Classifications

• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
  • H01H49/00—Apparatus or processes specially adapted to the manufacture of relays or parts thereof
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
  • H01H11/00—Apparatus or processes specially adapted for the manufacture of electric switches
  • H01H11/0056—Apparatus or processes specially adapted for the manufacture of electric switches comprising a successive blank-stamping, insert-moulding and severing operation
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
  • H01H50/00—Details of electromagnetic relays
  • H01H50/02—Bases; Casings; Covers
  • H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
  • H01H50/041—Details concerning assembly of relays
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
  • H01H50/00—Details of electromagnetic relays
  • H01H50/02—Bases; Casings; Covers
  • H01H50/023—Details concerning sealing, e.g. sealing casing with resin
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/4902—Electromagnet, transformer or inductor
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/4902—Electromagnet, transformer or inductor
  • Y10T29/49073—Electromagnet, transformer or inductor by assembling coil and core
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49105—Switch making
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T29/00—Metal working
  • Y10T29/49—Method of mechanical manufacture
  • Y10T29/49002—Electrical device making
  • Y10T29/49117—Conductor or circuit manufacturing
  • Y10T29/49121—Beam lead frame or beam lead device

Definitions

• the invention relates to a method for producing an electromagnetic relay
• a coil penetrated by a core with a winding and with connecting pins, the core forming pole plates at both ends outside the coil, - An armature bridging the pole plates to form working air and
• EP 0 531 890 AI describes a switching relay and a method for its production, the relay elements being arranged in the above-mentioned manner in a two-part housing.
• the two housing parts there do not form a closed housing, but are merely a base, which is preferably a printed circuit board with an integrally formed side wall, and a cover part, between which a housing gap remains open even after the assembly.
• the relay there is preferably designed as a multiple relay with a series of magnet systems lying next to one another, a common core pole plate lying on the base and forming a series of vertically projecting core sections, each of which is fitted with a coil.
• Each system also has a U-shaped armature, which is mounted on the core pole plate and encloses the coil in a frame shape with the contact spring.
• the cover part has slots with inserted mating contact elements and spring supports, these slots also not being tight.
• a conventional manufacturing technique is used for the relay there, the individual elements being subsequently attached to one or the other housing part by plugging, riveting or in a similar manner.
• the aim of the present invention is an inexpensive manufacture of relays of the type mentioned for different sizes and applications. In this case, high manufacturing accuracies for the mechanical relay characteristic values are to be achieved without the need for a separate adjustment process.
• the coil provided with the core is embedded with its connecting pins to form a first housing half-shell in plastic;
• a spring support for the contact spring and at least one fixed contact element are embedded in plastic to form a second housing half-shell;
• the anchor is inserted in one of the two half-shells and
• all parts are manufactured by injection molding or assembled. This achieves a high level of manufacturing accuracy, since the precise injection mold specifies the position tolerance of the individual parts.
• These individual parts are preferably made from flat sheet metal strips and overmolded in succession or simultaneously. This injection molding assembly is particularly well suited for a production by cycle Injection molding of parts connected on the belt, which means that large quantities can be manufactured at a reasonable price.
• FIG. 1 shows a relay produced in accordance with the invention in a perspective, partially cut-open representation
• FIG. 2 shows a sheet metal strip with partially cut-out core yoke sheets
• FIG. 4 shows a sheet metal strip with bobbins that are partially wound
• FIG. 5 shows a sheet metal strip from FIG. 4 with wound bobbins that are partially molded with plastic to form a first housing half-shell
• FIG. 6 shows a separated first half-shell in a view rotated in relation to FIG. 5
• FIG. 7 shows a finished second half-shell
• FIG. 8 shows a contact sheet strip with partially punched-out fixed contact elements in two toothed rows
• FIG. 9 shows a separated row of fixed contact elements connected to a sheet metal strip
• FIG Formation of second half shells by overmolding of fixed contact elements and spring supports
• FIG. 11 shows a series of contact springs punched out on the band and provided with an anchor
• FIG. 12 shows a row of second housing half-shells connected to the belt, which are provided with a spring anchor unit,
• FIG. 13 shows a modified form of a spring anchor unit
• FIG. 14 shows a schematic illustration of a modified version of a housing half-shell in section in an injection mold
• FIG. 15 shows a relay completed by stacking two housing half-shells in a section through the armature
• FIG. 16 shows a modified Aufet 'approximate shape of a relay according to the invention in perspective view.
• Figure 1 shows a relay manufactured with the inventive method. It consists of a first half-shell 1 and a second half-shell 2, the half-shell 1 being formed by overmolding a coil 3, namely a coil former 31 with a winding 34, and the second half-shell is formed by overmolding a spring support 21 and two fixed contact elements 22 and 23.
• An L-shaped contact spring 4 is fastened to the spring support 21 with two legs 41 and 42, which in turn carries an armature 5.
• the ends of the approximately Z-shaped armature 5 each form working air gaps with two pole faces 63 and 64 of two pole plates 61 and 62, which are part of a U-shaped core 6, the pole plate 62 being bent upward from the core plane .
• FIG. 2 shows the production of core yoke sheets 6, which are successively cut and bent from a soft magnetic sheet metal strip 60 in the production cycle.
• FIG. 3 shows the sheet metal strip 6 with the core yoke sheets 6 in a later process stage, but still in a continuous manner.
• the core yoke plates 6 are already overmolded with a thermoplastic, so that a coil former 31 is formed in such a way that the two pole plates 61 and 62 are free of plastic.
• two pins 32 and 33 are also embedded, which are also related to a sheet metal strip 30.
• connection sections 32b and 33b are also saved in the coil former which are later contacted to the winding ends.
• the coil connecting pins 32 and 33 on the one hand and the core yoke plate 6 on the other hand could also be produced from a common soft magnet sheet metal strip, the separation being able to be carried out in a corresponding manner after the extrusion coating.
• the coil former units formed by extrusion coating are separated on one side, for example from the sheet metal strip 60, so that they are only connected on one side, for example via the sheet metal strip 30 according to FIG. 4. In this state, they are gradually provided with the winding 34, the winding ends being connected to the terminal portions 32b and 33b.
• the coil units according to FIG. 5 are gradually overmolded in the production cycle with a thermoplastic to form the half-shells 1, as shown in FIG. 5.
• These overmolded half-shells 1 are still connected via the metal strip 30.
• the individual half-shells are then separated from the sheet metal strip, and the cut-out coil connecting pins 32 and 33 are angled, as shown in another view in FIG. 6.
• the coil including the winding is now completely encased in the plastic of the first half-shell 1, only the pole faces of the pole sheets 61 and 62 being kept free from the plastic.
• the second housing half-shell 2 of the relay is shown in FIG. 7 in the finished state.
• the following figures show individual process sections in their manufacture. 8 shows the extraction of fixed contact elements 22 and 23 from a sheet metal strip 20 which is plated with a central strip 20C made of contact material, for example AgNi015, AgSn0 2 or the like.
• the contact material layer 20C is plated as an inlay in the strip material 20 so that it does not form a surface increase, as a result of which the contact elements can be easily sealed in the injection mold.
• the fixed contact elements 22 and 23 are cut out like a zipper from the inlaid band 20 so that the precious metal portion of the plated layer 20C is optimally used.
• FIG. 9 shows a contact strip 20A detached from the composite with the partially cut-off fixed contact elements 22 and their contact-making zone 22c.
• the mutually twisted contact strips 20A and 20C are extrusion-coated with the plastic material of the second half-shell 2, the plated sections 22c and 23c facing each other. Due to the asymmetrical design of the fixed contact elements 22 and 23, the contacting sections 22c and 23c lie one above the other, while their connecting ends 22a and 23a lie offset in the wall of the half-shell 2.
• spring supports 21 are also injected, which are likewise connected to a common sheet-metal strip 10.
• the spring supports 21 each have a fastening tab 44 bent open at right angles for the contact spring, which will be described later.
• the second half-shell forms a cavity for receiving the movable armature-spring unit 4, 5, which is shown in FIG. 11.
• 11a shows a spring band 40, from which the individual contact springs 4 are gradually cut free, bent and provided with the movable contacts 43 in the production cycle.
• the armature 5 which is also cut from sheet metal and pre-bent, is fastened to the contact spring, for example via a welding point 51.
• This armature-contact spring unit is then arranged in the second half-shell on the spring support 21 and fastened, for example, via a welding point 46 (FIG. 12) .
• the connection of the contact spring 4 to the armature 5 can, however, also be carried out by injection molding around with an insulating material sheath 52, as shown in FIG. In this way, electrical insulation between the contact spring 4 and the armature 5 or the magnet system is also achieved.
• the distance between the two flat contact strips 20A and 20B is achieved with the high accuracy of a slide in the tool, so that there is an adjustment-free contact position in the later relay.
• the relay construction is arranged in the two half shells so that the contact surfaces are perpendicular in the second half shell.
• a corresponding arrangement is shown schematically in FIG. 14, where a lower half-shell 102 is formed between two mold halves 110 and 120. Two fixed contact elements 122 and 132 with corresponding inlay contact layers are arranged in this lower half-shell in such a way that they are perpendicular to the mold parting plane 130.
• a molded projection 111 gives the precisely specified contact distance a between the two fixed contact elements 122 and 132 and seals the contact area well, since the pressure of the thermoplastic injection molding compound 103 for the half-shell 102 presses the two fixed contact elements 122 and 132 against this spacing projection.
• a peripheral wall 12 of the half-shell 1 engages in a box-like manner over the half-shell 2, which for this purpose has a web 24 which runs around the inside.
• one of the half-shells also has a circumferential rib 25 which is deformed during the joining, for example by means of ultrasound, and creates a tight connection between the two half-shells. Sealing is very easy in this way, as all connections have been made beforehand are overmolded in the respective half-shell and the joining plane is formed by thermoplastic plastic of the two half-shells.
• the pull-through voltage of the armature is measured, the armature being attracted to the pole faces 63 and 64 of the pole plates 61 and 62.
• a predetermined characteristic value of the pull-through voltage as a measure of the erosion size or the overstroke of the contact is reached, the joining process is ended.
• the relay is adjusted and sealed at the same time.
• the joint seam on one level without a height difference ensures that the two half-shells can be securely sealed, but also with other technologies, for example by gluing, clamping, casting or using an elastomer seal that can be molded onto a half-shell using the two-component injection molding process.
• the pins of the relay are arranged on two opposite sides of the housing and bent downwards at right angles. In this way, they can be used as solder pins or can also be used as SMT connectors by further bending them horizontally. With a corresponding modification of the construction, however, a different connection geometry is also possible, so that, if necessary, all connection elements emerge on one housing side. These can of course be designed both as solder pins and as flat tabs.
• a variant of the relay is shown in FIG. 16, with all connections emerging from the housing on only one side and the parting plane extending perpendicularly to the connection side of the relay.
• a first half-shell 201 contains the magnet system with coil pins 232 and 233, while the second half-shell 202 carries the contact system with contact pins 221, 222 and 223.
• the two half-shells are joined together along a parting plane 203, with a corresponding one also here Construction can be done by assembling an adjustment.

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• Engineering & Computer Science (AREA)
• Manufacturing & Machinery (AREA)
• Physics & Mathematics (AREA)
• Electromagnetism (AREA)
• Electromagnets (AREA)
• Manufacture Of Switches (AREA)
• Insulated Conductors (AREA)

Applications Claiming Priority (3)

Publications (2)

Family

ID=7799472

Family Applications (1)

Country Status (7)

Families Citing this family (5)

Family Cites Families (22)

• 1996
  • 1996-07-10 DE DE19627845A patent/DE19627845C1/de not_active Expired - Fee Related
• 1997
  • 1997-06-12 CN CN97196239A patent/CN1075237C/zh not_active Expired - Fee Related
  • 1997-06-17 WO PCT/DE1997/001229 patent/WO1998001878A1/fr active IP Right Grant
  • 1997-06-17 JP JP10504637A patent/JP2000514234A/ja active Pending
  • 1997-06-17 DE DE59701119T patent/DE59701119D1/de not_active Expired - Fee Related
  • 1997-06-17 US US09/214,743 patent/US6272734B1/en not_active Expired - Fee Related
  • 1997-06-17 EP EP97931620A patent/EP0910861B1/fr not_active Expired - Lifetime
  • 1997-06-17 AT AT97931620T patent/ATE189746T1/de not_active IP Right Cessation

Non-Patent Citations (1)

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