JP2003068181A - Electromagnetic relay - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an electromagnetic relay never causing a dispersion in operation characteristic. SOLUTION: An anchor projection 22b extended substantially axially from the connection receiving part 22a of a common terminal 22 is insert-molded in the side wall of a base.

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electromagnetic relay, and more particularly to an electromagnetic relay in which a coil terminal and a common terminal are insert-molded on a base. 2. Description of the Related Art A conventional electromagnetic relay is disclosed in, for example, Japanese Patent Application Laid-Open No. 63-231829. That is, the common terminal 12, the fixed terminal 13, and the coil terminal 14 integrally formed on the base 51 of the lead frame 50 by punching one conductive plate material are insert-molded on the base 1. [0003] However, the electromagnetic relay is arranged so that the common terminal 1 is connected to the base 51 facing the lead frame 50 in order to form a contact mechanism symmetrically.
2. The fixed terminal 13 and the coil terminal 14 are arranged in parallel so as to extend substantially in parallel. Therefore, the effective length from the base 51 to the free end of the coil terminal 14 is less than half the width of the lead frame 50,
The effective length cannot be obtained sufficiently. As a result, when the base of the coil terminal 14 is largely bent in the thickness direction in order to form a large step and secure a desired insulation distance between the fixed terminal 13 and the coil terminal 14, the free end of the coil terminal 14 Move outward, and the floor area of the electromagnetic relay increases. Therefore, the fixed terminal 1 can be fixed without increasing the floor area of the electromagnetic relay.
Even if an attempt is made to form a large step between the coil terminal 3 and the coil terminal 14, it is difficult to secure a desired insulation distance because there is a limit to the size of the step that can be formed. Further, a coil terminal 14 and a common terminal 12,
In order to reduce the size while securing insulation from the fixed terminal 13, it is necessary to arrange the coil terminal 14 on the outermost side. In order to simultaneously cut out the fixed terminal 13 and the coil terminal 14 from one conductive plate, the fixed terminal 13 has to be formed inside the coil terminal 14. Therefore, the pair of fixed terminals 13 cannot be sufficiently separated from each other, and the distance between the fixed contacts 13a cannot be increased. As a result, the movable contact piece 31 could not be lengthened, and desired spring characteristics could not be obtained. Further, the common terminal 12 is connected to the electromagnet block 2
After insert molding into the base 5 of the lead frame 50,
1 and bent when separated from each other.
Since 2a and 12a are lifted up from the opening edge of the electromagnet block 2, there is a problem that the operating characteristics are apt to vary. [0006] In view of the above problems, it is an object of the present invention to provide an electromagnetic relay in which the operating characteristics do not vary. [0007] In order to achieve the above object, an electromagnetic relay according to the present invention forms a common terminal integral with a lead frame by punching a single conductive plate. Part of the connection receiving part located at the free end of
In the electromagnetic relay which is insert-molded on the side wall of the base, an anchor protrusion extending substantially in the axial direction from the connection receiving portion of the common terminal may be insert-molded on the side wall of the base. According to the first aspect of the present invention, the mounting of the common terminal to the base is reinforced by insert-molding the anchor projection extending from the connection receiving portion on the base. . Next, an embodiment of the present invention will be described with reference to the accompanying drawings of FIGS. The electromagnetic relay according to the present embodiment generally includes a base block 20 formed by subjecting the electromagnet block 10 to secondary molding, a permanent magnet 30, an armature block 40, and a case 50. As shown in FIGS. 5 and 6, the electromagnet block 10 is formed by winding a coil 16 around a spool 12 in which an iron core 11 having a substantially U-shaped cross section is insert-molded. For convenience of explanation, in FIG.
6 is omitted. The spool 12 is, as shown in FIG.
The magnetic pole faces 11a, 11b located at both ends of the iron core 11 are exposed from the upper end faces of the flanges 13, 14 formed at both ends thereof, respectively, while a pair of relay terminals 17, 18 are insert-molded, and the barbs 17a and 18a protrude from both end surfaces of the flanges 13 and 14, respectively. Further, a guide groove 13a is formed in the flange portion 13 along the side end surface, and one opening portion is located near the base of the barb portion 17a, and the other opening portion is formed in the flange portion 13a. The inner side surface is located near the outer peripheral surface of the first trunk portion 12a. A guide groove 14a similar to the guide groove 13a is also formed in the flange portion 14. An insertion hole 15a for inserting a permanent magnet is formed in a central flange portion 15 provided at a position eccentric from the center of the spool 12, and furthermore, this insertion hole 15
Parallel guide grooves 15b and 15c are provided so as to sandwich “a”. Therefore, after one end of the coil 16 is wrapped around the buckling portion 17a of the relay terminal 17 insert-molded in the flange portion 13, the spool 16 is moved along the guide groove 13a provided in the flange portion 13. After winding about 20% of the desired number of turns, and then pulling out along the guide groove 15b formed in the central flange portion 15 to the second body 12b to obtain the desired number of turns (100 %), And the first groove is wound along the guide groove 15c of the central flange portion 15.
The coil 16 is pulled out again to the body 12a and wound up to the remaining 80% of the number of turns.
After being tied to 8a, soldering to the kinked portions 17a and 18a completes the winding operation of the coil 16. According to the present embodiment, the number of turns in the first winding operation of the coil 16 on the first body portion 12a is about 20.
%, And the remaining number of turns is about 80%, so that the final winding end portion of the coil 16 is
The coil 16 is separated by a predetermined distance from the end of winding of the coil 16 in the first winding operation in a. For this reason, even if the insulating film of the coil 16 located on the outermost peripheral surface is slightly melted or peeled off by the heat of the resin material during the secondary molding to be described later, the coil 16 located on the outermost peripheral surface and the coil 16 located immediately below the coil 16 are located at Since the voltage difference from the coil 16 is small, there is an advantage that a short circuit is less likely to occur and the yield is improved. In the present embodiment, about 20% is wound in the first winding operation on the first body part 12a, and then the second body part 1a is wound.
After performing the winding operation of 100% in 2b, the remaining approximately 80% of the winding operation in the first body 12a was performed again. However, the invention is not limited to this. For example, the first operation in the first body 12a is performed. In the winding operation, about 50% of the predetermined number of turns may be wound. The base block 20 is formed by integrally forming the electromagnet block 10 on a lead frame 60, and the lead frame 60 is fixed at a predetermined position on a conductive plate as shown in FIG. 23a, 24a
The coil terminal 21, the common terminal 22, a part of the fixed contact terminals 23 and 24, and the connection protrusion 62 are formed inside the substantially rectangular frame shape, and are shown by hatching in FIG. The part is cut off and bent in the thickness direction (FIGS. 8 to 10). That is, in the lead frame 60, the connection protrusions 62, 62 respectively protrude from substantially the center of one side of the lead frame 60, and the coil terminal 21 extends from the base of the lead frame 60 via the connecting portion 61 in a substantially ∪ shape. Things. Further, the lead frame 60 has a connecting portion 63 extending substantially at the center of one side adjacent to the side on which the connection protrusion 62 is provided.
A common terminal 22 having a U-shaped connection receiving portion 22a at a free end extends. The fixed contact terminals 23 and 24 extend from the connecting portion 63 and are arranged side by side on both sides of the common terminal 22. The fixed contact terminals 23a and 24a are fixed to the free ends bent outward at substantially right angles. 24a are provided respectively. Then, as shown in FIGS. 11 to 13, the lead frame 60 is inverted, and the relay terminals 17, 18 of the electromagnet block 10 are connected to the free ends of the coil terminals 21.
Are placed and positioned, and connected and integrated by laser welding. Next, as shown in FIG. 14, the electromagnet block 10 integrated with the lead frame 60 is assembled into a lower mold 70, and an upper mold 73 is combined with the lower mold 70.
By locking the corners of the iron core 11 with the positioning members 74, 74 assembled to the upper mold 73, the electromagnet block 10
Locating pin 7 projecting through insertion hole 15a of lower mold 70
1 and the magnetic pole surfaces 11a, 11
b, butts against the protruding pins 72, 72, and positions the electromagnet block 10 in the cavity 77. The runner 75 provided on the upper mold 73
Resin material melted from the gate 76 of the electromagnet block 10
Of the electromagnet block 10 by resin pressure.
Is pressed against the lower mold 70 to position it firmly, and the resin material overflowing from the injection hole 15d is
The base block 20 is formed by filling the inside. Next, after lowering the lower mold 70, the iron core 11 is protruded with the protruding pins 72, 72, thereby obtaining the base block 20 (FIG. 16). In addition, by the above-mentioned secondary molding, at the upper edge of the outer surface of the base block 20,
A continuous fitting surface 25 indicated by hatching in FIG. 1 is formed, and an inclined surface 26 for guiding a sealing material is formed on a lower edge of an outer surface thereof. In the above-mentioned embodiment, the electromagnet block 10 is fixed to the lower mold 7 by the positioning members 74, 74 provided on the upper mold 73.
Although the case where the initial positioning is performed at 0 and the positioning is performed firmly by the resin pressure of the resin material injected from the gate 76 of the runner 75 has been described, the invention is not limited to this. As shown in FIG. Gate 7 of runner 75 provided
6, and the electromagnet block 10 may be pressed against the lower mold 70 with the resin pressure of the resin material injected from the gates 79, 79 of the runners 78, 78 to firmly position the electromagnet block 10. In the above-described embodiment, the coil terminals 21
Extending from one side different from the fixed contact terminals 23 and 24 has been described, but the present invention is not limited to this.
As shown in FIG. 19, the coil terminal 61 extends from the connecting portion 63 of the fixed contact terminals 23 and 24 outwardly through the connecting portion 61 in a substantially rectangular shape, and the connecting portion 61 is moved in the thickness direction. By bending, a step may be provided between the fixed contact terminals 23 and 24 and the coil terminals 21 and 21. Next, as shown in FIG. 17, the lead frame 60 integral with the base block 20 obtained by the secondary molding is subjected to press working, the coil terminal 21 is cut out from the connecting portion 61 from the connecting portion, and the common terminal 22 is fixed. The base block 20 is completed by separating the contact terminals 23 and 24 from the connecting portion 63, bending the tip of each terminal downward, and further bending each terminal downward from the base. According to this embodiment, since the connection projections 62 of the lead frame 60 are insert-molded on the outer surface of the base block 10, even if the terminals 22, 23, and 24 are separated from the lead frame 60, even if the terminals 22, 23, and 24 are separated from the lead frame 60. 20
Does not fall from the lead frame 60, and the lead frame 6
0 and can be transported together. In addition, since the anchor projection 22b extending in the axial direction from the substantially T-shaped connection receiving portion 22a of the common terminal 22 is insert-molded at the opening edge of the base block 20, the outer surface of the base block 20 Even if the projecting common terminal 22 is bent from its base, there is an advantage that the connection receiving portion 22a of the common terminal 22 does not rattle. In the above embodiment, each of the terminals 21, 22, 2
Although the case where the distal end portions of 3, 24 are bent inward in advance has been described, the present invention is not necessarily limited to this, and may be bent outward in advance, or sealed with a sealing material 80 described later, After the preliminary soldering, it may be bent inward or outward. In addition, bending the tip of each terminal inward has the advantage of reducing the floor area and increasing the mounting density, while bending the tip of each terminal outward allows soldering. There is an advantage that the bonding becomes easier and the bonding reliability is increased. The permanent magnet 30 has a substantially rectangular parallelepiped shape formed by sintering a rare earth element. The permanent magnet 30 is inserted from above into the insertion hole 15a of the electromagnet block 10 supported by the lead frame 60, and its lower magnetic pole surface is formed. The magnet 31 is magnetized after assembling so as to be in contact with the upper surface of the iron core 11. As shown in FIG. 1, the armature block 40 has movable contact pieces 42, 42 arranged in parallel on both sides of the armature 41.
Are integrally formed with the support portion 43. The armature 41 is a flat rectangular plate made of a magnetic material, and has a support projection 41c formed at the center of the lower surface thereof by projection (FIG. 3). The movable contact pieces 42, 42
It has a twin contact structure in which movable contacts 42a and 42b are respectively provided on both divided ends. The movable contact pieces 42, 42 extend laterally from a central portion of the connecting portion 42c having a substantially T-shape in a plane, and the connecting portion 42c protrudes from a side surface of the support portion 43. The support portion 43 is provided with the armature 4
1 and the movable contact pieces 42, 42 are formed by insert molding and integrated, and the support projection 41c of the iron core 41 is exposed from the center of the lower surface thereof. Accordingly, the armature block 40 is assembled from above to the base block 20 supported by the lead frame 60, the support projection 41c of the armature 41 is placed on the magnetic pole surface 32 of the permanent magnet 30, and the connection portion 42c is connected. Common terminal 22
The two ends 41a and 41b of the armature 41 are positioned on the connection receiving portion 22a of the iron core 1 by laser welding.
And alternately contacting and separating the magnetic pole surfaces 11a and 11b,
The movable contacts 42a, 42b alternately contact and separate from the fixed contacts 23a, 24a. In this embodiment, since the supporting projection 41c of the armature 41 is positioned at a position eccentric from the center of the magnetic pole surface 32 of the permanent magnet 30, the left and right magnetic balance is lost, and the self-recovery is performed. It is a type. The case 50 is a box-shaped resin molded product which can be fitted to the base block 20 in which the armature block 40 is incorporated.
1. Notches 51, 51, 52, 53 and 54 are formed to be fitted to the common terminal 22 and the fixed contact terminals 23 and 24, and a vent hole 55 is formed at a corner of the ceiling surface. When the case 50 is partially fitted into the base block 20 supported by the lead frame 60 and pressed down, the base block 20 falls off the connection protrusions 62 of the lead frame 60, and The case 50 is completely fitted into the base block 20, the middle portions of the terminals 21 to 24 are fitted into the notches 51 to 54 of the case 50, and the outer surface of the middle portion of each of the terminals 21 to 24 is the case 50. Flush with the outside surface of However, the case 5
Since the height of the base block 20 is smaller than the height of the base block 20, the bottom of the base block 20 projects from the opening of the case 50, and the inclined surface 26 provided on the side edge near the bottom of the base block 20 is exposed. I do. In this embodiment, since the connection projections 62 are not cut, there is an advantage that chips generated by the cutting do not enter the base block 20. In the above-described embodiment, the case where the base block 20 is detached from the connection protrusion 62 and separated is described. However, the present invention is not limited to this.
2 may be deeply insert-molded in the base block 20, and the connection protrusion 62 may be cut to separate the base block 20. Next, as shown in FIG. 4, when the sealing material 80 is injected toward the inclined surface 26 formed near the bottom surface of the base block 20, the sealing material 8 is formed along the inclined surface 26.
0 flows down and seals the gap between the base block 20 and the case 50. However, the continuous fitting surface 25 provided on the outer surface of the base block 20 abuts on the inner surface corner of the case 50 to prevent the sealing material 80 from entering the base block 20. After the internal gas is sucked from the gas vent hole 55 of the case 50, the assembly is completed by heat sealing. Next, the operation of the electromagnetic relay having the above configuration will be described. First, in the case of non-excitation, since the left and right magnetic balance is lost, one end 41a of the armature 41
Are attracted to the magnetic pole surface 11a of the iron core 11, and the movable contact 42a of the movable contact piece 42 is in contact with the fixed contact 23a, while the movable contact 42b is separated from the fixed contact 24a. When the electromagnet block 10 is energized by applying a voltage to the coil 16 so that a magnetic flux is generated in a direction to cancel the magnetic force of the permanent magnet 30, the armature 41 is supported against the magnetic force of the permanent magnet 30. The armature 41 rotates about the fulcrum 41c, and one end 41a of the armature 41 is
a, and then the movable contact 42a is
After the movable contact 42b separates from the fixed contact 24a and the movable contact 42b contacts the fixed contact 24a, the other end 41b of the armature 41 is attracted to the magnetic pole surface 11b of the iron core 11. Further, when the excitation of the coil 16 is released,
Since the right and left magnetic balance is lost, the armature 41 performs the reverse operation by the magnetic force of the permanent magnet 30, and the armature block 40 rotates to return to the original state. As is apparent from the above description, according to the electromagnetic relay according to the first aspect of the present invention, the anchor projection extending from the connection receiving portion of the common terminal is insert-molded on the electromagnet block. Is done. For this reason, even if the common terminal protruding from the outer surface of the electromagnet block is bent, the connection receiving portion does not rise due to the anchor effect of the anchor projection, and there is an effect that the operating characteristics do not vary.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view showing an embodiment of an electromagnetic relay according to the present invention. FIG. 2 is a partial plan sectional view of the electromagnetic relay shown in FIG. FIG. 3 is a front partial sectional view of the electromagnetic relay shown in FIG. 1; FIG. 4 is a partial left side sectional view for explaining a sealing operation of the electromagnetic relay shown in FIG. 1; FIG. 5 is a perspective view showing an electromagnet block of the electromagnetic relay according to the present invention. FIG. 6 is a cross-sectional view of the electromagnet block shown in FIG. FIG. 7 is a plan view of a lead frame used for manufacturing the electromagnetic relay according to the present invention. FIG. 8 is a plan view showing a state where the lead frame of FIG. 7 is subjected to a bending process. FIG. 9 is a front view of the lead frame shown in FIG. 8; FIG. 10 is a right side view of the lead frame shown in FIG. 8; FIG. 11 is a plan view showing a state where an electromagnet block is mounted on a lead frame used for manufacturing an electromagnetic relay according to the present invention. FIG. 12 is a front view of the lead frame shown in FIG. 11; FIG. 13 is a left side view of the lead frame shown in FIG. 11; FIG. 14 is a cross-sectional view showing a method of secondary molding performed when manufacturing the electromagnetic relay according to the present invention. 15 is a cross-sectional view showing another method different from the secondary molding shown in FIG. FIG. 16 is a perspective view showing a base block formed by secondary molding according to the present invention. FIG. 17 is a perspective view showing a state where a base block formed by secondary molding according to the present invention is subjected to press working. FIG. 18 is a plan view of a lead frame showing another embodiment of the electromagnetic relay according to the present invention. FIG. 19 is a front view of the lead frame shown in FIG. 18; [Description of Reference Numerals] 20: base block, 21: coil terminal, 22: common terminal, 22a: connection receiving portion, 22b: projection for anchor,
23, 24: fixed contact terminal, 23a, 24a: fixed contact, 60: lead frame, 61: connecting portion, 62: connecting protrusion, 63: connecting portion.

   ────────────────────────────────────────────────── ─── Continuation of front page    (72) Inventor Mitsuhiro Kawai             Shiokyo-ku, Shimogyo-ku, Kyoto             801 Jidocho OMRON Corporation (72) Inventor Masakatsu Tani             Shiokyo-ku, Shimogyo-ku, Kyoto             801 Jidocho OMRON Corporation

Claims (1)

Claims: 1. A single conductive plate is punched out to form a common terminal integral with a lead frame, and a part of a connection receiving portion located at a free end of the common terminal is used as a base. An electromagnetic relay which is insert-molded on a side wall, wherein an anchor projection extending in a substantially axial direction from a connection receiving portion of the common terminal is insert-molded on a side wall of a base.