Electromagnetic relay

Abstract

The present disclosure suppresses a manufacturing cost by simplifying an assembly structure of an electromagnetic relay provided with a contact mechanism capable of suppressing an electromagnetic repulsive force at the time of large current energization. An electromagnetic relay (1) according to one aspect of the present disclosure comprises: a contact mechanism (10) provided with a movable element (13) having a first movable contact (131) and a second movable contact (132) respectively provided on both end sides, in a first direction, of a first surface of a conductive plate (130) extending in the first direction, a first fixed element (11) having a first fixed contact (111) provided so as to be connectable to the first movable contact (131), and a second fixed element (12) having a second fixed contact (121) provided so as to be connectable to the second movable contact (132); and a case (30) that accommodates the contact mechanism (10).

Description

Electromagnetic relay

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

[0002] An electromagnetic relay having a contact mechanism is widely used in fields such as communication devices, automotive electrical components, and electrical appliances. Patent Document 1 discloses a technology related to a contact mechanism capable of suppressing an electromagnetic repulsive force acting in a direction to open the mover during energization. Patent Document 2 discloses a technology related to a contact mechanism capable of reducing the height of the contact device while suppressing the electromagnetic repulsive force generated between the mover and the stator.

[0003] Japanese Unexamined Patent Application Publication No. 2012-028252, Japanese Unexamined Patent Application Publication No. 2012-243584

[0004] When a large current is passed, an electromagnetic repulsive force acts on the contact mechanism, which may cause a decrease in contact pressure and lead to a malfunction of the electromagnetic relay. As a countermeasure, for example, the structure of the contact mechanism shown in FIG. 2 is effective. However, the structure of the contact mechanism in which the paths leading to the outside of the electromagnetic relay of the two stators are in the reverse direction is more difficult to assemble into the electromagnetic relay compared to the structure of the contact mechanism in which the two stators are in the same direction toward the outside of the electromagnetic relay. Therefore, it is difficult to ensure the airtightness desired to be introduced into each part connecting the inside and outside of the electromagnetic relay for the purpose of preventing a decrease in contact stability due to dust in particular, and there is a risk that the manufacturing cost of the electromagnetic relay will increase.

[0005] In view of the above problems, an object of the present disclosure is to reduce the manufacturing cost by simplifying the assembly structure of an electromagnetic relay provided with a contact mechanism capable of suppressing an electromagnetic repulsive force during large current energization.

[0006] An electromagnetic relay according to one aspect of the present disclosure comprises a contact mechanism having a movable element having a first movable contact and a second movable contact provided on both ends in the first direction of a first surface of a conductive plate extending in a first direction; a first stator having a first fixed contact provided to connect to the first movable contact; and a second stator having a second fixed contact provided to connect to the second movable contact; and a case housing the contact mechanism, the case comprising a bucket-shaped housing case housing the contact mechanism in a recess formed in the first direction, and a lid covering the opening of the housing case, wherein the first stator is arranged to pass through a first hole formed in the bottom surface of the recess of the housing case, and the second stator is arranged to pass through a second hole formed in the lid.

[0007] This disclosure simplifies the assembly structure of an electromagnetic relay equipped with a contact mechanism capable of suppressing electromagnetic repulsion when high current is flowing, thereby reducing manufacturing costs.

[0008] This is a perspective view showing an example configuration of an electromagnetic relay according to Embodiment 1. This is a front view showing an example configuration of a contact mechanism according to Embodiment 1. This is a perspective view showing an example configuration of a contact mechanism and case according to Embodiment 1. This is a perspective view showing an example configuration of an electromagnetic relay according to Embodiment 1. This is a perspective view showing an example configuration of an electromagnetic relay according to Embodiment 1. This is a side view showing an example configuration of an electromagnetic relay according to Embodiment 2. This is a cross-sectional view along the cutting line VII-VII in Figure 7. This is an enlarged view of the area enclosed by the solid rectangle in Figure 8. This is an enlarged view of the area enclosed by the solid rectangle in Figure 8. This is an enlarged view of the area enclosed by the solid rectangle in Figure 8. This is a front view showing an example configuration of a contact mechanism according to Embodiment 3. This is a perspective view showing an example configuration of a contact mechanism according to Embodiment 3. This is a side view showing an example configuration of an electromagnetic relay according to Embodiment 3. This is a cross-sectional perspective view along the cutting line XIV-XIV in Figure 14. This is a side view showing an example configuration of an electromagnetic relay with the cover removed, according to Embodiment 3. This is a front view showing an example configuration of a contact mechanism and electromagnetic mechanism according to Embodiment 4. This is a cross-sectional view of the cutting line XVII-XVII in Figure 17 when the device is not energized. This is a cross-sectional view of the cutting line XVII-XVII in Figure 17 when the device is energized. This is a perspective view showing an example of the configuration of the contact mechanism and electromagnetic mechanism according to Embodiment 5. This is a front view of the electromagnetic relay according to Embodiment 5. This is a cross-sectional view of the cutting line XXI-XXI in Figure 21. This is a side view showing an example of the configuration of the electromagnetic relay according to Embodiment 6. This is a perspective view showing an example of the configuration of the electromagnetic relay according to Embodiment 7. This is a cross-sectional view showing an example of the configuration of the electromagnetic relay according to Embodiment 8 perspective view showing an example of the configuration of the contact mechanism according to Embodiment 9. This is a bottom view showing an example of the configuration of the contact mechanism according to Embodiment 9. This is a side view showing an example of the configuration of the contact mechanism according to Embodiment 9 when the device is not energized. This is a diagram showing the direction of the current flowing through the contact mechanism according to Embodiment 9 and the direction of the magnetic field.

[0009] <Embodiment 1> Hereinafter, embodiments will be described with reference to the drawings. Figure 1 is a perspective view showing an example of the configuration of an electromagnetic relay according to Embodiment 1. As shown in Figure 1, the electromagnetic relay 1 according to this embodiment comprises a contact mechanism 10, an electromagnetic mechanism 20, a case 30, and a sealing resin 40.

[0010] Figure 2 is a front view showing an example of the configuration of a contact mechanism according to Embodiment 1. As shown in Figure 2, the contact mechanism 10 comprises a first stator 11, a second stator 12, and a movable element 13.

[0011] The movable element 13 includes a conductive plate 130 extending in the x-axis direction (first direction), and a first movable contact 131 and a second movable contact 132, respectively, provided on both ends of the first surface (the surface on the z-axis positive side) of the conductive plate 130 in the x-axis direction. The first movable contact 131 and the second movable contact 132 of the movable element 13 are formed by providing convex-shaped members on the first surface of both ends of the conductive plate 130 in the x-axis direction. Each member constituting the movable element 13 is made of a conductive material such as a metal material. The first movable contact 131 and the second movable contact 132 may be formed integrally with the conductive plate 130.

[0012] The first stator 11 includes a conductive plate 110 extending in the x-axis direction and a first fixed contact 111 provided to be connectable to a first movable contact 131 of the movable element 13. The first fixed contact 111 of the first stator 11 is formed by providing a convex-shaped member on the negative z-axis side of the conductive plate 110. Each member constituting the first stator 11 is made of a conductive material such as a metal. The first fixed contact 111 may be formed integrally with the conductive plate 110.

[0013] The second stator 12 includes a conductive plate 120 extending in the x-axis direction and a second fixed contact 121 that is connectable to the second movable contact 132 of the movable element 13. The second fixed contact 121 of the second stator 12 is formed by providing a convex-shaped member on the negative z-axis side of the conductive plate 120. Each member constituting the second stator 12 is made of a conductive material such as a metal. The second fixed contact 121 may be formed integrally with the conductive plate 120.

[0014] The contact mechanism 10 switches between energized and de-energized states by displacing the movable element 13 in the z-axis direction (second direction). Specifically, when the movable element 13 is displaced to the negative side in the z-axis direction, the first movable contact 131 and the first fixed contact 111 become disconnected, and the second movable contact 132 and the second fixed contact 121 become disconnected, so the first stator 11 and the second stator 12 become de-energized. On the other hand, when the movable element 13 is displaced to the positive side in the z-axis direction, the first movable contact 131 and the first fixed contact 111 become connected, and the second movable contact 132 and the second fixed contact 121 become connected, so the first stator 11 and the second stator 12 become energized via the movable element 13. Figure 2 illustrates the case when the contact mechanism 10 is de-energized.

[0015] In the contact mechanism 10, the first stator 11, the second stator 12, and the movable element 13 are configured to extend in the x-axis direction. That is, when the contact mechanism 10 is energized, the direction of current flow in the first stator 11, the second stator 12, and the movable element 13 is the same. When current flows through the contact mechanism 10, a magnetic field is generated in the y-axis direction (third direction) on the movable element 13. More specifically, when a current flows in the contact mechanism 10 toward the positive x-axis direction, the first stator 11 and the second stator 12 generate a magnetic field on the movable element 13 toward the positive y-axis direction. On the other hand, when a current flows in the contact mechanism 10 toward the negative x-axis direction, the first stator 11 and the second stator 12 generate a magnetic field on the movable element 13 toward the negative y-axis direction.

[0016] When the contact mechanism 10 is energized, a Lorentz force is generated in the movable element 13 (conductive plate 130) in the direction that maintains the energized state (positive side in the z-axis direction) due to the magnetic field generated by the first stator 11 and the second stator 12. Therefore, by using the Lorentz force acting in the positive side in the z-axis direction, the electromagnetic repulsive force (force acting in the negative side in the z-axis direction) acting between the movable element 13 and the first stator 11 and the second stator 12 when energized can be effectively suppressed.

[0017] As shown in Figure 1, the electromagnetic mechanism 20 is provided at a position on the negative side of the z-axis direction of the contact mechanism 10. The electromagnetic mechanism 20 can displace the movable element 13 in the z-axis direction. More specifically, when the electromagnetic mechanism 20 is off, the movable element 13 is stationary at the position on the negative side of the z-axis direction. In this state, the first movable contact 131 and the first fixed contact 111 are disconnected, and the second movable contact 132 and the second fixed contact 121 are disconnected, so the first stator 11 and the second stator 12 are not energized.

[0018] On the other hand, when the electromagnetic mechanism 20 is on, the movable element 13 is displaced to the positive side in the z-axis direction. In this state, the first movable contact 131 and the first fixed contact 111 are connected, and the second movable contact 132 and the second fixed contact 121 are connected, so the first stator 11 and the second stator 12 are energized via the movable element 13.

[0019] In this way, the electromagnetic relay 1 uses the electromagnetic mechanism 20 to switch between connecting and disconnecting the first movable contact 131 and the first fixed contact 111, and connecting and disconnecting the second movable contact 132 and the second fixed contact 121. Therefore, the electromagnetic relay 1 can switch between conducting and not conducting the first stator 11 and the second stator 12.

[0020] The case 30 houses the contact mechanism 10 and the electromagnetic mechanism 20. Figure 3 is a perspective view showing an example of the configuration of the contact mechanism and case according to Embodiment 1. As shown in Figure 3, the case 30 comprises a bucket-shaped housing case 31 having a recess 311 formed in the x-axis direction, and a lid 32 covering the opening of the housing case 31.

[0021] As shown in Figure 3, a mounting structure 35 may be formed on at least one of the housing case 31 or the lid 32. The mounting structure 35 is used to fix and position the electromagnetic relay 1 relative to other members. For example, as shown in Figure 3, the mounting structure 35 has a shape that protrudes vertically from the surface of the housing case 31 or the lid 32 and has a hole through which a male screw can pass. The electromagnetic relay 1 is then fixed and positioned relative to other members by the mounting structure 35 and the male screw.

[0022] The contact mechanism 10 is housed in a recess 311 of the housing case 31. The first stator 11 is positioned to pass through a first hole 312 formed in the bottom surface (the negative x-axis side) of the recess 311 of the housing case 31. The first stator 11 and the first hole 312 are hermetically sealed. The second stator 12 is positioned to pass through a second hole 321 formed in the lid 32. The second stator 12 and the second hole 321 are hermetically sealed. In other words, the electromagnetic relay 1 can be hermetically sealed by hermetically sealing two sides in the x-axis direction relative to the case 30, resulting in good manufacturing efficiency. Therefore, an electromagnetic relay that can ensure hermetically sealed operation while keeping manufacturing costs down can be realized.

[0023] Furthermore, at least one of the cross-sectional shapes of the first stator 11 at the position where it penetrates the first hole 312 and the second stator 12 at the position where it penetrates the second hole 321 may be rectangular in shape, with at least one corner having curvature. This reduces stress concentration at the corners of the first hole 312 and the second hole 321, and suppresses the reduction in airtightness due to cracking of the sealing resin 40, which will be described later.

[0024] As shown in Figure 1, the sealing resin 40 comprises a first sealing resin 41 and a second sealing resin 42. Figures 4 to 6 are perspective views showing an example of the configuration of an electromagnetic relay according to Embodiment 1. As shown in Figure 4, the first stator 11 and the first hole 312 are hermetically sealed using the first sealing resin 41. Also, as shown in Figure 5, the second stator 12 and the second hole 321 are hermetically sealed using the second sealing resin 42.

[0025] Furthermore, to further improve airtight sealing, the storage case 31 and the lid 32 may be airtightly joined to each other by thermal melting. For example, the storage case 31 and the lid 32 shown in Figure 6 each have a welding rib 34 protruding in the positive x-axis direction near the boundary between the storage case 31 and the lid 32. By heating and melting the welding rib 34 and then cooling and hardening it, the storage case 31 and the lid 32 are airtightly joined to each other.

[0026] As described above, the electromagnetic relay 1 according to this embodiment has a structure in which the contact mechanism 10 is housed in a housing case 31 that opens in the x-axis direction, and the opening of the housing case 31 is closed with a lid 32. When resin sealing is performed with this structure, the negative x-axis side of the electromagnetic relay 1 having the first stator 11 and the first hole 312, and the positive x-axis side of the electromagnetic relay 1 having the second stator 12 and the second hole 321 are hermetically sealed by the sealing resin 40. In other words, since the hermetically sealed electromagnetic relay 1 is completed by sealing two sides in the x-axis direction to the case 30, the manufacturing efficiency is good. Therefore, airtightness can be ensured while keeping manufacturing costs down.

[0027] The disclosure described above makes it possible to provide an electromagnetic relay that can ensure airtightness while keeping manufacturing costs down.

[0028] <Embodiment 2> Next, an electromagnetic relay according to Embodiment 2 will be described. Figure 7 is a side view showing an example of the configuration of an electromagnetic relay according to Embodiment 2. Figure 8 is a cross-sectional view taken along the cutting line VII-VII in Figure 7. Figures 9 to 11 are enlarged views of the area enclosed by the solid rectangle in Figure 8. As shown in Figure 7, the electromagnetic relay 1a according to this embodiment comprises a contact mechanism 10a, an electromagnetic mechanism 20a, a case 30a, and a sealing resin 40a. The contact mechanism 10a comprises a first stator 11a, a second stator 12a, and a movable element 13a. The case 30a comprises a housing case 31a and a lid 32a.

[0029] In this specification, corresponding components are indicated by the same number. For example, the "contact mechanism 10" shown in Figure 1 and the "contact mechanism 10a" shown in Figure 8 are both represented by the same number "10," indicating that they are corresponding components. In this specification, the addition of "a" to reference numeral 11 indicates that it is the "first stator 11a" of the contact mechanism 10a shown in Figure 8. In other words, the "first stator 11a" in Embodiment 2 corresponds to the "first stator 11" in Embodiment 1, and redundant explanations are omitted as appropriate in this specification. The same applies to each component described below.

[0030] Case 30a according to Embodiment 2 differs from case 30 according to Embodiment 1 in that a first fitting portion 313 is formed in the housing case 31a and a second fitting portion 322 is formed in the lid 32a (see Figure 9). The other configurations are the same as those of the electromagnetic relay 1 described in Embodiment 1, so a redundant explanation will be omitted.

[0031] As shown in Figure 9, the storage case 31a has a convex first fitting portion 313 on at least one side facing the opening. The lid 32a has a concave second fitting portion 322 at a position corresponding to the first fitting portion 313 of the storage case 31a. When the first fitting portion 313 of the storage case 31a is inserted into the second fitting portion 322 of the lid 32a, the first fitting portion 313 of the storage case 31a is fitted with the second fitting portion 322 of the lid 32a, and the lid 32a is fixed to the storage case 31a. This improves the sealing strength between the storage case 31a and the lid 32a.

[0032] As shown in Figure 10, the first fitting portion 313 may be fitted with the second fitting portion 322 by press-fitting. This further improves the sealing strength between the storage case 31a and the lid 32a. Furthermore, the number of first fitting portions 313 is not limited to one, and there may be multiple. In the case of multiple first fitting portions, the first fitting portions 313 may be formed on two opposing long sides of the opening side of the storage case 31a (i.e., two long sides extending in the z-axis direction).

[0033] After the first fitting portion 313 is fitted with the second fitting portion 322, a second sealing resin 42a, which is a resin material, may be provided between the storage case 31a and the lid 32a. This ensures that the storage case 31a and the lid 32a are airtightly sealed, further improving the sealing strength between the storage case 31a and the lid 32a.

[0034] As shown in Figure 11, after the first fitting portion 313 is fitted with the second fitting portion 322, the first fitting portion 313 and the second fitting portion 322 may be further heat-crimped to form a heat-crimped portion 33. In this way, the first fitting portion 313 of the storage case 31a is fitted with the second fitting portion 322 of the lid 32a and heat-crimped, and a second sealing resin 42a, which is a resin material, is provided between the storage case 31a and the lid 32a, thereby further improving the sealing strength between the storage case 31a and the lid 32a.

[0035] In this embodiment, this configuration improves the sealing strength between the storage case 31a and the lid 32a. Furthermore, when the storage case 31a attempts to bulge outward due to internal pressure expansion at high temperatures, the first fitting portion 313 is restrained by the lid 32a, thereby reducing the bulging of the storage case 31a and suppressing a decrease in the airtightness inside the case 30a. Note that the first fitting portion 313 of the storage case 31a may be concave, and the second fitting portion 322 of the lid 32a may be convex.

[0036] <Embodiment 3> Next, an electromagnetic relay according to Embodiment 3 will be described. First, the contact mechanism according to Embodiment 3 will be described with reference to Figures 12 and 13. Figures 12 and 13 are a front view and a perspective view, respectively, showing an example of the configuration of the contact mechanism according to Embodiment 3. As shown in Figures 12 and 13, the contact mechanism 10b according to this embodiment comprises a first stator 11b, a second stator 12b, a movable element 13b, a first permanent magnet 14, and a second permanent magnet 15.

[0037] The contact mechanism 10b according to Embodiment 3 differs from the contact mechanism 10 according to Embodiment 1 in that it includes a first permanent magnet 14 and a second permanent magnet 15 for arc extinguishing. The other configurations are the same as those of the contact mechanism 10 described in Embodiment 1, so a redundant explanation will be omitted.

[0038] As shown in Figure 12, the first permanent magnet 14 for arc extinguishing is located on the outside of the first movable contact 131b and the first fixed contact 111b in the x-axis direction (i.e., on the negative side in the x-axis direction). The second permanent magnet 15 for arc extinguishing is located on the outside of the second movable contact 132b and the second fixed contact 121b in the x-axis direction (i.e., on the positive side in the x-axis direction).

[0039] Furthermore, the first permanent magnet 14 and the second permanent magnet 15 are configured such that the magnetic field extends in the x-axis direction. For example, the first permanent magnet 14 is configured such that the negative x-axis side of its face is the north pole, and the positive x-axis side of its face is the south pole. Similarly, the second permanent magnet 15 is configured such that the negative x-axis side of its face is the south pole, and the positive x-axis side of its face is the north pole. Note that the north and south poles may be reversed.

[0040] As described above, in this embodiment, a first permanent magnet 14 is provided to generate a magnetic field in the x-axis direction near the first movable contact 131b and the first fixed contact 111b. Similarly, in this embodiment, a second permanent magnet 15 is provided to generate a magnetic field in the x-axis direction near the second movable contact 132b and the second fixed contact 121b. Therefore, the arcs generated when the first movable contact 131b and the first fixed contact 111b change from a connected state to a disconnected state, and the arcs generated when the second movable contact 132b and the second fixed contact 121b change from a connected state to a disconnected state, can be extinguished.

[0041] In other words, in this embodiment, arcs generated near the first movable contact 131b and the first fixed contact 111b can be demagnetized by stretching them in the y-axis direction using the magnetic field of the first permanent magnet 14. Similarly, arcs generated near the second movable contact 132b and the second fixed contact 121b can be demagnetized by stretching them in the y-axis direction using the magnetic field of the second permanent magnet 15. The direction in which the arc stretches is either the positive or negative side of the y-axis direction, and the direction in which the arc stretches is determined according to the direction of the current flowing through the contact mechanism 10b and the direction of the magnetic fields of the first permanent magnet 14 and the second permanent magnet 15.

[0042] The contact mechanism 10b according to this embodiment may further include a yoke 16. As shown in FIG. 13, a yoke 16 for strengthening the magnetic field for arc extinction is provided for the first permanent magnet 14 and the second permanent magnet 15. Specifically, as shown in FIG. 13, the yoke 16 has a U-shaped configuration in which a plate member extending in the z-axis direction and a plate member extending in the x-axis direction are perpendicularly connected. The first permanent magnet 14 is attached to the plate member on the minus side in the x-axis direction that extends in the z-axis direction of the yoke 16. Further, the second permanent magnet 15 is attached to the plate member on the plus side in the x-axis direction that extends in the z-axis direction of the yoke 16. Note that the yoke 16 may be formed by bending a single metal plate into a U shape.

[0043] Next, referring to FIGS. 14 and 15, the electromagnetic relay according to Embodiment 3 will be described. FIGS. 14 and 15 are a side view and a cross-sectional perspective view respectively showing a configuration example of the electromagnetic relay according to Embodiment 3. As shown in FIGS. 14 and 15, the electromagnetic relay 1b according to this embodiment includes the contact mechanism 10b, the electromagnetic mechanism 20b, the case 30b, and the sealing resin 40b described above.

[0044] The case 30b according to Embodiment 3 is different in that a third hole portion 314 (see FIG. 15) is formed in the housing case 31b and a fourth hole portion 323 is formed in the lid body 32b as compared with the case 30 according to Embodiments 1 and 2. Since the other configurations are the same as those of the electromagnetic relays 1 and 1a described in Embodiments 1 and 2, duplicate descriptions will be omitted.

[0045] As shown in FIG. 15, the third hole portion 314 is formed at a position corresponding to the first permanent magnet 14 on the bottom surface of the recess 311b of the housing case 31b. The first permanent magnet 14 is adhered to the housing case 31b by a resin material introduced from the third hole portion 314. As shown in FIGS. 14 and 15, the fourth hole portion 323 is formed at a position corresponding to the second permanent magnet 15 of the lid body 32b. The second permanent magnet 15 is adhered to the lid body 32b by a resin material introduced from the fourth hole portion 323. The shapes of the third hole portion 314 and the fourth hole portion 323 are not particularly limited, such as circular or square.

[0046] In this embodiment, the first permanent magnet 14 and the second permanent magnet 15 are adhered to the case 30b by the resin material introduced from the third hole 314 and the fourth hole 323 opened in the case 30b. With such a configuration, displacement of the first permanent magnet 14 and the second permanent magnet 15 with respect to the contact mechanism 10b due to vibration, impact, etc. is suppressed, and arcing can be more suitably extinguished.

[0047] FIG. 16 is a side view showing a configuration example of an electromagnetic relay with the lid removed according to Embodiment 3. As shown in FIG. 16, when the contact mechanism 10b is housed in the case 30b, the contact mechanism 10b may be arranged so as to be eccentric in the direction opposite to the direction in which an arc extends (the minus y-axis direction in FIG. 16) from the center position z1 in the y-axis direction of the opening of the housing case 31b.

[0048] That is, when the opening of the housing case 31b is viewed in plan, the opening is rectangular. When the direction in which the long side of the rectangular opening extends is defined as the z-axis direction and the direction in which the short side extends is defined as the y-axis direction, the first permanent magnet 14 and the second permanent magnet 15 are arranged in the housing case 31b so that an arc extends in the minus y-axis direction. Further, the contact mechanism 10b is arranged in the housing case 31b so as to be eccentric in the direction opposite to the direction in which an arc extends from the center position z1 in the y-axis direction of the opening of the housing case 31b. With such a configuration, the space for extinguishing the arc can be made larger. Therefore, the arc can be more suitably extinguished.

[0049] <Embodiment 4> Next, an electromagnetic relay according to Embodiment 4 will be described. First, referring to FIGS. 17 to 19, the electromagnetic mechanism according to Embodiment 4 will be described. FIG. 17 is a front view showing a configuration example of a contact mechanism and an electromagnetic mechanism according to Embodiment 4. FIG. 18 is a cross-sectional view taken along the cutting line XVII-XVII of FIG. 17 in a non-energized state. FIG. 19 is a cross-sectional view taken along the cutting line XVII-XVII of FIG. 17 in an energized state. As shown in FIG. 17, the electromagnetic relay 1c according to the present embodiment includes a contact mechanism 10c, an electromagnetic mechanism 20c, a case 30c (not shown), and a sealing resin 40c (not shown).

[0050] As shown in Figure 17, the contact mechanism 10c according to this embodiment comprises a first stator 11c, a second stator 12c, a movable element 13c, and a movable plate 17. The contact mechanism 10c according to Embodiment 4 differs from the contact mechanism 10 according to Embodiment 1 in that it includes a movable plate 17. The other configurations are the same as those of the contact mechanism 10 described in Embodiment 1, so redundant explanations are omitted.

[0051] As shown in Figures 17 to 19, the movable plate 17 comprises a plate-shaped member 170 and a plate-shaped member 171. As shown in Figures 18 and 19, the plate-shaped member 170 is connected to the second surface (the negative side in the z-axis direction) of the conductive plate 130c provided on the movable element 13c. The plate-shaped member 170 is provided to extend in the negative side in the y-axis direction. The negative end of the plate-shaped member 170 in the y-axis direction is connected to the plate-shaped member 171. The plate-shaped member 171 is provided to extend in the negative side in the z-axis direction. The movable plate 17 can be constructed using a metal material. The plate-shaped members 170 and 171 that constitute the movable plate 17 may be formed integrally. In other words, the movable plate 17 may be formed by bending a single metal plate into an L-shape.

[0052] As shown in Figures 17 and 18, the electromagnetic mechanism 20c according to Embodiment 4 comprises an electromagnetic mechanism body 21, a yoke 22, and a movable iron piece 23. As shown in Figure 18, a plate-shaped member 171 of the movable plate 17 is fixed to the movable iron piece 23. The movable iron piece 23 is connected to the yoke 22 near the connection point between the movable iron piece 23 and the plate-shaped member 171. Therefore, as shown in Figures 18 and 19, when the movable iron piece 23 rotates around the connection point with the yoke 22 as the center of rotation, the movable plate 17 also rotates, and the movable element 13c is displaced in the y-axis direction and the z-axis direction.

[0053] Specifically, when the electromagnetic mechanism body 21 is off, as shown in Figure 18, the movable iron piece 23 is not attracted to the electromagnetic mechanism body 21, so the movable element 13c remains stationary at a position on the negative side of the z-axis. In this state, the first movable contact 131c and the first fixed contact 111c are disconnected, and the second movable contact 132c (not shown) and the second fixed contact 121c (not shown) are disconnected, so the first stator 11c and the second stator 12c are not energized.

[0054] On the other hand, when the electromagnetic mechanism body 21 is ON, as shown in Figure 19, the movable iron piece 23 is attracted to the electromagnetic mechanism body 21, so the movable element 13c is displaced to the positive side in the z-axis direction. In this state, the first movable contact 131c and the first fixed contact 111c are connected, and the second movable contact 132c (not shown) and the second fixed contact 121c (not shown) are connected, so the first stator 11c and the second stator 12c are energized via the movable element 13c.

[0055] As described above, the electromagnetic relay 1c according to this embodiment is equipped with an electromagnetic mechanism 20c that can displace the movable element 13c in the z-axis direction. The electromagnetic mechanism 20c is used to switch between connecting and disconnecting the first movable contact 131c and the first fixed contact 111c, and connecting and disconnecting the second movable contact 132c and the second fixed contact 121c. Therefore, the electromagnetic relay 1c can switch between conducting and not conducting the first stator 11c and the second stator 12c.

[0056] Furthermore, in this embodiment, when switching between conductivity and non-conductivity between the first stator 11c and the second stator 12c, the electromagnetic relay 1c displaces the movable element 13c not only in the z-axis direction but also in the y-axis direction. As a result of the displacement of the movable element 13c in the y-axis direction, the surface of the first movable contact 131c and the surface of the first fixed contact 111c rub against each other, and similarly, the surface of the second movable contact 132c and the surface of the second fixed contact 121c rub against each other. This removes contaminating films and foreign matter adhering to the surfaces of the first movable contact 131c, the first fixed contact 111c, the second movable contact 132c, and the second fixed contact 121c. Therefore, it is possible to suppress the increase in electrical resistance and the obstruction of conductivity between contacts caused by contaminating films and foreign matter. Furthermore, since the movable element 13c is also displaced in the y-axis direction, the rebound (i.e., bounce) of the first movable contact 131c and the second movable contact 132c in the z-axis direction during connection between the contacts, which affects electrical durability, can be reduced.

[0057] <Embodiment 5> Next, an electromagnetic relay according to Embodiment 5 will be described. Figure 20 is a perspective view showing an example of the configuration of the contact mechanism and electromagnetic mechanism according to Embodiment 5. Figure 21 is a front view of the electromagnetic relay according to Embodiment 5. Figure 22 is a cross-sectional view taken along the cutting line XXI-XXI in Figure 21. As shown in Figures 20 to 22, the electromagnetic relay 1d comprises a contact mechanism 10d, an electromagnetic mechanism 20d, a case 30d, a sealing resin 40d, and a base 50.

[0058] As shown in Figure 22, the electromagnetic relay 1d according to this embodiment differs from the electromagnetic relay 1c according to Embodiment 4 in that it includes a base 50. Note that, apart from the configuration including the base 50, it is the same as the electromagnetic relay 1c described in Embodiment 4, so a redundant explanation will be omitted.

[0059] As shown in Figure 20, the yoke 22 supporting the first stator 11d, the second stator 12d, and the movable element 13d, as well as the first permanent magnet 14 and the second permanent magnet 15, are fixed to the base 50. The base 50 is, for example, frame-shaped or box-shaped, and is configured to have an opening in the direction in which the arc extends (in the case of Figure 22, the negative y-axis direction). With this configuration, the base 50 can suppress obstruction of the arc, and the space for arc extinguishing can be made larger. Therefore, the arc can be extinguished more effectively.

[0060] <Embodiment 6> Next, an electromagnetic relay according to Embodiment 6 will be described. Figure 23 is a side view showing an example of the configuration of an electromagnetic relay according to Embodiment 6. As shown in Figure 23, the electromagnetic relay 1e according to this embodiment comprises a contact mechanism 10e, an electromagnetic mechanism 20e, a case 30e, and a sealing resin 40e.

[0061] Furthermore, as shown in Figure 23, the electromagnetic relay 1e according to this embodiment has a terminal 24 for supplying drive current to the electromagnetic mechanism body 21.

[0062] The terminal 24 is positioned to extend from the electromagnetic mechanism body 21 in the x-axis direction. The terminal 24 passes through the fifth hole 324 formed in the lid 32e. The fifth hole 324 may be provided on the bottom surface of the recess of the housing case 31e.

[0063] In case 30e, the holes that need to be resin-sealed are the first hole 312, the second hole 321, and the fifth hole 324. The first hole 312 is on the negative side in the x-axis direction, the second hole 321 is on the positive side in the x-axis direction, and the fifth hole 324 is on one of the two faces in the x-axis direction. Therefore, sealing the two faces in the x-axis direction completes the airtight bond, resulting in good manufacturing efficiency.

[0064] <Embodiment 7> Next, an electromagnetic relay according to Embodiment 7 will be described. Figure 24 is a perspective view showing an example of the configuration of an electromagnetic relay according to Embodiment 7. As shown in Figure 24, the electromagnetic relay 1f according to this embodiment comprises a contact mechanism 10f, an electromagnetic mechanism 20f (not shown), a case 30f, and a sealing resin 40f.

[0065] As shown in Figure 24, the electromagnetic relay 1f according to this embodiment differs from the electromagnetic relay 1 according to Embodiment 1 in that the housing case 31f is equipped with a ventilation hole 315. The other configurations are the same as those of the electromagnetic relay 1f described in Embodiment 1, so a redundant explanation will be omitted.

[0066] The ventilation holes 315 formed in the housing case 31f release at least one of the pressure generated when the first stator 11f and the first hole 312f are airtight sealed using the first sealing resin 41f, and the pressure generated when the second stator 12f and the second hole 321f are airtight sealed using the second sealing resin 42f.

[0067] If the ventilation holes 315 are not formed, the high pressure inside the case 30f when the first sealing resin 41f and the second sealing resin 42f are heat-cured will try to escape to the outside of the case 30f through the first sealing resin 41f and the second sealing resin 42f. In this case, the first sealing resin 41f and the second sealing resin 42f may harden with holes, for example, and there is a risk that airtight sealing cannot be ensured. Therefore, the electromagnetic relay 1f according to this embodiment ensures airtight sealing of the first sealing resin 41f and the second sealing resin 42f by releasing the high pressure inside the case 30f to the outside of the case 30f through the ventilation holes 315. Note that the ventilation holes 315 may be formed not only in the housing case 31f but also in the lid 32f.

[0068] The ventilation holes 315 are sealed after the first sealing resin 41f and the second sealing resin 42f have been heat-cured, that is, after the first stator 11f and the first hole 312f, and the second stator 12f and the second hole 321f have been airtightly sealed. The sealing of the ventilation holes 315 is not particularly limited to methods other than sealing the ventilation holes 315 by melting them with heat, such as filling them with a resin material.

[0069] <Embodiment 8> Next, an electromagnetic relay according to Embodiment 8 will be described. Figures 25 to 27 are cross-sectional views showing an example of the configuration of an electromagnetic relay according to Embodiment 8. As shown in Figure 25, the electromagnetic relay 1g according to this embodiment comprises a contact mechanism 10g, an electromagnetic mechanism 20g (not shown), a case 30g, and a sealing resin 40g (not shown).

[0070] As shown in Figure 25, the contact mechanism 10g according to this embodiment differs from the contact mechanism 10g according to Embodiment 1 in that screw structures 112 and 122 are formed on the first stator 11g and the second stator 12g. The other configurations are the same as those of the contact mechanism 10 described in Embodiment 1, so a redundant explanation will be omitted.

[0071] As shown in Figure 25, the threaded structures 112 and 122 are formed on the conductive plate 110g of the first stator 11g and the conductive plate 120g of the second stator 12g. More specifically, the threaded structures 112 and 122 are formed on the portions of the conductive plates 110g and 120g that are not housed in the case 30g, with the rotation axis direction being the z axis direction. Furthermore, since the threaded structures 112 and 122 are formed to fit within the plate thickness of the conductive plates 110g and 120g, it is possible to process and form the threaded structures 112 and 122 before housing the first stator 11g and the second stator 12g in the case 30g, thereby increasing the degree of freedom in the manufacturing process.

[0072] The conductive plates 110g and 120g are fixed to a predetermined member by the screw-type structures 112 and 122, and are electrically connected. The predetermined member is, for example, a terminal connected to an electrical component in a circuit into which the contact mechanism 10g is incorporated. The conductive plates 110g and 120g are fixed to the predetermined member by reverse-threaded bolts in addition to the screw-type structures 112 and 122. The screw-type structures 112 and 122 firmly fix the conductive plates 110g and 120g to the predetermined member, thereby improving the stability of the electrical connection.

[0073] Alternatively, instead of forming the screw structures 112 and 122 on the conductive plates 110g and 120g as shown in Figure 25, the screw structures may be formed by fixing screw members 113 and 123, which are members equipped with the screw structures 112 and 122, to the conductive plates 110g and 120g, as shown in Figures 26 and 27. Since the screw structures 112 and 122 shown in Figure 25 are female threads, the screw structure of a given member is limited to a male thread. On the other hand, the screw structures 112 and 122 shown in Figure 26 are male threads, and the screw structures 112 and 122 shown in Figure 27 are female threads. Therefore, in the case of the screw members 113 and 123 shown in Figures 26 and 27, the screw structure of a given member can be either a male or female thread.

[0074] Here, when fixing the conductive plates 110g and 120g to a predetermined member, in the case of the screw structures 112 and 122 shown in Figures 25 and 27, the user does not need to prepare nuts separately, and in the case of Figure 26, the user does not need to prepare bolts.

[0075] <Embodiment 9> Next, an electromagnetic relay according to Embodiment 9 will be described. Figures 28 to 30 are perspective views, bottom views, and side views, respectively, showing an example of the configuration of the contact mechanism according to Embodiment 9. As shown in Figures 28 to 30, the contact mechanism 10h according to this embodiment comprises a first stator 11h, a second stator 12h, and a movable element 13h.

[0076] The contact mechanism 10h according to this embodiment differs from the contact mechanism 10 according to Embodiment 1 in that the second stator 12h has an excitation section 124. The other configurations are the same as those of the contact mechanism 10 described in Embodiment 1, so a redundant explanation will be omitted.

[0077] The second stator 12h has a second fixed contact 121h that is connectable to the second movable contact 132h of the movable element 13h, and an excitation unit 124. The excitation unit 124 of the second stator 12h is configured to generate a magnetic field in the y-axis direction when the contact mechanism 10h is energized (see Figure 31). Specifically, as shown in Figure 30, the excitation unit 124 has an annular structure in which a first conductive member 125 and a third conductive member 127 extending in the x-axis direction and a second conductive member 126 and a fourth conductive member 128 extending in the z-axis direction are connected in the order of the first conductive member 125, the second conductive member 126, the third conductive member 127, and the fourth conductive member 128. The fourth conductive member 128 is connected to a conductive member (fifth conductive member) 129, and the second fixed contact 121h is provided on the negative z-axis side surface of the conductive member 129. In other words, the second fixed contact 121h is located on the side of the fourth conductive member 128 among the first to fourth conductive members 125 to 128 that constitute the excitation section 124. Therefore, when the contact mechanism 10h is energized, current flows through the excitation section 124, and the current flows through the first conductive member 125, the second conductive member 126, the third conductive member 127, and the fourth conductive member 128 in that order (see Figure 31).

[0078] When the contact mechanism 10h is energized, current flows through the excitation unit 124, and as shown in Figure 31, a magnetic field is generated inside the excitation unit 124 that is directed toward the negative side in the y-axis direction. Also, as shown in Figure 31, the excitation unit 124 is positioned so as to overlap with the movable element 13h (conductive plate 130h) when viewed from the y-axis direction. Therefore, as shown in Figure 31, when the contact mechanism 10h is energized, a Lorentz force is generated on the movable element 13h (conductive plate 130h) in the direction that maintains the energized state (positive side in the z-axis direction) due to the magnetic field generated by the excitation unit 124. Thus, by using the Lorentz force acting toward the positive side in the z-axis direction, the electromagnetic repulsive force (force acting toward the negative side in the z-axis direction) acting between the movable element 13h and the first stator 11h and the second stator 12h when energized can be effectively suppressed.

[0079] Furthermore, in this embodiment, as shown in Figures 29 and 30, the first conductive member 125 and the third conductive member 127 are configured to overlap with the movable element 13h (conductive plate 130h) when viewed from the z-axis direction. In other words, as shown in Figure 30, the excitation unit 124 is configured to have a U-shaped cross-section when viewed from the x-axis direction.

[0080] As shown in Figure 31, when the contact mechanism 10h is energized, the direction of the current flowing through the conductive plate 130h of the movable element 13h and the direction of the current flowing through the first conductive member 125 are the same, while the direction of the current flowing through the conductive plate 130h of the movable element 13h and the direction of the current flowing through the third conductive member 127 are opposite. Therefore, when the contact mechanism 10h is energized, an attractive force due to the Lorentz force is generated between the first conductive member 125 and the conductive plate 130h of the movable element 13h. Also, a repulsive force due to the Lorentz force is generated between the third conductive member 127 and the conductive plate 130h of the movable element 13h. Therefore, when energized, a Lorentz force acts on the conductive plate 130h of the movable element 13h in the positive z-axis direction, so the electromagnetic repulsive force (force acting in the negative z-axis direction) acting between the movable element 13h and the first stator 11h and the second stator 12h can be effectively suppressed. In this embodiment, the same effect can be obtained even if the direction of the current flowing through the contact mechanism 10h is opposite to the direction of the current shown in Figure 31.

[0081] It should be noted that the present invention is not limited to the embodiments described above, and can be modified as appropriate without departing from the spirit of the invention. Furthermore, each embodiment may be combined with others.

[0082] Although the present invention has been described above in accordance with the above embodiments, the present invention is not limited to the configuration of the above embodiments, and of course includes various modifications, alterations, and combinations that can be made by a person skilled in the art within the scope of the claims of the present patent application.

[0083] This application claims priority based on Japanese Patent Application No. 2024-206263, filed on 27 November 2024, and incorporates all of its disclosures herein.

[0084] 1 Electromagnetic relay 10 Contact mechanism 11 First stator 12 Second stator 13 Movable element 14 First permanent magnet 15 Second permanent magnet 16 Yoke 17 Movable plate 20 Electromagnetic mechanism 21 Electromagnetic mechanism body 22 Yoke 23 Movable iron piece 24 Terminal 30 Case 31 Housing case 32 Cover 33 Heat crimping part 34 Welding rib 35 Mounting structure 40 Sealing resin 41 First sealing resin 42 Second sealing resin 50 Base 110 Conductive plate 111 First fixed contact 112 Screw structure 113 Screw member 120 Conductive plate 121 Second fixed contact 122 Screw structure 123 Screw member 124 Excitation part 125 First conductive member 126 Second conductive member 127 Third conductive member 128 Fourth conductive member 129 Fifth conductive member 130 Conductive plate 131 First movable contact 132 Second movable contact 170, 171 Plate-shaped member 311 Recess 312 First hole 313 First fitting part 314 Third hole 315 Ventilation hole 321 Second hole 322 Second fitting part 323 Fourth hole 324 Fifth hole

Claims

1. An electromagnetic relay comprising: a movable element having a first movable contact and a second movable contact provided on both ends in the first direction of a first surface of a conductive plate extending in a first direction; a first stator having a first fixed contact provided to connect to the first movable contact; and a second stator having a second fixed contact provided to connect to the second movable contact; and a case housing the contact mechanism, wherein the case comprises a bucket-shaped housing case housing the contact mechanism in a recess formed in the first direction, and a lid covering the opening of the housing case, the first stator being arranged to pass through a first hole formed in the bottom surface of the recess of the housing case, and the second stator being arranged to pass through a second hole formed in the lid.

2. The electromagnetic relay according to claim 1, wherein a mounting structure is formed in at least one of the housing case or the lid.

3. The electromagnetic relay according to claim 1 or 2, wherein the first stator and the first hole are hermetically sealed using a sealing resin, and the second stator and the second hole are hermetically sealed using a sealing resin.

4. The electromagnetic relay according to claim 1 or 2, wherein the housing case and the lid are hermetically joined to each other by thermal fusion.

5. An electromagnetic relay according to claim 1 or 2, wherein a first fitting portion is formed on at least one side of the housing case on the opening side, a second fitting portion is formed on the lid at a position corresponding to the first fitting portion of the housing case, and the lid is fixed to the housing case by the first fitting portion of the housing case fitting with the second fitting portion of the lid.

6. The electromagnetic relay according to claim 5, wherein the first fitting portion of the housing case is fitted with the second fitting portion of the lid and heat-crimped, and a resin material is provided between the housing case and the lid, thereby hermetically sealing the housing case and the lid.

7. The electromagnetic relay according to claim 5, wherein the first fitting portion of the housing case fits with the second fitting portion of the lid, and a resin material is provided between the housing case and the lid, thereby hermetically sealing the housing case and the lid.

8. The electromagnetic relay according to claim 5, wherein the first fitting portion is formed on two opposing long sides of the housing case on the opening side.

9. An electromagnetic relay according to claim 1 or 2, wherein a first permanent magnet for arc extinguishing is provided on the outer side of the first movable contact and the first fixed contact in the first direction, and a second permanent magnet for arc extinguishing is provided on the outer side of the second movable contact and the second fixed contact in the first direction.

10. The electromagnetic relay according to claim 9, wherein the first and second permanent magnets are provided with yokes for strengthening the magnetic field for arc extinguishing.

11. An electromagnetic relay according to claim 9, wherein a third hole is formed in the bottom surface of the recess of the housing case at a position corresponding to the first permanent magnet, the first permanent magnet is bonded to the housing case by a resin material introduced through the third hole, and a fourth hole is formed in the lid at a position corresponding to the second permanent magnet, the second permanent magnet is bonded to the lid by a resin material introduced through the fourth hole.

12. When the opening of the housing case is viewed from above, the opening is rectangular, and when the direction in which the long side of the rectangular opening extends is designated as the second direction and the direction in which the short side extends is designated as the third direction, the first and second permanent magnets are arranged such that the arcs generated near the first movable contact and the first fixed contact and near the second movable contact and the second fixed contact extend in the third direction, and the contact mechanism is arranged so as to be eccentric from the center position of the opening of the housing case in the third direction to the side opposite to the direction in which the arcs extend, the electromagnetic relay according to claim 9.

13. The electromagnetic relay according to claim 1 or 2, wherein, when the opening of the housing case is viewed from above, the opening is rectangular, and when the direction in which the long side of the rectangular opening extends is designated as the second direction and the direction in which the short side extends is designated as the third direction, the movable element is configured to be displaced in the second direction and the third direction.

14. The electromagnetic relay according to claim 1 or 2, wherein at least one of the cross-sectional shape of the first stator at a position passing through the first hole and the cross-sectional shape of the second stator at a position passing through the second hole is rectangular in shape, with at least one corner having curvature.

15. The electromagnetic relay according to claim 9, wherein the first stator, the second stator, the yoke supporting the movable element, the first permanent magnet, and the second permanent magnet are fixed to a base, and the base is configured to have openings in the direction from which arcs generated near the first movable contact and the first fixed contact and near the second movable contact and the second fixed contact extend.

16. The electromagnetic relay according to claim 1 or 2, further comprising an electromagnetic mechanism capable of displacing the movable element, wherein a terminal for supplying a drive current to the electromagnetic mechanism is arranged to extend in the first direction and is configured to penetrate a fifth hole formed in the bottom surface of the recess of the housing case or the lid.

17. The housing case or the lid is provided with vents to release at least one of the pressure generated when the first stator and the first hole are airtightly sealed with a sealing resin, and the pressure generated when the second stator and the second hole are airtightly sealed with a sealing resin, wherein the vents are sealed after the first stator and the first hole, and the second stator and the second hole are airtightly sealed. The electromagnetic relay according to claim 1 or 2.

18. The electromagnetic relay according to claim 1 or 2, wherein the first stator and the second stator are formed with a screw structure capable of fixing a predetermined member.

19. The electromagnetic relay according to claim 18, wherein the screw structure is formed by fixing a member having the screw structure to the first stator and the second stator.

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