Plate-shaped component, method for manufacturing a plate-shaped component, and method for manufacturing an electromagnetic relay

Abstract

To provide a plate-shaped component that can enhance the cleaning effect. [Solution] The plate-shaped part 10 includes at least one of the following: a bent portion 13 that bends so as to be convex or concave in the thickness direction DT, a convex portion 16 that protrudes in the thickness direction DT from a surface facing one side in the thickness direction DT, and a groove portion 17 formed on a surface facing one side in the thickness direction DT and leading to the outer edge of the plate-shaped part 10.

Description

Technical Field

[0001] The present disclosure relates to a plate-shaped component, a method for manufacturing the plate-shaped component, and a method for manufacturing an electromagnetic relay.

Background Art

[0002] Conventionally, plate-shaped components used in magnetic circuits such as automotive parts or electrical equipment have been processed into a desired shape by press working, and then a cleaning process for removing dirt such as processing oil and a heating process for magnetic annealing have been performed, after which they have been assembled into products. In particular, when there is a risk that the adhesion of dirt to the plate-shaped component may lead to a decrease in product performance or a failure, before the normal cleaning process, a preliminary cleaning process such as oscillating cleaning with high detergency or a sorting process for sorting out insufficiently cleaned products after cleaning needs to be added. Therefore, problems such as an increase in lead time and a decrease in productivity due to the preliminary cleaning process and the sorting process, and an increase in manufacturing costs have occurred. Also, if the preliminary cleaning process and the sorting process were abolished or simplified, there was a risk that the quality of the product would decrease.

[0003] By the way, Patent Document 1 describes providing convex portions on plate-shaped metal parts for plating.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, the convex portions provided on the metal parts for plating described in Patent Document 1 are for the purpose of eliminating plating defects, and the purpose is different from that of the present disclosure.

[0006] In view of the above points, this disclosure aims to provide a plate-shaped component capable of enhancing the cleaning effect, a method for manufacturing a plate-shaped component, and a method for manufacturing an electromagnetic relay. [Means for solving the problem]

[0007] According to one aspect of this disclosure, the plate-shaped part comprises at least one of a bent portion (13) that bends to be convex or concave in the thickness direction (DT), a convex portion (16) that protrudes in the thickness direction from a surface (11) facing one side in the thickness direction, and a groove portion (17) formed on a surface facing one side in the thickness direction and leading to the outer edge of the plate-shaped part.

[0008] According to this, the plate-shaped parts have a shape that is excellent for cleaning. Specifically, when multiple plate-shaped parts and cleaning solution are placed in a container and the cleaning solution is agitated to clean the plate-shaped parts, at least one of the bent parts, protrusions, and grooves creates gaps between the multiple plate-shaped parts that serve as pathways for the cleaning solution. Specifically, in the case of bent parts and protrusions, their shapes cause the multiple plate-shaped parts to separate, creating gaps between them. In the case of grooves, the water pressure of the cleaning solution flowing from the outer edge of the plate-shaped parts into the grooves causes the multiple plate-shaped parts to separate, creating gaps between them. As a result, the cleaning solution flows into the gaps between the multiple plate-shaped parts, increasing the contact area between the plate-shaped parts and the cleaning solution, thus enhancing the cleaning effect of the plate-shaped parts even with normal cleaning power. Therefore, this shape of the plate-shaped parts can eliminate or simplify the pre-cleaning process and the sorting process for insufficiently cleaned products, thereby reducing manufacturing costs and improving productivity and quality.

[0009] According to another aspect of this disclosure, a plate-shaped component used as an armature (25) that is magnetically attracted to an electromagnetic coil (23) by energizing the electromagnetic coil (23) of an electromagnetic relay (20) is, The plate comprises at least one of the following: a bent portion (13) that bends in the thickness direction so that the side facing the electromagnetic coil is concave; a convex portion (16) that protrudes in the thickness direction from the surface facing the electromagnetic coil; and a groove portion (17) formed on the surface facing the electromagnetic coil and leading to the outer edge of the plate-shaped component.

[0010] According to this, the plate-shaped component used as the armature of an electromagnetic relay is a pressed magnetic material. If processing oil or other contaminants adhere to the armature, magnetic annealing will be insufficient, which may lead to a decrease in product performance or failure. In contrast, the plate-shaped component of this disclosure has a shape that is easy to clean, so the pre-cleaning process and the sorting process for insufficiently cleaned products can be eliminated or simplified, thereby reducing manufacturing costs and improving productivity and quality.

[0011] According to yet another aspect of this disclosure, the method for manufacturing a plate-shaped component is: Forming a plate-shaped part by press work (S1, S21) having at least one of a bent portion (13) that bends so as to be convex or concave in the thickness direction, a convex portion (16) that protrudes in the thickness direction from a surface facing one side in the thickness direction, and a groove portion (17) formed on a surface facing one side in the thickness direction and leading to the outer edge of the plate-shaped part, This includes placing multiple plate-shaped parts and a cleaning solution in a container, and cleaning the multiple plate-shaped parts by stirring the cleaning solution (S2, S22).

[0012] According to this, the manufacturing method of the plate-shaped part of this disclosure also results in a shape that is easy to clean due to at least one of the bent portion, convex portion, and groove portion of the plate-shaped part, thereby enhancing the cleaning effect of the plate-shaped part. Therefore, the pre-cleaning process and the sorting process for insufficiently cleaned products can be eliminated or simplified, reducing manufacturing costs and improving productivity and quality.

[0013] From yet another perspective of this disclosure, the method for manufacturing an electromagnetic relay is: A plate-shaped part is formed by press working (S21) having at least one of the following: a bent portion (13) that bends in the thickness direction so that the side facing the electromagnetic coil (23) is concave, a convex portion (16) that protrudes in the thickness direction from the surface facing the electromagnetic coil, and a groove portion (17) formed on the surface facing the electromagnetic coil and leading to the outer edge of the plate-shaped part. The process involves placing multiple plate-shaped parts and a cleaning solution into a container, stirring the cleaning solution, and cleaning the multiple plate-shaped parts (S22). Heating the multiple cleaned plate-shaped parts (S23), It includes assembling a plate-shaped component as an armature (25) magnetically attracted to an electromagnetic coil by energizing the electromagnetic coil to a spring terminal (26) (S24).

[0014] According to this, if dirt such as processing oil adheres to the armature of the electromagnetic relay, magnetic annealing becomes insufficient, which may lead to a decrease in product performance and failure. On the contrary, in the manufacturing method of the electromagnetic relay of the present disclosure, since the plate-shaped component has a shape excellent in cleaning property, the preliminary cleaning process and the sorting process of insufficiently cleaned products can be abolished or simplified, reducing the manufacturing cost, and improving productivity and quality.

[0015] The reference numerals with parentheses attached to each component etc. show an example of the correspondence relationship between the component etc. and the specific components etc. described in the embodiments described later.

Brief Description of the Drawings

[0016] [Figure 1] It is a side view of a plate-shaped component according to the first embodiment. [Figure 2] It is a bottom view of the plate-shaped component as viewed from the II direction of FIG. 1. [Figure 3] It is a flowchart showing a manufacturing method of a plate-shaped component according to the first embodiment. [Figure 4] It is an explanatory diagram for explaining the state of the cleaning process of the plate-shaped component according to the first embodiment. [Figure 5] It is a side view of a plate-shaped component of the first comparative example. [Figure 6] It is a bottom view of the plate-shaped component as viewed from the VI direction of FIG. 5. [Figure 7] It is a flowchart showing a manufacturing method of a plate-shaped component of the first comparative example. [Figure 8] It is an explanatory diagram for explaining the state of the cleaning process of the plate-shaped component of the first comparative example. [Figure 9] It is a side view of a plate-shaped component according to the second embodiment. [Figure 10] It is a bottom view of the plate-shaped component as viewed from the X direction of FIG. 9. [Figure 11]It is an explanatory diagram for explaining a state when a plurality of plate-shaped parts and a cleaning liquid according to the second embodiment are placed in a container and cleaned. [Figure 12] It is a side view of a plate-shaped part according to the third embodiment. [Figure 13] It is a bottom view of the plate-shaped part as viewed from the XIII direction of FIG. 12. [Figure 14] It is a bottom view of a plate-shaped part according to the fourth embodiment. [Figure 15] It is a side view of a plate-shaped part according to the fifth embodiment. [Figure 16] It is a bottom view of the plate-shaped part as viewed from the XVI direction of FIG. 15. [Figure 17] It is an explanatory diagram for explaining a state of a cleaning process of a plurality of plate-shaped parts according to the fifth embodiment. [Figure 18] It is an explanatory diagram for explaining a state of a cleaning process of a plurality of plate-shaped parts according to the fifth embodiment, following FIG. 17. [Figure 19] It is a bottom view of a plate-shaped part according to the sixth embodiment. [Figure 20] It is a cross-sectional view of an electromagnetic relay as an example of a product in which a plate-shaped part according to the seventh embodiment is used. [Figure 21] It is a flowchart showing a part of a manufacturing method of an electromagnetic relay. [Figure 22] It is a flowchart showing a part of a manufacturing method of an electromagnetic relay of the second comparative example.

Modes for Carrying Out the Invention

[0017] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals, and the description thereof is omitted. In the following description, the direction indicated by the arrow DT in the figure is referred to as the plate thickness direction DT, the direction indicated by the arrow DA is referred to as the front-rear direction DA, and the direction indicated by the arrow DW is referred to as the width direction DW.

[0018] (First Embodiment) A first embodiment will now be described. As shown in Figures 1 and 2, the plate-shaped part 10 of the first embodiment is formed into a desired shape, for example, by press working. The plate-shaped part 10 has a surface 11 facing one direction in the thickness direction DT and a surface 12 facing the other direction in the thickness direction DT. In the following description, the surface 11 facing one direction in the thickness direction DT will be referred to as the "first surface 11," and the surface 12 facing the other direction in the thickness direction DT will be referred to as the "second surface 12."

[0019] The plate-shaped part 10 has a bent portion 13 that bends so as to be convex or concave in the thickness direction DT. Specifically, the bent portion 13 is curved or bent so as to be concave from the first surface 11 toward the second surface 12. The bent portion 13 is bent at an obtuse angle. In Figures 1 and 2, the bend line of the bent portion 13 that is furthest from the imaginary line VL connecting one outer edge of the first surface 11 in the front-rear direction DA and the other outer edge of the first surface 11 in the front-rear direction DA extends in the width direction DW of the plate-shaped part 10. Note that the bent portion 13 is not limited to a shape in which the bend line is visible as a straight line as shown in Figures 1 and 2; for example, the bent portion 13 may have a gently curved shape.

[0020] The plate-shaped part 10 has a cylindrical projection 14 that protrudes from the second surface 12 in the thickness direction DT. The plate-shaped part 10 also has two L-shaped projections 15 on one outer edge in the front-rear direction DA. The L-shaped projections 15 extend from one outer edge of the plate-shaped part 10 in the front-rear direction DA to the other side of the front-rear direction DA, and from that end to the other side in the thickness direction DT. The shape of the outer edge of the plate-shaped part 10, the bent portion 13, the cylindrical projection 14, and the L-shaped projections 15 are formed by press working. Note that the extrusion holes formed on the first surface 11 when the cylindrical projections 14 are formed by press working are not shown in the illustration. The shapes of the outer edge, bent portion 13, projections 14, and L-shaped projections 15 of the plate-shaped part 10 can be arbitrarily set. The projections 14 and L-shaped projections 15 may also be omitted. The above describes an example of the configuration of the plate-shaped part 10.

[0021] Next, an example of a method for manufacturing the plate-shaped part 10 of the first embodiment will be described with reference to the flowchart in Figure 3. In the following description and figures, each step will be simply denoted as "S".

[0022] In Figure 3, at S1, a plate-shaped part 10 is formed by press working. Specifically, the shape of the outer edge of the plate-shaped part 10, the bent portion 13, the cylindrical projection 14, and the L-shaped projection 15 are formed by press working.

[0023] Next, in S2, a cleaning process is performed to remove processing oil and other contaminants that adhered to the plate-shaped parts 10 during press working. In the cleaning process, multiple plate-shaped parts 10 and a cleaning solution are placed in a container, and the cleaning solution is agitated to clean the multiple plate-shaped parts 10. At this time, as shown in Figure 4, in the first embodiment, even when the first surface 11 of one plate-shaped part 10 faces the first surface 11 of another plate-shaped part 10, the bent portion 13 creates a gap G between the two plate-shaped parts 10 that serves as a passage for the cleaning solution. Therefore, the first surface 11 of the plate-shaped part 10 comes into contact with the cleaning solution, increasing the contact area between the plate-shaped part 10 and the cleaning solution, thereby enhancing the cleaning effect of the plate-shaped parts 10.

[0024] Next, in step S3 of Figure 3, the plate-shaped component 10 is assembled into the product. Examples of products include automotive parts, electrical equipment, electronic equipment, home appliances, and industrial equipment.

[0025] Here, in order to compare it with the plate-shaped part 10 of the first embodiment described above, the plate-shaped part 10 of the first comparative example will be described. As shown in Figures 5 and 6, the plate-shaped part 100 of the first comparative example has a first surface 11 that is flat and does not have a bent portion 13. Except for this, the plate-shaped part 100 of the first comparative example and the plate-shaped part 10 of the first embodiment have the same shape.

[0026] Next, an example of a manufacturing method for the plate-shaped part 100 of the first comparative example will be explained with reference to the flowchart in Figure 7. In S11 of Figure 7, a plate-shaped part 100 is formed by press working. Specifically, the shape of the outer edge of the plate-shaped part 100, the cylindrical projection 14, and the L-shaped projection 15 are formed by press working.

[0027] Next, in S12, a preliminary cleaning process is performed. In the preliminary cleaning process, for example, oscillating cleaning is performed in which multiple plate-shaped parts 100 are cleaned by shaking them up and down or left and right. Subsequently, in S13, a normal cleaning process is performed. During the preliminary cleaning process and the normal cleaning process, as shown in Figure 8, in the plate-shaped parts 100 of the first comparative example, when the first surface 11 of one plate-shaped part 100 faces the first surface 11 of another plate-shaped part 100, the first surfaces 11 of the two plate-shaped parts 100 may come into close contact with each other. As a result, the cleaning liquid may not come into contact with the first surface 11 of the plate-shaped part 100, and dirt may remain on the plate-shaped part 100.

[0028] Next, in step S14 of Figure 7, a sorting process is performed. In the sorting process, among the multiple plate-shaped parts 100, those that are not properly cleaned and have dirt attached are selected and removed. Finally, in step S15, the plate-shaped component 100 is assembled into the product.

[0029] Compared to the plate-shaped part 100 of the first comparative example, the plate-shaped part 10 of the first embodiment provides the following effects due to its configuration. (1) The plate-shaped part 10 of the first embodiment is provided with a bent portion 13 that bends so as to be convex or concave in the thickness direction DT. According to this, the plate-shaped part 10 has a shape that is excellent for cleaning. Specifically, when multiple plate-shaped parts 10 and cleaning solution are placed in a container and the cleaning solution is stirred to clean the plate-shaped parts 10, the bent portion 13 creates gaps G between the multiple plate-shaped parts 10 that serve as pathways for the cleaning solution. As a result, the cleaning solution flows into the gaps G between the multiple plate-shaped parts 10, increasing the contact area between the plate-shaped parts 10 and the cleaning solution, thus enhancing the cleaning effect of the plate-shaped parts 10 even with normal cleaning power. Therefore, this shape of the plate-shaped part 10 eliminates or simplifies the pre-cleaning process and the sorting process for insufficiently cleaned products, thereby reducing manufacturing costs and improving productivity and quality.

[0030] (2) The plate-shaped part 10 of the first embodiment is a press-formed product. According to this, since press-formed products have dirt such as processing oil adhering to them during press-forming, it is necessary to perform a cleaning process to remove this dirt before assembling them into the product. In particular, if the adhesion of dirt to the plate-shaped part 10 may lead to a decrease in product performance or failure, it was necessary to add a pre-cleaning process such as agitation cleaning or a sorting process to select out insufficiently cleaned products before the normal cleaning process. In contrast, the plate-shaped part 10 of the first embodiment can enhance the cleaning effect of the plate-shaped part 10 even with normal cleaning power, eliminating or simplifying the pre-cleaning process and the sorting process for insufficiently cleaned products, thereby reducing manufacturing costs and improving productivity and quality.

[0031] Furthermore, the manufacturing method of the plate-shaped component 10 according to the first embodiment provides the following effects and advantages. (3) The method for manufacturing the plate-shaped part 10 of the first embodiment includes forming the plate-shaped part 10 having a bent portion 13 by press working, and washing the plate-shaped part 10 by placing a plurality of plate-shaped parts 10 and a cleaning solution in a container and stirring the cleaning solution. According to this, during the cleaning process, the bent portion 13 provided on the plate-shaped part 10 creates a gap G between multiple plate-shaped parts 10 that serves as a passage for the cleaning liquid. As a result, the first surface 11 of the plate-shaped part 10 comes into contact with the cleaning liquid, increasing the contact area between the plate-shaped part 10 and the cleaning liquid, thereby enhancing the cleaning effect of the plate-shaped part 10. Therefore, the shape of this plate-shaped part 10 allows for the elimination or simplification of the pre-cleaning process and the sorting process for insufficiently cleaned products, thereby reducing manufacturing costs and improving productivity and quality.

[0032] (Second Embodiment) A second embodiment will now be described. The second embodiment is similar to the first embodiment in that the shape of the plate-shaped component 10 has been changed, and other aspects are the same as the first embodiment. Therefore, only the parts that differ from the first embodiment will be described.

[0033] As shown in Figures 9 and 10, the plate-shaped part 10 of the second embodiment has a protrusion 16 projecting in the thickness direction DT from the first surface 11. One or more protrusions 16 are provided on the first surface 11. Although Figure 10 illustrates two protrusions 16, the number of protrusions 16 can be arbitrarily set. The height of the protrusion 16 on the cylindrical part is lower than the height of the cylindrical projection 14 provided on the second surface 12. The shape of the outer edge of the plate-shaped part 10, the protrusion 16, the cylindrical projection 14, and the L-shaped projection 15 are formed by press working. The shapes of the outer edge of the plate-shaped part 10, the protrusion 16, the projection 14, and the L-shaped projection 15 can be arbitrarily set. The projection 14 and the L-shaped projection 15 may also be omitted. An example of the configuration of the plate-shaped part 10 has been described above.

[0034] The manufacturing method for the plate-shaped part 10 in the second embodiment is the same as the manufacturing method for the plate-shaped part 10 in the first embodiment. In the manufacturing method for the plate-shaped part 10, a cleaning process is also performed. In this case, as shown in Figure 11, even when the first surface 11 of a predetermined plate-shaped part 10 faces the first surface 11 of another plate-shaped part 10, the protrusion 16 creates a gap G between the two plate-shaped parts 10 that serves as a passage for the cleaning liquid. As a result, the first surface 11 of the plate-shaped part 10 comes into contact with the cleaning liquid, increasing the contact area between the plate-shaped part 10 and the cleaning liquid, thereby enhancing the cleaning effect of the plate-shaped part 10.

[0035] The plate-shaped component 10 and its manufacturing method according to the second embodiment described above also provide the same effects and advantages as those of the first embodiment.

[0036] (Third embodiment) A third embodiment will now be described. The third embodiment is a modified version of the second embodiment.

[0037] As shown in Figures 12 and 13, the plate-shaped part 10 of the third embodiment also has protrusions 16 projecting in the thickness direction DT from the first surface 11. The protrusions 16 are provided on the first surface 11 in the shape of two rails. The number and shape of the rails can be arbitrarily set. Otherwise, the plate-shaped part 10 of the third embodiment and its manufacturing method are the same as those of the second embodiment.

[0038] The plate-shaped component 10 and its manufacturing method according to the third embodiment described above also provide the same effects and advantages as those of the first embodiment and the like.

[0039] (Fourth Embodiment) A fourth embodiment will now be described. The fourth embodiment is also a modification of the second embodiment.

[0040] As shown in Figure 14, the plate-shaped part 10 of the fourth embodiment also has protrusions 16 projecting in the thickness direction DT from the first surface 11. The protrusions 16 are arranged in a mesh pattern on the first surface 11. Alternatively, it can be said that the protrusions 16 are arranged in a cross pattern on the first surface 11. Otherwise, the plate-shaped part 10 of the fourth embodiment and its manufacturing method are the same as those of the second embodiment.

[0041] The plate-shaped component 10 of the fourth embodiment and its manufacturing method described above also provide the same effects and advantages as those of the first embodiment and the like. Furthermore, the shape of the protrusions 16 described in the second to fourth embodiments is not limited to cylindrical, rail-shaped, mesh-shaped, or cross-shaped, but can be arbitrarily set to, for example, radial, circular, or spiral shapes.

[0042] (Fifth embodiment) Next, we will describe the fifth embodiment. The fifth embodiment is similar to the first embodiment in that the shape of the plate-shaped component 10 has been changed, and other aspects are the same as the first embodiment, so only the parts that differ from the first embodiment will be described.

[0043] As shown in Figures 15 and 16, the plate-shaped part 10 of the fifth embodiment has grooves 17 formed on the first surface 11. The grooves 17 lead to the outer edge of the plate-shaped part 10. In other words, the grooves 17 open to the outer edge of the plate-shaped part 10. Although Figures 15 and 16 illustrate a shape in which the grooves 17 open to both outer edges in the front-rear direction DA of the plate-shaped part 10, the grooves 17 are not limited to this, and may open to only one location on the outer edge of the plate-shaped part 10. Multiple (for example, two) rail-shaped grooves 17 are provided on the first surface 11. The number and shape of the rails can be arbitrarily set. The shape of the outer edge of the plate-shaped part 10, the grooves 17, the cylindrical projections 14, and the L-shaped projections 15 are formed by press working. The shapes of the outer edge of the plate-shaped part 10, the grooves 17, the projections 14, and the L-shaped projections 15 can be arbitrarily set. Furthermore, the projection 14 and the L-shaped projection 15 may be omitted. The above describes an example of the configuration of the plate-shaped component 10.

[0044] The manufacturing method for the plate-shaped part 10 in the fifth embodiment is the same as the manufacturing method for the plate-shaped part 10 in the first embodiment. A cleaning process is also performed in the manufacturing method for the plate-shaped part 10. In this case, as shown in Figure 17, in the plate-shaped part 10 of the fifth embodiment, the first surface 11 of one plate-shaped part 10 may face the first surface 11 of another plate-shaped part 10. In this case, as shown by the arrow WP in Figure 18, the water pressure of the cleaning liquid flowing from the outer edge of the plate-shaped part 10 into the groove 17 acts to pull the multiple plate-shaped parts 10 apart. As a result, the water pressure of the cleaning liquid separates the multiple plate-shaped parts 10, creating a gap G between the multiple plate-shaped parts 10 that serves as a passage for the cleaning liquid. Therefore, the first surface 11 of the plate-shaped part 10 comes into contact with the cleaning liquid, increasing the contact area between the plate-shaped part 10 and the cleaning liquid, thus enhancing the cleaning effect of the plate-shaped part 10.

[0045] The plate-shaped component 10 and its manufacturing method according to the fifth embodiment described above also provide the same effects and advantages as those of the first embodiment.

[0046] (Sixth Embodiment) A sixth embodiment will now be described. The sixth embodiment is a modification of the fifth embodiment.

[0047] As shown in Figure 19, the plate-shaped part 10 of the sixth embodiment also has grooves 17 formed on the first surface 11. The grooves 17 are arranged in a mesh-like pattern on the first surface 11. Alternatively, the grooves 17 can be said to be arranged in a cross pattern on the first surface 11. Otherwise, the plate-shaped part 10 of the sixth embodiment and its manufacturing method are the same as those of the fifth embodiment.

[0048] The plate-shaped component 10 and its manufacturing method according to the fifth embodiment described above also provide the same effects and advantages as those of the first embodiment and the like. Furthermore, the shape of the groove 17 described in the fifth and sixth embodiments is not limited to rail-shaped, mesh-shaped, or cross-shaped, but can be arbitrarily set to, for example, radial, circular, or spiral shapes.

[0049] (Seventh Embodiment) A seventh embodiment will now be described. The seventh embodiment describes an example in which the plate-shaped component 10 described in the above embodiments is used as an armature (i.e., a movable iron piece) in an electromagnetic relay, as an example of an electrical device.

[0050] First, we will describe an example of the configuration and operation of an electromagnetic relay. As shown in Figure 20, the electromagnetic relay 20 includes a case 21, a base 22, an electromagnetic coil 23, a yoke 24, an armature 25, a spring terminal 26, a fixed terminal 27, a first load terminal 28, a second load terminal 29, a first coil terminal 30, and a second coil terminal (not shown).

[0051] The case 21 and base 22 form the outer shell of the electromagnetic relay 20. The electromagnetic coil 23, yoke 24, spring terminal 26, fixed terminal 27, first load terminal 28, second load terminal 29, first coil terminal 30, and second coil terminal are directly or indirectly fixed to the base 22, and the case 21 covers them.

[0052] The electromagnetic coil 23 includes a spool 31, a coil 32, a core 33, and the like. The spool 31 has a cylindrical tube portion 310, a first base portion 311 provided on one side in the direction in which the axis CL of the tube portion 310 extends, and a second base portion 312 provided on the other side in the direction in which the axis CL of the tube portion 310 extends. Hereinafter, the direction in which the axis CL of the tube portion 310 extends will simply be referred to as the "axial direction." The coil 32 is wound around the outside of the tube portion 310 of the spool 31. One end of the wire forming the coil 32 is connected to a first coil terminal 30, and the other end is connected to a second coil terminal (not shown).

[0053] The core 33 is formed in a cylindrical shape from a magnetic material and is inserted inside the cylindrical portion 310 of the spool 31. The portion of the core 33 that protrudes from the cylindrical portion 310 of the spool 31 in one axial direction is fixed to the yoke 24. The yoke 24 is formed in an L-shape from a magnetic material and has a first plate portion 241 fixed to the base 22 and a second plate portion 242 that extends axially from the first plate portion 241. A spring terminal 26 is crimped and fixed to the second plate portion 242. The end of the spring terminal 26 on the base 22 side is connected to the first load terminal 28. The portion of the spring terminal 26 that protrudes from the second plate portion 242 of the yoke 24 on the opposite side from the base 22 is bent so that it faces the core 33. The movement of the spring terminal 26 away from the core 33 (i.e., in the other axial direction) is restricted by a stopper 34. A movable contact 35 is provided at the end of the spring terminal 26 opposite to the second plate portion 242. An armature 25, which is a plate-shaped component 10, is crimped and fixed to the part of the spring terminal 26 facing the core 33. The armature 25 is formed in a plate shape from a magnetic material. The armature 25 has a projection 14 on the side facing away from the electromagnetic coil 23 (i.e., the second surface 12). This projection 14 is used to crimp and fix the spring terminal 26. The armature 25 also has an L-shaped projection 15 on the outer edge of the yoke 24 on the side of the second plate portion 242. The plate-shaped component 10 is provided so as to be able to swing with the contact point between the L-shaped projection 15 and the second plate portion 242 as the pivot point.

[0054] A fixed contact 36 is provided opposite the movable contact 35 on the spring terminal 26. The fixed contact 36 is connected to the fixed terminal 27. The end of the fixed terminal 27 opposite to the fixed contact 36 is connected to the second load terminal 29.

[0055] With the above configuration, when current flows through the first coil terminal 30, the second coil terminal, and the coil 32, the magnetic field generated by the coil 32 causes magnetic flux to flow through the magnetic circuit composed of the core 33, the yoke 24, and the armature 25. As a result, when the armature 25 is magnetically attracted to the core 33 against the elastic force of the spring terminal 26, the movable contact 35 and the fixed contact 36 come into contact. This causes current to flow through the first load terminal 28, the spring terminal 26, the movable contact 35, the fixed contact 36, the fixed terminal 27, and the second load terminal 29. The above describes an example of the configuration and operation of the electromagnetic relay 20. Note that the electromagnetic relay 20 is not limited to the configuration exemplified above and can employ various other configurations.

[0056] The plate-shaped component 10 of the seventh embodiment is used as an armature 25, which is a component of the magnetic circuit of the electromagnetic relay 20. This plate-shaped component 10, as described in the second embodiment, has a protrusion 16 that projects in the thickness direction DT from the surface facing the electromagnetic coil 23 (i.e., the first surface 11). The protrusion 16 is provided at a position offset from the core 33 of the electromagnetic coil 23 (specifically, at a position opposite the second base 312 of the spool 31). The height of the protrusion 16 that projects in the thickness direction DT is lower than the height of the projection 14 provided on the surface facing the opposite side of the electromagnetic coil 23. Therefore, interference between the protrusion 16 and the second base 312 of the spool 31 is prevented.

[0057] Next, the part of the manufacturing method of the electromagnetic relay 20 that relates to the armature 25 will be explained with reference to the flowchart in Figure 21.

[0058] In step S21 of Figure 21, a plate-shaped part 10 (i.e., an armature 25) is formed by press working. Specifically, the shape of the outer edge of the plate-shaped part 10, the convex portion 16, the cylindrical projection 14, and the L-shaped projection 15 are formed by press working.

[0059] Next, in S22, a cleaning process is performed to remove processing oil and other contaminants that adhered to the plate-shaped parts 10 during press working. In the cleaning process, multiple plate-shaped parts 10 and cleaning liquid are placed in a container, and the cleaning liquid is agitated to clean the multiple plate-shaped parts 10. At this time, as explained with reference to Figure 11 in the second embodiment, in the seventh embodiment, even when a predetermined plate-shaped part 10 faces another plate-shaped part 10, the protrusion 16 creates a gap G between the two plate-shaped parts 10 that serves as a passage for the cleaning liquid. Therefore, the first surface 11 of the plate-shaped part 10 comes into contact with the cleaning liquid, increasing the contact area between the plate-shaped part 10 and the cleaning liquid, thereby enhancing the cleaning effect.

[0060] Next, in S23, magnetic annealing is performed by a heating process. Note that if dirt adheres to the product, it will cause problems during magnetic annealing, so it is necessary to thoroughly remove the dirt in the cleaning process before the heating process. Next, in S24, the product assembly process is performed. In the product assembly process, the projection 14 of the plate-shaped part 10 is crimped and fixed to the spring terminal 26 of the electromagnetic relay 20. The spring terminal 26 is crimped and fixed to the second plate portion 242 of the yoke 24, and the first plate portion 241 of the yoke 24 is fixed to the base 22.

[0061] Here, in order to compare it with the plate-shaped part 10 of the seventh embodiment described above, we will now describe the plate-shaped part 100 of the second comparative example. The plate-shaped component 100 of the second comparative example is formed with a flat surface facing the electromagnetic coil 23, just like the one shown in Figures 5 and 6 in the description of the first comparative example. Except for this, the plate-shaped component 100 of the second comparative example and the plate-shaped component 10 of the seventh embodiment have the same shape.

[0062] Next, the part of the manufacturing method for the electromagnetic relay 20 in which the plate-shaped component 100 of the second comparative example is used as the armature 25 will be explained with reference to the flowchart in Figure 22. In step S31 of Figure 22, a plate-shaped part 100 (i.e., the armature 25) is formed by press working. Specifically, the shape of the outer edge of the plate-shaped part 100, the cylindrical projection 14 for fixing to the spring terminal 26, and the L-shaped projection 15 are formed by press working.

[0063] Next, in S32, a preliminary cleaning process is performed. In the preliminary cleaning process, for example, oscillating cleaning is performed in which multiple plate-shaped parts 100 are cleaned by shaking them up and down or left and right. Subsequently, in S33, a normal cleaning process is performed. During the preliminary cleaning process and the normal cleaning process, as shown in Figure 8 in the explanation of the first comparative example, in the second comparative example as well, when a predetermined plate-shaped part 100 and another plate-shaped part 100 face each other, the first surfaces 11 of the two plate-shaped parts 100 may come into close contact with each other. As a result, the contact area between the plate-shaped part 100 and the cleaning liquid is small, and dirt may remain on the plate-shaped part 100.

[0064] Next, in S34, a sorting process is performed. In the sorting process, insufficiently cleaned plate-shaped parts 100 with dirt attached are selected from among the multiple plate-shaped parts 100 and removed. Subsequently, in S35, magnetic annealing is performed by a heating process. In S36, the product assembly process is carried out. In the product assembly process, the plate-shaped part 100 is attached to the spring terminal 26 of the electromagnetic relay 20.

[0065] Compared to the plate-shaped part 100 of the second comparative example, the plate-shaped part 10 of the seventh embodiment provides the following effects and advantages due to its configuration. (1) The plate-shaped component 10 of the seventh embodiment is an armature 25 that is magnetically attracted to the electromagnetic coil 23 by energizing the electromagnetic coil 23 of the electromagnetic relay 20. According to this, the plate-shaped component 10 used as the armature 25 of the electromagnetic relay 20 is a pressed product made of magnetic material. If dirt such as processing oil adheres to the armature 25, magnetic annealing will be insufficient, which may lead to a decrease in the performance or failure of the electromagnetic relay 20. In contrast, the plate-shaped component 10 of the seventh embodiment has a shape that is easy to clean, so the pre-cleaning process and the sorting process for insufficiently cleaned products can be eliminated or simplified, thereby reducing manufacturing costs and improving productivity and quality.

[0066] (2) The plate-shaped component 10 of the seventh embodiment is provided with a projection 14 on the side facing away from the electromagnetic coil 23 for fixing to the spring terminal 26. According to this, during the cleaning process, a gap G is created between the plate-shaped part 10 and another plate-shaped part 10 due to the protrusion 14. Therefore, the cleaning effect of the plate-shaped part 10 can be further enhanced.

[0067] (3) In the seventh embodiment, the height of the protrusion 16 on the side of the plate-shaped component 10 facing the electromagnetic coil 23 is lower than the height of the projection 14 on the side facing away from the electromagnetic coil 23. According to this, the low height of the protrusion 16 of the plate-shaped component 10 prevents interference between the protrusion 16 and the electromagnetic coil 23 when assembled to the electromagnetic relay 20.

[0068] Furthermore, the manufacturing method of the electromagnetic relay 20 described in the seventh embodiment provides the following effects due to its configuration. (4) The manufacturing method of the electromagnetic relay 20 of the seventh embodiment includes forming a plate-shaped part 10 having a protrusion 16 by press working, washing the plate-shaped part 10 by placing the plate-shaped part 10 and a cleaning solution in a container, heating the washed plate-shaped part 10, and assembling the plate-shaped part 10 as an armature 25 to a spring terminal 26. According to this, if the plate-shaped component 10 used in the armature 25 of the electromagnetic relay 20 is contaminated with processing oil or other contaminants, magnetic annealing will be insufficient, which may lead to a decrease in the performance or failure of the electromagnetic relay 20. In contrast, in the manufacturing method of the electromagnetic relay 20 of the seventh embodiment, since the plate-shaped component 10 used in the armature 25 has a shape that is easy to clean, the pre-cleaning and sorting processes can be eliminated or simplified, thereby reducing manufacturing costs and improving productivity and quality.

[0069] (Other embodiments) (1) In the seventh embodiment described above, the plate-shaped component 10 used as the armature 25 of the electromagnetic relay 20 is provided with a protrusion 16 described in the second embodiment on the surface facing the electromagnetic coil 23, but it is not limited to this. The plate-shaped component 10 used as the armature 25 of the electromagnetic relay 20 may also be provided with a bent portion 13 described in the first embodiment. Furthermore, the plate-shaped component 10 used as the armature 25 of the electromagnetic relay 20 may be provided with a protrusion 16 described in the third and fourth embodiments on the surface facing the electromagnetic coil 23, or it may be provided with a groove 17 described in the fifth and sixth embodiments.

[0070] (2) In the seventh embodiment described above, a plate-shaped component 10 used as an armature 25 constituting the magnetic circuit of the electromagnetic relay 20 was described, but the invention is not limited to this. The plate-shaped component 10 can be used as a component in products in various fields, such as automobile parts, electronic equipment, electrical equipment, home appliances, and industrial equipment.

[0071] (3) In the seventh embodiment described above, the plate-shaped component 10 was described as a magnetic material used in a magnetic circuit, but it is not limited to that. The plate-shaped component 10 may be used for purposes other than a magnetic circuit, for example, it may be made of metal, resin, ceramic, etc.

[0072] (4) In the above embodiments, the plate-shaped part 10 has been described as being formed by press working, but it is not limited to this. Various processing methods can be used for the plate-shaped part 10, such as CNC machining.

[0073] (5) In the third to sixth embodiments, the protrusions 16 and grooves 17 are formed in a rail shape, but are not limited to this. The protrusions 16 and grooves 17 can be formed in various shapes, such as circular, elliptical, semicircular, polygonal, or combinations thereof.

[0074] This disclosure is not limited to the embodiments described above, and modifications may be made as appropriate within the scope of the claims. Furthermore, the embodiments and parts thereof are not unrelated to each other and can be combined as appropriate, except in cases where the combination is clearly impossible. In addition, it goes without saying that the elements constituting the embodiments are not necessarily essential, except in cases where they are explicitly stated to be particularly essential or where they are clearly considered essential in principle. Furthermore, in the embodiments, when numerical values ​​such as the number, numerical values, quantities, or ranges of the components of the embodiments are mentioned, the embodiments are not limited to those specific numbers, except in cases where they are explicitly stated to be particularly essential or where they are clearly limited to a specific number in principle. Furthermore, when the shapes, positional relationships, etc., of the components, etc., are mentioned in the embodiments, the embodiments are not limited to those shapes, positional relationships, etc., except in cases where they are explicitly stated to be particularly essential or where they are clearly limited to a specific shape, positional relationship, etc., in principle. [Explanation of symbols]

[0075] 10 Plate-shaped parts 13 Bend section 16 Convex part 17 Groove DT Thickness direction

Claims

1. In plate-shaped parts, A plate-shaped part comprising at least one of the following: a bent portion (13) that bends so as to be convex or concave in the thickness direction (DT), a convex portion (16) that protrudes in the thickness direction from a surface (11) facing one side in the thickness direction, and a groove portion (17) formed on a surface facing one side in the thickness direction and leading to the outer edge of the plate-shaped part.

2. The plate-shaped part according to claim 1, wherein the bent portion is curved or bent so as to be concave from one surface facing in the thickness direction toward the other surface (12).

3. The plate-shaped component according to claim 1, wherein the protrusions are provided on a surface facing one direction in the thickness direction of the plate in a rail-like, mesh-like, cross-like, radial, circular, or spiral shape.

4. The plate-shaped component according to claim 1, wherein the groove portion is provided on a surface facing one direction in the thickness direction of the plate in a rail-like, mesh-like, cross-like, radial, circular, or spiral shape.

5. The plate-shaped part is a pressed product of a magnetic material used in a magnetic circuit, according to any one of claims 1 to 4.

6. The plate-shaped component is an armature (25) that is magnetically attracted to the electromagnetic coil (23) provided in the electromagnetic relay (20) by energizing the electromagnetic coil (23), as described in any one of claims 1 to 4.

7. In a plate-shaped component used as an armature (25) that is magnetically attracted to an electromagnetic coil (23) provided by an electromagnetic relay (20) by energizing the electromagnetic coil (23), A plate-shaped part comprising at least one of the following: a bent portion (13) that bends in the thickness direction such that the side facing the electromagnetic coil becomes concave; a convex portion (16) that protrudes in the thickness direction from the surface facing the electromagnetic coil; and a groove portion (17) formed on the surface facing the electromagnetic coil and leading to the outer edge of the plate-shaped part.

8. The plate-shaped component according to claim 7, further comprising a projection (14) on the side facing away from the electromagnetic coil for fixing to a spring terminal (26).

9. The plate-shaped part according to claim 8, wherein the height of the protrusion in the thickness direction is lower than the height of the projection.

10. In a method for manufacturing plate-shaped parts, Forming a plate-shaped part by press work (S1, S21) having at least one of a bent portion (13) that bends so as to be convex or concave in the thickness direction, a convex portion (16) that protrudes in the thickness direction from a surface facing one side in the thickness direction, and a groove portion (17) formed on a surface facing one side in the thickness direction and leading to the outer edge of the plate-shaped part, A method for manufacturing plate-shaped parts, comprising placing multiple plate-shaped parts and a cleaning solution in a container, and cleaning the multiple plate-shaped parts by stirring the cleaning solution (S2, S22).

11. In a method for manufacturing an electromagnetic relay, A plate-shaped part is formed by press working (S21) having at least one of a bent portion (13) that bends in the thickness direction so that the side facing the electromagnetic coil (23) is concave, a convex portion (16) that protrudes in the thickness direction from the surface facing the electromagnetic coil, and a groove portion (17) formed on the surface facing the electromagnetic coil and leading to the outer edge of the plate-shaped part. The process involves placing multiple plate-shaped parts and a cleaning solution into a container, stirring the cleaning solution, and cleaning the multiple plate-shaped parts (S22). Heating the washed plate-shaped parts (S23), A method for manufacturing an electromagnetic relay, comprising assembling a plate-shaped component to a spring terminal (26) as an armature (25) that is magnetically attracted to the electromagnetic coil by energizing the electromagnetic coil (S24).

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