Electromagnetic relay

Abstract

To provide an improved electromagnetic relay.SOLUTION: An electromagnetic relay 1 includes: an electromagnet 8; multiple springs 4 each including a terminal and a contact that opens and closes according to the action of the electromagnet 8; and a base 2 supporting the springs 4. At least one of the multiple springs 4 has a locked part 29 that is locked to the base 2 utilizing the spring nature of the spring 4 and the base 2 has a locking portion 31 that locks the locked part 29.SELECTED DRAWING: Figure 5A

Description

[Technical field]

[0001] The present invention relates to an electromagnetic relay. [Background technology]

[0002] In small electromagnetic relays with a rated load capacity level of about 8 to 10 A, when inserting a spring with contacts and terminals into a base, it is difficult to ensure sufficient press-fitting due to the small size, resulting in insufficient press-fitting strength and various trade-offs to obtain the press-fitting strength. For this reason, electromagnetic relays often adopt the measures described below, and are commercialized at the expense of the manufacturing process and product costs.

[0003] If the spring remains thin, it will be able to maintain its spring properties, but there is a risk of deformation during the press-fitting process, so the spring is made thicker and pressed firmly into the short press-fit allowance. Only the terminal part of the spring is made of a thick plate, and the spring part is made of a thin plate and welded to the terminal part. However, in this case, the processing cost increases. If the press-fit strength cannot be secured, the spring is temporarily attached after it is inserted. However, this increases manufacturing costs, and there is a risk that the spring may move from its correct position when a load is applied to the spring terminal between the time the spring is inserted into the base and the time the temporary attachment is performed. Therefore, there is a need for an electromagnetic relay that prevents the spring from slipping out.

[0004] Also, commonly known contact methods for the contacts of electromagnetic relays are single-point contact, sliding (contacts rub against each other), and rolling (contacts roll against each other). When the contacts slide, a contact cleaning action occurs, such as the destruction of the oxide film on the contact surface and the rubbing away of wear powder, improving contact reliability. Furthermore, low contact resistance can also suppress heat generation. On the other hand, in the case of rolling, the contact cleaning action is reduced, but a large change in the contact point can be expected, improving resistance to welding when the contacts come into contact.

[0005] In the case of the sliding type, if large unevenness occurs on the contacts due to contact wear, extra force is required for the contacts to overcome the unevenness when sliding, and if that force exceeds the attractive force of the electromagnet that presses the spring, the card may not be able to completely press the spring. One method to prevent this is to reduce the stiffness of the spring and provide a margin for the attractive force of the electromagnet, but in that case, it is necessary to design the spring with consideration for its current carrying capacity.

[0006] Patent Document 1 discloses an electromagnetic relay in which the fixed parts of the movable contact spring and the fixed contact terminal plate are supported by a fixed block made of an insulator, and the fixed blocks are crimped together and inserted and fixed into an opening in an insulating base. This allows the movable contact spring and the fixed contact terminal plate to be fixed perpendicularly to the insulating base, realizing stable contact pressure and contact gap.

[0007] Patent Document 2 discloses an electromagnetic relay in which a protrusion is formed on at least one of the side of the housing or the inner surface of the cover, which allows adhesive to flow into the gap between the housing and the cover even if the cover is warped.

[0008] Patent Document 3 discloses that the contact life of a movable contact and a fixed contact is increased by bringing the movable contact and the fixed contact into contact with each other by rolling. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Utility Model Application Publication No. 2-145752 [Patent Document 2] JP 2020-21594 A [Patent Document 3] JP 2006-59702 A Summary of the Invention [Problem to be solved by the invention]

[0010] SUMMARY OF THE PRESENT EMBODIMENT In view of the various problems inherent in the prior art, an object of the present invention is to provide an improved electromagnetic relay. [Means for solving the problem]

[0011] One aspect of the present disclosure includes an electromagnet, a plurality of springs having contacts and terminals that open and close in response to the operation of the electromagnet, and a base that supports the springs, wherein at least one of the plurality of springs has a locked portion that is locked to the base by utilizing the spring properties of the spring, and the base has a locking portion that locks the locked portion. the locked portion is configured to be elastically deformed when the locked portion is subjected to an external force, and the locking portion fixes an end of the locked portion on the opposite side to an insertion direction of the spring relative to the base, thereby restricting movement of the spring in the insertion direction. An electromagnetic relay is provided. Another aspect of the present disclosure provides an electromagnetic relay comprising an electromagnet, a plurality of springs having contacts and terminals that open and close in response to operation of the electromagnet, a base supporting the springs, and a cover covering the base, wherein a step is formed on the outer surface of the base facing the inner surface of the cover or on the inner surface of the cover facing the outer surface of the base to ensure an adhesive layer between the base and the cover. Another aspect of the present disclosure provides an electromagnetic relay comprising an electromagnet, a plurality of springs each having contacts and terminals that open and close in response to operation of the electromagnet, and a base supporting the springs, wherein the base has a reference surface that defines a reference position of the spring and an insertion hole through which the terminal is inserted, the inner surface of the insertion hole being flush with the reference surface, and the base has a notch on the reference surface side near the terminal exit of the insertion hole.

[0012] Yet another aspect of the present disclosure includes a base, an electromagnet mounted on the base, a movable member that moves with the operation of the electromagnet, and a movable spring having a base supported by the base and a main spring portion extended from the base and provided with a movable contact on a tip side thereof, the movable member having first and second protrusions that press both sides of the movable contact in the movable spring, respectively, the movable spring having an extension formed so as to extend from a portion of the main spring portion where the movable contact is provided toward a portion pressed by the first protrusion, and a branch portion that branches off from a portion between the portion of the main spring portion where the movable contact is provided and the base on the side opposite to the side where the extension is located, with the movable contact as a reference, and extends to a portion pressed by the second protrusion. and a slit formed between the branch portion and a portion of the main spring portion to which the movable contact is attached is formed so as not to cross a straight line extending from the center of the movable contact to the base portion in the main spring portion. An electromagnetic relay is provided. Yet another aspect of the present disclosure provides an electromagnetic relay comprising an electromagnet, a plurality of springs having contacts and terminals that open and close in response to operation of the electromagnet, and a base supporting the plurality of springs, wherein the base has an insertion hole for inserting at least one terminal of the plurality of springs, and the insertion hole is formed in a recess formed in the base in the internal space of the electromagnetic relay and having a spatial size larger than the opening of the insertion hole on the internal space side. Yet another aspect of the present disclosure provides an electromagnetic relay comprising: a base; an electromagnet mounted on the base; a movable spring provided with a movable contact; a fixed spring having a base supported by the base and a spring portion extending from the base and provided with a fixed contact; the base is formed to stand upright from a bottom surface of the base on the movable spring side relative to the fixed spring; and has a position regulating portion having a surface that contacts an area from a connection position of the spring portion with the base to a predetermined height when the fixed spring falls towards the movable spring in reaction to being pushed by the movable spring. Effect of the Invention

[0013] According to one aspect of the present disclosure, an improved spring dislodgement prevention technology can be provided. In other words, the press-fit strength of the spring that was previously required can be reduced, and even thin springs can be prevented from dislodgement. This is particularly useful for small electromagnetic relays. In addition, since the spring is inserted by utilizing its spring properties, it also leads to a reduction in mold chipping and wear powder during press-fitting. Furthermore, since there is no need for temporary bonding, the temporary bonding and drying processes can be eliminated, leading to a reduction in equipment costs, product costs, etc. According to another aspect of the present disclosure, even if the cover warps inward, a sufficient adhesive layer can be obtained between the inner surface of the cover and the outer surface of the base. According to another aspect of the present disclosure, the adhesive flows into the notch on the reference surface side near the terminal exit of the insertion hole, ensuring a sufficient adhesive layer between the base and the terminal.

[0014] According to yet another aspect of the present disclosure, it is possible to incorporate a rolling motion in addition to a sliding motion in the contact operation between the contacts, which allows the effect of unevenness on the sliding path to be dispersed while still enjoying the advantage of the contact cleaning action caused by the sliding motion, and also realizes the advantage of rolling, which is improved resistance to welding during contact. According to yet another aspect of the present disclosure, adhesive poured into the through hole from outside the electromagnetic relay can be retained near the through hole by surface tension and prevented from flowing into the internal space. According to yet another aspect of the present disclosure, it is possible to restrict the fixed spring from collapsing toward the movable spring in reaction to being pushed in by the movable spring. [Brief description of the drawings]

[0015] [Figure 1] FIG. 2 is an exploded perspective view showing an example of an electromagnetic relay. [Diagram 2] FIG. 2 is an exploded side view showing an example of an electromagnetic relay. [Diagram 3] FIG. 2 is a plan view showing a part of the electromagnetic relay. [Figure 4] FIG. 2 is a perspective view showing an example of a movable spring. [Figure 5A] FIG. 5 is a cross-sectional view taken along line VV showing an example of a spring structure. [Figure 5B] FIG. 5 is a cross-sectional view taken along line VV showing an example of a spring structure. [Figure 6] FIG. 4 is a perspective view showing an example of a second fixed spring. [Figure 7] FIG. 7 is a cross-sectional perspective view taken along line VII-VII showing another example of the spring structure. [Figure 8A] FIG. 11 is a partial perspective view showing a modified example of the locked portion. [Figure 8B] FIG. 11 is a partial cross-sectional view showing a modified example of the spring structure. [Figure 9A] FIG. 11 is a partial perspective view showing another modified example of the locked portion. [Figure 9B] FIG. 11 is a cross-sectional view showing another modified example of the spring structure. [Figure 10A] A cross-sectional view showing the stress range when a dowel is used for the raised portion. [Figure 10B]FIG. 2 is a cross-sectional view taken along line XX showing a stress range when a cut-and-raised piece is used for the raised portion. [Figure 11] FIG. 13 is a diagram showing the influence of inward warping of a cover. [Figure 12] FIG. 13 is a perspective view of a base showing an example of a step. [Figure 13] FIG. 13 is a schematic cross-sectional view taken along line XIII-XIII showing an example of a base-cover structure ratio. [Figure 14] 13 is a perspective view of a base showing a modified example of a step. FIG. [Figure 15] FIG. 4 is a schematic cross-sectional view showing an adhesive layer between a terminal and a base. [Figure 16A] FIG. 13 is a bottom perspective view of an example of a base that secures an adhesive layer. [Figure 16B] FIG. 1 is a cross-sectional view of an example of a base that secures an adhesive layer. [Figure 17] FIG. 2 is a perspective view of the electromagnetic relay without the cover. [Figure 18] FIG. [Figure 19] FIG. [Figure 20] FIG. [Figure 21A] 13 is a side view illustrating a state in which the movable spring begins to come into contact with the second fixed spring. FIG. [Figure 21B] 13 is a side view showing a state in which the movable spring is completely pressed by the card. FIG. [Figure 21C] This is a top view of FIG. 21B. [Figure 22] FIG. 13 is a diagram illustrating a contact path by rolling on a movable contact. [Figure 23] FIG. 1 is a perspective view of an electromagnetic relay having a movable spring mounted on a base. [Figure 24] 11 is a perspective view of a portion of the base where a first fixed spring, a movable spring, and a second fixed spring are mounted. FIG. [Diagram 25] FIG. 4 is a partial perspective view of a base on which a first fixed spring is mounted. [Figure 26] 26 is a cross-sectional view taken along line XXVI-XXVI in FIG. 25. [Figure 27]27 is a cross-sectional view taken along line XXVII-XXVII of FIG. 24. [Figure 28] 4 is a perspective view showing an initial state of a first fixed spring, a movable spring, and a second fixed spring. FIG. [Figure 29] FIG. 4 is a front view of a second fixed spring. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, the embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. In each drawing, the same or similar components are given the same or similar reference numerals. In addition, the embodiments described below do not limit the technical scope and meaning of the terms of the invention described in the claims.

[0017] 1 and 2 are an exploded perspective view and an exploded side view of an electromagnetic relay 1 according to an example, and Fig. 3 is a plan view of a portion of the electromagnetic relay 1. The electromagnetic relay 1 comprises a base 2 in which components are assembled, and a box-shaped cover 3 that covers the base 2. For example, the base 2 and the cover 3 may be molded parts made of resin. The components assembled in the base 2 include an electromagnet 8, a hinge spring 9, an armature 10, a card 11, and a spring 4 equipped with contacts and terminals that are opened and closed by the electromagnet 8.

[0018] The spring 4 includes a plurality of springs, a first fixed spring 5, a movable spring 6, and a second fixed spring 7, each of which is made of metal. Hereinafter, the plurality of springs will be collectively referred to as "spring 4." The first fixed spring 5 has a first fixed contact 12, the movable spring 6 has a movable contact 13, and the second fixed spring 7 has a second fixed contact 14. Each of the springs 4 has a spring portion 15 and a terminal 16. For example, the spring portion 15 is formed as a leaf spring. The spring portion 15 and the terminal 16 may be welded together, or may be formed from a single thin plate.

[0019] The electromagnet 8 includes a coil assembly 21, an iron core 22, and a yoke 23. The coil assembly 21 includes two terminals 24, a coil 25 with a winding connected to the terminals 24, and a bobbin 26 around which the coil 25 is wound.

[0020] In the electromagnetic relay 1, the electromagnet 8 is excited by applying a voltage between the terminals 24. The excitation of the electromagnet 8 causes the armature 10 to swing and be attracted to the iron core 22. The card 11 is attached to the armature 10, and as the armature 10 swings, it presses the movable spring 6, moving the movable contact 13 from the first fixed contact 12 to contact the second fixed contact 14. The hinge spring 9 is attached to the armature 10 and the yoke 23, and elastically urges one end of the armature 10 in a direction away from the iron core 22.

[0021] When the application of voltage to terminal 24 is stopped, the bias of hinge spring 9 causes armature 10 to return away from iron core 22. As a result of the return movement of armature 10, the pressing force from card 11 to movable spring 6 is released, and movable contact 13 moves away from second fixed contact 14.

[0022] With the above configuration, the electromagnetic relay 1 opens and closes the first fixed contact 12 and the movable contact 13, and the movable contact 13 and the second fixed contact 14. It should be noted that the above configuration is an example, and any components and principles may be adopted.

[0023] (Spring structure) Fig. 4 is a perspective view of an example of the movable spring 6, and Figs. 5A and 5B are VV cross-sectional views of an example of a spring structure. The movable spring 6 has a raised portion 28 that presses the movable spring 6 against a reference surface 27 of the base 2, and an engaged portion 29 that is engaged with the base 2. For example, the end of a U-shaped piece formed in the spring portion 15 serves as the engaged portion 29, and the end of the U-shaped piece is formed so as to face backward in the insertion direction I of the movable spring 6. The engaged portion 29 elastically deforms due to its spring properties when subjected to an external force F, and returns to its original shape when the external force F is released.

[0024] The base 2 has a reference surface 27 that defines a reference position of the movable spring 6 when the movable spring 6 is attached to the base 2, a press-fit surface 30 that faces the reference surface 27, and a locking portion 31 that locks the movable spring 6. For example, a claw-shaped protrusion formed on the reference surface 27 may be used as the locking portion 31, and the claw-shaped protrusion may be protruded in a direction different from the insertion direction I of the movable spring 6. The different direction may be any direction that can lock the locked portion 29, and may be a direction perpendicular to the insertion direction I or a direction inclined toward the front of the insertion direction I (the same applies below). The claw-shaped protrusion may be formed on a surface perpendicular to the reference surface 27 instead of being formed on the reference surface 27. At the beginning of insertion of the movable spring 6 into the base 2 shown in FIG. 5A, the raised portion 28 contacts the press-fit surface 30, and the locked portion 29 contacts the locking portion 31 and elastically deforms under the force of the locking portion 31. At the later stage of insertion of the movable spring 6 into the base 2 shown in FIG. 5B, the raised portion 28 receives a force from the press-fit surface 30 and presses the movable spring 6 against the reference surface 27, and the locked portion 29 slips under the locking portion 31 due to a restoring force and engages with the lower portion of the locking portion 31. In other words, the movable spring 6 is self-locked during the insertion process. The locking portion 31 restricts the movement of the locked portion 29 in the direction opposite to the insertion direction I of the movable spring 6, thereby preventing the movable spring 6 from coming off. Note that although the electromagnetic relay 1 described here is a type in which the movable spring 6 is inserted vertically into the base 2, it may also be a type in which the movable spring is inserted horizontally.

[0025] This allows the spring press-fit strength to be reduced, and even a thin spring can be prevented from coming loose. Therefore, the spring structure of this example is particularly useful for small electromagnetic relays. In addition, since the movable spring 6 is inserted by utilizing the spring properties of the engaged portion 29, this also leads to a reduction in mold chipping and wear powder during press-fitting. Furthermore, since temporary bonding of the movable spring is no longer necessary, the temporary bonding and drying processes can be eliminated, leading to reductions in equipment costs, product costs, etc. Furthermore, the potential risk of spring coming loose during the process from spring insertion to bonding, which previously occurred, is eliminated.

[0026] The self-locking structure of this example may be applied to the first fixed spring 5 or the second fixed spring 7. FIG. 6 is a perspective view of an example of the second fixed spring 7, and FIG. 7 is a perspective view of a cross section taken along line VII-VII of another example of the spring structure. The second fixed spring 7 has a protruding portion 28 that presses the second fixed spring 7 against a reference surface 27 of the base 2, and a locked portion 29 that is locked to the base 2. For example, the base 32 of the terminal 16 is tilted to form an inclined end portion as the locked portion 29, and the inclined end portion is formed so as to face backward in the insertion direction I of the second fixed spring 7. When an external force F is applied to the locked portion 29, the locked portion 29 is elastically deformed due to its spring properties, and when the external force F is released, the locked portion 29 is restored to its original shape.

[0027] The base 2 has a reference surface 27 that defines the reference position of the second fixed spring 7, a press-fit surface 30 that faces the reference surface 27, and a locking portion 31 that locks the second fixed spring 7. For example, a recess edge formed on the press-fit surface 30 side serves as the locking portion 31, and the recess edge is extended in a direction different from the insertion direction I of the second fixed spring 7. It should be noted that the recess edge includes not only the recess side wall portion but also the press-fit surface 30 portion (the same applies below). At the beginning of the insertion of the second fixed spring 7 into the base 2, the protruding portion 28 (not shown in FIG. 7) comes into contact with the press-fit surface 30, and the locked portion 29 comes into contact with the locking portion 31 (portion of the press-fit surface 30) and elastically deforms under the force of the locking portion 31 (portion of the press-fit surface 30) (not shown). In the latter stage of insertion of the second fixed spring 7 into the base 2, the raised portion 28 receives a force from the press-fitting surface 30 and presses the second fixed spring 7 against the reference surface 27, and the locked portion 29 fits into and engages with the locking portion 31 due to a restoring force. In other words, the second fixed spring 7 is self-locked during the insertion process. The locking portion 31 restricts the movement of the locked portion 29 in the direction opposite to the insertion direction I of the second fixed spring 7, thereby preventing the second fixed spring 7 from coming loose.

[0028] FIG. 8A is a partial perspective view showing a modified example of the locked portion 29 of the movable spring 6, and FIG. 8B is a partial cross-sectional view showing a modified example of the self-locking structure. In FIG. 8A, the end of a V-shaped piece formed near the base of the terminal 16 of the movable spring 6 serves as the locked portion 29. The end of the V-shaped piece is formed so as to face backward in the insertion direction I of the movable spring 6. The locked portion 29 elastically deforms due to its springiness when it receives an external force F, and returns to its original shape when the external force F is released. In FIG. 8B, a recessed edge portion formed on the press-fit surface 30 serves as the locking portion 31, and the recessed edge portion extends in a direction different from the insertion direction I of the movable spring 6. At the beginning of insertion of the movable spring 6 into the base 2, the locked portion 29 comes into contact with the locking portion 31 (part of the press-fit surface 30) and elastically deforms upon receiving a force from the locking portion 31 (part of the press-fit surface 30). In the later stage of insertion of the movable spring 6 into the base 2, the locked portion 29 slides into the locking portion 31 due to a restoring force and engages with the locking portion 31. In other words, the movable spring 6 is self-locked during the insertion process. The locking portion 31 restricts the movement of the locked portion 29 in the direction opposite to the insertion direction I of the movable spring 6, thereby preventing the movable spring 6 from coming off.

[0029] Fig. 9A is a partial perspective view showing another modified example of the locked portion 29, and Fig. 9B is a cross-sectional view showing another modified example of the self-locking structure. The locked portion 29 in Fig. 9A is also a protrusion protruding laterally from the terminal 16, and the protrusion is formed so as to face laterally in the insertion direction I of the movable spring 6. The locked portion 29 is elastically deformed due to its springiness when subjected to an external force F, and returns to its original shape when the external force F is released. Moreover, the locking portion 31 in Fig. 9B is a claw-shaped protrusion protruding from the reference surface 27, and the claw-shaped protrusion is protruding in a direction different from the insertion direction I of the movable spring 6.

[0030] (Spring reference surface pressing shape) Referring again to Fig. 4, the raised portion 28 that presses the movable spring 6 against the reference surface may be a half-punched dowel (convex portion) (raised portion 28 on the right side of Fig. 4), but if one of the various spring-fallout prevention structures described above is adopted, a cut-and-raised piece formed by cutting and raising a part of the movable spring 6 is preferable (raised portion 28 on the left side of Fig. 4). Fig. 10A is a cross-sectional view showing the range A of the spring stress when a dowel is adopted for the raised portion, and Fig. 10B is a cross-sectional view taken along line XX showing the range B of the spring stress when a cut-and-raised piece is adopted for the raised portion.

[0031] When the movable spring 6 is attached to the base, when the locked portion 29 overcomes the locking portion 31, the movable spring 6 needs to elastically deform by the height of the locking portion 31 to absorb that height. If the raised portion 28 is formed by a dowel, stress is concentrated in a relatively narrow range A of the movable spring 6 due to the distance between the locking portion 31 and the raised portion 28, causing the spring to plastically deform and leading to a decrease in self-locking performance. In order to relieve the stress while keeping the dowel, the spring width can be widened or the locking portion 31 can be provided at a higher position on the base 2, thereby dispersing the stress, but application to a small electromagnetic relay also affects the insulation distance and the width of the spring roll material.

[0032] Therefore, from the viewpoint of suppressing the plastic deformation of the spring, the raised portion 28 is formed of a cut-and-raised piece rather than a dowel, thereby dispersing stress. When a cut-and-raised piece is used as the raised portion 28, when the movable spring 6 elastically deforms by the height of the locking portion 31 and the locked portion 29 overcomes the locking portion 31 of the base 2, the distance between the locking portion 31 and the base 28a of the cut-and-raised piece becomes relatively long, and the stress is dispersed over a relatively wide range B of the movable spring 6, thereby suppressing the plastic deformation of the spring. Note that the cut-and-raised piece can also be used for the first fixed spring 5 and the second fixed spring 7 instead of the movable spring 6.

[0033] (Ensuring adhesive layer between base and cover) The cover 3 of the electromagnetic relay 1 is thin, and the cover 3 may be warped inward during molding. Figure 11 is a diagram showing the effect of the warping of the cover 3. The base 2 has an outer surface 41 facing the inner surface 40 of the cover, but if the outer surface 41 is flat, when the warped cover 3 is placed on the base 2, the designed clearance (design size of the gap between the base 2 and the cover 3) between the base 2 and the cover 3 provided as the adhesive layer 42 between the base and the cover is crushed, and a portion C where the adhesive layer 42 becomes thin is generated. If the adhesive layer 42 becomes thin, the cover and the base cannot be sealed sufficiently, which may cause poor airtightness.

[0034] Therefore, a step is formed on the outer surface 41 facing the inner surface 40 to ensure the adhesive layer 42. Fig. 12 is a perspective view of the base 2 on which an example of the step 43 is formed. For example, the step 43 is a recess 46 that is one step lower than the outer surface 41. As shown in Fig. 11, the inward warping of the cover 3 is maximum near the middle of the opening edge of the cover 3. Therefore, by forming the step 43 on the outer surface 41 on the cover edge 44 side and near the middle 45 of the side surface of the cover 3 (see Figs. 1 and 2), an adhesive layer that ensures sufficient clearance between the inner surface 40 and the outer surface 41 can be obtained even if the cover 3 warps inward.

[0035] The optimal structural ratio of the thickness of the adhesive layer 42 and the height and depth of the step 43 may be determined in accordance with the relationship with the warp shape and amount of warp of the cover 3, the properties of the adhesive, and the bonding strength of the resin material (base-cover), etc.

[0036] Fig. 13 is a schematic cross-sectional view of the base-cover structure ratio shown by the line XIII-XIII. The reference character "3" indicates a cover without warping, the reference character "3'" indicates a cover with warping, and the reference character "3''" indicates a cover with warping regulated by a step 43 formed on the outer surface 41 of the base 2. For example, when the design clearance z between the base 2 and the cover 3 is 0.05 mm, the target adhesive layer thickness (desired adhesive layer thickness) y1 at the position of the cover edge 44 is 0.04 mm or more, the depth y2 of the step 43 is 1.5 mm, the height a of the step 43 is 0.1 mm, the length L of the cover warping occurrence is 12.7 mm, and the amount of cover warping d at the position of the cover edge 44 is 0.1 mm, the amount of cover warping after regulating x (=0.057 mm) at the position of the cover edge 44 can be calculated from the following formula.

[0037]

number

[0038] Furthermore, the adhesive layer thickness (=0.093 mm) at the position of the cover edge 44 after assembly can be calculated from the following formula. Therefore, in the case of the above structural ratio, the minimum adhesive thickness is 0.093 mm, the adhesive flow depth (corresponding to the depth of the step 43) is 1.5 mm, and it can be seen that the target adhesive layer thickness y1 of 0.04 mm or more is obtained.

[0039]

number

[0040] If the target adhesive layer thickness y1 of 0.04 mm or more cannot be obtained based on the above formula, the target adhesive layer thickness can be obtained by readjusting at least one of the height a and the depth y2 of the step 43. The height and depth of the step 43 can be set in this manner.

[0041] The step 43 may be a protrusion 47 protruding from the outer surface 41 instead of the recess 46. FIG. 14 is a perspective view of the base 2 showing a modified example of the step 43. The protrusion 47 corrects the inwardly warped cover 3 from the inside, and ensures a designed clearance between the cover and the base. In the example of FIG. 14, the protrusions 47 are formed on the outer surface 41 on the edge 44 side of the cover and at approximately equal intervals from the middle 45 of the side surface. The height of the protrusions 47 is appropriate for the designed clearance between the base and the cover during assembly. The above step 43 ensures an adhesive layer with sufficient clearance even if the cover warps inward, so that the adhesive flows in from the edge 44 of the cover to ensure the sealing performance of the electromagnetic relay 1. The step 43 may also be formed on the inner surface 40 instead of the outer surface 41.

[0042] (bonding between terminal and base) In small electromagnetic relays, the spring terminals are often thin and there is a height restriction, so that the adhesive layer obtained between the terminal and the base is also restricted. FIG. 15 is a schematic cross-sectional view showing the adhesive layer 50 between the terminal and the base. When such a terminal 16 is subjected to a load, stress is generated in the adhesive around the terminal 16, peeling of the adhesive layer 50 occurs, and cracks occur in the adhesive layer around the terminal 16, and there is a risk of poor airtightness in the case of a sealed product. In addition, if the inner surface 52 of the insertion hole 51 through which the terminal 16 is inserted is the same surface as the reference surface 27, the adhesive is difficult to penetrate into the inner surface 52 because the terminal 16 and the reference surface 27 are in contact with each other, so that a thin portion D occurs in the adhesive layer 50 on the reference surface 27 side. As a countermeasure, there is a method of lowering the entire area around the terminal 16 of the base 2 by one step, but there is a limit to this.

[0043] Therefore, it is necessary to secure the adhesive layer 50 on the reference surface 27 side near the lower side of the insertion hole 51. FIG. 16A is a bottom perspective view of an example of the base 2 that secures the adhesive layer, and FIG. 16B is a cross-sectional view of the base 2 taken along the line XVI-XVI. The base 2 has a notch 54 on the reference surface 27 side near the terminal exit of the insertion hole 51. For example, the notch 54 has an inclined surface inclined with respect to the reference surface 27. By forming an inclined surface, the adhesive can easily flow into the notch 54. The notch 54 may be a recess stepped down from the reference surface 27 instead of an inclined surface. The notch 54 can increase the adhesive layer between the terminal and the base on the reference surface side, improving the airtight performance of the electromagnetic relay. In addition, the resistance to cracking of the adhesive layer when a load is applied to the terminal 16 is improved. Even if the entire periphery of the terminal is stepped down in addition to the notch 54, the terminal strength can be improved.

[0044] (Movable spring slit shape) The shape of the slits in the movable spring and other configurations will be described. Fig. 17 is a perspective view of the electromagnetic relay 200 without the cover. Fig. 18 is an exploded perspective view of the electromagnetic relay 200. As shown in Figs. 17 and 18, the electromagnetic relay 200 includes a base 204 in which components are assembled, and a cover 206 that covers the base 204. The base 204 and the cover 206 are molded parts made of, for example, resin. The base 204 and the cover 206 form a housing.

[0045] The components incorporated in the base 204 include a plurality of springs (a first fixed spring 260, a movable spring 270, and a second fixed spring 280), an electromagnet 207, an armature 208, and a card 209 as a moving member. Each of the plurality of springs is a metal plate-shaped spring member. The card 209 is a molded part made of, for example, resin.

[0046] The first fixed spring 260 has a terminal 261 and a first fixed contact 262 (see FIG. 26). The movable spring 270 has a terminal 271 and a movable contact 272. The second fixed spring 280 has a terminal 281 and a second fixed contact 282. The electromagnet 207 includes a coil assembly 227, an iron core 228, a yoke 229, and terminals 207a and 207b.

[0047] In the electromagnetic relay 200, a voltage is applied between the terminals 207a and 207b to excite the electromagnet 207, whereby the armature 208 swings and is attracted to the iron core 228. Two projections 208a and 208b are formed on the upper end of the armature 208 to engage with the engagement claws 209a and 209b of the card 209. As the armature 208 swings, the two projections 209c and 209d formed on the tip of the card 209 press the holes 270a and 270b formed on both sides of the movable contact 272 of the movable spring 270 toward the second fixed spring 280. As a result, the movable contact 272 moves away from the first fixed contact 262 and comes into contact with the second fixed contact 282. A hinge spring (not shown) is attached to the armature 208 and the yoke 229 to elastically bias the armature 208 in a direction away from the iron core 228 .

[0048] When the voltage application to the coil is stopped, the bias of the hinge spring causes armature 208 to return away from iron core 228. As a result of the return movement of armature 208, the pressing force from card 209 to movable spring 270 is released, and movable contact 272 moves away from second fixed contact 282 and again comes into contact with first fixed contact 262.

[0049] With the above configuration, electromagnetic relay 200 opens and closes first fixed contact 262 and movable contact 272 as break contacts, and also opens and closes second fixed contact 282 and movable contact 272 as make contacts. Note that the configuration of electromagnetic relay 200 is an example, and for example, another type of moving mechanism or moving member that presses movable spring 270 in conjunction with the operation of electromagnet 207 may be used. The number of multiple springs implemented in electromagnetic relay 200 is also an example, and for example, the number of multiple springs may be two, a movable spring and a fixed spring.

[0050] 19 and 20 are respectively a perspective view and a front view of the movable spring 270. As shown in Fig. 19 and Fig. 20, the movable spring 270 has a flat base 273 supported by the base 204, a terminal 271 extending downward from one lateral end of the base 273, and a main spring portion 274 extending upward from the center of the lower end of the base 273 in a U-shaped curve so as to be convex downward and having a movable contact 272 at its upper end. An extension portion 275 is formed that extends linearly from the portion where the movable contact 272 at the upper end of the main spring portion 274 is attached toward the position pressed by the protrusion 209c and has a hole 270a at its tip. Furthermore, a branched portion 276 is formed on the opposite side of the extension portion 275 from the movable contact 272 between the movable contact 272 and the base portion 273 of the main spring portion 274, the branched portion 276 extending to approximately the same height as the upper end portion of the main spring portion 274 and having a hole 270b formed at its tip portion. A slit 278 is formed between the branched portion 276 and the portion of the main spring portion 274 where the movable contact 272 is attached.

[0051] By forming the upper end portion of the movable spring 270 in a shape in which the slit 278 is formed at one end of the movable contact 272 as in the above configuration, when the upper end portion of the movable spring 270 is pressed toward the second fixed spring 280 by the card 209, it becomes possible to add lateral movement in addition to vertical sliding to the contact path between the movable contact 272 and the second fixed contact 282, thereby making it possible to add rolling to the contact operation of the contacts. The effect of forming the slit 278 will be described in more detail with reference to Figures 21A-21C and 22.

[0052] 21A is a side view showing a state in which the movable spring 270 is pushed toward the second fixed spring 280 by the card 209 and the movable contact 272 begins to contact the second fixed contact 282. FIG. 21B shows a state in which the movable spring 270 is completely pushed in by the card 209 from the state of FIG. 21A. FIG. 21C is a view of FIG. 21B seen from above. In FIG. 21C, the portion of the main spring portion 274 where the movable contact 272 is provided receives a pressing force from the second fixed contact 282 toward the first fixed spring 260. At this time, since the slit 278 is formed on the hole 270b side of the upper end portion of the movable spring 270, the portion of the main spring portion 274 where the movable contact 272 is provided is twisted so that the side where the slit 278 is provided falls slightly toward the first fixed spring 260. As a result, as shown in FIG. 21C, the portion of main spring portion 274 where movable contact 272 is provided is inclined by angle θ toward card 209 with respect to the direction perpendicular to the moving direction of card 209 in the drawing.

[0053] In this way, when the movable contact 272 and the second fixed contact 282 come into contact with each other, a lateral movement (a direction perpendicular to the moving direction and up-down direction of the card 209) is applied between the movable contact 272 and the second fixed contact 282, which makes it possible to apply a rolling motion. Fig. 22 shows an example of a contact path C1 of the second fixed contact 282 on the movable contact 272 when a rolling motion is applied to the contact movement between the movable contact 272 and the second fixed contact 282.

[0054] In this embodiment, by forming a slit 278 at the upper end of the movable spring 270, the stiffness of the movable spring 270 can be reduced without adopting a design that would be difficult in terms of current carrying capacity, such as reducing the spring width or the spring thickness. In this embodiment, by providing a slit 278 only on one side of the movable contact 272 at the upper end portion of the movable spring 270, it is possible to incorporate a lateral rolling movement into the contact contact movement of the sliding in the vertical direction. This can be expected to improve the resistance to adhesion during contact contact, which is the advantage of rolling, in addition to the contact cleaning action of destroying the oxide film on the contact surface and scraping off worn powder. If the movable spring does not have a slit, the contacts slide in the vertical direction, so if unevenness occurs on the sliding path in the vertical direction, the contacts will be 100% affected by it. On the other hand, when slit 278 is provided on only one side of movable contact 272 of movable spring 270 as in this embodiment, the upper end portion of movable spring 270 twists in the direction of slit 278 when the contacts come into contact with each other, so that the influence of unevenness occurring on the contacts due to sliding can be dispersed laterally by the twisting action of movable spring 270 and avoided.

[0055] (U-shaped movable spring) 23 is a perspective view showing a state in which the movable spring 270 is mounted on the base 204, with the front portion cut away. The movable spring 270 is supported by the base 204 with its position restricted by a base portion 273, and is bonded at a portion of a terminal 271 inserted into an insertion hole 244 (see FIG. 24) of the base 204. The main spring portion 274 of the movable spring 270 is formed so as to extend upward from the lower end of the base portion 273, curving in a U-shape.

[0056] By forming the main spring portion 274 in a U-shape as shown in Fig. 23, it becomes easy to mount the movable spring 270 in the vertical direction relative to the base 204. Also, by forming the elastic deformation region of the movable spring 270 as the main spring portion 274 curved in a U-shape, it is possible to increase the gap between the base 204 and the base 273 side of the main spring portion 274, and it is possible to prevent the adhesive from flowing from the insertion hole 244 (see Fig. 24) to the rigid point of the main spring portion 274, thereby preventing the occurrence of variations in stiffness. Also, it is possible to ensure a longer length that functions as a spring compared to when the main spring portion is L-shaped, and it is possible to improve the spring properties.

[0057] (Adhesive flow suppression shape) Fig. 24 is a perspective view of a portion of the base 204 on which the first fixed spring 260, the movable spring 270, and the second fixed spring 280 are mounted. Fig. 25 is a perspective view of the base 204 on which the first fixed spring 260 is mounted. Fig. 26 is a cross-sectional view taken along line XXVI-XXVI of Fig. 25. The first fixed spring 260 has a terminal 261, a base portion 263 supported by the base 204, and a spring portion 264 extending from the base portion 263 and having a first fixed contact point 262 on the tip side.

[0058] As shown in FIG. 24, a first support portion 241 and a second support portion 242 that support a base portion 263 of the first fixed spring are formed on the bottom surface of the base 204. The first support portion 241 has reference surfaces 241a and 241b that define the position of the base portion 263 in the moving direction of the card 209. The second support portion 242 has reference surfaces 242a and 242b that define the position of the base portion 263 in the moving direction of the card 209. An insertion hole 243 for inserting a terminal 261 of the first fixed spring 260 is formed on the bottom wall of the base 204. The first fixed spring 260 is mounted on the base 204 from above so that the base portion 263 of the first fixed spring 260 is supported by the first support portion 241 and the second support portion 242 and the terminal 261 passes through the insertion hole 243 (see FIG. 25). With the first fixing spring 260 attached to the base 204 , an adhesive is poured into the insertion hole 243 from the outside, whereby the terminal 261 is fixed to the base 204 .

[0059] 24, in the region of the base 204 where the terminal 261 is arranged, a recess R1 is formed by an outer surface 351 on the insertion hole 243 side of the second support part 242, a side wall surface 352, a wall surface 353 on the movable spring 270 side, and a wall surface 354 on the electromagnet 207 side, and the insertion hole 243 is formed at the bottom of the recess R1. The recess R1 prevents the adhesive from flowing into the terminal insertion region from the outside by surface tension.

[0060] As shown in Fig. 26, the terminal 261 has a shape bent in a crank shape. Specifically, the terminal 261 has a first portion 261a extending downward from a base portion 263, a second portion 261b bending from a lower end of the first portion 261a and extending obliquely downward, and a third portion 261c bending from a tip end of the second portion 261b and extending downward. A gap G between a surface 261f of the second portion 261b on the bottom surface 204a side of the base 204 and the bottom surface 204a is formed in a shape that expands from the position of an opening end 243a on the internal space side of the insertion hole 243 toward the internal space of the electromagnetic relay 200, that is, in a tapered shape in the cross-sectional view of Fig. 26.

[0061] In this way, by forming the gap G so that it gradually widens from the opening end of the insertion hole 243 toward the internal space, the adhesive poured into the insertion hole 243 from the external space side can be retained near the insertion hole 243 by surface tension, and prevented from flowing into the internal space.

[0062] As shown in FIG. 24, the bottom wall of the base 204 is formed with an insertion hole 244 for inserting the terminal 271. FIG. 27 is a cross-sectional view of the base 204 with the movable spring 270 mounted thereon, taken along the line XXVII-XXVII in FIG. 24. As shown in FIG. 27, in the space of the portion of the base 204 where the terminal 271 is arranged, a recess R2 is defined by wall surfaces 361 and 362 located on both sides of the terminal 271 in the moving direction of the card 209, a wall surface 363 on the front side in FIG. 24, and a peripheral surface of the locking protrusion 364. The recess R2 has a width W2 larger than the width W1 of the opening end of the insertion hole 244 on the internal space side. By forming the recess R2 larger in size than the opening end of the insertion hole 244 on the internal space side of the portion where the insertion hole 244 is located, the adhesive poured into the insertion hole 244 from the outside can be kept inside the insertion hole 244 by surface tension and prevented from flowing into the internal space.

[0063] 24, in the region of the insertion hole 245 into which the terminal 281 of the second movable spring 280 of the base 24 is inserted, a recess R3 having a spatial size larger than the width WX in the short side direction and the width WY in the long side direction of the rectangular through hole 245 is defined by the inner surfaces 371, 372 of the base 204 and the side surface 311b of the restricting portion 311 on the through hole 245 side. By forming such a recess R3, the adhesive poured into the insertion hole 245 from the outside can be kept inside the insertion hole 245 by surface tension and prevented from flowing into the internal space.

[0064] (Spring recoil suppression shape) Fig. 28 is a perspective view showing an initial state of the first fixed spring 260, the movable spring 270, and the second fixed spring 280 mounted on the base 204 when no pressing force from the card 209 is acting. Fig. 29 is a front view of the second fixed spring 280 as seen from the right side of Fig. 28. The second fixed spring 280 has a terminal 281 inserted into an insertion hole 245 formed in the base 204, a base portion 283 supported by the base 204, and a spring portion 284. The base 204 is formed with a restricting portion 311 having a reference surface 311a that contacts the surface of the spring portion 284 on the card 209 side in the initial state shown in Fig. 28, standing from the inside of the bottom wall. When electromagnet 207 is activated and second fixed spring 280 is pushed in by movable spring 270, the electromagnet is de-energized and card 209 returns to its initial position, and the force of card 209 pushing second fixed spring 280 disappears, and second fixed spring 280 returns vigorously to card 209 in reaction, causing it to fall toward movable contact 272 from its initial position. Restriction unit 311 restricts second fixed spring 280 from falling toward card 209 in reaction when second fixed contact 282 is pushed into movable contact 272 and second fixed spring 280 returns to its initial state from a state in which second fixed contact 282 is pushed into movable contact 272 and second fixed spring 280 is bent in the opposite direction to card 209.

[0065] On the opposite side of the base 204 from the restricting portion 311 with respect to the base portion 283 as a reference, restricting portions 321 and 322 are formed which come into contact with the two protrusions 283a and 283b of the base portion 283, respectively, to restrict the position of the base portion 283 (see FIG. 24). With this configuration, when the second fixed spring 280 is pressed by the movable spring 270, the second fixed spring 280 elastically deforms so that the entire spring portion 284 falls to the opposite side to the card 209, with the boundary position P0 (see FIG. 29) between the spring portion 284 and the base portion 283 as the swing fulcrum.

[0066] The reference surface 311a abuts on the spring portion 284 up to a position P1 higher than the boundary position P0 in the height direction. That is, the height of the regulating portion on the movable spring 270 side relative to the second fixed spring 280 is higher than the height of the regulating portion on the opposite side. In FIG. 29, the contact area 280s where the second fixed spring 280 and the regulating portion 311 contact each other is indicated by a dashed diagonal line. With this configuration, when the second fixed spring 280 falls toward the card 209 side in reaction to being pushed by the movable spring 270, the rocking fulcrum rises from position P0 to position P1, and the elastic deformation area in the spring portion 284 is shortened, thereby increasing the stiffness of the second fixed spring 280. This makes it possible to prevent the second fixed spring 280 from falling toward the movable contact 272 side more than the initial position, and reduces the effect of arcing caused by the contact gap between the movable contact 272 and the second fixed contact 282 being momentarily blocked.

[0067] Although various embodiments have been described herein, it should be appreciated that the present invention is not limited to the above-described embodiments, but may be modified in various ways within the scope of the appended claims. [Explanation of symbols]

[0068] 1, 200 electromagnetic relay; 2, 204 base; 3, 206 cover; 4 spring; 5, 260 first fixed spring; 6, 270 movable spring; 7, 280 second fixed spring; 8, 207 electromagnet; 9 hinge spring; 10, 208 armature; 11, 209 card; 12, 262 first fixed contact; 13, 272 movable contact; 14, 282 second fixed contact; 15, 264, 284 spring part; 16, 207a, 207b, 261, 271, 281 terminal; 21, 227 coil assembly; 22, 228 iron core; 23, 229 yoke; 24 coil terminal; 25 coil; 26 bobbin; 27, 311a reference surface; 28 raised portion; 28a base; 29 engaged portion; 30 press-fit surface; 31 engaged portion; 32 base; 40 inner surface; 41 outer surface; 42 adhesive layer; 43 step; 44 cover edge; 45 middle of side; 46 recess; 47 protrusion; 50 adhesive layer; 51 insertion hole; 52 inner surface; 54 notch; 209a, 209b engagement claw; 208a, 208b protrusion; 209c, 209d protrusion; 243, 244, 245 insertion hole; 270a, 270b hole; 274 main spring portion; 278 slit; 263, 273, 283 Base; 311, 321, 322 Restriction; G Gap; R1, R2 Recess

Claims

1. An electromagnet, a plurality of springs having contacts and terminals that open and close in response to the operation of the electromagnet; a base supporting the spring; At least one of the plurality of springs has a locked portion that is locked to the base by utilizing the spring property of the spring, the base has a locking portion that locks the locked portion, The engaged portion is configured to be elastically deformed when the engaged portion is subjected to an external force, The locking portion fixes an end of the locked portion opposite to an insertion direction of the spring relative to the base, thereby restricting movement of the spring in the insertion direction.

2. the base includes a reference surface that defines a reference position of the spring; 2. The electromagnetic relay according to claim 1, wherein the spring has a raised portion formed by cutting out a part of the spring and pressing the spring against the reference surface.

3. An electromagnet, a plurality of springs having contacts and terminals that open and close in response to the operation of the electromagnet; A base supporting the spring; A cover that covers the base, An electromagnetic relay, wherein a step is formed on an outer surface of the base facing an inner surface of the cover or on an inner surface of the cover facing the outer surface of the base, to ensure an adhesive layer between the base and the cover.

4. An electromagnet, a plurality of springs having contacts and terminals that open and close in response to the operation of the electromagnet; a base supporting the spring; the base includes a reference surface that defines a reference position of the spring and an insertion hole through which the terminal is inserted, The inner surface of the insertion hole is flush with the reference surface, The base has a notch on the reference surface side near the terminal exit of the insertion hole.

5. With the base, an electromagnet mounted on the base; A moving member that moves in response to the operation of the electromagnet; a movable spring having a base portion supported by the base and a main spring portion extending from the base portion and provided with a movable contact; the movable member has first and second protrusions that press both side portions of the movable contact of the movable spring, the movable spring has an extension portion formed so as to extend from a portion of the main spring portion where the movable contact is provided toward a position pressed by the first protrusion, and a branch portion branching off from a portion of the main spring portion between the portion of the main spring portion where the movable contact is provided and the base portion, on the opposite side of the movable contact to the side where the extension portion is located, and extending to a position pressed by the second protrusion, An electromagnetic relay, wherein a slit formed between the branch portion and the portion of the main spring portion to which the movable contact is attached is formed in the main spring portion so as not to cross a straight line extending from the center of the movable contact to the base.

6. An electromagnet, a plurality of springs having contacts and terminals that open and close in response to the operation of the electromagnet; and a base supporting the plurality of springs, The base is formed with an insertion hole for inserting at least one terminal of the plurality of springs therethrough, An electromagnetic relay, wherein the insertion hole is formed in a recess formed in the base in the internal space of the electromagnetic relay and having a spatial size larger than the opening of the insertion hole on the internal space side.

7. With the base, an electromagnet mounted on the base; a movable spring provided with a movable contact; a fixed spring having a base portion supported by the base and a spring portion extending from the base portion and provided with a fixed contact; The base is An electromagnetic relay having a position regulating portion formed to stand upright from the bottom surface of the base on the movable spring side relative to the fixed spring, and having a surface that contacts an area from the connection point of the spring portion with the base to a predetermined height when the fixed spring falls toward the movable spring in reaction to being pushed by the movable spring.

Images