EP0914665B1 - Electromagnetic relay and process for producing the same - Google Patents

Abstract

The relay comprises a first housing part in which a coil having a U-shaped core is embedded, as well as a second housing part in which at least one spring support as well as at least one mating contact element are anchored. A contact spring with a flat armature is attached to the spring support. The relay is adjusted and additionally sealed by joining the two half-shells.

Description

• einem ersten Gehäuseteil, der eine Spule sowie einen die Spule durchsetzenden, außerhalb der Spule an deren beiden Enden Polbleche bildenden Kern trägt,
• einem zweiten Gehäuseteil, in welchem mindestens ein Federträger sowie mindestens ein Gegenkontaktelement verankert sind, wobei der Federträger eine mit dem Gegenkontaktelement zusammenwirkende Kontaktfeder trägt, und
• einem Anker, der mit der Kontaktfeder verbunden ist und die Polbleche unter Bildung von Arbeitsluftspalten überbrückt. Außerdem betrifft die Erfindung ein Verfahren zur Herstellung eines solchen Relais.

The invention relates to an electromagnetic relay

• a first housing part which carries a coil and a core which passes through the coil and forms pole sheets outside the coil at its two ends,
• a second housing part, in which at least one spring carrier and at least one counter-contact element are anchored, the spring carrier carrying a contact spring which interacts with the counter-contact element, and
• an armature, which is connected to the contact spring and bridges the pole plates with the formation of working air gaps. The invention also relates to a method for producing such a relay.

EP 0 531 890 A1 describes a switching relay, which basically a structure of the type mentioned having. However, the two housing parts do not form there closed housing, it is just about a base, which is preferably a printed circuit board with molded Is sidewall, and a lid part, between which too after the assembly, a large housing gap remains open. The relay there is preferably a multiple relay a series of magnet systems lying side by side, with a common core pole plate on the base lies and a series of vertically protruding core sections forms, on each of which a coil is attached. Each System also has a U-shaped anchor attached to the Core pole plate is mounted and the coil with the contact spring encloses in a frame shape. The cover part has slots inserted mating contact elements and spring supports, whereby these slots are also not tight. An adjustment the contacts are obviously made by the big one Housing opening in the area of the contacts.

A relay is already known from WO 91/07770, in which the magnet system is fixed in the upper area of a housing while a contact system is from the open bottom is pushed in until the magnet system is excited Contact closes. After creating this contact system a desired overstroke by a predetermined amount inserted, it is fastened in the housing. On this way, manufacturing tolerances become apparent during assembly balanced, so that a subsequent adjustment is not more is needed.

DE-A-2 506 626 describes a lockable with a housing, Contact carrier for switching elements made of insulating material known, anchor contacts either in a glass tube or attached in a plastic frame as a carrier are, these carriers to the outside through two housing caps be completed. All moving parts are in one and the same support part held while the housing caps no influence on the positioning of the functional elements of the relay.

EP-A-0 251 035 also describes a relay which of two half-shell-shaped, forming a bobbin Basic body parts exist that carry the winding. In one of the basic body parts are in a common plane two pole plates embedded, the ends of which are in a contact space can be bridged within the coil by an armature contact. The anchor itself is in via a frame-shaped spring the parting plane between the two base parts.

The aim of the present invention is to provide a relay of the input to create the type mentioned with a flat structure that for different sizes and applications is designed and that when using appropriate manufacturing processes in large Quantity can be produced very inexpensively. Due to the construction, a high level of accuracy is intended can already be achieved in production, so that even without Subsequent adjustment of the relay parameters with only small Scattering are observed.

According to the invention, this goal is achieved with such a relay achieved in that the two housing parts as approximately trough-shaped half-shells made of plastic with their edges are sealed together that the connections for the Coil winding and for the contact elements each by the Wall of its associated housing part embedded to the outside are guided, and that the main joining planes between the two Housing parts perpendicular to the switching movement of the contact spring stand.

In the relay according to the invention, the two half-shells form not just an easy-to-seal housing, but it also serve as carriers for the functional elements of the relay, these functional elements, i.e. the magnet system in one Part and the contact system in the other part already the manufacture of the respective half-shell positioned very precisely can be. The main joining planes are between two housing parts perpendicular to the switching movement of the Contact spring so that by joining the two housing parts the distance between the magnet system and contacts can be adjusted. Fixation is particularly easy of the functional parts in the housing and the sealing of the connections achieved in that this in the respective housing half-shell are embedded. The joining levels consist of Plastic, preferably thermoplastic, so that a tight connection, for example with ultrasound is easy to do.

In a preferred embodiment there is the magnet system from a U-shaped core yoke sheet, which is preferably as well as at least two coil connections in a plastic coil body are embedded. The on both ends of the Core formed pole plates then extend vertically to the coil axis in the area next to the coil, where it is from an armature lying next to the coil can be bridged. This Anchor can be designed more or less as a flat sheet be bent or bent at different heights at both ends to be offset accordingly in height as well Interacting pole plates. In this way, the Space in the housing for housing the contacts and the various connections can be used optimally. An L-shaped Contact spring, which is front with a leg in front of the coil and with the other leg next to the coil Extending below or above the anchor results in a narrow space a large feather length; the anchor is preferably in the transition area between the two spring legs on the contact spring attached.

A preferred method for producing the relay is that the first housing part is obtained by embedding the coil with the core, including the coil connections, according to the invention.
that the second housing part is obtained by embedding the spring support and at least one counter-contact element, that the contact spring connected to the armature is connected to the spring support, and
that the two housing parts are then placed on top of one another with their edges and connected. Preferably, the coil former is also formed beforehand by embedding the core and the coil connections, with the first housing part being produced by a second embedding after winding the coil and after connecting the coil ends to the coil connections. Before the two housing parts are joined together, the armature is connected to the contact spring, an electrically conductive connection by welding or the like or an insulating connection by overmolding being possible, depending on the application. The contact spring is then attached to the spring support anchored in the second housing part in an electrically conductive manner, for example by welding or also by means of a plug-in fastening.

A major advantage of the invention can also be seen in the fact that that when joining the two housing parts, the contact lift can be set, for example, when joining measured the pull-through voltage of the anchor and then the joining process when reaching a predetermined electrical Characteristic value of the pull-through voltage - which is a measure of the erosion size or the overstroke of the contact is interrupted becomes. Instead of the connection via ultrasound or another However, the two half-shells can be welded also with other technologies, for example by gluing, Clamping, casting or using a two-component injection molding process molded elostomer seal sealed become.

Figur 1 ein erfindungsgemäß gestaltetes Relais mit teilweise aufgeschnittenem Gehäuse,

Figur 2 eine Spule für das Relais von Figur 1,

Figur 3 eine durch Umspritzen der Spule gewonnene erste Halbschale,

Figur 4 eine zweite Halbschale mit eingesetztem Anker,

Figur 5 die zweite Halbschale von Figur 4 ohne Anker in Draufsicht,

Figur 6 einen mit einer Kontaktfeder verschweißten Anker,

Figur 7 einen mit der Kontaktfeder durch Umspritzen verbundenen Anker,

Figur 8 die zweite Halbschale in Draufsicht mit Anker und aufgesteckter Kontaktfeder,

Figur 9 einen Schnitt IX-IX aus Figur 8, jedoch mit zusätzlich aufgesetzter erster Halbschale,

Figur 10 ein etwas gegenüber Figur 1 abgewandeltes Relais beim Fügen der beiden Halbschalen,

Figur 11 eine weitere Abwandlung des Relais von Figur 1 mit geänderter Anschlußkonfiguration.

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

1 shows a relay designed according to the invention with a partially cut-open housing,

FIG. 2 shows a coil for the relay from FIG. 1,

FIG. 3 shows a first half-shell obtained by extrusion coating the coil,

FIG. 4 shows a second half-shell with an anchor inserted,

FIG. 5 shows the second half-shell of FIG. 4 without an anchor in a top view,

FIG. 6 shows an armature welded to a contact spring,

FIG. 7 shows an armature connected to the contact spring by injection molding,

FIG. 8 the second half-shell in a top view with an anchor and an attached contact spring,

FIG. 9 shows a section IX-IX from FIG. 8, but with an additional first half-shell attached,

FIG. 10 shows a relay modified somewhat compared to FIG. 1 when joining the two half-shells,

Figure 11 shows a further modification of the relay of Figure 1 with a changed connection configuration.

The relay shown in Figures 1 to 5 consists of a first half-shell 1 and a second half-shell 2, the Half-shell 1 by overmolding a coil 3 and the second Half shell by overmolding a spring support 21 and two Mating contact elements 22 and 23 is formed. On the spring support 21, an L-shaped contact spring 4 is attached in turn carries an anchor 5. The almost Z-shaped curve Anchor 5 forms working air gaps with its ends with two pole faces 63 and 64 of the pole plates 61 and 62, which are part of a U-shaped core 6, but this Pole plate 62 is bent up from the core plane.

During manufacture, the coil is first obtained by the middle section of the core 6 with thermoplastic material is overmolded, whereby a bobbin 31 is formed becomes. The pole plates 61 and 62 are kept free. Moreover are two coil connections 32 in the coil body and 33 injected, so that not only the after externally directed pins 32a and 33a, but also the inner ones intended for contacting the winding ends Connecting surfaces 32b and 33b remain free of the embedding. After applying a coil winding 34 to the bobbin the ends of which are connected to the connecting surfaces 32b and 33b connected. The winding ends are protected guided behind ribs 35 in channels 36 of the bobbin. Subsequently the entire coil is overmolded again, so to win the first half-shell according to FIG. 3. The pole faces 63 and 64 of the pole plates 61 and 62 also remain from this Overmolding free, while the rest of the parts, in particular also the coil winding 34, in the plastic 11 of the first Half shell 1 can be embedded. The coil connector pins 32a and 33a are close to the outside in this new embedding performed where it is angled downwards according to FIG. 1 or FIG. 3 or in a manner not shown, also for education from SMT connections in a horizontal plane can.

The second half-shell 2 is, as already mentioned, by injection molding the spring support 21 and the mating contact elements 22 and 23 won, with a cavity for the coil and for the movable armature contact spring unit is free. The Mating contact elements each have a close to Outside guided pin 22a or 23a, while in Inside each a fixed contact section 32b or 33b with a Precious metal contact layer 32c or 33c is provided. in the The present example is the contact material as an inlay plated in the surface of the respective contact element, so that a cover when overmoulding easily possible is. Otherwise, other technologies would also apply of the contact material conceivable. Instead of the two mating contact elements 22 and 23 could of course only be a mating contact element to form an opener or a closer be provided.

The L-shaped contact spring 4 has a first Spring leg 41, which extends in front of the coil, and a second spring leg 42, which is laterally extends next to the coil below the armature and one movable contact 43 carries. The first spring leg 41 is via an upwardly angled fastening tab 44 the spring support 21 via a welded connection 46 according to FIG 4 or attached via a clamping claw 45 according to FIG. 8. Thanks to this connection technology, the mounting height is Contact spring 4 on the spring support 21 variable, which also the position of the second spring leg 42 relative to the mating contact elements can be adjusted. In this way the anchor restoring force or the rest contact force during the assembly process to compensate for tolerances become.

Before attaching the contact spring to the spring carrier 21 it is connected to the anchor 5, which, for example, according to 6 done electrically conductive via a welded joint 51 can. Should be insulation between the contact spring and the magnet system can be reached, so the connection made by an insulating material sheath 52 according to FIG. 7 become. For certain cases of use, it is also possible to conduct the current to the contact spring via a wire. For example, higher tax levels can be achieved through such Low-resistance wire to the contact point to to avoid excessive heating of the spring.

When joining the two half shells 1 and 2 (see figure 9) engages a peripheral wall 12 in a box shape over the lower housing part 2, which has an inner circumferential for this purpose Has web 24. For precise adjustment of the distances to reach between magnet system and contact system, one of the housing parts also has a circumferential rib 25, which is deformed during the joining by means of ultrasound and the tight connection between the two half-shells manufactures. When joining the two half shells, the Pull-through voltage of the armature measured, the armature connected to the Pole surfaces 63 and 64 of the pole plates 61 and 62 is attracted. As soon as a specified characteristic value of the pull-in voltage as Measure of the erosion size or the overstroke of the contact reached the joining process is ended. The relay is now adjusted and sealed at the same time.

FIG. 10 shows a variant of the relay from FIG. 1. In this case, the two half-shells 101 and 102 are not in a single joining plane, but with mutually graduated Joining planes 103 and 104 connected. The interior structure of the Relay is the same as in the previous example, except that a mating contact element, namely a normally open mating contact plate 105 with its pin 105a in the first half-shell is injected with the magnet system. At the In this case, the distance between the two half-shells can be added the counter contacts are influenced. With this variant you can thanks to a slide-free injection mold, welding, Rivet and inlay contacts on the mating contact elements be provided.

The construction of the relay allowed by the application of the relative parts also plan other embodiments of the connection geometry, so that the connections also on only one relay side can emerge from the housing. Such an opportunity is shown in Figure 11, with a first half-shell 110 the contact elements with pins 111, 112 and 113 and a second half shell 120 the magnet system with coil pins 121 and 122 carries. Such a relay is required only a small footprint for plugging or soldering. Instead of of the solder pins shown in Figure 11 Of course, flat plugs can also be provided. As before Mentioned earlier, the connector pins can of course also designed as surface-mountable SMT connections his.

Claims (20)

1. Electromagnetic relay having

   a first housing part (1), which is fitted with a coil (3) as well as a core (6) which passes through the coil and, outside the coil, forms pole plates (61, 62) at its two ends,

   a second housing part (2) in which at least one spring support (21) and at least one mating contact element (22, 23) are anchored, the spring support (21) being fitted with a contact spring (4) which interacts with the mating contact element (22, 23), and

   an armature (5) which is connected to the contact spring (4) and bridges the pole plates (61, 62) forming air gaps,

   characterized
   in that the two housing parts (1, 2) are joined together at their edges, forming a seal, as roughly trough-shaped half-shells made of plastic, while the connections (21a, 22a, 23a, 32a, 33a) for the coil winding (34) and for the contact elements (21, 22, 23) are each passed out through the wall of their respective housing parts (1, 2), and in that the main joint planes between the two housing parts (1, 2) are at right angles to the switching movement of the contact spring (4).
2. Relay according to Claim 1, characterized in that the coil (3) which is formed from a coil former (31) with a winding (34) is embedded together with the core (6) in the plastic of the first housing part (1), leaving free pole surfaces (63, 64) in the region of the air gaps, while the spring support (21) and the at least one mating contact element (22, 23) are embedded in the plastic of the second housing part (2).
3. Relay according to Claim 2,
   characterized in that the core (6) is embedded in the plastic of the coil former (31).
4. Relay according to Claim 3,
   characterized in that connecting elements (32, 33) for the coil winding (34) are embedded both in the coil former (31) and in the plastic of the first housing part (1).
5. Relay according to one of Claims 1 to 4,
   characterized in that the core (6) is U-shaped, a centre section being fitted with the coil (3), and two pole plates (61, 62) projecting essentially at right angles to the coil axis, and in that the armature (5) extends essentially parallel to the coil axis alongside the coil (3) and forms the air gaps with the two pole plates (61, 62).
6. Relay according to Claim 5,
   characterized in that the contact spring (4) is cut in an L-shape, so that it has two limbs (41, 42) which essentially run in one plane, of which the first extends at the end in front of the coil, and the second extends at the side alongside the coil, this second limb (42) and the armature (5) being located parallel one above the other and being connected in the corner region between the two limbs of the contact spring.
7. Relay according to Claim 6,
   characterized in that the armature (5) is metallically connected to the contact spring (4), namely by means of welding (51), riveting or the like.
8. Relay according to Claim 6,
   characterized in that the armature (5) is connected to the contact spring (4) via a common dielectric sheath (52).
9. Relay according to one of Claims 1 to 8,
   characterized in that two mating contact elements (22, 23) are anchored in the second housing part (2) and form a changeover contact with the contact spring (4).
10. Relay according to one of Claims 1 to 8,
    characterized in that a second mating contact element (105) is anchored in the first housing part (101) and forms a changeover contact with the mating contact element (23), which is anchored in the second housing part (102), and with the contact spring (4).
11. Relay according to one of Claims 1 to 10,
    characterized in that the two housing parts (1, 2) have edges (103, 104) which are designed to be stepped in at least two mutually parallel offset separating planes.
12. Method for producing a relay according to Claim 1, in which

    a first housing part (1) has anchored in it a coil (3) as well as a core (6) which passes through the coil and, outside the coil, forms pole plates (61, 62) at its two ends,

    a second housing part (2) has anchored in it at least one spring support (21) and at least one mating contact element (22, 23), the spring support (21) being fitted with a contact spring (4) which interacts with the mating contact element (22, 23), and in which

    an armature (5) is connected to the contact spring (4) and bridges the pole plates (61, 62) forming air gaps,

    characterized,

    in that the first housing part (1) is produced by embedding the coil (3) with the core (6) including the coil connections (32, 33),

    in that the second housing part (2) is produced by embedding the spring support (21) and at least one mating contact element (22, 23),

    the two housing parts (1, 2) each being formed like troughs such that their edges form at least one main joint plane which is at right angles to the movement direction of the armature,

    such that the contact spring (4) which is connected to the armature (5) is connected to the spring support (21), and

    such that the edges of the two housing parts (1, 2) then rest on one another and are connected.
13. Method according to Claim 12,
    characterized in that a coil former (31) is formed first of all by embedding the core (6) and the coil connections (32, 33), in that this coil former (31) is provided with a coil winding (34) and is then embedded once again in order to form the first housing part (1).
14. Method according to Claim 12 or 13,
    characterized in that the armature (5) is connected to the contact spring (4) by welding, and the latter is then connected to the spring support (21).
15. Method according to Claim 12 or 13,
    characterized in that the armature (5) is connected to the contact spring (4) by being embedded in dielectric (52).
16. Relay according to one of Claims 12 to 15,
    characterized in that the contact spring (4) is connected to the spring support (21) by welding.
17. Relay according to one of Claims 12 to 15,
    characterized in that the contact spring (4) is connected to the spring support (21) by plug-in attachment.
18. Method according to one of Claims 12 to 17,
    characterized in that, when the two housing parts (1, 2) are being joined together, the armature travel and/or the overtravel are measured indirectly (electrically via the seal-in voltage) and the joining process is ended when a predetermined magnitude is reached.
19. Method according to Claim 18,
    characterized in that the edge region (25) of at least one of the two half-shells (1) is deformed during the joining process until the predetermined overtravel is reached.
20. Method according to Claim 19,
    characterized in that the edge or a rib (25), which is integrally formed on the edge, of one of the two half-shells (1) is deformed by ultrasound during the joining process.

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