Electromagnetic relays

Abstract

To provide an electromagnetic relay that prevents poor contact conductivity, simplifies the configuration, and allows for a smaller size. [Solution] The spool 3 has a cylindrical portion 30 on which the coil 4 is wound, a first spool base 31 provided on one side in the axial direction, and a second spool base 32 provided on the other side in the axial direction. The fixed terminal 5 has a fixed contact 51 in the region opposite to the coil 4 relative to the first spool base 31. The movable terminal 9 has a movable contact 91 that contacts and separates from the fixed contact 51. The case 10 covers the fixed contact 51 and the movable contact 91 and fits over the first spool base 31, housing the fixed contact 51 and the movable contact 91 in a sealed space S formed together with the first spool base 31, and exposing the coil 4 to the air outside the sealed space S. The sealing member 11 seals the gap between the first spool base 31 and the case 10.

Description

Technical Field

[0001] The present disclosure relates to an electromagnetic relay.

Background Art

[0002] Conventionally, an electromagnetic relay is known that opens and closes an electric circuit by controlling energization to a coil of an electromagnet to contact and separate a fixed contact and a movable contact (hereinafter referred to as "contact"). The electromagnetic relay has a problem that when water vapor evaporated from the film of the coil condenses on the contact after the energization of the coil is stopped and the moisture freezes, conduction failure occurs.

[0003] The electromagnetic relay described in the first embodiment of Patent Document 1 has a configuration in which the contact is accommodated inside the case and the coil is exposed outside the case. Further, the electromagnetic relay described in the second embodiment of Patent Document 1 includes a partition wall that partitions a space for accommodating the contact and a space for accommodating the coil inside the case. Thereby, in the electromagnetic relay described in each embodiment of Patent Document 1, water vapor evaporated from the film of the coil during energization of the coil is suppressed from entering the space for accommodating the contact.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the electromagnetic relay described in the first embodiment of Patent Document 1, the opening of the case only touches the base member, and the inside of the case is not a completely sealed space. Therefore, in this electromagnetic relay, there is a risk that water vapor may enter the inside of the case through the gap between the opening of the case and the base member, and when the moisture condensed on the contact freezes, conduction failure of the contact may occur.

[0006] In the electromagnetic relay described in the second embodiment of Patent Document 1, the opening and partition wall of the case are only in contact with the base member, and the space housing the contacts is not a completely sealed space. Therefore, in this electromagnetic relay, water vapor may enter the space housing the contacts from the space housing the coil, and if the moisture that condenses on the contacts freezes, there is a risk of poor conductivity at the contacts.

[0007] Furthermore, in the electromagnetic relay described in the first embodiment of Patent Document 1, the coil and the spool on which the coil is wound are all located outside the case. Specifically, the spool has a cylindrical portion around which the coil is wound, and plate-shaped bases provided on one and the other axial sides of the cylindrical portion. The bases of the spool and the case are arranged to overlap.

[0008] Furthermore, in the electromagnetic relay described in the second embodiment of Patent Document 1, the base of the spool and the partition wall are arranged to overlap. As a result, the electromagnetic relays described in each embodiment of Patent Document 1 have a complex structure and are larger in size due to the thickness of the base of the spool.

[0009] In view of the above points, this disclosure aims to provide an electromagnetic relay that prevents poor conductivity at the contacts, simplifies the configuration, and can be made smaller. [Means for solving the problem]

[0010] According to one aspect of this disclosure, an electromagnetic relay is, A magnetic core (2), A spool (3) having a cylindrical portion (30) into which a core is inserted, a first spool base (31) provided on one side of the cylindrical portion in the axial direction, and a second spool base (32) provided on the other side of the cylindrical portion in the axial direction, A coil (4) is wound around the outside of the cylindrical part between the base of the first spool and the base of the second spool, A fixed terminal (5) having a fixed contact (51) in the region opposite to the coil relative to the base of the first spool, An armature (8) is provided in the region opposite to the coil relative to the base of the first spool and operates by the magnetic field generated by the coil, A movable terminal (9) having a movable contact (91) that moves in conjunction with the movement of the armature and makes contact with and separates from a fixed contact, A case (10) that covers the fixed contact and the movable contact and fits over the first spool base, housing the fixed contact and the movable contact in a sealed space (S) formed together with the first spool base, and exposing the coil to the air outside the sealed space, It includes a sealing member (11) that seals the gap between the first spool base and the case.

[0011] According to this design, water vapor evaporated from the coil's coating when the coil is energized is released into the air outside the sealed space formed by the first spool base, the case, and the sealing member, without entering the sealed space. Therefore, this electromagnetic relay can prevent poor contact due to condensation and freezing after the coil is de-energized. Furthermore, this electromagnetic relay forms a sealed space for housing the fixed contact and the movable contact using the first spool base, the case, and the sealing member. Therefore, by not having a configuration in which multiple components overlap as in Patent Document 1, this electromagnetic relay simplifies the structure of the electromagnetic relay, reduces the amount of material used to form the case, and further reduces the axial size of the cylindrical part of the electromagnetic relay.

[0012] The reference numerals in parentheses attached to each component indicate an example of the correspondence between that component and the specific components described in the embodiments described later. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view of an electromagnetic relay according to the first embodiment. [Figure 2] This is a front view of the electromagnetic relay in direction II of Figure 1. [Figure 3] This is a side view of the electromagnetic relay in direction III of Figure 1. [Figure 4]It is a bottom view of the electromagnetic relay in the IV direction of FIG. 1. [Figure 5] It is a cross-sectional view of the electromagnetic relay along the V-V line of FIG. 2. [Figure 6] It is an explanatory diagram for explaining the manufacturing method of the electromagnetic relay. [Figure 7] It is an explanatory diagram for explaining the manufacturing method of the electromagnetic relay following FIG. 6. [Figure 8] It is an explanatory diagram for explaining the manufacturing method of the electromagnetic relay following FIG. 7. [Figure 9] It is an explanatory diagram for explaining the manufacturing method of the electromagnetic relay following FIG. 8. [Figure 10] It is a perspective view of the electromagnetic relay according to the second embodiment. [Figure 11] It is a front view of the electromagnetic relay in the XI direction of FIG. 10. [Figure 12] It is a side view of the electromagnetic relay in the XII direction of FIG. 10. [Figure 13] It is a bottom view of the electromagnetic relay in the XIII direction of FIG. 10. [Figure 14] It is a cross-sectional view of the electromagnetic relay along the XIV-XIV line of FIG. 11. [Figure 15] It is an explanatory diagram for explaining the manufacturing method of the electromagnetic relay.

Embodiments for Carrying out the Invention

[0014] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, parts that are identical or equivalent to each other are denoted by the same reference numerals, and the description thereof will be omitted. In the present disclosure, terms such as "upper", "lower", and "vertical" are used for convenience of explanation and do not limit the mounting direction of the electromagnetic relay.

[0015] (First Embodiment) A first embodiment will now be described. As shown in Figures 1 to 5, the electromagnetic relay 1 of the first embodiment is a mechanical relay that can be mounted on a printed circuit board. The electromagnetic relay 1 includes a core 2, a spool 3, a coil 4, a fixed terminal 5, a yoke 6, a plate member 7, an armature 8, a movable terminal 9, a case 10, and a sealing member 11, etc.

[0016] Core 2 is formed in a cylindrical shape from a magnetic material such as iron. Core 2 is inserted inside the cylindrical portion 30 of the spool 3 and positioned in the center of the coil 4. Hereinafter, the axis CL of Core 2 will be simply referred to as "axis CL," and the direction in which the axis CL extends will be referred to as the "axial direction." Note that the axis CL of Core 2 coincides with the axis CL of the cylindrical portion 30 of the spool 3. In this embodiment, with respect to the center of Core 2, the side on which the contacts of the fixed terminal 5 and the movable terminal 9 (i.e., the fixed contact 51 and the movable contact 91) are provided will be described as the "one axial side," and the opposite side will be described as the "other axial side."

[0017] The spool 3 has a cylindrical portion 30, a first spool base 31, and a second spool base 32, and is integrally formed from an insulator such as resin. The core 2, which is inserted inside the cylindrical portion 30, protrudes from the cylindrical portion 30 to one side and the other side in the axial direction. The first spool base 31 is formed in a plate shape that expands perpendicular to the axial direction and is provided on one side in the axial direction. The second spool base 32 is formed in a plate shape that expands perpendicular to the axial direction and is provided on the other side in the axial direction. The second spool base 32 is formed with a plate thickness in the axial direction greater than that of the first spool base 31 and has a yoke insertion hole 33 into which a part of the yoke 6 is inserted.

[0018] Coil 4 consists of a coil wire, with an insulating film covering the outside of the conductor, wound around the outside of the cylindrical portion 30 between the first spool base 31 and the second spool base 32. One end of the coil wire is electrically connected to the first coil terminal 41, and the other end of the coil wire is electrically connected to the second coil terminal 42. The first coil terminal 41 and the second coil terminal 42 are press-fitted and fixed into holes 34 and 35 provided in the second spool base 32. The axial ends 43 and 44 of the first coil terminal 41 and the second coil terminal 42 extend outward from the second spool base 32.

[0019] The fixed terminal 5 is formed of a conductor and bent into an L-shape. The portion of the fixed terminal 5 that extends in the axial direction is called the fixed terminal base 52, and the portion that extends perpendicular to the axial direction is called the extension portion 53. A part of the fixed terminal base 52 is press-fitted and fixed into a hole 36 provided in the second spool base 32. The other axial end 54 of the fixed terminal base 52 extends outward from the second spool base 32. The portion of the fixed terminal base 52 on one axial side is inserted through a hole 37 provided in the first spool base 31. The extension portion 53 of the fixed terminal 5 is provided parallel to the first spool base 31. A fixed contact 51 is provided on the extension portion 53 of the fixed terminal 5. The fixed contact 51 is provided in the region of the first spool base 31 opposite to the coil 4.

[0020] The yoke 6 is made of a magnetic material and bent into an L-shape. The portion of the yoke 6 that extends perpendicular to the axial direction is called the bottom yoke portion 61, and the portion that extends axially from the bottom yoke portion 61 is called the vertical yoke portion 62. The bottom yoke portion 61 is inserted into the yoke insertion hole 33 of the second spool base 32 and fixed to the second spool base 32. The end portion 21 of the core 2 that protrudes axially from the second spool base 32 is inserted into the hole 63 of the bottom yoke portion 61 and crimped and fixed. The vertical yoke portion 62 is provided on the opposite side of the coil 4 from the fixing terminal 5.

[0021] A plate member 7 is provided between the vertical yoke portion 62 and the coil 4. The plate member 7 has a portion on one axial side that is in contact with or close to the first spool base portion 31, and a portion on the other axial side that is in contact with or close to the second spool base portion 32.

[0022] The armature 8 is formed from a magnetic material and is located in the region opposite to the coil 4 relative to the first spool base 31. The portion of the armature 8 facing the vertical yoke 62 abuts against one end of the vertical yoke 62 on the axial side. The armature 8 is axially pivotable, with the point of contact with the vertical yoke 62 as the pivot point. The portion of the armature 8 opposite to the vertical yoke 62 faces a portion 22 of the core 2 that protrudes from the first spool base 31 on one axial side. The core 2, yoke 6, and armature 8 constitute a magnetic circuit through which the magnetic flux of the magnetic field generated by the coil 4 flows. The armature 8 operates in response to the magnetic field generated by the coil 4, making contact with and separating from the core 2.

[0023] The movable terminal 9 has a connecting terminal 92 and a spring terminal 93. Both the connecting terminal 92 and the spring terminal 93 are made of conductors and are connected by soldering or welding. A portion of the connecting terminal 92 is fixed to the second spool base 32. The other axial end 94 of the connecting terminal 92 extends outward from the second spool base 32.

[0024] The spring terminal 93 is crimped and fixed to a projection 64 on the vertical yoke portion 62. The portion of the spring terminal 93 that is fixed to the projection 64 on the vertical yoke portion 62 is called the "terminal fixing portion 95". The portion of the spring terminal 93 that protrudes from the vertical yoke portion 62 in one axial direction is bent so as to face the core 2 and the fixed contact 51. The spring terminal 93 is restricted from moving away from the core 2 (i.e., in one axial direction) by a stopper 96. A movable contact 91 is provided on the portion of the spring terminal 93 that faces the fixed contact 51. In addition, the armature 8 is crimped and fixed to the portion of the spring terminal 93 that faces the first spool base 31 and the core 2. The spring terminal 93 moves in conjunction with the movement of the armature 8. The stopper 96 is inserted through a hole 38 provided in the first spool base 31, extends axially, and is press-fitted and fixed into a hole 39 provided in the second spool base 32.

[0025] With the above configuration, when current is supplied to coil 4 from the first coil terminal 41 and the second coil terminal 42, the magnetic field generated by coil 4 causes magnetic flux to flow through the magnetic circuit composed of core 2, yoke 6, and armature 8. As a result, the armature 8 is magnetically attracted to core 2 against the elastic force of spring terminal 93, and the movable contact 91 and fixed contact 51 come into contact. Therefore, the circuit composed of fixed terminal 5, fixed contact 51, movable contact 91, and movable terminal 9 closes, and current can flow through that circuit.

[0026] Conversely, when the current from the first coil terminal 41 and the second coil terminal 42 to coil 4 is stopped, the magnetic field of coil 4 disappears. As a result, the elastic force of the spring terminal 93 causes the armature 8 to separate from the core 2, and the movable contact 91 and the fixed contact 51 separate. Consequently, the circuit consisting of the fixed terminal 5, the fixed contact 51, the movable contact 91, and the movable terminal 9 opens, and the flow of current in the circuit is interrupted.

[0027] Case 10 has an upper case portion 12, a vertical case portion 13, and a lower case portion 14. In Figures 1, 3, and 4, for the sake of explanation, the boundary between the upper case portion 12 and the vertical case portion 13 is shown by a dashed line 15, and the boundary between the vertical case portion 13 and the lower case portion 14 is shown by a dashed line 16. However, the upper case portion 12, the vertical case portion 13, and the lower case portion 14 are integrally formed from, for example, resin.

[0028] The upper case portion 12 covers the fixed contact 51, the movable contact 91, the armature 8, etc., and overlaps the first spool base 31, forming a sealed space S together with the first spool base 31. Hereinafter, the region of the sealed space S formed by the upper case portion 12 and the first spool base 31 may be referred to as the "first sealed space S1". The first sealed space S1 houses the fixed contact 51, the movable contact 91, the armature 8, a part of the fixed terminal 5, a part of the spring terminal 93, and a portion 22 of the core 2 that protrudes axially from the first spool base 31.

[0029] The vertical case portion 13 covers the terminal fixing portion 95 and the vertical yoke portion 62 and overlaps the plate member 7, forming a sealed space S together with the plate member 7. Hereinafter, the region of the sealed space S formed by the vertical case portion 13 and the plate member 7 may be referred to as the "second sealed space S2". The terminal fixing portion 95 and the vertical yoke portion 62 are housed in the second sealed space S2. The first sealed space S1 and the second sealed space S2 are in communication and form a single continuous sealed space S. The lower case portion 14 surrounds the second spool base portion 32 and the bottom yoke portion 61.

[0030] The sealing member 11 is provided at locations where the case 10, the first spool base 31, the second spool base 32, and the plate member 7 are in contact with or adjacent to each other. The sealing member 11 is also provided on the side opposite to the coil 4 relative to the second spool base 32 and the bottom yoke portion 61. In Figures 1, 2, and 4, hatching is applied to the sealing member 11 for clarity, although it is not a cross-section, for the sake of explanation.

[0031] Of the sealing members 11, the one provided at the point where the first spool base 31 and the upper case portion 12 are in contact or adjacent is called the upper sealing portion 111. The upper sealing portion 111 seals the gap between the first spool base 31 and the upper case portion 12, preventing outside air from the sealed space S from entering the first sealed space S1. The upper sealing portion 111 isolates the fixed contact 51 and the movable contact 91 from the outside air of the sealed space S.

[0032] Of the sealing members 11, those provided at locations where the plate member 7 and the vertical case portion 13 are in contact or adjacent are called vertical sealing portions 112. The vertical sealing portions 112 seal the gap between the plate member 7 and the vertical case portion 13, preventing outside air from the sealed space S from entering the second sealed space S2. The vertical sealing portions 112 also isolate the terminal fixing portion 95 and the vertical yoke portion 62 from the outside air of the sealed space S.

[0033] Of the sealing members 11, the one provided at the point where the second spool base 32 and the lower case portion 14 are in contact or adjacent is called the lower sealing portion 113. The lower sealing portion 113 seals the gap between the second spool base 32 and the lower case portion 14. Of the sealing members 11, the one that seals the side of the second spool base 32 and the bottom yoke portion 61 opposite to the coil 4 is called the bottom sealing portion 114. The lower sealing portion 113 and the bottom sealing portion 114 prevent outside air from the sealed space S from entering the yoke insertion hole 33, etc. The lower sealing portion 113 and the bottom sealing portion 114 block the bottom yoke portion 61, etc. from outside air in the sealed space S.

[0034] Although not limited thereto, the sealing member 11 may be provided in the first spool base 31 in the gap between the hole 37 through which the fixing terminal 5 is inserted and the fixing terminal 5, and in the gap between the hole 38 through which the stopper 96 is inserted and the stopper 96. Also, although not limited thereto, the sealing member 11 may be provided in the second spool base 32 in the gap between the hole 36 into which the fixing terminal 5 is press-fitted and the fixing terminal 5, in the gap between the hole 39 into which the stopper 96 is press-fitted and the stopper 96, and in the gap between the holes 34 and 35 into which the first and second coil terminals 41 and 42 are press-fitted and the first and second coil terminals 41 and 42.

[0035] The case 10, the first spool base 31, the plate member 7, the second spool base 32, and the sealing member 11 form a single sealed space S. By providing the sealing member 11 in the gaps between each member, the sealed space S is completely isolated from the air outside the sealed space S. The fixed contact 51, the movable contact 91, the terminal fixing part 95, and the yoke 6 are housed in this sealed space S. The coil 4 is exposed to the air outside the sealed space S. Therefore, even if the coil 4 heats up due to current flow and water vapor evaporates from the coating of the coil 4, the electromagnetic relay 1 can prevent that water vapor from entering the sealed space S.

[0036] Next, an example of a method for manufacturing the electromagnetic relay 1 of the first embodiment will be described. First, as shown in Figure 6, a spool 3 with coiled wire wound around it is prepared. The bottom yoke portion 61 of the yoke 6 is inserted into the yoke insertion hole 33 of the spool 3, and then the core 2 is inserted into the cylindrical portion 30 of the spool 3. The other end 21 of the core 2 on the axial side is then crimped into the hole 63 of the bottom yoke portion 61.

[0037] Next, as shown in Figure 7, the plate member 7 is temporarily fixed to the first spool base 31 and the second spool base 32. At least one of the first spool base 31 and the second spool base 32 is configured to allow the plate member 7 to be temporarily fixed.

[0038] Next, as shown in Figure 8, the fixed terminal 5 is press-fitted and fixed to the second spool base 32. The movable terminal 9, to which the armature 8 is fixed, is crimped and fixed to the projection 64 of the vertical yoke portion 62. The stopper 96 is also press-fitted and fixed to the second spool base 32.

[0039] Subsequently, as shown by arrow M1 in Figure 9, the case 10 is placed over the intermediate component, which has the yoke 6, fixed terminal 5, and movable terminal 9 fixed to the spool 3.

[0040] Next, as shown in Figures 1 to 5, sealing members 11 (i.e., upper sealing portion 111, vertical sealing portion 112, and lower sealing portion 113) are provided at locations where the case 10, the first spool base 31, the second spool base 32, and the plate member 7 are in contact with or adjacent to each other. In addition, sealing members 11 (i.e., bottom sealing portion 114) are also provided on the side of the second spool base 32 and the bottom yoke portion 61 opposite to the coil 4.

[0041] The electromagnetic relay 1 of the first embodiment described above provides the following effects. (1) The case 10 of the electromagnetic relay 1 of the first embodiment covers the fixed contact 51 and the movable contact 91 and fits over the first spool base 31, forming a sealed space S together with the first spool base 31. The case 10 houses the fixed contact 51 and the movable contact 91 in the sealed space S, and exposes the coil 4 to the air outside the sealed space S. The sealing member 11 seals the gap between the first spool base 31 and the case 10. According to this, the water vapor evaporated from the coating of the coil 4 when the coil 4 is energized is released into the air outside the first sealed space S1 formed by the first spool base 31, the case 10, and the sealing member 11, without entering the first sealed space S1. Therefore, this electromagnetic relay 1 can prevent poor contact conductivity due to condensation and freezing after the energization of the coil 4 is stopped. Furthermore, this electromagnetic relay 1 forms a first sealed space S1 that houses the fixed contact 51 and the movable contact 91 using the first spool base 31, the case 10, and the sealing member 11. Therefore, by not having a configuration in which multiple members overlap as in Patent Document 1, this electromagnetic relay 1 simplifies the structure of the electromagnetic relay 1, reduces the amount of material used to form the case 10, and further reduces the axial size of the electromagnetic relay 1.

[0042] (2) The vertical case portion 13 of the electromagnetic relay 1 of the first embodiment covers the terminal fixing portion 95 and the vertical yoke portion 62, and overlaps the plate member 7 which is positioned between the vertical yoke portion 62 and the coil 4, thereby forming a second sealed space S2 together with the plate member 7. The vertical case portion 13 houses the terminal fixing portion 95 and the vertical yoke portion 62 in the second sealed space S2, and exposes the coil 4 to the air outside the second sealed space S2. The vertical seal portion 112 seals the gap between the plate member 7 and the vertical case portion 13. According to this, the terminal fixing portion 95 and the vertical yoke portion 62 are housed in the second sealed space S2 formed by the vertical case portion 13, the plate member 7, and the vertical seal portion 112. Therefore, in the sealed space S, it is possible to prevent water vapor from entering the area where the fixed contact 51 and the movable contact 91 are housed (i.e., the first sealed space S1) via the area where the terminal fixing portion 95 and the vertical yoke portion 62 are housed (i.e., the second sealed space S2).

[0043] (3) In the first embodiment, the electromagnetic relay 1 has a first sealed space S1 in which the fixed contact 51 and the movable contact 91 are housed, and a second sealed space S2 in which the terminal fixing part 95 and the vertical yoke part 62 are housed, which are in communication with each other, forming one continuous sealed space S. According to this, the configuration of Case 10 can be simplified.

[0044] (4) The lower case portion 14 of the electromagnetic relay 1 of the first embodiment surrounds the second spool base portion 32 and the bottom yoke portion 61. The lower seal portion 113 seals the gap between the second spool base portion 32 and the lower case portion 14, and the bottom seal portion 114 seals the side of the second spool base portion 32 and the bottom yoke portion 61 that is opposite to the coil 4. According to this, the bottom yoke portion 61 is housed in the region formed by the lower case portion 14, the second spool base portion 32, the lower seal portion 113, and the bottom seal portion 114 (i.e., the third sealed space S3). Therefore, in the sealed space S, it is possible to prevent water vapor from entering the first sealed space S1 via the second sealed space S2 from the region where the bottom yoke portion 61 is housed (i.e., the third sealed space S3).

[0045] (Second Embodiment) A second embodiment will now be described. The second embodiment is a modification of the configuration of the electromagnetic relay 1 compared to the first embodiment, and is otherwise the same as the first embodiment. Therefore, only the parts that differ from the first embodiment will be described.

[0046] As shown in Figures 10 to 14, the electromagnetic relay 1 of the second embodiment is a mechanical relay that can be mounted in a vehicle's relay box or the like. The electromagnetic relay 1 of the second embodiment includes a core 2, a spool 3, a base plate 71, a coil 4, a yoke 6, a fixed terminal 5, an armature 8, a movable terminal 9, a first case 101, a second case 102, and a sealing member 11, etc.

[0047] In the second embodiment as well, the side of the core 2 where the contacts of the fixed terminal 5 and the movable terminal 9 (i.e., the fixed contact 51 and the movable contact 91) are provided will be described as the "one axial side," and the opposite side will be described as the "other axial side." However, in the second embodiment, the one axial side is the bottom side of the drawing, and the other axial side is the top side of the drawing.

[0048] The spool 3 has a cylindrical portion 30, a first spool base 31, and a second spool base 32, and is integrally formed from an insulator such as resin. The first spool base 31 is formed in a plate shape that extends perpendicular to the axial direction and is provided on one side in the axial direction. The second spool base 32 is formed in a plate shape that extends perpendicular to the axial direction and is provided on the other side in the axial direction.

[0049] A base plate 71 is provided on one axial side of the first spool base 31, at a predetermined distance from the first spool base 31. A fixed contact 51, a movable contact 91, an armature 8, and the like are provided in the region between the first spool base 31 and the base plate 71.

[0050] Coil 4 consists of a coil wire, with an insulating coating on the outside of the conductor, wound around the outside of the cylindrical portion 30 between the first spool base 31 and the second spool base 32. One end of the coil wire is electrically connected to the first coil terminal 41, and the other end of the coil wire is electrically connected to the second coil terminal 42. The first coil terminal 41 and the second coil terminal 42 are press-fitted and fixed to the base plate 71. One axial end of the first coil terminal 41 and the second coil terminal 42 extends outward from the base plate 71.

[0051] The yoke 6 is made of a magnetic material and bent into a U-shape. The yoke 6 is also called the stationary. The portion of the yoke 6 that extends perpendicular to the axial direction is called the bottom yoke portion 61. The portion that extends axially from one side of the bottom yoke portion 61 is called the first vertical yoke portion 65, and the portion that extends axially from the other side of the bottom yoke portion 61 is called the second vertical yoke portion 66. The bottom yoke portion 61 is positioned to overlap with the second spool base portion 32. The end portion 21 of the core 2 that protrudes axially from the second spool base portion 32 is inserted into the hole 63 of the bottom yoke portion 61 and crimped into place. The first vertical yoke portion 65 is inserted through the hole 301 provided in the first spool base portion 31 and press-fitted into place in the base plate 71. The second vertical yoke portion 66 passes outside the first spool base portion 31 and press-fitted into place in the base plate 71.

[0052] The portion of the fixed terminal 5 that extends perpendicular to the axial direction is called the extension portion 53, and the portion that extends in the axial direction is called the fixed terminal base portion 52. Although not shown in the illustration, the extension portion 53 and the fixed terminal base portion 52 are connected on the near side of the page in Figure 5. A fixed contact 51 is provided on the extension portion 53. The fixed contact 51 is provided in the region opposite to the coil 4 relative to the first spool base portion 31 (i.e., the region between the first spool base portion 31 and the base plate 71). A part of the fixed terminal base portion 52 is press-fitted and fixed to the base plate 71. One end portion 54 of the fixed terminal base portion 52 on the axial side extends outward from the base plate 71.

[0053] The armature 8 is located in the region opposite to the coil 4 relative to the first spool base 31 (i.e., the region between the first spool base 31 and the base plate 71). The portion of the armature 8 facing the second vertical yoke 66 abuts against one axial end of the second vertical yoke 66. The armature 8 is axially pivotable, with the point of contact with the second vertical yoke 66 as the pivot point. The portion of the armature 8 opposite to the second vertical yoke 66 faces a portion 22 of the core 2 that protrudes axially from the first spool base 31. The armature 8 operates in response to the magnetic field generated by the coil 4, making contact with and separating from the core 2.

[0054] The movable terminal 9 has a connecting terminal 92 and a spring terminal 93. Both the connecting terminal 92 and the spring terminal 93 are made of conductors and are electrically connected on the front side of the page in Figure 5. A portion of the connecting terminal 92 is fixed to the base plate 71. One end 94 of the connecting terminal 92 on the axial side extends outward from the base plate 71.

[0055] The spring terminal 93 is crimped and fixed to a projection 64 on the second vertical yoke portion 66. The portion of the spring terminal 93 that is fixed to the projection 64 on the second vertical yoke portion 66 is called the "terminal fixing portion 95". The portion of the spring terminal 93 that protrudes from the second vertical yoke portion 66 in one axial direction is bent so as to face the core 2 and the fixed contact 51. The spring terminal 93 is restricted from moving away from the core 2 (i.e., in one axial direction) by a stopper 96. A movable contact 91 is provided on the portion of the spring terminal 93 that faces the fixed contact 51. The armature 8 is fixed to the portion of the spring terminal 93 that faces the core 2 and the first spool base portion 31. The spring terminal 93 moves in conjunction with the movement of the armature 8. The stopper 96 is press-fitted and fixed to the base plate 71.

[0056] The first case 101 covers the base plate 71, the fixed contact 51, the movable contact 91, the armature 8, etc., and fits over the first spool base 31, forming a sealed space S together with the first spool base 31. Hereinafter, the region of the sealed space S formed by the upper case portion 12 and the first spool base 31 may be referred to as the "first sealed space S1". The first sealed space S1 houses the fixed contact 51, the movable contact 91, the armature 8, part of the fixed terminal 5, part of the spring terminal 93, and part 22 of the core 2 that protrudes axially from the first spool base 31.

[0057] The second case 102 covers the terminal fixing portion 95 and overlaps the second vertical yoke portion 66, forming a sealed space S together with the second vertical yoke portion 66. Hereinafter, the region of the sealed space S formed by the second case 102 and the second vertical yoke portion 66 may be referred to as the "second sealed space S2". The terminal fixing portion 95 and the like are housed in the second sealed space S2. The first sealed space S1 and the second sealed space S2 are in communication with each other, forming a single continuous sealed space S.

[0058] The sealing member 11 is provided at locations where the first case 101, the first spool base 31, the second vertical yoke 66, and the second case 102 are in contact with or adjacent to each other. In Figures 10 to 13, hatching is applied to the sealing member 11, although it is not a cross-section, for the sake of clarity in the explanation.

[0059] Of the sealing members 11, those provided at the locations where the first spool base 31 and the first case 101 are in contact or adjacent, and where the first spool base 31 and the second vertical yoke portion 66 are in contact or adjacent, are called upper sealing portions 111. The upper sealing portions 111 seal the gaps between the first spool base 31 and the first case 101, and the gaps between the first spool base 31 and the second vertical yoke portion 66, preventing outside air from the sealed space S from entering the first sealed space S1. The upper sealing portions 111 isolate the fixed contact 51 and the movable contact 91 from outside air in the sealed space S.

[0060] Of the sealing members 11, the portion provided where the second vertical yoke portion 66 and the second case 102 are in contact or adjacent is called the vertical sealing portion 112. The vertical sealing portion 112 prevents air from outside the sealed space S from entering the second sealed space S2. The vertical sealing portion 112 also blocks the terminal fixing portion 95 and the like from the air outside the sealed space S. Although not limited thereto, the sealing member 11 may be provided in the gap between the first case 101 and the second case 102.

[0061] Furthermore, although not limited, the sealing member 11 may be provided in the first spool base 31 in the gap between the hole 301 through which the first vertical yoke portion 65 is inserted and the first vertical yoke portion 65, and in the gap between the hole 303 through which the first and second coil terminals 41 and 42 are inserted and the first and second coil terminals 41 and 42. Furthermore, although not limited, the sealing member 11 may be provided in the first case 101 in the gap between the hole 103 through which the fixed terminal 5 is inserted and the fixed terminal 5, in the gap between the hole 104 through which the connecting terminal 92 is inserted and the connecting terminal 92, and in the gap between the holes 105 and 106 through which the first and second coil terminals 41 and 42 are inserted and the first and second coil terminals 41 and 42.

[0062] The first case 101, the first spool base 31, the second vertical yoke 66, and the second case 102 form a single sealed space S. By providing sealing members 11 in the gaps between each component, the sealed space S is completely isolated from the air outside the sealed space S. The fixed contact 51, the movable contact 91, and the terminal fixing part 95 are housed in the sealed space S. The coil 4 is exposed to the air outside the sealed space S. Therefore, even if the coil 4 heats up due to current flow and water vapor evaporates from the coating of the coil 4, the electromagnetic relay 1 can prevent that water vapor from entering the sealed space S.

[0063] Next, an example of a method for manufacturing the electromagnetic relay 1 of the second embodiment will be described. As shown by arrows M2 and M3 in Figure 15, the first case 101 and the second case 102 are placed over the intermediate components, which consist of a spool 3, coil 4, core 2, yoke 6, fixed terminal 5, armature 8, movable terminal 9, etc., fixed to the base plate 71.

[0064] Next, as shown in Figures 10 to 14, sealing members 11 (i.e., upper sealing portion 111 and vertical sealing portion 112, etc.) are provided at locations where the first case 101, the first spool base 31, the second vertical yoke portion 66, and the second case 102 are in contact with or adjacent to each other.

[0065] The electromagnetic relay 1 of the second embodiment described above provides the following effects. (1) The first case 101 of the electromagnetic relay 1 of the first embodiment covers the fixed contact 51 and the movable contact 91 and fits over the first spool base 31, forming a sealed space S together with the first spool base 31. The second case 102 covers the terminal fixing portion 95 and fits over the second vertical yoke portion 66, forming a sealed space S together with the second vertical yoke portion 66. The first case 101, the second case 102, the first spool base 31, and the second vertical yoke portion 66 house the fixed contact 51 and the movable contact 91 in the sealed space S, and expose the coil 4 to the air outside the sealed space S. The sealing member 11 seals the gap between the first case 101 and the first spool base 31, and the gap between the second case 102 and the second vertical yoke portion 66. According to this, the water vapor evaporated from the coating of coil 4 when current is supplied to coil 4 is released into the air outside the sealed space S without entering the sealed space S. Therefore, this electromagnetic relay 1 can prevent poor contact due to condensation and freezing after the current to coil 4 is stopped. Furthermore, this electromagnetic relay 1 forms a sealed space S with the first case 101, the second case 102, the first spool base 31, the second vertical yoke 66, and the sealing member 11. Therefore, by not having a configuration in which multiple members overlap as in Patent Document 1, this electromagnetic relay 1 simplifies the structure of the electromagnetic relay 1 and reduces the amount of material used to form the first case 101 and the second case 102. Moreover, this electromagnetic relay 1 can be made smaller in the axial direction and in the direction perpendicular to the axis CL.

[0066] (2) In the electromagnetic relay 1 of the second embodiment, a first sealed space S1 in which a fixed contact 51 and a movable contact 91 are housed and a second sealed space S2 in which a terminal fixing part 95 is housed are in communication, forming one continuous sealed space S. According to this, the configuration of Case 10 can be simplified.

[0067] (Other embodiments) (1) In the first embodiment described above, a mechanical relay that can be mounted on a printed circuit board was used as an example, and in the second embodiment, a mechanical relay that can be mounted in a vehicle relay box was used as an example. However, the electromagnetic relay 1 is not limited to these and can be used for a variety of purposes.

[0068] (2) In the first embodiment described above, the case 10 was described as having an upper case portion 12, a vertical case portion 13, and a lower case portion 14 as an integral part. However, it is not limited to this, and for example, the upper case portion 12, the vertical case portion 13, and the lower case portion 14 may each be made of separate components. Alternatively, the case 10 may consist only of the upper case portion 12. Or, the case 10 may consist only of the upper case portion 12 and the vertical case portion 13. In other words, the case 10 only needs to be configured to house at least a fixed contact 51 and a movable contact 91 in a sealed space S.

[0069] (3) In the second embodiment described above, the first case 101 and the second case 102 were described as separate components, but the invention is not limited to this, and the first case 101 and the second case 102 may be a single component. Alternatively, the case may consist of only the first case 101. That is, the case only needs to be configured to house at least the fixed contact 51 and the movable contact 91 in a sealed space S.

[0070] 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]

[0071] 1: Electromagnetic relay, 2: Core, 3: Spool, 4: Coil, 5: Fixed terminal, 8: Armature, 9: Movable terminal, 10: Case, 11: Seal member, 30: Cylindrical section, 31: First spool base, 32: Second spool base, 51: Fixed contact, 91: Movable contact, S: Sealed space.

Claims

1. In electromagnetic relays, A magnetic core (2), A spool (3) having a cylindrical portion (30) into which the core is inserted, a first spool base (31) provided on one side of the cylindrical portion in the axial direction, and a second spool base (32) provided on the other side of the cylindrical portion in the axial direction, A coil (4) wound around the outside of the cylindrical portion between the first spool base and the second spool base, A fixed terminal (5) having a fixed contact (51) in the region opposite to the coil relative to the base of the first spool, An armature (8) is provided in the region opposite to the coil relative to the base of the first spool, and operates by the magnetic field generated by the coil, A movable terminal (9) having a movable contact (91) that moves in conjunction with the movement of the armature and makes contact with and separates from the fixed contact, A case (10) that covers the fixed contact and the movable contact and covers the first spool base, housing the fixed contact and the movable contact in a sealed space (S) formed together with the first spool base, and exposing the coil to the air outside the sealed space, An electromagnetic relay comprising a sealing member (11) that seals the gap between the first spool base and the case.

2. A yoke (6) having a bottom yoke portion (61) fixed to the base of the second spool, and a vertical yoke portion (62) extending axially from the bottom yoke portion, The system comprises a plate member (7) positioned between the vertical yoke portion and the coil, The case has a terminal fixing portion (95) of the movable terminal that is fixed to the vertical yoke portion, and a vertical case portion (13) that covers the vertical yoke portion and covers the plate member, housing the terminal fixing portion and the vertical yoke portion in the sealed space formed together with the plate member, and exposing the coil to the air outside the sealed space. The electromagnetic relay according to claim 1, wherein the sealing member has a vertical sealing portion (112) that seals the gap between the plate member and the vertical case portion.

3. The electromagnetic relay according to claim 2, wherein the sealed space (S1) housing the fixed contact and the movable contact and the sealed space (S2) housing the terminal fixing portion and the vertical yoke portion are in communication, forming one continuous sealed space.

4. The case has a lower case portion (14) that surrounds the second spool base and the bottom yoke portion. The electromagnetic relay according to claim 2 or 3, wherein the sealing member has a lower sealing portion (113) that seals the gap between the second spool base and the lower case portion, and a bottom sealing portion (114) that seals the side of the second spool base and the bottom yoke portion opposite to the coil.

5. A yoke (6) having a bottom yoke portion (61) provided in the region of the second spool base opposite to the coil, and a vertical yoke portion (62) extending axially from the bottom yoke portion, When the aforementioned case is referred to as the first case (101), it comprises a second case (102) that covers the terminal fixing portion (95) of the movable terminal that is fixed to the vertical yoke portion, and covers the vertical yoke portion, and houses the terminal fixing portion in the sealed space formed together with the vertical yoke portion. The electromagnetic relay according to claim 1, wherein the sealing member seals the gap between the first case and the first spool base, and the gap between the second case and the vertical yoke portion.

6. The electromagnetic relay according to claim 5, wherein the sealed space (S1) housing the fixed contact and the movable contact and the sealed space (S2) housing the terminal fixing portion are in communication, forming one continuous sealed space.

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