JPH0353732B2 - - Google Patents

Description

[Detailed Description of the Invention] (1) Technical Field of the Invention The present invention relates to a thin and small relay that is mainly used mounted on a printed board, and particularly relates to a relay with fixed and movable contact spring terminals inserted into a surrounding wall. The present invention relates to an electromagnetic relay having a structure in which an electromagnet having at least an iron core, a coil, and an armature is housed in a box-shaped insulating casing, and a method for manufacturing the same.

(2) Background of the technology, conventional technology, and problems Figure 1 is a perspective view showing a conventional small electromagnetic relay (hereinafter simply referred to as a relay), and Figure 2 is an exploded perspective view of the relay shown in Figure 1. . In these figures, reference numeral 10 denotes a supporting member made of an insulating material and having a rectangular box shape with an opening at the top and a bottom, and a through hole 12 for inserting a terminal is formed in the opposing side wall 11 of the supporting member 10. ing. Further, on the upper surface of the both side walls 11, there are protrusions 13 and recesses 1 for fixing the movable contact spring mold.
4 is integrally formed with a protrusion 15 for fixing the yoke plate. Furthermore, a slit 17 is formed in the other side wall 16.

Further, 20, 20' and 21, 21' are fixed contact terminals, 22, 22' are coil terminals, and 23, 23' are contact pull-out terminals.
It is provided with a retaining piece 24 which is bent after being inserted into the through hole 12 of 1. In addition, fixed contact terminal 20 (2
1) and 20'(21') have a step at the contact portion 25, and a movable contact spring, which will be described later, is arranged between the contact portions 25 to form a transfer contact.

30 is an iron core 32 around which a coil 31 is wound, which is shown by a dotted line, an L-shaped yoke plate 33, and an L-shaped armature 34.
It is an electromagnet part having a The lead wires in and out of the coil 31 are connected to the connection portion 2 of the coil terminals 22 and 22'.
6 and then solder connected. Also, iron core 3
2 is caulked to the yoke plate 33 at one end,
The other end acts as a suction portion 35 of the armature 34.
Furthermore, the yoke plate 33 has a protrusion 37 with holes 36 on both sides.
The armature 34 is provided with a movable contact spring driving piece 38 and a protrusion 39 in its extension. 40
connects a pair of movable contact springs 41 to the molded body 4 at one end.
This is a movable contact spring body fixed by 2.

The movable contact spring 41 is bent somewhat into a chevron shape,
Fixed contacts 20 (21) and 20' (2
1'), and an insulator 44 with molded contact parts 43, 43' facing toward and away from the contact part 43, 43' in the center part, and a connecting piece 45 which is directly soldered connected to the connecting part 27 of the contact extraction terminals 23, 23' at the other end. have Also, mold end 4
2 is provided with holes 46 on both sides thereof into which the protrusions 13 are fitted. Reference numeral 50 denotes a recovery spring plate which also serves as a spring to prevent the armature 34 from falling off, and is composed of an integral plate consisting of an L-shaped spring piece 52 with a hole 51 at one end and a fitting piece 54 with a cut-out 53. 60 is a transparent relay cover.

Next, a method of assembling the above-mentioned relay will be explained. In the above-mentioned relay, each member is a support member 1
All can be mounted from the opening side of 0. That is, the fixed contact terminal 2 is first attached to the support member 10.
0, 20', 21, 21' and coil terminals 22, 2
2' and contact pull-out terminals 23, 23' are respectively inserted into the through hole 12 and fixed with the retaining piece 24. The electromagnet part 30 has the iron core 32 side facing downward and the yoke plate 33 facing the opening side, and the protrusion 37 and hole 36 are connected to the recess 14 and the protrusion 15.
to be inserted into. Further, the armature 34 is arranged so that the drive piece 38 is placed on the yoke plate 33 and one end a of the yoke plate 33 and the side wall 16
2, and arranged so that one end a and the bending position b coincide with each other. In this state, the armature 34 is
5 and the bending angle at bending position b is
Since the bending angle is somewhat larger than 90°, the suction part 35
A gap is formed between them.

Further, the restoration spring plate 50 is inserted into the slit 17 and held by the elasticity of the cut and raised portion 53. Then, the spring piece 52 of the restoration spring plate 50 is attached to the armature 44.
position it above, and fit the hole 51 into the protrusion 39.

The movable contact spring mold 40 is a movable contact spring 41
is positioned between the fixed contacts 20 (21) and 20'(21'), and with the insulator 44 placed on the drive piece 38, the hole 46 is fitted into the protrusion 13, and the molded body 42 is placed on the side wall 11. Place it in After that, hole 3
The heads of the protrusions 13 and 15 protruding from the yoke plates 6 and 46 are heat caulked, and the yoke plate 33 and the movable contact spring mold 40 are attached.
is attached to the side wall 11 of the support member 10. Further, the solder connection process for the lead wire of the coil 31 wound around the connection part 26 and the solder connection process for the connection part 27 and the connection piece 45 are also performed. And finally relay cover 60
This relay is manufactured by attaching this to the support member 10.

In the above-described relay, when the electromagnet is not energized, the movable contact spring 41 is connected to the fixed contact terminal 20.
(21') is electrically connected. electromagnet 30
When energized, the armature 34 is attracted by the suction part 35, and the drive piece 38 pushes up the movable contact spring 41 via the insulator 44, and the movable contact spring 41 connects with the fixed contact spring 20 (21'). Contact switching occurs upon contact.

However, in the conventional relay, the electromagnet 30, the movable contact spring body 40, the recovery spring plate 50, the contact spring terminals 20, 20', 21,
21' etc. are assembled one after another, which causes the following disadvantages.

(1) The number of assembly steps required to manufacture one relay becomes extremely large, requiring a long time for assembly and lengthening the assembly line.

(2) As the assembly of parts progresses, the assembly work becomes complicated, and each part is likely to be deformed, making it difficult to obtain a highly reliable relay.

(3) Because it is necessary to assemble many parts into the housing, if the relay is made too small, the disadvantages of (1) and (2) mentioned above will become more and more obvious, so it is difficult to obtain a sufficiently small relay. I can't.

(3) Purpose of the Invention The present invention enables relay assembly work to be carried out efficiently and easily in a short time, reduces the number of component parts, and therefore provides a low-cost, thin and small relay. The purpose is to provide a manufacturing method that can obtain

(4) Structure of the Invention In order to achieve the above object, the present invention forms a box-shaped insulating casing in which a fixed contact spring terminal and a movable contact spring terminal are inserted into the surrounding wall and whose upper and lower surfaces are open. After the fixed contact spring terminal and the movable contact spring terminal are bent, an iron core and a yoke are attached to the coil bobbin, and a coil is wound thereon;
An electromagnet characterized in that an electromagnet having at least a rotatably supported armature whose bent portion abuts one end of the yoke is inserted through a lower opening of the insulating casing and incorporated into the insulating casing. A method for manufacturing a relay is provided.

(5) Embodiment of the invention FIG. 3 is a perspective view showing a relay according to an embodiment of the invention, FIG. 4 is a partially sectional side view showing the relay of FIG. 3, and FIG. 6 is a perspective view showing a lead frame used in the relay shown in FIG. 3; FIG. 7 is a perspective view showing an insert mold base including the lead frame shown in FIG. 6; 8 is a schematic perspective view showing equipment for manufacturing the insert mold base shown in FIG. 7, and FIGS. 9A and 9B are perspective views for explaining the assembly process of the electromagnet shown in FIG. 5.

Embodiments of the present invention will be described below using the drawings of FIGS. 3 to 9. 3 and 4 respectively show a relay cover 1 of a relay according to an embodiment of the present invention.
01 is a perspective view and a side view showing an open state. In FIG. 3, 110 is a box-shaped insulating casing molded with an insulating material such as synthetic resin and open on both upper and lower sides, 111a and 111b are fixed contact terminals on the make side, and 112a
and 112b are fixed contact terminals on the break side, 1
13a and 113b indicate movable contact mounting terminals. These fixed contact terminals 111a, 111b,
112a, 112b and movable contact mounting terminal 1
13a and 113b are attached to opposing side walls 114a and 114b of the housing 110 by insert molding. Further, these fixed contact terminals 111a, 111b, 112a, 112b and movable contact mounting terminals 113a, 113b are terminal portions 111a', 111 for external connection, respectively.
b', 112a', 112b' and 113a', 113
has b′. However, in Figure 3, the terminal part 1
11b', 112b', 113b' are not shown.
Fixed contact terminals 111a (or 111b) and 11
A step is provided between the contact portions 111a'' (or 111b'') of 2a (or 112a') and 112a'' (or 112b''), and the movable contact spring 115a
(or 115b) is the contact portion 111a'' (or 1
11b'') and 112a'' (or 112b'') to form a transfer contact.The rear ends of each movable contact spring 115a and 115b are attached by welding to movable contact mounting terminals 113a and 113b, respectively. In addition, the movable contact springs 115a and 115b are both biased in the direction of the break-side fixed contact terminals 112a and 112b, so in the restored state where the electromagnet 116 is not excited, the movable contact springs 115a and 115b 115b is the fixed contact terminal 1 on the break side, respectively.
12a and 112b.

An electromagnet 116 is housed in the housing 110, and in FIG.
17, armature holding spring 118, coil terminal 119
a, 119b and movable contact springs 115a, 11
An insulator 120 is shown attached to the end of armature 117 pushing up 5b. Housing 1
Protrusions 121a and 121b are integrally molded at the upper ends of the central portions of opposing side walls 114a and 114b of housing 110, and position and hold the electromagnet inserted from the lower opening of housing 110. In addition, there are other protrusions 12 near 121a and 121b.
2a, 122b are provided, and these protrusions 122a, 122b fit into recesses (not shown) provided in the relay cover 101 to close the housing 11.
To strengthen the connection between 0 and the relay cover. however,
In FIG. 3, protrusions 121b and 122b are not shown.

The relay cover 101 is made by molding an insulating material such as transparent synthetic resin, for example. A partition wall 102 for contact separation is integrally molded inside the relay cover 101 so as to fit between the fixed contact terminals 111a, 112a and 111b, 112b of each circuit, thereby improving the withstand voltage between each contact terminal. . Further, a protrusion 103 is provided at one corner of the relay cover 101, and the protrusion 103 is used to remove solder flux, which is applied after the relay is assembled and mounted on a printed circuit board by solder dipping, for example. After a relay cleaning process, a ventilation hole for heat dissipation is formed on the relay cover 101 by cutting it out.

Further, as shown in FIG. 4, a relay cover 101 is provided at the upper end of each side wall of the housing 110.
A step portion 123 is provided which engages the thin wall portion 105 of the lower portion of the peripheral wall. A groove 124 is formed in the step 123 and serves as a holding area for adhesive for bonding the housing 110 and the relay cover 101. This groove 124 also covers the relay cover 10.
1 engages with a protrusion 104 provided at the lower end of the peripheral wall of 1.

FIG. 5 is an exploded perspective view showing each component of the above-mentioned relay. That is, the relay is composed of a housing assembly in which each contact spring etc. are insert-molded, an electromagnet 116 inserted from a lower opening of the housing assembly, a back cover 128, and a relay cover 101 not shown in the figure. be done.

In the housing assembly, the fixed contact terminal 11 is attached to the housing 110 made of insulating material as described above.
1a, 111b, 112a, 112b and movable contact mounting terminals 113a, 113b are insert molded. Movable contact mounting terminal 113
Twin contact shaped movable contact springs 115a and 115b are spot welded to a and 113b, respectively. Contact members 126a, 126b are attached to the upper surfaces of the contact portions 112a″, 112b″ of the fixed contact terminals 112a, 112b, respectively, and the contact portions 111 of the fixed contact terminals 111a, 111b
Contact members (not shown) are welded to the lower surfaces of a'' and 111b, respectively. Furthermore, the movable contact spring 1
Contact members 125a and 125b are welded to the upper surfaces of the twin-shaped portions of the twin-shaped portions 15a and 115b at positions opposite to the contact members of the fixed contacts 111a and 111b, and the lower surfaces of the twin-shaped portions are welded to the fixed contacts 112.
Contact members (not shown) are welded to positions facing the contact members 126a, 126b of a, 112b.

The electromagnet 116 includes a coil bobbin 129, a coil 129' wound on the coil bobbin, an iron core 130,
Approximately L-shaped armature 117 and armature pressing spring 11
8. The iron core 130 has a U-shape in which a yoke part 131 and an iron core part 132 to be inserted into the coil bobbin 129 are integrated, although not shown in FIG. be done. There are protrusions 132 on both sides of the yoke part 131.
a, 132b are provided, and these protrusions 1
32a and 132b are respectively inserted into the housing 110 when the electromagnet 116 is inserted into the housing 110.
Guide grooves 127a, 1 provided on the opposing inner walls of
27b, and serves to define the positional relationship between the electromagnet 116 and the housing. The above-mentioned insulator 120 is attached to the tip of the arm 117' of the approximately L-shaped armature 117, which is located approximately parallel to the yoke portion 131.
is attached in a direction perpendicular to the length direction of the arm,
Armature 117 and movable contact springs 115a, 115b
insulation between the Furthermore, a projection 135 is provided on the upper surface of the arm to engage with an opening 134 at the tip of the spring piece 133 of the armature pressing spring 118. Recesses 136a and 136b are provided on the outside of the bent portion of armature 117, and these recesses 136a and 136b engage with tongues 137a and 137b of armature pressing spring 118, respectively. The armature pressing spring 118 is a coil bobbin 129
A groove 139 provided in one flange portion 138 of
a, 139b. Further, coil terminals 119a and 119b are insert-molded in the flange portion 138, and the coil terminals 1
Lead wires from the coil 129' are soldered to the upper ends of the coils 19a and 119b.

The back cover 128 has the guide groove 1 of the housing 110.
Protrusions 140a, 14 that fit into 27a, 127b
0b and the coil terminal 119a of the electromagnet 116,
Notches 141a, 14 for passing through 119b
1b is formed.

When manufacturing a relay using the above-mentioned components, the electromagnet 116 is inserted through the lower opening of the housing assembly, and the back cover 128 and relay cover 101 are adhesively fixed to the housing 110. These back cover 128 and relay cover 10
1 protects internal contact springs, electromagnets, etc. In particular, the back cover 128 has functions such as preventing intrusion of solder used when mounting on a printed board. Next, the entire relay is cleaned with a cleaning liquid, and then the protrusion 103 of the relay cover 101 is cut out to form a ventilation hole for heat radiation, thereby completing the assembly of the relay.

Next, the operation of the above-mentioned relay will be explained. In the recovery state where the electromagnet 116 is not excited,
As is clear from FIGS. 3 to 5, the armature 1 is
One arm 117' of the iron core 130 is pressed against the yoke of the iron core 130. Therefore, the movable contact spring 1
15a and 115b are fixed contact terminals 112a and 112 on the break side respectively due to their own elasticity.
maintains electrical contact with b. When the electromagnet 116 is excited, the other arm of the armature 117 is attracted to the iron core 132, and the arm 117' is pushed up against the force of the spring piece 133 of the armature pressing spring 118. As a result, the movable contact spring 115
a and 115b are pushed up through the insulator 120 to form fixed contacts 111a and 111 on the make side, respectively.
It makes electrical contact with b, and the contact switching is performed.

Next, a method of manufacturing each component of the above-mentioned relay will be explained. As described above, the housing assembly includes a housing 110 consisting of a rectangular frame.
It is created by insert molding each contact terminal etc. That is, as shown in FIG. 6, fixed contact terminals 111a, 112a, movable contact mounting terminals 113a, and fixed contact terminals 111b, 112b are formed by pressing adjacent bronze hoop materials, respectively.
Two lead frames 150a and 150b including a movable contact mounting terminal 113b are arranged facing each other at a predetermined interval. Next, as shown in FIG. 7, an insert mold base is fabricated by molding the housing 110 so that opposing terminal portions are included in opposing side walls.

FIG. 8 schematically shows equipment for insert molding the housing assembly described above. In the figure, two lead frames 15 are shown.
0a and 150b are guide plates 151a and 15, respectively.
1b at a predetermined interval, and is moved in the direction of arrow A at predetermined time intervals using holes 152 provided in the upper and lower connecting bands of each lead frame 150a, 150b. In FIG. 8, each lead frame 150a, 150b is arranged vertically and horizontally inverted from the arrangement shown in FIG. 6, so that the housing assembly is formed in an upside-down direction. The outer molds 153a and 153b are inserted from both sides of the lead frames 150a and 150b arranged at a predetermined interval in this way, the core mold 154 is inserted between the lead frames 150a and 150b from above, and the lead frame is inserted from the bottom from below. 150
a, 150b, sandwiching the receiving shape 155 of the core shape 154, and then attaching the outer shape 153.
A resin material is injected through the gate portion 156 formed at portions a and 153b. After the injected resin material hardens, the outer molds 153a, 153b, the core mold 154, and the receiving mold 155 are moved in the directions of arrows B, C, D, and E, respectively, and the lead frames 150a, 1
50b is moved by a predetermined distance in the direction of arrow A, and the next molding process is performed. In this way, an insert mold base as shown in FIG. 7 is manufactured continuously and automatically.

The housing assembly includes each lead frame 150a of the above-mentioned insert mold base,
After cutting out the upper and lower connecting band portions of 150b, the fixed contact terminals 111a, 112a, 111b, 11
2b and movable contact mounting terminals 113a, 113
The upper part of b is bent at a right angle, and a contact member is welded to each fixed contact terminal, and the movable contact mounting terminal 11
3a, 113b have movable contact springs 115a, 115
b is spot welded and completed. In addition, in the above, it is assumed that the contact members are welded after the upper part of each fixed contact terminal is bent at right angles, but it is also possible to weld the contact members before bending the upper part of each fixed contact terminal at right angles. It is.

Next, a method for assembling the electromagnet 116 will be explained with reference to FIGS. 9A and 9B. As shown in FIG. 9A, one flange 138 of the coil bobbin 129 on which the coil 129' of the electromagnet 116 is wound has a protruding wall 138 extending vertically from the outer surface of the flange 138.
a, 138b, etc. are integrally molded,
The protruding walls 138a, 138b have grooves 139a, 139b into which the armature pressing spring 118 is inserted, and a coil terminal 119 on the outer side far from the flange surface.
Insertion holes 139a' and 139a into which holes a and 119b are inserted
9b' is provided. To assemble the electromagnet, first,
Coil terminals 119 are inserted into the insertion holes 139a' and 139b'.
After fitting and fixing a and 119b, coil bobbin 1
A coil 129' is wound around the coil 129.
9' connecting lead wire to coil terminals 119a, 11
Connect to the upper end of 9b by soldering. next,
The core portion 132 of the core 130 is firmly inserted into the core insertion hole 129a of the coil bobbin 129, thereby fixing the coil bobbin 129 and the core 130. Next, the bent corner 117' of the armature 117 is connected to the yoke portion 131.
At the same time, the armature pressing spring 118 is placed in the groove 139 of the coil bobbin 129.
a, 139b and fix it. In this case, the opening 1 at the tip of the spring piece 133 of the armature pressing spring 118
34 engages with the protrusion 135 of the armature 117, and the tongue pieces 137a, 137b of the armature pressing spring 118
are adapted to engage with the recesses 136a, 136b of the armature 117. In this way, the armature 117
are the tongue pieces 137a, 137 of the armature pressing spring 118
b is pressed against the end 131a of the yoke portion 131, and becomes rotatable about the end 131'.
Here, the spring piece 133 of the armature pressing spring 118 is a spring body that presses down the arm 117' of the armature 117, and functions as a recovery spring for the armature 117. Further, the cut and raised pieces 118a and 118b of the armature pressing spring 118 prevent the armature pressing spring 118 from falling out of the grooves 139a and 139b of the flange 38. In this way,
An electromagnet 116 as shown in FIG. 9B is manufactured.

Iron core 13 used in the electromagnet 116 described above
0 is made by bending one magnetic member into a U shape. The magnetic member used has different widths and thicknesses between the iron core corresponding part having a rectangular cross section which becomes the iron core part 132 by bending, and the rectangular yoke corresponding part having a rectangular cross section which becomes the yoke part 131.

(6) Effects of the Invention As described above, according to the manufacturing method of the present invention, the electromagnet part and the contact spring part are assembled separately and then integrated to obtain the desired relay, so that the assembly work can be performed efficiently and easily in a short time. Of course, since it is possible to position the electromagnet when inserting it from the bottom opening of the housing, the assembly work becomes easier and more accurate.

In addition, since the electromagnet is inserted through the bottom opening of the housing and then a bottom plate is attached that closes the bottom opening, it is possible to protect the electromagnet during the mounting process, etc., which has a great practical effect.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing a conventional relay, FIG. 2 is an exploded perspective view of the relay shown in FIG. 1, FIG. 3 is a perspective view showing a relay according to an embodiment of the present invention, and FIG. 3 is a partially sectional side view showing the relay of FIG. 3; FIG. 5 is an exploded perspective view showing each component of the relay of FIG. 3;
Fig. 6 is a perspective view showing the lead frame used in the relay shown in Fig. 3, Fig. 7 is a perspective view showing the insert mold base including the lead frame shown in Fig. 6, and Fig. 8 is a perspective view showing the insert mold base shown in Fig. 7. A schematic perspective view showing the equipment for manufacturing, FIG. 9A,
B is a perspective view for explaining the assembly process of the electromagnet shown in FIG. 5; [Explanation of symbols], 110...Housing, 11
6... Electromagnet, 117... Armature, 128... Back cover, 129... Coil bobbin, 138... Flange section.

Claims (1)

[Claims] 1. A fixed contact terminal and a movable contact mounting terminal are attached to the surrounding wall, and a box-shaped insulating casing is formed with openings on the top and bottom surfaces and a protrusion that closes a part of the open top surface. After bending the fixed contact terminal and the movable contact mounting terminal, the iron core and yoke are attached, and the bent part comes into contact with the coil bobbin around which the coil is wound and one end of the yoke, making it possible to rotate. An electromagnet having at least a supported armature is inserted into the insulating casing through the opening on the lower surface thereof and assembled into the insulating casing so as to be positioned by the protrusion, and then a bottom plate for covering the electromagnet is inserted into the insulating casing. A method for manufacturing an electromagnetic relay characterized by being attached to the body.