EP0758484B1 - Modular relay - Google Patents

Abstract

PCT No. PCT/EP95/01657 Sec. 371 Date Sep. 26, 1996 Sec. 102(e) Date Sep. 26, 1996 PCT Filed May 2, 1995 PCT Pub. No. WO95/30995 PCT Pub. Date Nov. 16, 1995The modular relay has a base (1) on which a relay system (2, 3, 4) is constructed, as well as a printed circuit board (6) which stands upright on the base. Contact elements (41c, 42c, 43) of the relay are directly connected to flat connectors in the base, via conductor elements. Further conductor elements in the base likewise form flat connectors as connections for a modular circuit which is arranged on the printed circuit board. All conductor elements of the base additionally form solder connecting pins (51b to 56b), which are integrally formed, which all emerge in a row on one side wall of the base, and which are soldered to the printed circuit board in the lower edge region of said printed circuit board. This results in a compact modular structure for a relay having a maximum number of connecting elements, the allocation of these connecting elements being variable for different modular circuits.

Description

The invention relates to a module relay with a base, in which plug-in connection elements for at least one load circuit, for a relay excitation circuit and for a module circuit are anchored to a bobbin that a Electro-magnet system with coil, core and armature carries and on the base is fixed standing, further with at least one fixed and at least one coupled to the anchor movable contact element, the contact elements directly with the associated connection elements anchored in the base are connected, and with one at the base level vertical PCB, which is the module circuit carries and with at least part of the connection elements of the Base is electrically connected.

For certain applications, for example in automotive engineering, relays are combined for specific functions with its control circuit to a compact unit, a so-called module, in a housing with plug connections summarized so that the relay together with its control circuit can be exchanged with one hand. Typical examples are relays for flasher units, glow plugs and the like. The constructive connection of the relay system and the module circuit arranged on a small circuit board So far, however, has required a relatively large amount of effort, there is a separate construction for every application was developed.

From DE 30 05 460 A1 (& GB-A-2 069 765) is an electromagnetic switch with the basic module structure of the above Kind known. However, there is a special one Design as a glow time relay, which is not easy can be used for other purposes. The connections between base and circuit board are not in detail shown; the connection elements contain circular plugs, which riveted separately into holes in a plate-shaped connecting part Need to become.

From DE 33 06 019 C2 a relay is known in which one PCB parallel to the base on the top of the magnet system is arranged. All electrical Connections between the circuit board and the base via rail-shaped conductor parts are manufactured, which are extend to the side of the relay system perpendicular to the base level. Such a construction could be used at high load currents lead to heating problems because the switch contacts lie on the top of the relay in the area of the circuit board. The connection elements are also in this case as round plugs executed, which must be riveted in the base.

DE 38 34 413 A1 also describes the arrangement of a relay known on a circuit board, with load connection elements in Form of tabs arranged on the circuit board and at least partially via a lead frame with the others Components of the circuit board are connected. It is there However, it is not a pluggable, on a base built module; rather, the relay only sits in addition to other circuits on a larger circuit board that separate from the conventional load connector plugs mentioned PCB connections must have.

Finally, from US 4,400,761 is a compact relay system known, in which a socket provided with tabs carries a vertical PCB. The relay is not on the base, but with all connections the printed circuit board, so that the load circuit are routed to the base connections via the printed circuit board got to. This not only brings heating problems, but requires also additional electrical conductor elements and connection points.

The aim of the present invention is to provide a pluggable module relay of the type mentioned to create that with as much as possible few parts have a compact structure and also can carry high load currents without any problems. The structure should be also be designed so that with a single basic structure different applications can be mastered, so that with a uniform base structure relay with different Module circuits can be manufactured.

According to the invention, this goal is achieved in a module relay of the type mentioned in that all electrical connections between the respective pluggable Connection elements and the printed circuit board by side by side, stamped in one piece with their connecting elements Conductor elements are formed in the top area of the Socket are arranged completely or partially sunk and in a row approximately at the same height next to each other in the Connected to the bottom edge of the circuit board are, and that the circuit board with its lower end portion on a side wall running perpendicular to the base plane is applied, in the area of the conductor elements each solder pins form.

The module relay according to the invention has a universal one Base design with a predetermined maximum number of Ladder elements, which are next to each other on the top of the base or can be arranged sunk in this and all Connectors and connectors to the circuit board for different module relays with different Contact systems and different module circuits for Make available. The individual conductor elements are stamped in this way and preformed that they each integrally to the base of the base emerging in a desired connection grid Flat connector and with its other end to the circuit board side form solder pins that exit. Requires a module relay including its module circuit less than the maximum intended Number of connections, so that can not be used Conductor elements either not wired or during manufacture of the base can be omitted without the used Conductor elements changed in shape or arrangement will.

As already mentioned at the beginning, the relay magnet system attached to the base, and the contact elements are directly connected to the associated connection elements. It is advantageous that the fixed contact elements integrally formed with the associated conductor elements are, which are also the plug connections and the Form solder pins. For one connected to the anchor Contact spring, the power supply is conveniently via a strand that is welded to the associated conductor element is. The magnet system can be placed on the base via the contact elements and, if necessary, additional anchorages attached to either the plastic bobbin or on one of the metallic magnetic circuit parts, such as on Yoke, are molded.

In an expedient embodiment, provision can also be made be that the coil connections directly to the circuit board are connected. In an advantageous embodiment forms a flange of the bobbin in the base opposite top area of the relay columnar Supports that rest on the circuit board and from which Coil pins come out in holes in the circuit board are soldered. By such a soldering of coil connection pins at the top of the relay the overall structure is preserved of base, circuit board and relay a special good stability and dimensional accuracy.

The conductor elements arranged in or on the base can be fixed in slots of the base by insertion. So far less than the maximum number in certain embodiments individual slots not occupied by conductor elements are, at least to the underside of the base with the Plastic material of the base must be closed.

In another expedient embodiment, provision can be made be that at least part of the conductor elements in the insulating material of the base is embedded. In this case, too it is possible to use conductor elements that are not required for an embodiment when shaping the base, for example when plastic injection molding, not to put in the form, causing her Place is filled with plastic. Mixed forms of Embedding and insertion are possible. For example provided in an expedient embodiment that the conductor elements for the connections of the module circuit in the Sockets are embedded while the ladder elements for the Load connections can be retrofitted by inserting them.

For coupling the circuit board with its lower edge area it is on the one hand to the solder pins of the conductor elements advantageous if the base is in the appropriate area forms a step so that the circuit board on the vertical Wall of this step is present; the solder pins of the In this case, conductor elements expediently occur in the area this vertical wall from the higher base section and are thus immediately in the area of the level with the PCB soldered. So the step is the assembly the printed circuit board at the connection pins, in particular the connection tight fit is improved. The one through the Part of the base set back step down also forms a bottom cover of the circuit board so that by sealing of the base edge opposite an attached housing cap the relay including the circuit board is tightly enclosed becomes.

On the other hand, the step somewhat complicates the soldering process because it must be covered when wave soldering. To this problem Avoiding when soldering is in a development of the invention provided to run the base in two parts, wherein the graded part only after soldering the circuit board the actual base, for example by plugging becomes.

The aforementioned arrangement of the solder pins in a row side by side can mean that all solder pins in lie on a common level. Within the scope of the invention but also a mutual height offset of these solder pins quite conceivable as long as they are arranged side by side are.

Figur 1 ein Relaismodul mit dem auf einem Sockel aufgebauten Relaissystem und einer in strichpunktierten Linien angedeuteten Leiterplatte in perspektivischer Darstellung,

Figur 2 den Sockel und die Einzelteile des Relais von Figur 1 (ohne Leiterplatte) in Explosionsdarstellung,

Figur 3 ein zusammengebautes Relaismodul mit aufgesetzter Gehäusekappe,

Figur 4 zwei Blechplatinen mit gruppenweise ausgestanzten Leiterelementen vor dem Einbetten in einen Sockel,

Figur 5 einen Sockel nach dem Umspritzen mit eingebetteten Leiterelementen gemäß Figur 4,

Figur 6 einen Sockel gemäß Figur 5 mit zusätzlich eingesteckten Leiterelementen für die Lastanschlüsse des Relais,

Figur 7 einen zweiteiligen Sockel und

Figur 8 eine etwas abgewandelte Ausführungsform eines Relaismoduls im Zustand vor der Endmontage mit vormontierten einzelnen Baugruppen in perspektivischer Ansicht.

The invention is explained in more detail below using exemplary embodiments with reference to the drawing. It shows

FIG. 1 shows a relay module with the relay system built on a base and a circuit board indicated in dash-dotted lines in a perspective view,

FIG. 2 shows the base and the individual parts of the relay from FIG. 1 (without printed circuit board) in an exploded view,

FIG. 3 shows an assembled relay module with an attached housing cap,

FIG. 4 two sheet metal boards with conductor elements punched out in groups before being embedded in a base,

5 shows a base after overmolding with embedded conductor elements according to FIG. 4,

FIG. 6 shows a base according to FIG. 5 with additionally inserted conductor elements for the load connections of the relay,

7 shows a two-part base and

Figure 8 is a slightly modified embodiment of a relay module in the state before final assembly with pre-assembled individual modules in a perspective view.

The relay module shown in Figures 1 to 3 has a base 1 with insertion slots open to the top 11, which contain invisible openings to the bottom. Furthermore, a step-shaped shoulder 12 is formed on one side.

There is a conventional one on the base Relay system with a bobbin 2 as a carrier for one Winding 21 and a magnet system 3. The latter essentially consists from an angular yoke 31, one inside of the coil arranged core 32 and a plate-shaped a yoke edge mounted armature 33, which has an armature return spring 34 is biased to a rest position.

The coil former has two on both sides of the winding Flanges 22, which on the opposite of the base 1 Form the top of each column-like supports 23. In these Supports 23 are each approximately parallel to the plane of the base 1 Anchor coil pins 24 anchored. For support and fastening on the base 1, the coil body also has downwardly projecting pin 25 or supports 27 and one Approach 26, the latter at the same time for guidance and attachment of fixed contact elements to be described later 41c and 42c serves.

A contact arrangement for switching the relay circuit in the present example consists of a fixed one Normally open contact element 41c and a fixed normally closed contact element 42c and a contact spring 43, which as Extension of the armature return spring 34 already mentioned is. The fixed contact elements 41c and 42c are in one piece with a conductor element 41 and 42, respectively formed which in corresponding slots 11 of the Socket 1 can be attached by inserting. The ladder element 41 also has one through an opening in the base downward emerging flat connector 41a and a parallel solder terminal pin emerging from the step wall 13 to the top of the base 41b; the conductor element forms in a corresponding manner 42 a molded flat tab 42a and a solder pin 42b molded to the side. As a connection element a conductor element serves for the center contact spring 43 44, a flat plug 44a to the underside of the base and a solder pin 44 toward the step sidewall 13 forms. There is also a connecting web on the conductor element 44 44c, from which the load current via a strand 45 is guided to the contact spring 43. The contact arrangement 4 could of course be modified by, for example, only a break contact or a make contact is provided; also a Bridge contact could be realized, then the two fixed contact elements 41c and 42c in one Lay level and the contact spring 43 as a bridge without its own Connection would be formed.

Furthermore, a module connection arrangement 5 is provided in the base, consisting of six conductor elements 51, 52, 53, 54, 55 and 56. All of these conductor elements are in slots 11 of the Base fixed by plugging, in such a way that it a flat connector 51a, 52a, 53a, 54a, 55a and 56a and towards the step wall 13 a solder pin 51b, 52b, 53b, 54b, 55b and 56b form. All Flat plugs on the underside of the base are according to a specified Grid arranged, while all solder pins in Area of the step wall 13 lie side by side in a row. These solder pins, which are made from the relevant conductor elements are punched, can vary slightly in cross section be a larger one for the load circuit Have cross-section and - different from that shown Embodiment - possibly also in the height arrangement vary. They correspond to contact holes 61 on a printed circuit board 6, which with its lower edge on paragraph 12 of the base 1 is vertical and with its lower edge area abuts the step side wall 13. Also owns the circuit board 6 in the area of the relay top two contact holes 62 for receiving the coil connecting pins 24. Others Contact holes 63 serve as an example for receiving and Contacting other components for a module circuit, which, like the conductor tracks, are not visible.

When assembling the module relay, the conductor elements are first 51 to 56 and the contact conductor elements 41, 42 and 44 inserted into the base 1 and optionally fixed. Then the coil body with the magnet system is put on and attached. Finally, the circuit board 6 laterally over the module solder pins 51b to 56b Contact solder pins 41b, 42b and 44b as well as over the Coil connector pins 62 inserted and soldered. The supports 23 have in the area of their on the circuit board Each face a conical recess 23a around the Solder pins 62 around so that the solder is not by capillary action can flow to the relay side of the circuit board. Furthermore, the franking is used for tolerance compensation and This makes assembly of the circuit board easier. By plugging on a housing cap 7 on the base 1 creates a closed Housing that are sealed at the lower edge area can. Due to the stepped shoulder 12 is also the lower edge the printed circuit board 6 covered.

In the embodiment described so far, all conductor elements were fixed in the base by insertion. So far in one embodiment less than the maximum number shown of nine conductor elements can be used, the corresponding breakthroughs for the tabs already the manufacture of the base filled in or to the bottom be sealed with a spray skin.

Another embodiment is illustrated in FIGS. 4 to 6 of a base shown in different stages of manufacture, some of the conductor elements in the plastic of the Base is embedded. An embodiment is shown in which the conductor elements by as few individual steps as possible can be won. Here, as in Figure 4, three conductor elements 81, 82, 83 and 84, 85 and 86 obtained from a sheet metal plate. The Flat plugs 81a, 82a and 83a of a sheet metal board or 84a, 85a and 86a of the other sheet metal plate are located in each case in one plane while the top sections of the Ladder elements each cut, angled and cranked are that the solder pins formed at the ends 81b, 82b, 83b, 84b, 85b and 86b all in a row lie.

The conductor elements of a board are initially over Web 87 connected to each other, so that only two sheet metal parts in the injection mold must be inserted. By overmolding the a base 91 according to FIG. 5 is then formed on both boards, the dimensions of the base 1 in Figures 1 and 2 corresponds, with only the module connection elements already are embedded. The intermediate webs 87 are then cut off, so that the individual conductor elements are electrically separate from one another are isolated. Furthermore, the base 91 still has Plug slots 92 for receiving the conductor elements 41, 42 and 44 with the contact elements for the load circuit. These are like formed in the example of Figure 2 and are in the same Way as plugged in there. So you get one Base shape according to Figure 6. On this equipped base can then the coil body 2 with the magnet system 3 and the circuit board 6 as in the previous example.

In Figure 7 is a modification in the form of a two-part Socket described. The base 101 shown there corresponds the base 1 of Figures 1 and 2, with the exception of that instead of the level there or paragraph 12 here formed by a separately manufactured second base part 102 is that with side arms 103 each on locking tabs 104th of the base 101 are snapped on and fastened therewith can. First, however, the base 101 is without the second Base part 102 populated by as shown in Figure 2 Conductor elements are inserted into the slots 111. Then the circuit board 6 of Figure 1 on the side wall 113 placed or on the solder pins of the conductor elements attached. Then without the above plinth level the circuit board is simply soldered. Then the second base part 102 with the mentioned side arms 103 the socket 101 attached. Form the base parts 101 and 102 then a closed bottom part, which with the cap 7 together forms a closed housing. If necessary, can with the edge gap between base and cap also the joint additionally sealed between the base parts 101 and 102 will. This two-part design of the base can of course can also be used if the conductor elements at least to be partially embedded, as in the figures 4 to 6 is shown.

The relay module shown in FIG. 8 has one Base 201 with insertion slots 211 open to the top, which contain invisible openings to the bottom. On a relay system with a coil former 202 sits on the base as a carrier for a winding 221 and a magnet system 203. The latter essentially consists of an angular one Yoke 231, a core disposed within the coil and one plate-shaped anchor 233 mounted on a yoke edge, which is biased into a rest position via an armature return spring 234 becomes.

In the base are in the only partially visible openings 211 conductor elements anchored 241 to 246; further lines are only partially visible. On each of the ladder elements is a flat connector 241a, 242a emerging downwards etc. molded on. In addition, each conductor element has one solder pin protruding horizontally above side wall 213, for example 241b, 242b etc. Most of these Solder pins are side by side in a straight row; individual, for example the solder pin 243b or the solder connection pin 246b, are also on the gap between two adjacent solder pins, however, are in height slightly shifted upwards to increase the insulation distance receive. There is a fixed one on the conductor element 246 Normally open contact element 246c formed vertically. In addition, the conductor element 243 has a connecting web 243c, which extends across the base surface and to which a strand 247 is welded, which the load current leads to a contact spring 248. This contact spring 248 is connected to the anchor 233 and is made in one piece with the return spring 234.

The coil former 202 faces that facing away from the armature Side a slightly raised coil flange 222 in which Coil connection pins 223 are anchored. These spool pins are angled so that they have parallel solder connections form the solder pins 241b to 246b. In addition, on Coil body on its underside T-shaped spring tabs 224 molded on which corresponding locking wedges 214 face on the base. It is also on the base near the side wall 213 a locking hook 215 is formed, to which a corresponding Not visible locking window on the underside of the coil flange 222 faces. When assembling the bobbin the locking tabs 224 slide with their on the base Side arms over the locking wedges 214 and snap at the end of the Touchdown movement behind this one. At the same time, the locking hook snaps 215 in the mentioned snap-in window of the coil former the opposite side so that the base and bobbin are positively and positively attached to each other.

A circuit board 206 becomes perpendicular to the base plane placed on the base 201 combined with the magnet system, namely on the side surface 213. In the circuit board 206 are contact holes 261 near their lower edge and 262 in a row corresponding to the solder pins 241b to 246b are provided. The contact holes 262 are there like the slightly raised pins 243b and 246b the straight row of contact holes 261 offset upwards, to the already described, increased insulation distance guarantee. In addition, the circuit board 206 has in the area the top of the magnet system 203 two contact holes 263 that fit the coil pins 223. After this Put the circuit board 206 with the solder pins soldered in the contact holes 261, 262 and 263, whereby the magnet system and those anchored in the base Conductor elements with an invisible circuit on the PCB 206 are connected.

Finally, one on the side surface 213 of the base 201 additional base part plugged in using fastening pin 213. In this way, the bottom of the previously Solder exposed circuit board 206 covered. So it is possible by attaching a housing cap, not shown on the base 201 with the additional part 212 a closed Form housing that at the bottom by pouring can be sealed by capillary joints.

In the examples described, the maximum number is in each case shown by conductor elements, so each next to three Load connections six additional connections are provided for the module are. These additional connections can vary depending on the application according to the module circuit. So far not all connections are needed, the corresponding ones Conductor elements also omitted in the production of the base be, or it is possible to unneeded connector cut into the base before or after installation.

Claims (14)

1. Modular relay having a base (1; 91; 201), in which plug-in connecting elements for at least one load circuit, for one relay energizing circuit and for one modular circuit are anchored, having a coil former (2; 202) which is fitted with an electromagnet system (3; 203) with a coil (21; 221), core (32), yoke (31; 231) and armature (33; 233) and which is mounted upright on the base (1; 91; 201), furthermore having at least one stationary contact element (41c, 42c; 246c) and at least one moving contact element (43; 248), the contact elements being connected directly to the associated connecting elements (41a, 42a, 44a; 241a to 246a) which are anchored in the base (1; 91; 201), and having a printed circuit board (6; 206) which stands upright on the base plane, is fitted with the modular circuit and is electrically connected to at least some of the connecting elements (41a, 42a, 44a, 51a to 56a; 81a to 86a; 241a to 245a) of the base (1; 91; 201), characterized in that the electrical connections between the respective plug-in connecting elements (41a, 42a, 44a, 51a to 56a; 81a to 86a; 241a to 246a) and the printed circuit board (6; 206) are formed by conductor elements (41, 42, 44, 51 to 56; 81 to 86; 241 to 246) which are located alongside one another, are stamped integrally with their connecting elements, are arranged in an entirely or partially recessed manner in the top area of the base (1; 91) and are connected to the printed circuit board (6; 206) in a row, approximately at the same height, alongside one another in the vicinity of the lower edge of said printed circuit board (6; 206), and in that the lower end section of the printed circuit board (6; 206) rests on a side wall (13; 213) which runs at right angles to the base plane and in whose region the conductor elements (41, 42, 44, 51 to 56; 81 to 86; 241 to 246) form solder connecting pins (41b, 42b, 44b, 51b to 56b; 81b to 86b; 241b to 246b).
2. Modular relay according to Claim 1, characterized in that some of the solder connecting pins (241b, 242b) are arranged in a straight row parallel to the base plane, and in that the other solder connecting pins (243b, 246b) are in each case arranged between the former, but are slightly offset upwards.
3. Modular relay according to Claim 1 or 2, characterized in that the coil connections of the relay are connected directly to the printed circuit board (6; 206).
4. Modular relay according to one of Claims 1 to 3, characterized in that the coil former (2; 202), whose winding axis is parallel to the base plane, has at least one flange (22; 222) which rests on the printed circuit board, and in that this flange or these flanges is or are provided in the top region of the relay with coil connecting pins (24; 223) which are connected directly to the printed circuit board (6; 206).
5. Modular relay according to one of Claims 1 to 4, characterized in that all the conductor elements (41, 42, 44, 51 to 56; 241 to 246) are mounted in slots (11; 211) in the base, by plugging in.
6. Modular relay according to Claim 5, characterized in that unoccupied slots in the base (1) are closed, at least towards the bottom of the base, by the plastic material of the base.
7. Modular relay according to one of Claims 1 to 4, characterized in that at least some of the conductor elements (81 to 86) are embedded in the insulating material of the base (91).
8. Modular relay according to Claim 7, characterized in that those conductor elements (81 to 86) which lie in preferably two common planes with the flat connectors (81a to 86a) which stand upright are angled and bent in the embedding region in such a manner that they lie alongside one another in the common row, integrally with the solder connecting pins (81b to 86b) which are cohesive with them.
9. Modular relay according to Claim 7 or 8, characterized in that the base (1; 91) forms a step (12) in the region of the printed circuit board (6), and in that the solder connecting pins (41b, 42b, 44b, 51b to 56b; 81b to 86b) emerge from the step wall (13).
10. Modular relay according to one of Claims 1 to 9, characterized in that the base comprises two parts (101, 102; 201, 212), in that the printed circuit board is mounted resting on a side closure wall (113; 213) of a first base part (101; 201), and in that a second base part (102; 212) is connected to the first base part (101; 201) underneath the printed circuit board (6; 206), adjacent to the closure wall (113; 213).
11. Modular relay according to Claim 10, characterized in that the second base part (102; 212) is connected to the first base part (101; 201) by means of plug elements or latching elements (103; 213).
12. Modular relay according to one of Claims 1 to 11, characterized in that the coil former (203) and the base (201) are connected to one another by means of interlocking latching elements (224, 214; 215).
13. Modular relay according to Claim 12, characterized in that at least one T-shaped latching lug (224) is integrally formed on the coil former (202) or on the base (201) and latches in behind inclined ramps (214) on the base (201) or on the coil former, respectively.
14. Modular relay according to Claim 12 or 13, characterized in that at least one latching hook (215) is integrally formed on the base (201) or on the coil former (202) and latches in a window in the coil former (202) or in the base (201), respectively.

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