate (511) to the first leg (512) to form the first clamp element (51); Fixing the first contact (52) to the first terminal element (51) to form the movable terminal unit (5); Providing the base element (2), the electromagnet (31), the armature unit (4) and the fixed clamp element (6); and Assembling the base element (2), the electromagnet (31), the armature unit (4), the movable connection unit (5) and the fixed terminal element (6). [7] Method according to claim 6, characterized by , that: the first leg (512) has at least one engagement projection (518) and at least one recess (519) formed on the rear side opposite the at least one engagement projection (518), wherein the mold (71) has at least one positioning cam (711), wherein the spring plate (511) has at least one engagement hole (5150); the step of positioning the first leg (512) on the mold (71) comprises arranging the first leg (512) on the mold (71) such that the at least one positioning cam (711) extends into the at least one recess (519); the step of arranging the spring plate (511) on the mold (71) causes the at least one engagement projection (518) of the first leg (512) to extend into the at least one engagement hole (5150) of the spring plate (511). [8] Method according to claim 6, characterized byin that the spring plate (511) further comprises an operating portion (513), wherein the mold (71) further comprises a step portion (712) for holding the operating portion (513), wherein the step portion (712) has a height in the direction of movement of the punch (72) which is greater than that of the at least one positioning cam (711). [9] Method according to claim 6, characterized byin that the punch (72) further comprises a frustoconical base element (721) with a conical end (720) extending towards the mold (71), the conical end (720) having two lateral flat sections (723) opposite the mold (71), a central section (725) projecting between the lateral flat sections (723) in the direction of the mold (71) and having a central flat end surface (7251) opposite the mold (71), and two inclined surfaces (724) each sloping upwards from the lateral flat sections (723) to the central flat end surface (7251), the punch head (722) extending downwards from the central flat end surface (7251). [10] Method according to claim 6, characterized bythat the step of actuating the punch (72) to move the punching head (722) towards the mold (71) comprises punching the engaging projection (518) to form the engaging projection (518) as a rivet, so that the spring plate (511) is riveted to the first leg (512).

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