Relay and method for manufacturing the same

Abstract

To provide a relay capable of restraining occurrence of contact failure between contacts.SOLUTION: A movable contact surface 321 is moved to approach and separate from a fixed contact surface 311 in a first direction D1. The fixed contact surface 311 has a groove-shaped concaved recess portion 312 extending in a groove extension direction Ds which is one of radial directions of a contact axis Cpc. Therefore, even if a foreign object such as glass fiber is present between the fixed contact surface 311 and the movable contact surface 321 in a region where the recess portion 312 is formed, the foreign object will enter the recess portion 312, so that the foreign object does not act to separate the fixed contact surface 311 and the movable contact surface 321 from each other. Therefore, as compared with a case where both the fixed contact surface 311 and the movable contact surface 321 are flat and include no uneven shape, it is possible to restrain occurrence of contact failure between a fixed contact 31 and a movable contact 32 caused by the foreign object.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present disclosure relates to a relay that opens and closes an energization path and a method for manufacturing the relay.

Background Art

[0002] In this type of conventional relay, a movable contact disposed opposite a fixed contact is moved into and out of contact with the fixed contact, thereby opening and closing the energization path. And each contact surface of the fixed contact and the movable contact has a planar shape or a slightly protruding spherical shape. Therefore, if foreign matter such as glass fiber intervenes between the contact surfaces of the fixed contact and the movable contact, there is a risk of poor contact between the fixed contact and the movable contact, that is, contact failure.

[0003] On the other hand, Patent Document 1 discloses an electromagnetic relay capable of suppressing the occurrence of contact failure.

[0004] Specifically, the electromagnetic relay of Patent Document 1 includes an electromagnet, an armature that is displaced by the magnetic force generated in the electromagnet, a movable spring provided with a movable contact, a first contact piece provided with a first fixed contact, and a second contact piece provided with a second fixed contact. And a fixed spring having. The fixed spring is provided such that the first fixed contact and the second fixed contact face the movable contact. Further, the electromagnetic relay of Patent Document 1 includes a connecting member, and the connecting member connects the armature and the movable spring and displaces the movable spring in conjunction with the armature.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] In the electromagnetic relay of Patent Document 1, it is possible to suppress the occurrence of poor contact between contacts. However, for this purpose, a specific mechanical structure in which two fixed contacts are provided for one movable contact is required. This has low versatility as a countermeasure against poor contact between contacts, and another countermeasure was required as a countermeasure against poor contact between contacts in the relay. As a result of the inventors' detailed examination, the above has been found.

[0007] In view of the above points, an object of the present disclosure is to provide a relay capable of suppressing the occurrence of poor contact between contacts by a structure different from that of Patent Document 1, and a method for manufacturing the relay.

Means for Solving the Problems

[0008] To achieve the above object, a relay according to one aspect of the present disclosure is a relay that opens and closes an energization path, a first contact portion (31) having a first contact surface (311) formed around a single axis line (Cpc) and facing the axial direction (D1) of the single axis line, and constituting a part of the energization path; a second contact portion (32) having a second contact surface (321) facing the first contact surface and constituting a part of the energization path, one of the first contact surface and the second contact surface is caused to move away from and toward the other, a concave portion (312) is formed on the first contact surface, which has a groove shape extending in the radial direction (Drpc) of the single axis line and is recessed.

[0009] In this way, between the first contact surface and the second contact surface, for example, even if foreign matter such as glass fiber is interposed in the region where the concave portion is formed, the foreign matter enters the concave portion, so it is difficult to act to separate the first contact surface and the second contact surface. Therefore, for example, compared with the case where there is no concave portion and both the first contact surface and the second contact surface are planar, it is possible to suppress the occurrence of poor contact between the first contact portion and the second contact portion due to foreign matter, that is, the occurrence of poor contact between contacts.

[0010] Also, a method for manufacturing a relay according to another aspect of the present disclosure is a first contact portion (31) having a first contact surface (311) formed around a uniaxial line (Cpc) and facing the axial direction (D1) of the uniaxial line, and constituting a part of an energization path; a second contact portion (32) having a second contact surface (321) facing the first contact surface and constituting a part of the energization path, and a method for manufacturing a relay in which one of the first contact surface and the second contact surface is moved into and out of contact with the other, preparing a contact component (35) to be the first contact portion and a contact pedestal (41) to which the contact component is attached (S01); performing caulking in a state where the contact component is combined with the contact pedestal to obtain the first contact portion, which is the caulked contact component fixed to the contact pedestal (S03), and in obtaining the first contact portion, during caulking, by pressing a mold (62) that contacts the first contact surface against the first contact surface, a concave portion (312) that forms a groove shape extending in the radial direction (Drpc) of the uniaxial line and is recessed is formed on the first contact surface.

[0011] In this way, the relay according to the above one aspect can be manufactured. Therefore, with the manufactured relay, it is possible to suppress the occurrence of poor contact between the first contact portion and the second contact portion due to foreign matter as described above.

[0012] In each column of the application documents, each element may be accompanied by a reference sign in parentheses. In this case, the reference sign merely indicates an example of the correspondence between the same element and the specific configuration described in the embodiments below. Therefore, the present disclosure is not limited by the description of the reference sign.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Mode for Carrying Out the Invention

[0014] Hereinafter, embodiments will be described with reference to the drawings. In the following embodiments including other embodiments to be described later, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings.

[0015] (First Embodiment) The relay 10 of this embodiment is mounted on a vehicle, for example. The relay 10 is an electromagnetic relay that opens and closes the energization path to in-vehicle components according to the switching of the energization state of an electromagnet. This relay 10 is also referred to as a relay device.

[0016] In the description of this embodiment, for the purpose of representing the orientation in the relay 10, the first direction D1, the second direction D2, and the third direction D3 shown in FIGS. 1 and 2 may be used. These first direction D1, second direction D2, and third direction D3 are directions that intersect each other, strictly speaking, directions that are perpendicular to each other. Further, in this embodiment, the second direction D2 corresponds to the intersection direction of the present disclosure, the contact axis Cpc in FIG. 3 described later corresponds to one axis of the present disclosure, and the first direction D1 corresponds to the axial direction of one axis of the present disclosure.

[0017] As shown in FIGS. 1 and 2, the relay 10 includes a spool 21, a coil winding 26, a core 27, a yoke 28, an armature plate 29, a leaf spring 30, a fixed contact 31, a movable contact 32, a stopper 33, a first load terminal 41, a second load terminal 42, a first coil terminal 46, a second coil terminal 47, a case 50, a base 51, and the like. For example, the spool 21, the case 50, and the base 51 are made of a resin containing a filler such as glass fiber.

[0018] The case 50 and the base 51 of the relay 10 form the outer shell of the relay 10. A case inner space 50a is formed inside the case 50. The spool 21, the coil winding 26, the core 27, the yoke 28, the armature plate 29, the leaf spring 30, the fixed contact 31, the movable contact 32, and the stopper 33 are accommodated in the case inner space 50a.

[0019] The base 51 closes the case inner space 50a from the side where the terminals 41, 42, 46, and 47 are provided and is fixed to the case 50. For example, the spool 21 and the yoke 28 accommodated in the case 50 are fixed to the base 51. Further, each of the terminals 41, 42, 46, and 47 of the relay 10 protrudes outward from the base 51.

[0020] The relay 10 is mounted on an electric circuit board 11 which is an external electric component with respect to the relay 10, and each terminal 41, 42, 46, 47 of the relay 10 is soldered to the electric circuit board 11. Each of these terminals 41, 42, 46, 47 is made of a metal material such as a copper alloy with high conductivity. In addition, in FIG. 1, the illustration of the fixed contact 31, the stopper 33, the first load terminal 41, the case 50, and the base 51 is omitted. Also, in FIG. 2, the electric circuit board 11 is illustrated by a two-dot chain line.

[0021] The spool 21 has a spool shaft portion 22, one-side spool base portion 23, and the other-side spool base portion 24. The spool shaft portion 22, the one-side spool base portion 23, and the other-side spool base portion 24 are integrated. For example, the spool 21 is configured as a single component including the spool shaft portion 22, the one-side spool base portion 23, and the other-side spool base portion 24.

[0022] The spool shaft portion 22 is a bobbin portion around which the coil winding 26 is wound in the spool 21, and has a cylindrical shape extending in the first direction D1. That is, both the spool shaft portion 22 and the coil winding 26 have a cylindrical shape centered on a common axis CL along the first direction D1. Therefore, the first direction D1 is also the axial direction of the spool shaft portion 22 and the axial direction of the coil winding 26. And the radial direction Dr of the coil winding 26 is also the radial direction of the spool shaft portion 22. In the description of the present embodiment, the axis CL of the coil winding 26 is also referred to as the coil axis CL, and the radial direction Dr of the coil winding 26 is also referred to as the coil radial direction Dr.

[0023] The one-side spool base 23 is provided on one side in the first direction D1 with respect to the coil winding 26 and the spool shaft portion 22, and one end of the spool shaft portion 22 is connected to the one-side spool base 23. The one-side spool base 23 is formed so as to extend from the spool shaft portion 22 in each of the second direction D2 and the third direction D3. Therefore, it can also be said that the one-side spool base 23 is formed so as to extend from the spool shaft portion 22 in the coil diameter direction Dr. For example, the one-side spool base 23 is formed so as to extend to the outside in the coil diameter direction Dr than the coil winding 26.

[0024] Also, the one-side spool base 23 is formed in a plate shape with the first direction D1 as the thickness direction. The one-side spool base 23 is in contact with the coil winding 26 in the first direction D1. In short, the one-side spool base 23 is in contact with the coil winding 26.

[0025] The other-side spool base 24 is provided on the other side opposite to the one side in the first direction D1 with respect to the coil winding 26 and the spool shaft portion 22, and the other end of the spool shaft portion 22 is connected to the other-side spool base 24. The other-side spool base 24 is formed so as to extend from the spool shaft portion 22 in each of the second direction D2 and the third direction D3. Therefore, it can also be said that the other-side spool base 24 is formed so as to extend from the spool shaft portion 22 in the coil diameter direction Dr. For example, the other-side spool base 24 is formed so as to extend to the outside in the coil diameter direction Dr than the coil winding 26.

[0026] Also, the other-side spool base 24 is formed in a plate shape with the first direction D1 as the thickness direction. The other-side spool base 24 is in contact with the coil winding 26 in the first direction D1. In short, the other-side spool base 24 is in contact with the coil winding 26.

[0027] Also, a spool through hole 21a is formed in the spool 21, which passes through the inside of the spool shaft portion 22 and penetrates the one-side spool base 23 and the other-side spool base 24. This spool through hole 21a extends in the first direction D1 around the coil axis CL.

[0028] The coil winding 26 is an electromagnetic coil that generates a magnetic force when energized. The coil winding 26 is formed by winding a wire along the outer peripheral wall surface of the spool shaft portion 22. The coil winding 26 has a coil one end face 261 provided on one side in the first direction D1 and a coil other end face 262 provided on the other side in the first direction D1. The coil one end face 261 is in contact with the one-side spool base portion 23, and the coil other end face 262 is in contact with the other-side spool base portion 24.

[0029] The core 27 forms a magnetic path and is made of a ferromagnetic metal material, and is formed in a substantially cylindrical shape centered on the coil axis CL. The core 27 is inserted into the spool through hole 21a. Thereby, when the coil winding 26 is energized, the coil winding 26 forms a magnetic field and the core 27 generates a magnetic attraction force.

[0030] The yoke 28 forms a magnetic path and is composed of a plate-shaped member made of a ferromagnetic metal material, and is substantially L-shaped. Specifically, the yoke 28 has a first yoke plate portion 281 and a second yoke plate portion 282. The first yoke plate portion 281 is plate-shaped with the second direction D2 as the thickness direction, and is formed to extend in the first direction D1. The first yoke plate portion 281 is arranged on one side in the second direction D2 away from the coil winding 26 with respect to the coil winding 26.

[0031] The second yoke plate portion 282 is plate-shaped with the first direction D1 as the thickness direction, and is formed to extend from the end portion on the other side in the first direction D1 of the first yoke plate portion 281 to the other side in the second direction D2. And the second yoke plate portion 282 is arranged on the other side in the first direction D1 with respect to the coil winding 26 with the other-side spool base portion 24 sandwiched between it and the coil winding 26. The end portion on the other side in the first direction D1 of the core 27 is caulked and fixed to the second yoke plate portion 282.

[0032] The armature plate 29 forms a magnetic path and is made of a ferromagnetic metal material and shaped like a plate. The armature plate 29 has a plate one - end portion 291 which is one - end portion provided on one side in the second direction D2. The plate one - end portion 291 is held by a yoke one - end portion 281a which is one - end portion on one side in the first direction D1 of the first yoke plate portion 281. And the armature plate 29 is swingable about the plate one - end portion 291 as a fulcrum. The plate one - end portion 291 of this armature plate 29 corresponds to the support base portion of the present disclosure.

[0033] Also, the armature plate 29 has a facing surface 29a disposed on the other side in the second direction D2 from the plate one - end portion 291. This facing surface 29a faces an end surface 27a on one side in the first direction D1 of the core 27.

[0034] With such a configuration, when the coil winding 26 is energized, the armature plate 29 is attracted by the magnetic attraction force of the core 27, swings about the plate one - end portion 291 as a fulcrum, and the facing surface 29a approaches the core 27.

[0035] The fixed contact 31 and the movable contact 32 are metal electrical contact members for switching the electrical connection and disconnection between the first load terminal 41 and the second load terminal 42. These fixed contact 31, movable contact 32, first load terminal 41, and second load terminal 42 each constitute a part of the energization path that the relay 10 opens and closes. For example, a silver alloy is adopted as the material of each of the fixed contact 31 and the movable contact 32. The fixed contact 31 corresponds to the first contact portion of the present disclosure, and the movable contact 32 corresponds to the second contact portion of the present disclosure.

[0036] The leaf spring 30 is composed of an elastic metal plate - like member and is formed in a substantially L - shape along the armature plate 29 and the first yoke plate portion 281. That is, the leaf spring 30 has a first plate portion 301 along the armature plate 29, a second plate portion 302 along the first yoke plate portion 281, and a connecting plate portion 303 connecting the first plate portion 301 and the second plate portion 302.

[0037] The first plate portion 301 of the leaf spring 30 is disposed on one side in the first direction D1 with respect to the armature plate 29 and is caulked and fixed to the armature plate 29. Therefore, the first plate portion 301 and the armature plate 29 integrated by the caulking fixation constitute a swinging portion that extends in the second direction D2 and is swingably provided with the plate one end portion 291 as a fulcrum.

[0038] Also, the second plate portion 302 is disposed on one side in the second direction D2 with respect to the first yoke plate portion 281 and is caulked and fixed to the first yoke plate portion 281. The leaf spring 30 biases the armature plate 29 in a direction to separate the facing surface 29a of the armature plate 29 from the one end surface 27a of the core 27.

[0039] Further, the first plate portion 301 of the leaf spring 30 has a contact connection portion 301a which is a free end portion provided on the other side in the second direction D2, and the contact connection portion 301a is disposed on the other side in the second direction D2 than the armature plate 29. And a movable contact 32 is connected to the contact connection portion 301a. Specifically, the movable contact 32 is caulked and fixed to the contact connection portion 301a. The contact connection portion 301a of this leaf spring 30 is disposed away from the plate one end portion 291 that functions as a fulcrum for the swinging operation of the first plate portion 301 and the armature plate 29 in the second direction D2.

[0040] The movable contact 32 is electrically connected to the second load terminal 42 via the leaf spring 30. On the other hand, the first load terminal 41 has a contact pedestal portion 411 at an end portion on one side in the first direction D1 of the first load terminal 41, and the fixed contact 31 is caulked and fixed to the contact pedestal portion 411. Thereby, the fixed contact 31 is electrically connected to the first load terminal 41.

[0041] The first load terminal 41 is fixed to the other side spool base portion 24. And as shown in FIG. 3, the fixed contact 31 is electrically connected to the movable contact 32 by contacting the movable contact 32.

[0042] As shown in FIGS. 1 to 3, a fixed contact 31 is disposed on the other side of the movable contact 32 in the first direction D1, and a stopper 33 is disposed on one side of the movable contact 32 in the first direction D1. That is, the stopper 33, the movable contact 32, and the fixed contact 31 are arranged in the first direction D1 in the order of the stopper 33, the movable contact 32, and the fixed contact 31 from one side of the first direction D1. And the stopper 33, the movable contact 32, and the fixed contact 31 are disposed on the other side of the second direction D2 with respect to the armature plate 29, and the movable contact 32 and the fixed contact 31 face each other in the first direction D1.

[0043] Specifically, the fixed contact 31 has a fixed contact surface 311 as a first contact surface facing the movable contact 32 on the other side. The fixed contact surface 311 is disposed on one side of the first direction D1 with respect to the contact pedestal portion 411, is formed around the contact axis Cpc, and faces the axial direction of the contact axis Cpc. In the present embodiment, the contact axis Cpc is a single axis extending along the first direction D1, and the axial direction of the contact axis Cpc coincides with the first direction D1. Therefore, the fixed contact surface 311 is formed facing one side of the first direction D1.

[0044] On the other hand, the movable contact 32 has a movable contact surface 321 as a second contact surface facing the fixed contact surface 311 in the first direction D1. The movable contact surface 321 is disposed on the other side of the first direction D1 with respect to the contact connection portion 301a of the leaf spring 30 and faces the other side of the first direction D1.

[0045] Then, when the armature plate 29 and the first plate portion 301 of the leaf spring 30 swing with the plate end portion 291 as a fulcrum, the movable contact surface 321 is moved into and out of contact with the fixed contact surface 311 in the first direction D1. The movement of the movable contact surface 321 into and out of contact with the fixed contact surface 311 means performing an operation of the movable contact surface 321 coming into contact with the fixed contact surface 311 and an operation of leaving the fixed contact surface 311. Further, the energization path including the fixed contact 31 and the movable contact 32 is opened and closed by the movement of the movable contact surface 321 into and out of contact with the fixed contact surface 311.

[0046] Specifically, when the coil winding 26 is energized, the armature plate 29 is attracted to the core 27 by the energization of the coil winding 26. Accordingly, the movable contact 32 moves to the other side in the first direction D1 and contacts the fixed contact 31. That is, the movable contact surface 321 contacts the fixed contact surface 311. Thereby, the first load terminal 41 and the second load terminal 42 are electrically connected.

[0047] Conversely, when the energization of the coil winding 26 is cut off, that is, when the coil winding 26 is in a non-energized state, the armature plate 29 is separated from the core 27 by the biasing force of the leaf spring 30. Therefore, the movable contact 32 moves away from the fixed contact 31 to one side in the first direction D1. That is, the movable contact surface 321 separates from the fixed contact surface 311, and at the same time, the movable contact 32 comes into contact with the stopper 33. Thereby, the electrical connection between the first load terminal 41 and the second load terminal 42 is cut off.

[0048] As described above, the coil winding 26 causes the movable contact 32 to contact and separate from the fixed contact 31 according to the energization state of the coil winding 26. Note that the armature plate 29, the first plate portion 301 of the leaf spring 30, and the movable contact 32 are displaced when the armature plate 29 is attracted to the core 27, but the fixed contact 31 and the stopper 33 are not displaced. Further, FIG. 2 shows a state where the coil winding 26 is not energized and the movable contact 32 is separated from the fixed contact 31 and contacts the stopper 33. On the other hand, FIG. 3 shows a state where the movable contact 32 is brought into contact with the fixed contact 31 by the energization of the coil winding 26.

[0049] As shown in FIG. 2, the stopper 33 defines the range within which the movable contact 32 fixed to the contact connection portion 301a of the leaf spring 30 moves to one side in the first direction D1. That is, the stopper 33 defines the movement range of the contact connection portion 301a of the leaf spring 30 and the movable contact 32 when the coil winding 26 is not energized. Specifically, when the coil winding 26 is not energized, the contact connection portion 301a of the leaf spring 30 or the movable contact 32 abuts against the stopper 33 from the other side in the first direction D1 due to the biasing force of the leaf spring 30. Note that the stopper 33 is formed by press-molding a metal material such as brass and is fixed to the other-side spool base 24 by press-fitting or adhesion or the like.

[0050] As shown in FIGS. 1 and 2, the first load terminal 41, the second load terminal 42, the first coil terminal 46, and the second coil terminal 47 each protrude from the base 51 to the other side in the first direction D1. And those terminals 41, 42, 46, 47 are each electrically connected to, for example, a wiring pattern provided on the electric substrate 11 by soldering. Also, those terminals 41, 42, 46, 47 are fixed to the other-side spool base 24 or the base 51 in the present embodiment.

[0051] The first coil terminal 46 and the second coil terminal 47 are terminals for electrically connecting the coil winding 26 to the electric substrate 11. Therefore, one of the pair of lead wires extending from the coil winding 26 is electrically connected to the first coil terminal 46, and the other of the pair of lead wires is electrically connected to the second coil terminal 47. In short, the first coil terminal 46 and the second coil terminal 47 are each electrically connected to the coil winding 26.

[0052] The first coil terminal 46 and the second coil terminal 47 are arranged side by side in the third direction D3. That is, the third direction D3 is the arrangement direction of the coil terminals 46, 47. Specifically, the first coil terminal 46 is arranged on one side in the third direction D3 with respect to the coil axis CL, and the second coil terminal 47 is arranged on the other side in the third direction D3 with respect to the coil axis CL.

[0053] Here, referring to each contact surface 311 and 321, as shown in FIGS. 3 to 5, the fixed contact surface 311 forms a circular shape in the direction view along the normal direction of the fixed contact surface 311 (i.e., the first direction D1). Similarly, the movable contact surface 321 also forms a circular shape in the direction view along the normal direction of the movable contact surface 321.

[0054] And the movable contact surface 321 is formed in a planar shape without an uneven shape or a slightly bulging curved surface shape. On the other hand, as shown in FIGS. 3 to 6, a recessed portion 312 is formed on the fixed contact surface 311 in a groove shape extending in the groove extension direction Ds and is recessed. This groove extension direction Ds is one direction among the radial directions Drpc of the contact axis Cpc and is parallel to the second direction D2.

[0055] For example, the amount of depression of the recessed portion 312 is slightly larger than the size of the filler contained in resin parts such as the case 50 constituting the relay 10. Further, the recessed portion 312 is arranged so that the contact axis Cpc passes through the range of the width W3 of the recessed portion 312. The width W3 of the recessed portion 312 is the width in the direction orthogonal to the first direction D1 and the groove extension direction Ds in the recessed portion 312.

[0056] Since the groove-shaped recessed portion 312 is formed on the fixed contact surface 311 in this way, a pair of convex portions 313 protruding in the first direction D1 with respect to the bottom surface 312a of the recessed portion 312 are also formed on both sides of the recessed portion 312 in the third direction D3 of the fixed contact surface 311. The pair of convex portions 313 are provided in parallel with the recessed portion 312 sandwiched therebetween and are formed in a rail shape extending in the groove extension direction Ds along the recessed portion 312.

[0057] And the pair of convex portions 313 each have a convex surface 313a provided at the tip on one side in the first direction D1, and the convex surface 313a is formed in a planar shape or a slightly bulging curved surface shape with the first direction D1 as the normal direction. Further, the fixed contact surface 311 including the recessed portion 312 and the pair of convex portions 313 is formed symmetrically with respect to the second direction D2, for example, and is also formed symmetrically with respect to the third direction D3.

[0058] Note that the radial direction Drpc of the above-mentioned contact axis Cpc is a direction that is orthogonal to the contact axis Cpc and separated from the contact axis Cpc. That is, the radial direction Drpc of the contact axis Cpc is the radial direction of a circle drawn in a virtual plane orthogonal to the contact axis Cpc with the intersection of the virtual plane and the contact axis Cpc as the center.

[0059] The recess 312 of the above-mentioned fixed contact surface 311 may be formed in advance in the state of the component alone before the caulking process of the fixed contact 31, but in this embodiment, it is formed simultaneously with the caulking process of the fixed contact 31.

[0060] Specifically, first, in step S01 of FIG. 7, as shown in FIGS. 7 and 8, a contact component 35 that becomes the fixed contact 31 after the caulking process and a first load terminal 41 that functions as a contact pedestal to which the contact component 35 is attached are each prepared. Since the contact component 35 prepared in this step S01 is the fixed contact 31 before the caulking process, it has the fixed contact surface 311 similar to the fixed contact 31, but the uneven shape including the above-mentioned recess 312 and protrusion 313 is not formed on the fixed contact surface 311 of the contact component 35.

[0061] Note that in this embodiment, for example, the fixed contact 31 and the movable contact 32 are shared as components alone. That is, the contact component 35 is a component that can become either the fixed contact 31 or the movable contact 32 by the caulking process. Therefore, the contact component 35 becomes the fixed contact 31 when caulked and fixed to the contact pedestal portion 411 of the first load terminal 41, and becomes the movable contact 32 when caulked and fixed to the contact connection portion 301a of the leaf spring 30.

[0062] In the subsequent step S02 of FIG. 7, as shown in FIG. 8, the first load terminal 41 and the contact component 35 are combined, and the first load terminal 41 and the contact component 35 are set in the lower die 62 of the caulking machine 60 in a state where the first load terminal 41 and the contact component 35 are combined. The lower die 62 of the caulking machine 60 is one of the dies of the caulking machine 60. The caulking machine 60 is a press machine having a lower die 62 and an upper die 63 which is the other die facing the lower die 62, and caulking is performed by pressing the upper die 63 against the lower die 62 as indicated by the arrow Prs.

[0063] In the subsequent step S03 of FIG. 7, caulking is performed in a state where the contact component 35 is combined with the first load terminal 41 as shown in FIG. 8. In this caulking, the upper die 63 is pressed against the lower die 62 as indicated by the arrow Prs in a state where the first load terminal 41 and the contact component 35 are combined, whereby the caulking boss 351 of the contact component 35 is crushed. As a result of this caulking, the fixed contact 31 fixed to the contact pedestal portion 411 of the first load terminal 41 is obtained. To state for confirmation, the fixed contact 31 is the contact component 35 after caulking in step S03.

[0064] Also, in this step S03, during the caulking process of crushing the caulking boss 351, as the upper die 63 approaches the lower die 62 as indicated by the arrow Prs, the opposing surface 621 of the lower die 62 is pressed against the fixed contact surface 311. The opposing surface 621 of the lower die 62 is the die surface of the lower die 62 that faces and contacts the fixed contact surface 311, and has an uneven shape corresponding to the uneven shape of the fixed contact surface 311 including the concave portion 312 and the convex portion 313. For example, the shape corresponding to the concave portion 312 of the fixed contact surface 311 is convex on the opposing surface 621 of the lower die 62, and the shape corresponding to the convex portion 313 of the fixed contact surface 311 is concave on the opposing surface 621 of the lower die 62.

[0065] Then, as described above, when the opposing surface 621 of the lower mold 62 is pressed against the fixed contact surface 311 in step S03, the shape of the opposing surface 621 is transferred to the fixed contact surface 311. As a result, an uneven shape including the recess 312 and the pair of convex portions 313 shown in FIG. 4 is formed on the fixed contact surface 311.

[0066] Note that the caulking process for fixing the movable contact 32 to the contact connection portion 301a of the leaf spring 30 is also carried out through the same manufacturing process as the process shown in FIG. 7 described above. However, no uneven shape is formed on the movable contact surface 321 in the caulking process of the movable contact 32.

[0067] Next, the effects achieved in the present embodiment will be described.

[0068] As described above, according to the present embodiment, as shown in FIGS. 2 to 5, the movable contact surface 321 is moved into and out of contact with the fixed contact surface 311 in the first direction D1. The fixed contact surface 311 is formed with a recess 312 that is recessed to form a groove shape extending in the groove extending direction Ds, which is one direction in the radial direction Drpc of the contact axis Cpc.

[0069] Therefore, even if a foreign object such as glass fiber is interposed between the fixed contact surface 311 and the movable contact surface 321, for example, within the region where the recess 312 is formed, the foreign object enters the recess 312, so it is difficult to act to separate the fixed contact surface 311 and the movable contact surface 321. Accordingly, it is possible to suppress the occurrence of poor contact (i.e., contact failure) between the fixed contact 31 and the movable contact 32 due to foreign objects as compared with a comparative example in which both the fixed contact surface 311 and the movable contact surface 321 are flat surfaces without an uneven shape.

[0070] Here, the mechanism of contact failure at the contacts due to glass fibers or the like will be described using the above comparative example. Note that the fixed contact 81 in the comparative example shown in FIGS. 9 and 10 corresponds to the fixed contact 31 of the present embodiment, and the surface 811 of the fixed contact in the comparative example corresponds to the surface 311 of the fixed contact of the present embodiment. In that comparative example, the surface 321 of the movable contact is a flat surface without an uneven shape, similar to the present embodiment. However, as shown in FIGS. 9 and 10, the surface 811 of the fixed contact is also a flat surface without an uneven shape. That is, the surface 811 of the fixed contact in the comparative example is different from the surface 311 of the fixed contact of the present embodiment in that it is a flat surface without an uneven shape. Except for this point, the comparative example is the same as the present embodiment.

[0071] In the comparative example, the diameters of the surfaces 811 and 321 of each contact are about 3 mm. On the other hand, when looking microscopically at the state where the surface 811 of the fixed contact and the surface 321 of the movable contact are in contact, the diameter of the contact portion Pa formed on the surfaces 811 and 321 of the contacts and in conductive contact is about several tens of μm, and an electric current path is formed by this fine contact portion Pa to ensure the contact function. Therefore, if foreign matter such as glass fibers intervenes in this contact portion Pa, contact failure occurs.

[0072] On the other hand, as shown in FIGS. 9 and 11, as the distance from the contact portion Pa along the surface 811 of the fixed contact or the surface 321 of the movable contact increases, the contact gap Ga, which is the gap between the two contact surfaces 811 and 321, expands. In FIG. 11, the contact gap Ga in the comparative example is shown. There is a contact portion Pa on the right side of the paper in FIG. 11, and it becomes farther from the contact portion Pa toward the left side of the paper (that is, the other side in the second direction D2).

[0073] For example, assuming that the diameter of the foreign matter that can intervene between the two contact surfaces 811 and 321 is 15 μm, even if the foreign matter intervenes in a range deviated from the contact portion Pa, if the intervening position of the foreign matter is at a portion where the contact gap Ga is less than 15 μm when there is no such foreign matter, contact failure will occur.

[0074] That is, in this case, if a foreign object such as a glass fiber intervenes between the two contact surfaces 811 and 321 within the NG region Ang that includes the contact portion Pa and where the contact gap Ga becomes less than 15 μm around it, a poor contact occurs. On the other hand, if it is within the OK region Aok that is formed outside the NG region Ang and where the contact gap Ga is 15 μm or more, even if a foreign object such as a glass fiber intervenes between the two contact surfaces 811 and 321, a poor contact does not occur. The dashed line Xa in Fig. 11 represents a foreign object that can intervene between the two contact surfaces 811 and 321. Also, in Figs. 9 and 5, for easy understanding, the NG region Ang is marked with dot-like hatching, and the contact portion Pa is marked with diagonal hatching.

[0075] Considering this embodiment based on the above, as shown in Fig. 5, since the concave portion 312 is formed on the fixed contact surface 311, the NG region Ang that causes a poor contact due to the intervention of a foreign object becomes narrower than the above comparative example. Therefore, in this embodiment, as described above, it is possible to suppress the occurrence of a poor contact due to a foreign object. Note that, as shown in Figs. 5 and 9, the area of the NG region Ang in this embodiment is approximately half that of the comparative example.

[0076] Also, in this embodiment, when the armature plate 29 is attracted to the core 27 and the movable contact 32 is pressed against the fixed contact 31, the movable contact surface 321 comes into contact with each of the pair of convex portions 313 on the fixed contact surface 311. Therefore, the contact portion Pa is one location as shown in Fig. 9 in the above comparative example, while in this embodiment, it is two locations as shown in Fig. 5.

[0077] That is, even if a foreign object intervenes in one of the two contact portions Pa, it is possible to obtain a fail-safe function in which the conduction between the fixed contact 31 and the movable contact 32 is ensured at the other contact portion Pa. Also because of this, in this embodiment, it is possible to suppress the occurrence of a poor contact due to a foreign object.

[0078] Even if the recess 312 is formed on the fixed contact surface 311, the size of the contact contact portion Pa remains the same as in the comparative example, so there is no influence on the contact function such as the contact energization function of the relay 10.

[0079] Also, when the technique of the present embodiment for suppressing the occurrence of contact failure is incorporated into a relay such as the above-described comparative example, a significant structural change to the relay is not required. Therefore, according to the present embodiment, it is possible to provide a countermeasure against contact failure with high versatility as compared with, for example, Patent Document 1.

[0080] Further, according to the present embodiment, the plate end portion 291 that functions as a fulcrum for the swinging operation of the armature plate 29 and the first plate portion 301 is disposed away from the contact connection portion 301a to which the movable contact 32 is connected in the second direction D2. When the armature plate 29 and the first plate portion 301 swing with the plate end portion 291 as a fulcrum, the movable contact surface 321 is brought into contact with and separated from the fixed contact surface 311. Then, as shown in FIG. 5, the groove shape of the recess 312 formed on the fixed contact surface 311 extends in the groove extension direction Ds parallel to the second direction D2.

[0081] Here, for example, in the operation where the movable contact 32 contacts the fixed contact 31, finally, the contact contact portion Pa is formed at the final position P1 shown by the solid line in FIG. 5. However, in the transient period of the operation where the movable contact 32 contacts the fixed contact 31, at the beginning of the contact between the two contacts 31 and 32, the contact contact portion Pa is first formed at the initial position P0 shown by the broken line in FIG. 5. Then, as the movable contact 32 is pressed against the fixed contact 31, the contact contact portion Pa moves along the second direction D2 from the initial position P0 to one side in the second direction D2 as indicated by the arrow Apa and reaches the final position P1.

[0082] And in this embodiment, as described above, the groove shape of the recess 312 extends in the second direction D2. Therefore, in the transient period of the operation in which the movable contact 32 contacts the fixed contact 31, the contact portion Pa of the contacts moves as indicated by the arrow Apa while the contact between the movable contact 32 and the fixed contact 31 is maintained. Accordingly, it is possible to stably bring the movable contact 32 into contact with the fixed contact 31 in the transient period of the operation in which the movable contact 32 contacts the fixed contact 31.

[0083] Also, according to this embodiment, in step S03 of FIG. 7, the shape of the opposing surface 621 of the lower mold 62 shown in FIG. 8 is transferred to the fixed contact surface 311 by pressing the opposing surface 621 against the fixed contact surface 311. Thereby, the recess 312 shown in FIG. 4 is formed in the fixed contact surface 311.

[0084] Therefore, it is not necessary to form the recess 312 in the contact component 35 which is the fixed contact 31 before caulking, so it is easy to make the parts of the fixed contact 31 and the movable contact 32 common. For example, when the parts of the fixed contact 31 and the movable contact 32 are made common, it is possible to prevent manufacturing mistakes caused by the replacement of the parts of the fixed contact 31 and the movable contact 32 in the caulking processes of the fixed contact 31 and the movable contact 32 respectively.

[0085] (Other Embodiments) (1) In the above-described first embodiment, the fixed contact 31 and the movable contact 32 are caulked and fixed to the mating parts that serve as the contact pedestals respectively, but the fixing method is not limited to caulking, and other methods such as screwing or welding may be used.

[0086] (2) In the above-described first embodiment, for example, the fixed contact 31 and the movable contact 32 are common as single parts, and the contact component 35 in FIG. 8 can be either the fixed contact 31 or the movable contact 32, but this is just an example. The contact component 35 in FIG. 8 may be dedicated to the fixed contact 31, and another component different from the contact component 35 may be made into the movable contact 32 by caulking.

[0087] (3) In the above-described first embodiment, as shown in FIG. 4, the concavo-convex shape including the concave portion 312 and the pair of convex portions 313 is formed on the fixed contact surface 311, but this is merely an example. For example, conversely, the fixed contact surface 311 may be formed in a planar shape without a concavo-convex shape, and a concavo-convex shape including a concave portion 312 and a pair of convex portions 313 as shown in FIG. 4 may be formed on the movable contact surface 321. In such a case, the movable contact 32 corresponds to the first contact portion of the present disclosure, the movable contact surface 321 corresponds to the first contact surface of the present disclosure, the fixed contact 31 corresponds to the second contact portion of the present disclosure, and the fixed contact surface 311 corresponds to the second contact surface of the present disclosure.

[0088] Furthermore, it can also be assumed that a concavo-convex shape including a concave portion 312 and a pair of convex portions 313 as shown in FIG. 4 is formed on each of the fixed contact surface 311 and the movable contact surface 321.

[0089] (4) In the above-described first embodiment, as shown in FIG. 2, the relay 10 is mounted on the electric substrate 11, but it may not be mounted on the electric substrate 11. For example, the relay 10 may be a plug-in type relay that is attached to the vehicle by being inserted into a socket provided in the vehicle.

[0090] (5) In the above-described first embodiment, as shown in FIG. 2, the fixed contact 31 is disposed on the other side of the first direction D1 with respect to the movable contact 32, and the stopper 33 is disposed on one side of the first direction D1 with respect to the movable contact 32, but this is merely an example. The positional relationship among the fixed contact 31, the movable contact 32, and the stopper 33 is not limited to the aspect shown in FIG. 2. Also, the relay 10 may be configured without the stopper 33.

[0091] (6) In the above-described first embodiment, the terminals 41, 42, 46, 47 of the relay 10 are arranged as shown in FIGS. 1 and 2, respectively, but this is merely an example. The arrangement of the terminals 41, 42, 46, 47 is not limited to the arrangement shown in FIGS. 1 and 2, and various arrangements are conceivable.

[0092] (7) In the above-described first embodiment, as shown in FIGS. 3 to 5, the fixed contact surface 311 forms a circular shape when viewed in the direction along the normal direction of the fixed contact surface 311, but it is not limited to a circular shape, and for example, it may be a quadrangular shape, a pentagonal shape, or the like. Similarly, the movable contact surface 321 also forms a circular shape when viewed in the direction along the normal direction of the movable contact surface 321, but it is not limited to a circular shape, and for example, it may be a quadrangular shape, a pentagonal shape, or the like.

[0093] (8) Note that the present disclosure is not limited to the above-described embodiments and can be implemented with various modifications. Also, in the above embodiments, the elements constituting the embodiments are not necessarily essential except in cases where it is explicitly stated that they are essential and cases where they are considered to be clearly essential in principle.

[0094] Also, in the above embodiments, when numerical values such as the number, numerical value, quantity, range, etc. of the components of the embodiments are mentioned, they are not limited to the specific number except in cases where it is explicitly stated that they are essential and cases where they are clearly limited to a specific number in principle. Further, in the above embodiments, when referring to the material, shape, positional relationship, etc. of the components, etc., they are not limited to the material, shape, positional relationship, etc. except in cases where it is explicitly stated and cases where they are clearly limited to a specific material, shape, positional relationship, etc. in principle.

Description of Reference Numerals

[0095] 10 Relay 31 Fixed Contact (First Contact Portion) 32 Movable Contact (Second Contact Portion) 311 Fixed Contact Surface (First Contact Surface) 312 Recess 321 Movable Contact Surface (Second Contact Surface) Cpc Contact Axis (Single Axis)

Claims

1. A relay for opening and closing an energization path, having a first contact surface (311) formed around a single axis line (Cpc) and facing the axial direction (D1) of the single axis line, and constituting a part of the energization path, a first contact portion (31); and a second contact portion (32) having a second contact surface (321) facing the first contact surface and constituting a part of the energization path, wherein one of the first contact surface and the second contact surface is moved into and out of contact with the other, and a recess (312) formed in the first contact surface in a groove shape extending in the radial direction (Drpc) of the single axis line and recessed, the relay.

2. having a contact connection portion (301a) to which one (32) of the first contact portion and the second contact portion is connected, and a support base portion (291) disposed away from the contact connection portion in an intersection direction (D2) intersecting the axial direction, and including a swing portion (29, 301) provided swingably with the support base portion as a fulcrum, wherein the contact making and breaking operation is performed by the swing portion swinging, and the groove shape of the recess extends in the intersection direction, the relay according to claim 1.

3. A method for manufacturing a relay having a first contact surface (311) formed around a single axis line (Cpc) and facing the axial direction (D1) of the single axis line and constituting a part of an energization path, a first contact portion (31), and a second contact portion (32) having a second contact surface (321) facing the first contact surface and constituting a part of the energization path, wherein one of the first contact surface and the second contact surface is moved into and out of contact with the other, the method comprising: preparing a contact component (35) to be the first contact portion and a contact pedestal (41) to which the contact component is to be attached (S01); and performing caulking in a state where the contact component is combined with the contact pedestal to obtain the first contact portion, which is the caulked contact component fixed to the contact pedestal (S03). In obtaining the first contact portion, a method for manufacturing a relay, in which during caulking, a die (62) that contacts the first contact surface is pressed against the first contact surface to form a recessed portion (312) that is recessed to form a groove shape extending in the radial direction (Drpc) of the one axis on the first contact surface.

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