JP3580165B2

JP3580165B2 - Electromagnetic relay and assembly method thereof

Info

Publication number: JP3580165B2
Application number: JP05950699A
Authority: JP
Inventors: 和久松田; 宗生仲田; 謙一松尾
Original assignee: Omron Corp
Current assignee: Omron Corp
Priority date: 1999-03-05
Filing date: 1999-03-05
Publication date: 2004-10-20
Anticipated expiration: 2019-03-05
Also published as: JP2000260286A

Description

【０００１】
【発明の属する技術分野】
本発明は、スプールの一方のフランジがケース開口部の内側に配置され、このケース開口側がシール材でシールされてなる電磁リレーに係わり、可動接点バネと一体に形成されてケース開口から突出状態に配置される可動接点端子の導出部の構成が改善され、シール材の充填状態が良好に維持され、かつ全体の高さ寸法の増加を伴うことなく、組立て性が向上された電磁リレーに関する。
【０００２】
【従来の技術】
一般に、車載用の回路基板などに搭載される小型電磁リレー（高さ寸法が例えば２０ｍｍ以下の小型なもの）にあっては、基板搭載後の洗浄などに耐え得るように、また、所定の防水性や防塵性を確保するために、密封されたタイプのリレー（即ち、シール型リレー）が主流となっている。特に上記洗浄は、基板搭載のための半田付けの後で行われるため、リレーが加熱された状態から洗浄液によって急激に冷やされることになり、リレー内外に気圧差が生じるため、僅かな隙間であってもそこから洗浄液が内部に吸込まれ易く、高度な気密性能が要求される。
また近年、この種の小型電磁リレーにおいては、小型化と低コスト化が強く求められており、そのためには、部品点数のいっそうの削減と各部品の高密度な組付け構造が重要となる。そこで、特開平１０−１６２７１２号公報にも開示されているように、従来組立ての基本となっていたベースと呼ばれる部材を廃止し、電磁石のコイルを巻回するためのスプールの一方のフランジをケースの開口部内側に配置し、この一方のフランジをベースとしても機能させたタイプのリレーが登場している。
【０００３】
図４乃至６は、このようなタイプのリレーの第１従来例を示す図であり、図４は主要部品の分解斜視図、図５はリレー全体をケース開口側から見た平面図、また図６は、図５における符号Ａ−Ａで示す部分の断面図である。なお、図５ではシール材の図示を省略している。また以下では、後述するケース１４の開口側（図４，６における上側）を場合によりケース開口側といい、後述するケース１４の奥側（図４，６における下側）を場合によりケース奥側という。
【０００４】
このリレー１は、図４に示すように、上下両端にフランジ２ａ，２ｂを有し電磁石を構成するコイルが巻回されるスプール２と、このスプール２内に形成された縦方向（コイル軸方向）の貫通穴に挿通された電磁石の鉄心３と、この鉄心３のケース開口側端部に連結されて磁力線の通り道となるＬ字形のヨーク４と、このヨーク４に基端側が接合し、コイル通電時に鉄心３に引き付けられて先端側が揺動する可動鉄片５と、ケース奥側の横方向板状部６ａが揺動可能な板バネであって、この横方向板状部６ａが可動鉄片５の外面側に取付けられるＬ字形の可動接点バネ６と、この可動接点バネ６の先端に取付けられる可動接点７と、コイル非通電時において可動接点７が圧接するＮＣ接点である第１固定接点（図示省略）と、この第１固定接点がケース奥側端部に取付けられた第１固定端子（図示省略）と、コイル通電時において可動接点７が圧接するＮＯ接点である第２固定接点（図示省略）と、この第２固定接点がケース奥側端部に取付けられた第２固定端子（図示省略）と、コイルの各口出し線にそれぞれ接続される第１コイル端子１２及び第２コイル端子１３（図５に示す）と、組付け側（図６では上側）が開口したケース１４（図５，６に示す）とを備える。
【０００５】
ここで、ヨーク４は、横方向板状部４ａと縦方向板状部４ｂを有し、横方向板状部４ａがスプール２のケース開口側のフランジ２ｂの外面に形成された凹部２ｃにはめ込まれて鉄心３の先端とカシメにより連結され、縦方向板状部４ｂが前記フランジ２ｂに形成された長方形状の開口部２ｄからコイル軸方向に沿ってケース奥側に伸びている。
また、可動接点バネ６は、前述した横方向板状部６ａと縦方向板状部６ｂを有し、縦方向板状部６ｂに形成されたカシメ用穴６ｃにヨーク４（縦方向板状部４ｂ）に形成されたカシメ用突起４ｃがはめ込まれ、このカシメ用突起４ｃの先端がカシメられることによって、ヨーク４（縦方向板状部４ｂ）に回り止めされて固着されている。
また、スプール２のフランジ２ｂにおける前記開口部２ｄの上側の位置には、図４に示すように、凹部２ｃを部分的に覆うようなカバー部２ｅが設けられ、このカバー部２ｅの側端面には、後述する可動接点端子の接続用端部２１はまり込む切り欠き２ｆが形成されている。
【０００６】
また、可動鉄片５の可動接点バネ６への取付けや、可動接点７の可動接点バネ６への取付けなども、いわゆるカシメにより行われている。
なお、一般に「カシメ」とは、二以上の部材を相互に固定するなどの目的で、部材（主に金属製の部材）を例えば部分的に塑性変形させることであるが、通常この種の電磁リレーでは、一方の部材に設けた突起（凸部）を他方の部材に設けた穴（切り欠きなどの開口含む）にはめ込んで貫通させた後、その突起の先端部をプレス機械等でたたいて潰し拡径することで、部材相互を固着する取付け方法のことである。このような方法によって、部材相互を組付ければ、例えばネジ部材などの別部品を使って締結する方法に比較して、格段に部品点数や組付け工数が削減され、低コスト化や小型化の点で有利となる。
【０００７】
そして、可動接点バネ６、第１固定端子、及び第２固定端子のケース開口端側（図４，６では上端側）の帯板状部分は、第１コイル端子１２や第２コイル端子１３と同様に、先端がケース１４の開口端よりも外側に突き出すように伸びており、各接点を基板の所定の回路導体に接続するための接続用端部２１，２２，２３（図５，６に示す）をそれぞれ構成している。なお図６では、接続用端部２２，２３或いは第１コイル端子１２や第２コイル端子１３の図示を省略してる。
またこのリレー１は、ケース１４を除く各部品がフランジ２ｂを中心にして組付けられ、こうして構成されたサブアセンブリに対して最後にケース１４を被せ、さらにその後、ケース１の開口側を熱硬化性樹脂（例えば、エポキシ樹脂）などのシール材２０（図６に示す）でシールして組み上げられている。
【０００８】
なお、スプール２への主要部品の組付けは、以下のように行われる。即ち、図４に示す如く、まずヨーク４を横方向に直線移動させて、その横方向板状部をフランジ２ｂの凹部２ｃ内にはめ込む。次いで、鉄心３をケース奥側からフランジ２に挿通して、その先端のカシメ用突起３ａをヨーク４（横方向板状部４ａ）に形成された穴４ｄに貫通させ、カシメ用突起３ａの先端をカシメることで、鉄心３とヨーク４をスプール２に固着する。次に、可動鉄片５が取付けられた可動接点バネ６を、図４に示す如くやはり横方向に直線移動させて、その縦方向板状部６ｂの先端側（即ち、前記接続用端部２１の基端部）をスプール２の前述の切り欠き２ｆにはめ込みつつ、前記カシメ用突起４ｃをカシメ用穴６ｃにはめ込んだ後、このカシメ用突起４ｃをカシメて固着する。
【０００９】
また、ケース１４の開口部内面には、スプール２の前述の切り欠き２ｆ内にはまり込み可動接点バネ６の一端側（即ち、前述の接続用端部２１の基端部）に当接する（又は僅かな隙間で対向する）凸部１４ａが形成されている。これにより、結局、前述の接続用端部２１は、前述の切り欠き２ｆとこの凸部１４ａで囲まれてなるスリット状窓部に僅かな隙間で挿通された状態に配置されることになり、シール材２０が適度にこの隙間に侵入するようになっている。
また、シール材２０は、通常次のようにして充填される。即ち、図６に示すようにリレー１のケース開口側を鉛直方向上側に向けた状態で、このケース開口側に所定量のシール材２０（未硬化状態のもの）を滴下又は流下し、重力と毛細管現象による自然流動によってシール材２０をケース開口側の各隙間に侵入させるとともに、ケース開口部内側に表面が平坦なシール層を形成する。その後、例えばリレー１全体をシール材２０の硬化温度以上に加熱して所定時間保持する硬化槽に入れて、シール材２０を硬化させる。
【００１０】
またなお、可動接点バネ６は可動接点端子（この場合コモン端子）としても機能しており、この可動接点バネ６の縦方向板状部６ｂの先端がケース開口から突出状態に設けられることによって形成された上記接続用端部２１は、この可動接点端子の接続用端部となる。そして、接続用端部２１，２２，２３は、基板搭載の容易性の確保や規格上の問題、或いは所定の強度確保のために、一定の厚さを要求され、小型電磁リレーの場合には、例えば、０．３ｍｍの厚さとされている。この場合、可動接点バネ６は、バネとしての可撓性を持たせるために、他の端子部材（第１固定端子や第２固定端子）よりも格段に薄い板材とする必要があり、例えば板厚が０．１５ｍｍの板材で構成されており、この板材の一端側を折り曲げて２枚折りにして重ねた後にプレスで圧着することによって、接続用端部２１が所定の厚さ（例えば、０．３ｍｍ）に形成されている。
【００１１】
次に図７乃至９は、この種のリレーの第２従来例を示す図であり、図７は主要部品の分解斜視図、図８はリレー全体をケース開口側から見た平面図、また図９は、図８における符号Ｂ−Ｂで示す部分の断面図である。なお、図８ではシール材の図示を省略している。また以下では、第１従来例と同様の構成要素には、同符号を使用して、重複する説明を省略する。
【００１２】
このリレー３１は、図７に示すように、やはり上下両端にフランジ３２ａ，３２ｂを有するスプール３２を中心として組立てられるものである。
ここで、ヨーク４の横方向板状部４ａは、スプール３２のケース開口側のフランジ３２ｂの外面に形成された凹部３２ｃにはめ込まれて鉄心３の先端とカシメにより連結され、ヨーク４の縦方向板状部４ｂは、前記フランジ３２ｂにおける凹部３２ｃの底面に形成された長方形状の開口部３２ｄからコイル軸方向に沿ってケース奥側に伸びている。
また、スプール３２のフランジ３２ｂの内側面（凹部３２ｃ及び開口部３２ｄの内側面）には、ヨーク４の二つのカシメ用突起４ｃとの干渉を避けるための二つの溝３２ｅや、可動接点バネ６（可動接点端子）の接続用端部２１を挿通するための溝３２ｆが形成されている。そして、可動接点バネ６（可動接点端子）の接続用端部２１は、図８，９に示すように、このスプール３２の溝３２ｆとヨーク４とで囲まれてなるスリット状窓部に僅かな隙間で挿通された状態に配置され、シール材２０が適度にこの隙間に侵入するようになっている。
【００１３】
また、スプール３２への主要部品の組付けは、以下のように行われる。即ち、図７に示す如く、まずヨーク４をケース開口側から縦方向に移動させて、その縦方向板状部４ｂをフランジ３２ｂの開口部３２ｄに挿通するとともに、その横方向板状部４ａをフランジ３２ｂの凹部３２ｃ内にはめ込む。次いで、鉄心３をケース奥側からフランジ３２に挿通して、その先端のカシメ用突起３ａをヨーク４（横方向板状部４ａ）の穴４ｄに貫通させ、カシメ用突起３ａの先端をカシメることで、鉄心３とヨーク４をスプール３２に固着する。次に、可動鉄片５が取付けられた可動接点バネ６を、図７に示す如くケース奥側からほぼ縦方向に移動させて、その縦方向板状部６ｂの先端側（即ち、接続用端部２１）をスプール３２の前述の溝３２ｆで構成されるスリット状窓部に挿入しつつ、前述のカシメ用突起４ｃをカシメ用穴６ｃにはめ込んだ後、このカシメ用突起４ｃをカシメて固着する。
なお、シール材２０の充填方法は、第１従来例と同様である。
【００１４】
【発明が解決しようとする課題】
上記従来のリレーは、スプールのフランジがベースを兼ねていて、ベースという独立の部材が削除されている点で優れている。
しかし、可動接点バネ６（可動接点端子）の接続用端部２１の導出部分の構成に起因して、リレー全体の高さ寸法が大型化する、或いは、組立てが困難で自動組立てができない（生産性が悪い）などの改善すべき問題点を有していた。
【００１５】
すなわち、まず第１従来例の場合、スプール２のフランジ２ｂに形成されたカバー部２ｅの切り欠き２ｆによって、前記接続用端部２１を僅かな隙間で導出するためのスリット状窓部が形成されており、カバー部２ｅが必須の要素となる。なぜなら、カバー部２ｅが仮に設けられていないと、第１従来例の構成では、ヨーク４の縦方向板状部４ｂとケース１４の内面との間の比較的大きな隙間（前記接続用端部２１の両側の部分）がケース開口側に露出してしまい、この隙間からシール材２０が内部のより奥側まで過度に（必要以上多量に）流入してしまう問題が避けられないからである。なお、この隙間からシール材２０が流入すると可動接点バネ６のバネ部分（板材１枚よりなる部分の奥側）にシール材２０が過度に付着するため、可動接点バネ６のバネとしての仕様（バネ定数など）が設計範囲から外れたり、大きくばらついたりするという重大な不具合が発生する恐れがある。また、シール材２０の充填量（滴下又は流下する量）の管理が困難になる問題もある。
【００１６】
したがって、第１従来例の構成では、カバー部２ｅが必須構成となっているが、このカバー部２ｅがあると、図６に示すように、このカバー部２ｅの厚さｔ４分だけ、リレー全体の高さ寸法が大きくなる（或いは、コイル高さ寸法が小さくなる）という問題点がある。なお、カバー部２ｅの厚さｔ４は、樹脂成形の限界から最低でも０．４ｍｍ程度必要であり、この種の小型電磁リレーにとっては、相当な寸法増となる。これは、コイル高さ寸法（スプール２の両フランジ間の距離）が例えば８ｍｍの場合、その５％に相当するため、この厚さｔ４分だけ例えばコイル高さ寸法を少なくして、リレー全体の高さ寸法を小型に維持しようとすれば、電磁石の吸引力（可動鉄片５を吸引する力）も５％低下することになり、相当な工数増、ひいてはコスト増を招く。というのは、吸引力が５％低下すると、可動接点バネ６の仕様（バネ定数など）のばらつきに対する吸引力の余裕が格段に少なくなり、可動接点バネ６の復元力の調整作業が極めて困難となって、生産工数が大幅増加する可能性があるのである。
このため、第１従来例の構成であると、僅かでもさらに小型化することが求められているタイプの電磁リレーでありながら、０．４ｍｍ以上もの余分な寸法増が避けられないことになる。
【００１７】
一方、第２従来例の場合には、第１従来例におけるカバー部２ｅに相当する構成は不要であり、その分の高さ寸法の増加の問題はないが、組立てが困難で自動組立てができず、生産性が悪いという問題がある。
というのは前述したように、可動接点バネ６を取付ける際には、可動接点バネ６の先端側（即ち、接続用端部２１）を、スプール３２の溝３２ｆで構成される接続用端部２１とほぼ同じ厚さ寸法の狭い空間（前述のスリット状窓部）に挿入する必要がある。しかも、このような困難な挿入作業と同時に、ヨーク４のカシメ用突起４ｃを可動接点バネ６のカシメ用穴６ｃにはめ込む必要もある。したがって、可動接点バネ６をケース奥側から上記狭い空間めがけて単に直線的に平行移動させるだけでは、可動接点バネ６の先端側の僅かな変形（湾曲）等によって上記狭い空間に挿通することが困難となり、しかもカシメ用突起４ｃと可動接点バネ６との干渉が起こるため、最終的な取付け状態に可動接点バネ６を取付けることはできない。
このため、特に上記第２従来例のようなカシメ用突起４ｃが設けられている場合には、少なくとも可動接点バネ６の自動組立ては非常に困難で実用的には不可能となる。したがって、人手による組立て作業を採用せざるを得ず、その分生産性が悪化し、生産国の人件費によっては大幅なコスト増を招く。
【００１８】
そこで本発明は、スプールの一方のフランジが、ケース開口部の内側に配置され、このケース開口側がシール材でシールされてなる電磁リレーであって、可動接点バネと一体に形成されてケース開口から突出状態に配置される可動接点端子の導出部の構成が改善され、シール材の充填状態が良好に維持され、かつ全体の高さ寸法の増加を伴うことなく、少なくとも可動接点バネの組立て性が向上された電磁リレーを提供することを目的としている。
【００１９】
【課題を解決するための手段】
上記目的を達成するため、請求項１記載の電磁リレーは、一端側が開口したケースで覆われ、電磁石のコイルが巻回されるスプールの一方のフランジが前記ケースの開口部内側に配置され、この一方のフランジの端面に形成された凹部にＬ字形ヨークの横方向板状部がはめ込まれ、このＬ字形ヨークの縦方向板状部が前記一方のフランジの凹部底面に形成された開口部から前記スプールのコイル軸方向に沿って前記スプールの他方のフランジの側に伸びるように配置され、可動接点バネが前記ヨークの縦方向板状部の外面に固着され、この可動接点バネの一端側が前記ケースの開口部から突出状態に伸びて可動接点端子の接続用端部が形成され、前記ケースの開口側にシール材が充填されることによってシールされた電磁リレーにおいて、
前記一方のフランジにおける前記縦方向板状部が配置される側の側面に、前記凹部及び開口部を臨む切り欠きを形成し、この切り欠きが前記ケースとヨークとで囲まれてなる窓部に前記可動接点バネの一端側を挿通した状態に配置し、
前記窓部内にも前記シール材を充填したことを特徴とする。
【００２０】
また、請求項２記載の電磁リレーは、前記ケースの開口側内面に、前記切り欠き内にはまり込み前記可動接点バネの一端側外面に当接又は対向する凸部を形成したことを特徴とする。
【００２１】
また、請求項３記載の電磁リレーは、前記ヨークの縦方向板状部の外面に、可動接点バネを固着するためのカシメ用突起、或いは可動接点バネの回動を阻止する回り止め用突起の少なくともいずれか一方を形成し、この突起の前記スプールのコイル軸方向に直交する方向であって、かつ前記ヨークの縦方向板状部の外面のうち当該突起が配置される面に沿った方向の位置を、前記切り欠きの幅寸法内に設定したことを特徴とする。
【００２２】
また、請求項４記載の電磁リレーの組立て方法は、前記ヨークが取付けられた状態の前記スプールの側方から、コイル軸方向に直交する横方向であって前記切り欠き及び前記縦方向板状部の外面に向う方向に前記可動接点バネを直線的に平行移動させ、前記可動接点バネの一端側を前記切り欠きにはめ込みつつ、前記可動接点バネを前記縦方向板状部の外面に固着することによって、前記可動接点バネを取付けることを特徴とする。
【００２４】
【発明の実施の形態】
以下、本発明を小型電磁リレー（シール型リレー）に適用した場合の実施の形態の一例を図面に基づいて説明する。
まず、本例のリレーの全体概略構成を説明する。
図１乃至３は、本例のリレー５１を示す図であり、図１は主要部品の分解斜視図、図２はリレー全体をケース開口側から見た平面図、また図３は、図２における符号Ｘ−Ｘで示す部分の断面図である。なお、図２ではシール材の図示を省略している。また以下では、後述するケース６４の開口側（図１，３における上側）を場合によりケース開口側といい、後述するケース６４の奥側（図１，３における下側）を場合によりケース奥側という。また、後述するスプール５２の軸方向、即ちコイル軸方向（図１，３における上下方向）を場合により縦方向といい、このコイル軸方向に直交する方向を場合により横方向という。
【００２５】
このリレー５１は、図１に示すように、上下両端にフランジ５２ａ，５２ｂを有し電磁石を構成するコイルが巻回されるスプール５２と、このスプール５２内に形成された縦方向の貫通穴に挿通された電磁石の鉄心５３と、この鉄心５３のケース開口側端部に連結されて磁力線の通り道となるＬ字形のヨーク５４と、このヨーク５４に基端側が接合し、コイル通電時に鉄心５３に引き付けられて先端側が揺動する可動鉄片５５と、ケース奥側の横方向板状部５６ａが揺動可能な板バネであって、この横方向板状部５６ａが可動鉄片５５の外面側に取付けられるＬ字形の可動接点バネ５６と、この可動接点バネ５６の先端に取付けられる可動接点５７と、コイル非通電時において可動接点５７が圧接するＮＣ接点である第１固定接点（図示省略）と、この第１固定接点がケース奥側端部に取付けられた第１固定端子（図示省略）と、コイル通電時において可動接点５７が圧接するＮＯ接点である第２固定接点（図示省略）と、この第２固定接点がケース奥側端部に取付けられた第２固定端子（図示省略）と、コイルの各口出し線にそれぞれ接続される第１コイル端子６２及び第２コイル端子６３（図２に示す）と、組付け側（図３では上側）が開口したケース６４（図２，３に示す）とを備える。
【００２６】
ここで、ヨーク５４は、横方向板状部５４ａと縦方向板状部５４ｂを有し、横方向板状部５４ａがスプール５２のケース開口側のフランジ５２ｂの外面に形成された凹部５２ｃにはめ込まれて鉄心５３の先端とカシメにより連結され、縦方向板状部５４ｂが前記フランジ５２ｂの凹部５２ｃの底面に形成された長方形状の開口部５２ｄからコイル軸方向に沿ってケース奥側に伸びている。
また、可動接点バネ５６は、可動鉄片５５に復元力を作用させるためのバネであるとともに、可動接点５７を所定の回路導体に接続するための可動接点端子としても機能しているものである。この可動接点バネ５６は、前述した横方向板状部５６ａと縦方向板状部５６ｂを有し、縦方向板状部５６ｂに形成されたカシメ用穴５６ｃと回り止め穴５６ｄに、ヨーク５４（縦方向板状部５４ｂ）に形成されたカシメ用突起５４ｃと回り止め用突起５４ｄがはめ込まれ、カシメ用突起５４ｃの先端がカシメられることによって、ヨーク５４（縦方向板状部５４ｂ）に回り止めされて固着されている。
【００２７】
また、スプール５２のフランジ５２ｂにおける前記縦方向板状部５４ｂが配置された側の側面には、前記凹部５２ｃ及び開口部５２ｄを臨む切り欠き５２ｅが形成され、この切り欠き５２ｅがケース６４の内面とヨーク５４の外面とで囲まれることによって、この場合スリット状の窓部６５（図２，３に示す）が形成されている。なお、この窓部６５の幅寸法（即ち、切り欠き５２ｅの幅寸法Ｗ１）は、後述する如くここにはめ込まれる可動接点バネ５６の一端側（即ち、接続用端部７１の基端側）の幅寸法Ｗ０よりも僅かに大きく設定され、また、この窓部６５の両側に形成されるスプール５２のＬ字形板状部５２ｆの厚さＴ１（図２に示す）は、後述するケース６４の凸部５４ａの厚さと接続用端部７１の厚さの合計値よりも僅かに大きく設定されており、これによってこの窓部６５内に流入した後述するシール材７０がこれら隙間に適度に侵入するようになっている。
【００２８】
そして、可動接点バネ５６、第１固定端子、及び第２固定端子のケース開口端側の帯板状部分は、第１コイル端子６２や第２コイル端子６３と同様に、先端がケース６４の開口端よりも外側に突き出すように伸びており、各接点を基板の所定の回路導体に接続するための接続用端部７１，７２，７３（図２，３に示す）をそれぞれ構成している。なお図３では、接続用端部７２，７３或いは第１コイル端子６２や第２コイル端子６３の図示を省略してる。
またこのリレー５１も、ケース６４を除く各部品がフランジ５２ｂを中心にして組付けられ、こうして構成されたサブアセンブリに対して最後にケース６４を被せ、さらにその後、ケース６４の開口側を熱硬化性樹脂（例えば、エポキシ樹脂）などのシール材７０（図３に示す）でシールして組み上げられている。なお本例では、前記窓部６５内にもシール材７０が充填される。
【００２９】
なお、スプール５２への主要部品の組付けは、例えば以下のように容易に行える。
即ち、図１に示す如く、まずヨーク５４をケース開口側から縦方向に直線的に平行移動させて、その縦方向板状部５４ｂの先端を開口部５２ｄに挿入し、次いで縦方向板状部５４ｂを開口部５２ｄにさらに挿通し、横方向板状部５４ａを凹部５２ｃにはめ込むことで、ヨーク５４をスプール５２に対して位置決める。
次に、鉄心５３をケース奥側からフランジ５２に挿通して、その先端のカシメ用突起５３ａをヨーク４（横方向板状部４ａ）に形成された穴５４ｅに貫通させ、カシメ用突起５３ａの先端をカシメることで、鉄心５３とヨーク５４をスプール５２に固着する。
その後、ヨーク４及び鉄心５３が取付けられた状態のスプール５２の側方から、切り欠き５２ｅ及び縦方向板状部５４ｂの外面に向う横方向に可動接点バネ５６（及び可動鉄片５５）を直線的に平行移動させ、可動接点バネ５６の一端側（接続用端部７１の基端側）を切り欠き５２ｄ内にはめ込むとともに、可動接点バネ５６に形成されたカシメ用穴５６ｃと回り止め用穴５６ｄにカシメ用突起５４ｃと回り止め用突起５４ｄをそれぞれはめ込んだ状態で、カシメ用突起５４ｃをカシメることによって、可動接点バネ５６（及び可動鉄片５５）を取付ける。
【００３０】
またこの場合、ケース６４の開口側内面には、スプール５２の切り欠き５２ｅ内にはまり込み可動接点バネ５６の一端側（即ち、前述の接続用端部７１の基端側）に当接する（又は僅かな隙間で対向する）凸部５４ａが形成されている。これにより、前述の接続用端部７１は、前述したように切り欠き５２ｅとケース６４及びヨーク５４で囲まれてなる窓部６５に僅かな隙間で挿通された状態に配置されることになり、シール材７０が適度にこの隙間に侵入するようになっている。
またなお、シール材７０は、前述の従来例と同様の方法で充填できる。
【００３１】
このように本例のリレー５１では、スプール５２の一方のフランジ５２ｂにおける側面に、ヨーク５４がはめ込まれる凹部５２ｃ及び開口部５２ｄを臨む切り欠き５２ｅを形成し、この切り欠き５２ｅがケース６４とヨーク５４とで囲まれてなる窓部６５に可動接点バネ５６の一端側（接続用端部７１）を挿通した状態に配置し、この窓部６５内にもシール材７０を充填した構成とした。
つまり本例では、前述した第１従来例におけるカバー部２ｅのような部分を設けないで、接続用端部７１の導出部を構成し、この導出部をシールするようにした。このため、図３に示すスプール総厚さＴは、図９に示した前述の第２従来例と同じにでき、リレー全体の高さ方向の大きさを小型に維持できる。
しかも、可動接点バネ５６の組付け時においては、前述した第２従来例のように狭い隙間であるスリット状窓部にその一端側を挿通する動作は不要であり、人手による作業の場合でも組付けが格段に楽になる。また、ヨーク５４や鉄心５３はもちろんのこと、可動接点バネ５６の組付けも、前述したように例えば横方向に直線的に平行移動させることで容易に可能であるため、組立ての自動化が可能となり、人件費の高い生産国においても高い生産性（低い生産コスト）が実現できる。
【００３２】
また本例では、前記切り欠き５２ｅの幅寸法Ｗ１をこの切り欠き５２ｅ内に位置する可動接点バネ５６の一端側（接続用端部７１）の幅寸法Ｗ０よりも僅かに大きな値に設定し、かつ、ケース６４の開口部内面に、前記切り欠き５２ｅ内にはまり込み可動接点バネ５６の一端側（接続用端部７１）外面に当接又は対向する凸部５４ａを形成して、前記窓部６５の内周面と前記可動接点バネの一端側（接続用端部７１）外周面との隙間を、シール材７０が適度に侵入する微小な隙間に設定した。このため、接続用端部７１の導出部（即ち、窓部６５）の隙間からシール材７０が内部に過度に流入する不具合がより確実に阻止される。
【００３３】
また、ケース６４の凸部５４ａがあることで、窓部６５の両側に位置するスプール５２のＬ字形板状部５２ｆの厚さＴ１を過度に小さくしなくてすむという利点もある。というのは、スプール５２は絶縁材料で構成する必要があり、通常は合成樹脂の成形品として製造されるが、一般に合成樹脂の成形品として実用的に成形できる肉厚の最少寸法は、現状の技術レベルでは通常０．４ｍｍ程度であり、それ以下は非常に困難で、製作コストをより安価にするにはできるだけこの限界最低寸法よりも大きくする必要がある。ところが前述したように、この種のリレーにおける端子の接続用端部の厚さは例えば０．３ｍｍと薄い。つまり、窓部６５に挿通状態とされる接続用端部７１の厚さは、現状では上記樹脂成形の限界最低寸法以下であるため、凸部５４ａが仮に設けられていない構成で窓部６５の厚さ寸法が上記Ｌ字形板状部５２ｆの厚さＴ１と等しくなると、このＴ１を仮に上記限界寸法に設定した場合でも例えば０．１ｍｍ程度の比較的大きな隙間ができてしまい、シール材７０の適度な侵入状態の管理が困難になる恐れがある。そして、逆にこの隙間を最適値に向けて小さくしようとすれば、上記Ｌ字形板状部５２ｆの厚さＴ１を樹脂成形の限界最低寸法近く或いはそれ以下にする必要が生じて、実用的な生産が不可能になるなどの問題が生じる。しかし本例では、上記凸部５４ａの厚さを相当量確保することで、上記Ｌ字形板状部５２ｆの厚さＴ１を樹脂成形の限界最低寸法以上（或いはそれより大きな値）に設定できるのである。
【００３４】
また本例では、図１に示すように、ヨーク４の縦方向板状部５４ｂの外面に形成されるカシメ用突起５４ｃや回り止め用突起５４ｄを、この場合縦方向板状部５４ｂの中心線上に縦に並べて配置し、これら突起の横方向位置を前記切り欠き５２ｅの幅寸法Ｗ１内に設定している。このため、前記切り欠き５２ｅが、ヨーク４を縦方向に直線移動させて前述の如く取付ける際に、上記突起とスプール５２との干渉を避ける空間（逃げ）を形成する機能をも果すことになり、前述の第２従来例の溝３２ｅ（図７に示す）のような構成を別途設ける必要がなくなり、その分コスト低減できる効果もある。また、このような溝３２ｅを設けると、この溝３２ｅからシール材がリレー内に過度に侵入して作動不良などの不具合の要因となる恐れがあり、場合によってはなんらかの対策が必要となるが、本例の場合そのような不具合の恐れもないという特長もある。
【００３５】
なお、本発明は上記形態例の態様に限られない。
例えば、ケース６４の開口部内面の凸部５４ａ（切り欠き５２ｅ内にはめ込まれる凸部）は必ずしも必要でない。というのは、端子の接続用端部の厚さ寸法が前述した樹脂成形の限界最低寸法より大きい場合、或いはこのような凸部がないことによって端子導出部の隙間が多少増加しても、シール材の過度の侵入が起きない場合（シール材の粘度が高い場合）などには、必要ないからである。
また、上述した形態例におけるＬ字形板状部５２ｆは、必ずしも必要でない。例えば、切り欠き５２ｅにはまり込む可動接点バネ５６の一端側（接続用端部７１の基端側）の幅寸法Ｗ０がヨーク５４の幅寸法と同じになった場合（即ち、切り欠き５２ｅの幅寸法Ｗ１が凹部５２ｃの幅寸法と同じ場合）には、上記Ｌ字形板状部５２ｆは結果的になくなり、そしてこの場合、このＬ字形板状部５２ｆがなくてもシール材の過度の流入を阻止できる。
【００３６】
また、可動接点バネ（可動接点端子）は、必ずしも上述したように直線的平行移動によって取付けられる必要はなく、また、自動機による自動組立てに限られず、人手作業によって組付けられてもよい。本発明のように、切り欠きに可動接点バネの接続用端部を挿通状態に配置する構成であると、ケース組付け前にこの切り欠きに前記接続用端部をはめ込むことで容易に可動接点バネが取付けられるので、必ずしも直線的平行移動でなくても取付けが可能である。また、この接続用端部をスリット状窓部（狭い隙間）に挿通して取付けるといった第２従来例のようなめんどうかつ困難な作業が不要であるため、人手作業によって組付ける場合でも組立て性が良い。
また、可動接点バネ以外の他の部品についても、自動機による自動組立てに限られず、人手作業によって組付けてもよいことはいうまでもない。但し、本発明のリレーであれば、自動組立ての障害となる問題がないので、例えば人件費の高い生産国においては自動組立てを行うことで、生産コストを低く抑えることができて有利である。
また上記形態例は、いわゆるｃ接点型（ａ接点とｂ接点を両方有するタイプ）の電磁リレーに本発明を適用した例であるが、ａ接点のみを有するａ接点型やｂ接点のみを有するｂ接点型にも同様に適用できることはいうまでもない。
【００３７】
【発明の効果】
本発明の電磁リレーでは、スプールの一方のフランジにおける側面に、ヨークがはめ込まれる凹部及び開口部を臨む切り欠きを形成し、この切り欠きがケースとヨークとで囲まれてなる窓部に可動接点バネの一端側（可動接点端子の接続用端部）を挿通した状態に配置し、この窓部内にもシール材を充填した構成とした。つまり本発明では、前述した第１従来例におけるカバー部２ｅ（図４に示す）のような部分を設けないで、可動接点端子の接続用端部の導出部を構成し、この導出部をシールするようにした。
このため、リレー全体の高さ方向の大きさを前述の第２従来例と同様に小型に維持できる。しかも、可動接点バネの組付け時においては、前述した第２従来例のように狭い隙間であるスリット状窓部にその一端側を挿通する動作は不要であり、人手による作業の場合でも組付けが格段に楽になる。
また本発明のリレーでは、請求項４記載の組立て方法のように、ケース取付け前の可動接点バネの組付けが、横方向に直線的に平行移動させることで容易に可能となるため、組立ての自動化が可能となり、高い生産性（低い生産コスト）が実現できる。
【００３９】
また、請求項２記載のリレーでは、ケースの開口部内面に、前記切り欠き内にはまり込み可動接点バネの一端側外面に当接又は対向する凸部を形成した。これにより、窓部の両側にスプールの板状部（例えば、前記形態例のＬ字形板状部５２ｆのような部分）が形成された場合、この板状部の厚さＴ１を過度に小さくしなくてすむという利点がある。
というのは、スプールは絶縁材料で構成する必要があり、通常は合成樹脂の成形品として製造されるが、一般に合成樹脂の成形品として実用的に成形できる肉厚の最少寸法は、現状の技術レベルでは通常０．４ｍｍ程度であり、それ以下は非常に困難で、製作コストをより安価にするにはできるだけこの限界最低寸法よりも大きくする必要がある。ところが前述したように、この種のリレーにおける端子の接続用端部の厚さは例えば０．３ｍｍと薄い。つまり、窓部に挿通状態とされる前記接続用端部の厚さは、現状では上記樹脂成形の限界最低寸法以下であるため、上記凸部が仮に設けられていない構成で窓部の厚さ寸法が上記板状部の厚さＴ１と等しくなると、このＴ１を仮に上記限界寸法に設定した場合でも例えば０．１ｍｍ程度の比較的大きな隙間ができてしまい、シール材の適度な侵入状態の管理が困難になる恐れがある。そして、逆にこの隙間を最適値に向けて小さくしようとすれば、上記板状部の厚さＴ１を樹脂成形の限界最低寸法近く或いはそれ以下にする必要が生じて、実用的な生産が不可能になるなどの問題が生じる。しかし本発明では、上記凸部の厚さを相当量確保することで、上記板状部の厚さＴ１を樹脂成形の限界最低寸法以上（或いはそれより大きな値）に設定できるのである。
【００４０】
また、請求項３記載のリレーでは、ヨークの縦方向板状部の外面に、可動接点バネを固着するためのカシメ用突起、或いは可動接点バネの回動を阻止する回り止め用突起のうちの少なくともいずれか一方を形成し、この突起又はこれらの突起の位置を、前記Ｌ字型ヨークの横方向板状部を前記一方のフランジの端面に形成された凹部にはめ込んだ際に、前記切り欠きの幅寸法内となるような位置に設定した。このため、可動接点バネのヨークに対する固着（或いは回り止め）が容易に可能となるとともに、このような突起の組付け時の干渉の問題が容易に解消できる効果がある。
すなわち、ヨークを縦方向に例えば直線移動させてスプールの一方のフランジの凹部及び開口部にはめ込んで取付ける際に、前記切り欠きが、上記突起とスプールとの干渉を避ける空間（逃げ）としての機能をも果すことになり、前述の第２従来例の溝３２ｅ（図７に示す）のような構成を別途設ける必要がなくなり、その分コスト低減できる効果もある。また、上記溝３２ｅのような空間（隙間）を設けると、この空間からシール材がリレー内に過度に侵入して作動不良などの不具合の要因となる恐れがあり、場合によってはなんらかの対策が必要となるが、本発明ではそのような不具合の恐れもないという特長もある。
【図面の簡単な説明】
【図１】電磁リレーを示す分解斜視図である。
【図２】電磁リレーを示す裏面側平面図である。
【図３】図２におけるＸ−Ｘ断面図である。
【図４】電磁リレーの第１従来例を示す分解斜視図である。
【図５】電磁リレーの第１従来例を示す裏面側平面図である。
【図６】図５におけるＡ−Ａ断面図である。
【図７】電磁リレーの第２従来例を示す分解斜視図である。
【図８】電磁リレーの第２従来例を示す裏面側平面図である。
【図９】図８におけるＢ−Ｂ断面図である。
【符号の説明】
５１小型電磁リレー
５２スプール
５２ｂ一方のフランジ
５２ａ他方のフランジ
５２ｃ凹部
５２ｄ開口部
５２ｅ切り欠き
５２ｆＬ字形板状部
５３鉄心
５４ヨーク
５４ａ横方向板状部
５４ｂ縦方向板状部
５４ｃカシメ用突起
５４ｄ回り止め用突起
５５可動鉄片
５６可動接点バネ（可動接点端子）
５７可動接点
６２第１コイル端子
６３第２コイル端子
６４ケース
７０シール材
７１可動接点端子の接続用端部（可動接点バネの一端側）
７２第１固定端子の接続用端部
７３第２固定端子の接続用端部
Ｗ１切り欠きの幅寸法
Ｗ０可動接点端子の接続用端部の基端側幅寸法[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an electromagnetic relay in which one flange of a spool is disposed inside a case opening, and the case opening is sealed with a sealing material, and is formed integrally with a movable contact spring to project from the case opening. The present invention relates to an electromagnetic relay in which the configuration of a lead-out portion of a movable contact terminal to be arranged is improved, a filling state of a sealing material is favorably maintained, and assemblability is improved without increasing the overall height.
[0002]
[Prior art]
In general, a small electromagnetic relay (a small one having a height of, for example, 20 mm or less) mounted on a circuit board or the like for a vehicle is provided with a predetermined waterproof so as to withstand washing after mounting the board. A sealed type relay (that is, a sealed type relay) is mainly used in order to ensure the performance and dustproofness. In particular, since the above cleaning is performed after soldering for mounting the substrate, the relay is rapidly cooled by a cleaning liquid from a heated state, and a pressure difference is generated between the inside and outside of the relay. Even so, the cleaning liquid is easily sucked into the inside from there, and high airtightness is required.
In recent years, in this type of small electromagnetic relay, there has been a strong demand for downsizing and cost reduction. To this end, it is important to further reduce the number of components and to assemble each component with high density. Therefore, as disclosed in Japanese Patent Application Laid-Open No. H10-162712, a member called a base, which has been the basis of the conventional assembling, is eliminated, and one flange of a spool for winding the coil of the electromagnet is provided as a case. There is a type of relay that has been placed inside the opening of one, and has one of the flanges functioning as a base.
[0003]
4 to 6 are views showing a first conventional example of such a type of relay. FIG. 4 is an exploded perspective view of main parts, and FIG. 5 is a plan view of the entire relay as viewed from the case opening side. FIG. 6 is a sectional view of a portion indicated by reference numeral AA in FIG. In FIG. 5, illustration of the sealing material is omitted. In the description below, the opening side of the case 14 (upper side in FIGS. 4 and 6) described below is sometimes referred to as the case opening side, and the back side of the case 14 (lower side in FIGS. 4 and 6) described later is sometimes referred to as the case back side. That.
[0004]
As shown in FIG. 4, the relay 1 includes a spool 2 having flanges 2a and 2b at both upper and lower ends and on which a coil constituting an electromagnet is wound, and a longitudinal direction (coil axial direction) formed in the spool 2. ), An iron core 3 of the electromagnet inserted into the through hole, an L-shaped yoke 4 connected to an end of the iron core 3 on the side of the case opening and serving as a path for magnetic force lines, and a base end side joined to the yoke 4 to form a coil. The movable iron piece 5 which is attracted to the iron core 3 when energized and whose tip side swings, and the horizontal plate-like portion 6a on the back side of the case are a swingable leaf spring, and this horizontal plate-like portion 6a , A movable contact 7 attached to the tip of the movable contact spring 6, and a first fixed contact (NC contact) against which the movable contact 7 is pressed when the coil is not energized. (Not shown) and the first fixed contact A first fixed terminal (not shown) attached to the rear end of the case, a second fixed contact (not shown) that is a NO contact with which the movable contact 7 is pressed when the coil is energized, and a second fixed contact. A second fixed terminal (not shown) attached to the rear end of the case, a first coil terminal 12 and a second coil terminal 13 (shown in FIG. 5) connected to respective lead wires of the coil are assembled. A case 14 (shown in FIGS. 5 and 6) having an open side (the upper side in FIG. 6) is provided.
[0005]
Here, the yoke 4 has a horizontal plate-like portion 4a and a vertical plate-like portion 4b, and the horizontal plate-like portion 4a is fitted into a concave portion 2c formed on the outer surface of the flange 2b on the case opening side of the spool 2. The vertical plate-like portion 4b extends from the rectangular opening 2d formed in the flange 2b to the inner side of the case along the coil axis direction.
The movable contact spring 6 has the above-described horizontal plate-like portion 6a and vertical plate-like portion 6b, and the yoke 4 (the vertical plate-like portion) is inserted into a caulking hole 6c formed in the vertical plate-like portion 6b. The caulking projection 4c formed in 4b) is fitted, and the tip of the caulking projection 4c is caulked, so that the yoke 4 (vertical plate portion 4b) is prevented from rotating and fixed.
As shown in FIG. 4, a cover 2e that partially covers the recess 2c is provided at a position above the opening 2d in the flange 2b of the spool 2, and a cover 2e is provided on a side end face of the cover 2e. Is formed with a notch 2f into which a connection end 21 of a movable contact terminal described later fits.
[0006]
The mounting of the movable iron piece 5 to the movable contact spring 6 and the mounting of the movable contact 7 to the movable contact spring 6 are also performed by so-called caulking.
In general, “crimping” refers to partially plastically deforming a member (mainly a metal member) for the purpose of, for example, fixing two or more members to each other. In a relay, after a protrusion (convex portion) provided on one member is fitted into a hole (including an opening such as a notch) provided on the other member and penetrated, the tip of the protrusion is hit with a press machine or the like. This is an attachment method in which the members are fixed to each other by crushing and expanding the diameter. By assembling the members by such a method, the number of parts and the number of assembling steps are remarkably reduced as compared with a method of fastening using separate parts such as a screw member, thereby reducing costs and miniaturization. This is advantageous.
[0007]
The strip-shaped portions of the movable contact spring 6, the first fixed terminal, and the second fixed terminal on the case opening end side (the upper end side in FIGS. 4 and 6) are connected to the first coil terminal 12 and the second coil terminal 13. Similarly, the distal end extends so as to protrude outward from the open end of the case 14, and the connecting ends 21, 22, 23 (see FIGS. 5 and 6) for connecting each contact to a predetermined circuit conductor on the substrate. Are shown). In FIG. 6, the connection end portions 22 and 23 or the first coil terminal 12 and the second coil terminal 13 are not shown.
Also, in this relay 1, the components except for the case 14 are assembled around the flange 2b, and the case 14 is finally put on the subassembly thus constituted, and thereafter the opening side of the case 1 is thermoset. It is assembled by sealing with a sealing material 20 (shown in FIG. 6) such as a conductive resin (for example, an epoxy resin).
[0008]
Assembling of the main parts to the spool 2 is performed as follows. That is, as shown in FIG. 4, first, the yoke 4 is linearly moved in the horizontal direction, and the horizontal plate portion is fitted into the recess 2c of the flange 2b. Next, the iron core 3 is inserted into the flange 2 from the back side of the case, and the crimping projection 3a at the tip is passed through a hole 4d formed in the yoke 4 (lateral plate portion 4a), and the tip of the crimping projection 3a is formed. To fix the iron core 3 and the yoke 4 to the spool 2. Next, the movable contact spring 6 to which the movable iron piece 5 is attached is also moved linearly in the horizontal direction as shown in FIG. 4, and the distal end side of the vertical plate-like portion 6b (that is, the connecting end 21). After fitting the crimping projection 4c into the crimping hole 6c while fitting the base end portion) into the aforementioned notch 2f of the spool 2, the crimping projection 4c is crimped and fixed.
[0009]
Further, the inner surface of the opening of the case 14 fits into the notch 2 f of the spool 2 and abuts on one end side of the movable contact spring 6 (that is, the base end of the connection end 21) (or). A convex portion 14a (which is opposed by a small gap) is formed. As a result, the connection end 21 is disposed in a state where the connection end 21 is inserted through the slit-shaped window surrounded by the notch 2f and the protrusion 14a with a small gap. The sealing material 20 enters the gap appropriately.
Further, the sealing material 20 is usually filled as follows. That is, as shown in FIG. 6, with the case opening side of the relay 1 facing upward in the vertical direction, a predetermined amount of the sealing material 20 (uncured state) is dropped or flows down to the case opening side to reduce gravity. The sealing material 20 is caused to enter the gaps on the case opening side by natural flow due to the capillary phenomenon, and a flat sealing layer is formed inside the case opening. After that, for example, the entire relay 1 is heated to a temperature equal to or higher than the curing temperature of the sealing material 20 and is placed in a curing tank that holds the sealing material 20 for a predetermined time to cure the sealing material 20.
[0010]
In addition, the movable contact spring 6 also functions as a movable contact terminal (in this case, a common terminal), and is formed by providing the tip of the vertical plate-shaped portion 6b of the movable contact spring 6 so as to protrude from the case opening. The connection end 21 thus formed serves as a connection end of the movable contact terminal. The connection ends 21, 22, and 23 are required to have a certain thickness in order to ensure the ease of mounting on the board and to ensure a standard problem or a predetermined strength. In the case of a small electromagnetic relay, For example, the thickness is 0.3 mm. In this case, the movable contact spring 6 needs to be made of a plate material much thinner than other terminal members (first fixed terminal and second fixed terminal) in order to have flexibility as a spring. The connection end portion 21 is formed of a plate material having a thickness of 0.15 mm, and one end side of the plate material is bent, folded into two pieces, and then pressed by a press, so that the connection end portion 21 has a predetermined thickness (for example, 0 mm). .3 mm).
[0011]
7 to 9 show a second conventional example of this type of relay. FIG. 7 is an exploded perspective view of main parts, and FIG. 8 is a plan view of the entire relay as viewed from the case opening side. 9 is a sectional view of a portion indicated by reference numeral BB in FIG. In FIG. 8, illustration of the sealing material is omitted. In the following, the same components as those of the first conventional example are denoted by the same reference numerals, and the duplicate description will be omitted.
[0012]
As shown in FIG. 7, the relay 31 is assembled around a spool 32 having flanges 32a and 32b at both upper and lower ends.
Here, the horizontal plate-like portion 4a of the yoke 4 is fitted into a concave portion 32c formed on the outer surface of the flange 32b on the case opening side of the spool 32 and connected to the tip of the iron core 3 by caulking. The plate-shaped portion 4b extends from the rectangular opening 32d formed on the bottom surface of the recess 32c in the flange 32b to the inner side of the case along the coil axis direction.
In addition, two grooves 32e for avoiding interference with the two caulking projections 4c of the yoke 4 and a movable contact spring 6 are provided on the inner surface of the flange 32b of the spool 32 (the inner surface of the recess 32c and the opening 32d). A groove 32f for inserting the connection end 21 of the (movable contact terminal) is formed. The connecting end 21 of the movable contact spring 6 (movable contact terminal) has a slight slit-like window surrounded by the groove 32f of the spool 32 and the yoke 4, as shown in FIGS. The seal member 20 is disposed so as to be inserted through the gap, and the sealing material 20 enters the gap appropriately.
[0013]
Assembly of the main parts to the spool 32 is performed as follows. That is, as shown in FIG. 7, first, the yoke 4 is moved in the vertical direction from the case opening side, the vertical plate portion 4b is inserted into the opening 32d of the flange 32b, and the horizontal plate portion 4a is moved. Fit into the recess 32c of the flange 32b. Next, the iron core 3 is inserted into the flange 32 from the back side of the case, and the crimping projection 3a at the tip is penetrated through the hole 4d of the yoke 4 (lateral plate portion 4a), and the tip of the crimping projection 3a is crimped. Thus, the iron core 3 and the yoke 4 are fixed to the spool 32. Next, as shown in FIG. 7, the movable contact spring 6 to which the movable iron piece 5 is attached is moved almost vertically from the back side of the case, and the distal end side of the vertical plate-shaped portion 6b (that is, the connection end portion). 21) is inserted into the slit-shaped window formed by the above-mentioned groove 32f of the spool 32, and the above-mentioned caulking projection 4c is fitted into the caulking hole 6c, and then the caulking projection 4c is caulked and fixed.
The method of filling the sealing material 20 is the same as in the first conventional example.
[0014]
[Problems to be solved by the invention]
The above-mentioned conventional relay is excellent in that the flange of the spool also serves as the base and the independent member called the base is eliminated.
However, due to the configuration of the lead-out portion of the connection end 21 of the movable contact spring 6 (movable contact terminal), the height of the entire relay is increased, or it is difficult to assemble and automatic assembling cannot be performed (production (Poor performance).
[0015]
That is, first, in the case of the first conventional example, a slit-like window portion for leading out the connection end portion 21 with a small gap is formed by the notch 2f of the cover portion 2e formed on the flange 2b of the spool 2. The cover 2e is an essential element. If the cover 2e is not provided, the relatively large gap between the vertical plate-like portion 4b of the yoke 4 and the inner surface of the case 14 (the connection end 21 Are exposed on the case opening side, and the problem that the sealing material 20 excessively (more than necessary) flows into the inner part from the gap to the inner side is inevitable. When the sealing material 20 flows from this gap, the sealing material 20 excessively adheres to the spring portion of the movable contact spring 6 (the back side of the portion made of one plate material), so that the specification of the movable contact spring 6 as a spring ( There is a possibility that a serious problem that the spring constant or the like is out of the design range or greatly varies. In addition, there is a problem that it is difficult to control the filling amount (the amount of dropping or flowing down) of the sealing material 20.
[0016]
Therefore, in the configuration of the first conventional example, the cover portion 2e is an essential component. However, if the cover portion 2e is provided, as shown in FIG. 6, the entire relay is limited by the thickness t4 of the cover portion 2e. However, there is a problem that the height of the coil becomes large (or the height of the coil becomes small). The thickness t4 of the cover 2e needs to be at least about 0.4 mm from the limit of resin molding, and this type of small electromagnetic relay has a considerable increase in size. This corresponds to 5% when the coil height (the distance between the two flanges of the spool 2) is, for example, 8 mm. Therefore, for example, the coil height is reduced by the thickness t4, and the entire relay is reduced. If the height is to be kept small, the attractive force of the electromagnet (the force for attracting the movable iron piece 5) is also reduced by 5%, which leads to a considerable increase in man-hours and, consequently, an increase in cost. This is because if the attraction force is reduced by 5%, the margin of the attraction force for variations in the specifications (spring constant, etc.) of the movable contact spring 6 is significantly reduced, and it is extremely difficult to adjust the restoring force of the movable contact spring 6. As a result, production man-hours may increase significantly.
Therefore, according to the configuration of the first conventional example, an extra dimension increase of 0.4 mm or more is unavoidable even though it is a type of electromagnetic relay that is required to be further miniaturized even slightly.
[0017]
On the other hand, in the case of the second conventional example, a configuration corresponding to the cover portion 2e in the first conventional example is unnecessary, and there is no problem of an increase in the height dimension, but the assembling is difficult and automatic assembling can be performed. And there is a problem that productivity is poor.
That is, as described above, when the movable contact spring 6 is mounted, the distal end side (that is, the connection end 21) of the movable contact spring 6 is connected to the connection end 21 formed by the groove 32 f of the spool 32. It is necessary to insert it into a narrow space (the above-mentioned slit-shaped window portion) having the same thickness dimension as the above. Moreover, it is necessary to fit the crimping projection 4c of the yoke 4 into the crimping hole 6c of the movable contact spring 6 simultaneously with such a difficult insertion work. Therefore, simply moving the movable contact spring 6 linearly in parallel from the back of the case toward the narrow space can cause the movable contact spring 6 to penetrate the narrow space due to slight deformation (curvature) or the like of the distal end side. It becomes difficult, and the interference between the swaging protrusion 4c and the movable contact spring 6 occurs. Therefore, the movable contact spring 6 cannot be attached to the final attachment state.
Therefore, in particular, when the crimping projection 4c is provided as in the second conventional example, at least the automatic assembly of the movable contact spring 6 is extremely difficult and practically impossible. Therefore, manual assembling work has to be employed, and the productivity deteriorates accordingly, resulting in a significant cost increase depending on the labor cost in the country of production.
[0018]
Therefore, the present invention is an electromagnetic relay in which one flange of a spool is disposed inside a case opening, and the case opening side is sealed with a sealing material, and is formed integrally with a movable contact spring and extends from the case opening. The structure of the lead-out portion of the movable contact terminal arranged in the protruding state is improved, the filling state of the sealing material is maintained well, and at least the assemblability of the movable contact spring is improved without increasing the overall height dimension. It is intended to provide an improved electromagnetic relay.
[0019]
[Means for Solving the Problems]
In order to achieve the above object, the electromagnetic relay according to claim 1 is covered with a case having one end opened, and one flange of a spool around which a coil of an electromagnet is wound is disposed inside an opening of the case. A horizontal plate-shaped portion of an L-shaped yoke is fitted into a recess formed on an end face of one flange, and a vertical plate-shaped portion of the L-shaped yoke is inserted through an opening formed on a bottom surface of the recess of the one flange. The movable contact spring is fixed to the outer surface of the vertical plate portion of the yoke, and is arranged so as to extend to the other flange side of the spool along the coil axis direction of the spool. An electromagnetic relay which is extended from the opening of the case so as to protrude from the opening to form a connection end of the movable contact terminal, and is sealed by filling the opening side of the case with a sealing material.
A notch facing the recess and the opening is formed on a side surface of the one flange on the side where the vertical plate-shaped portion is arranged, and the notch is formed in a window portion surrounded by the case and the yoke. Arranged such that one end side of the movable contact spring is inserted therethrough,
The window may be filled with the sealing material.
[0020]
The electromagnetic relay according to claim 2 is A convex portion that fits into the notch and that abuts or faces the outer surface on one end side of the movable contact spring is formed on the inner surface on the opening side of the case. .
[0021]
The electromagnetic relay according to claim 3 is On the outer surface of the vertical plate portion of the yoke, at least one of a crimping protrusion for fixing the movable contact spring and a rotation preventing protrusion for preventing rotation of the movable contact spring is formed. The position in the direction orthogonal to the coil axis direction of the spool and in the direction along the surface on which the protrusion is arranged on the outer surface of the vertical plate-like portion of the yoke is set within the width dimension of the notch. It is characterized by setting .
[0022]
Further, according to claim 4 The method for assembling the electromagnetic relay includes, from the side of the spool in a state where the yoke is attached, a lateral direction orthogonal to a coil axis direction and a direction toward an outer surface of the notch and the vertical plate-shaped portion. The movable contact spring is linearly moved in parallel, and the movable contact spring is fixed to the outer surface of the vertical plate-like portion by fitting one end of the movable contact spring into the notch, thereby fixing the movable contact spring. Characterized by mounting .
[0024]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, an example of an embodiment in which the present invention is applied to a small electromagnetic relay (sealed relay) will be described with reference to the drawings.
First, the overall schematic configuration of the relay of the present example will be described.
1 to 3 are views showing a relay 51 of the present embodiment. FIG. 1 is an exploded perspective view of main components, FIG. 2 is a plan view of the entire relay as viewed from the case opening side, and FIG. It is sectional drawing of the part shown by code | symbol XX. In FIG. 2, illustration of the sealing material is omitted. In the following, the opening side of the case 64 described later (upper side in FIGS. 1 and 3) is sometimes referred to as the case opening side, and the back side of the case 64 described below (lower side in FIGS. 1 and 3) is sometimes referred to as the case back side. That. An axial direction of the spool 52, which will be described later, that is, a coil axial direction (vertical direction in FIGS. 1 and 3) is sometimes referred to as a vertical direction, and a direction orthogonal to the coil axial direction is sometimes referred to as a lateral direction.
[0025]
As shown in FIG. 1, the relay 51 has flanges 52 a and 52 b at both upper and lower ends and a spool 52 around which a coil constituting an electromagnet is wound, and a vertical through hole formed in the spool 52. An iron core 53 of the inserted electromagnet, an L-shaped yoke 54 connected to the case opening side end of the iron core 53 and serving as a path for magnetic force lines, and a base end side joined to the yoke 54 so that the core 53 is connected to the core 53 when the coil is energized. The movable iron piece 55 that is attracted and swings on the tip side, and the horizontal plate-shaped portion 56a on the back side of the case are a swingable leaf spring, and the horizontal plate-shaped portion 56a is attached to the outer surface side of the movable iron piece 55. L-shaped movable contact spring 56, a movable contact 57 attached to the tip of the movable contact spring 56, and a first fixed contact which is an NC contact with which the movable contact 57 is pressed when the coil is not energized (not shown). A first fixed terminal (not shown) in which the first fixed contact is attached to the rear end of the case, and a second fixed contact (not shown) which is a NO contact with which the movable contact 57 is pressed when the coil is energized. The second fixed contact has a second fixed terminal (not shown) attached to the rear end of the case, and a first coil terminal 62 and a second coil terminal 63 (FIG. 2) connected to respective lead wires of the coil. ) And a case 64 (shown in FIGS. 2 and 3) having an opening on the assembly side (the upper side in FIG. 3).
[0026]
Here, the yoke 54 has a horizontal plate-like portion 54a and a vertical plate-like portion 54b, and the horizontal plate-like portion 54a is fitted into a concave portion 52c formed on the outer surface of the flange 52b on the case opening side of the spool 52. The longitudinal plate-like portion 54b extends from the rectangular opening 52d formed on the bottom surface of the concave portion 52c of the flange 52b toward the back of the case along the coil axis direction. I have.
The movable contact spring 56 is a spring for applying a restoring force to the movable iron piece 55 and also functions as a movable contact terminal for connecting the movable contact 57 to a predetermined circuit conductor. The movable contact spring 56 has the above-described horizontal plate-like portion 56a and vertical plate-like portion 56b. The yoke 54 (see FIG. 3) is formed in the caulking hole 56c and the detent hole 56d formed in the vertical plate-like portion 56b. The caulking protrusion 54c and the rotation preventing protrusion 54d formed on the vertical plate-like portion 54b) are fitted, and the tip of the caulking protrusion 54c is caulked, thereby preventing the yoke 54 (vertical plate-like portion 54b) from rotating. Has been fixed.
[0027]
A notch 52e facing the concave portion 52c and the opening 52d is formed on a side surface of the flange 52b of the spool 52 on the side where the vertical plate-shaped portion 54b is disposed. In this case, a slit-shaped window 65 (shown in FIGS. 2 and 3) is formed by being surrounded by the outer surface of the yoke 54. The width of the window 65 (that is, the width W1 of the notch 52e) is set at one end of the movable contact spring 56 to be fitted here (that is, at the base end of the connection end 71) as described later. The thickness T1 (shown in FIG. 2) of the L-shaped plate portion 52f of the spool 52 formed on both sides of the window portion 65 is set slightly larger than the width dimension W0. The thickness is set slightly larger than the total value of the thickness of the portion 54a and the thickness of the connection end portion 71, so that a sealing material 70 described later that has flowed into the window portion 65 can appropriately enter these gaps. It has become.
[0028]
The movable contact spring 56, the first fixed terminal, and the band-shaped portion on the case opening end side of the second fixed terminal have the tip end formed in the case 64 similarly to the first coil terminal 62 and the second coil terminal 63. It extends so as to protrude outward from the end, and constitutes connection ends 71, 72, 73 (shown in FIGS. 2 and 3) for connecting each contact to a predetermined circuit conductor of the substrate. In FIG. 3, the connection ends 72 and 73, the first coil terminal 62 and the second coil terminal 63 are not shown.
Also, in the relay 51, the components except the case 64 are assembled around the flange 52b, and the subassembly thus configured is finally covered with the case 64, and thereafter, the opening side of the case 64 is thermoset. Sealed with a sealing material 70 (shown in FIG. 3) such as a conductive resin (for example, epoxy resin). In this example, the sealing material 70 is also filled in the window 65.
[0029]
Assembling of the main components to the spool 52 can be easily performed, for example, as follows.
That is, as shown in FIG. 1, first, the yoke 54 is linearly moved in the vertical direction from the case opening side, and the tip of the vertical plate portion 54b is inserted into the opening 52d. The yoke 54 is positioned with respect to the spool 52 by further inserting the 54b through the opening 52d and fitting the lateral plate-like portion 54a into the concave portion 52c.
Next, the iron core 53 is inserted into the flange 52 from the back side of the case, and the crimping projection 53a at the tip thereof is passed through a hole 54e formed in the yoke 4 (lateral plate portion 4a). The core 53 and the yoke 54 are fixed to the spool 52 by caulking the tip.
Thereafter, the movable contact spring 56 (and the movable iron piece 55) is linearly moved laterally from the side of the spool 52 with the yoke 4 and the iron core 53 attached to the notch 52e and the outer surface of the vertical plate portion 54b. , One end of the movable contact spring 56 (the base end of the connection end 71) is fitted into the notch 52d, and the caulking hole 56c and the detent hole 56d formed in the movable contact spring 56 are formed. The movable contact spring 56 (and the movable iron piece 55) is attached by caulking the caulking projection 54c with the caulking projection 54c and the rotation preventing projection 54d fitted respectively.
[0030]
In this case, the inner surface of the opening of the case 64 fits into the notch 52e of the spool 52 and contacts one end of the movable contact spring 56 (that is, the base end of the connection end 71) (or). A convex portion 54a (which is opposed by a small gap) is formed. As a result, the connection end portion 71 described above is disposed in a state of being inserted through the window portion 65 surrounded by the notch 52e, the case 64, and the yoke 54 with a small gap as described above, The sealing material 70 enters the gap appropriately.
Further, the sealing material 70 can be filled in the same manner as in the above-described conventional example.
[0031]
As described above, in the relay 51 of the present embodiment, the notch 52e facing the concave portion 52c into which the yoke 54 is fitted and the opening 52d is formed on the side surface of the one flange 52b of the spool 52. One end of the movable contact spring 56 (the end 71 for connection) is inserted through a window 65 surrounded by 54 and a sealing material 70 is filled in the window 65.
That is, in the present example, the lead-out portion of the connection end portion 71 is formed without providing the portion like the cover portion 2e in the first conventional example described above, and this lead-out portion is sealed. Therefore, the total spool thickness T shown in FIG. 3 can be the same as that of the second conventional example shown in FIG. 9, and the size of the entire relay in the height direction can be kept small.
In addition, when the movable contact spring 56 is assembled, it is not necessary to insert one end of the slit-shaped window portion, which is a narrow gap, as in the second conventional example described above. The attachment is much easier. In addition, as described above, assembling of the movable contact spring 56 as well as the yoke 54 and the iron core 53 can be easily performed by, for example, linearly moving in a horizontal direction, so that the assembly can be automated. In addition, high productivity (low production cost) can be realized even in a production country where labor costs are high.
[0032]
Further, in this example, the width dimension W1 of the notch 52e is set to a value slightly larger than the width dimension W0 of one end (connection end portion 71) of the movable contact spring 56 located in the notch 52e. A convex portion 54a that fits into the notch 52e and abuts or faces the outer surface of one end (connection end 71) of the movable contact spring 56 is formed on the inner surface of the opening of the case 64. The gap between the inner peripheral surface of the movable contact spring 65 and the outer peripheral surface of one end of the movable contact spring (the end 71 for connection) is set to a minute clearance into which the sealing material 70 can appropriately enter. Therefore, the problem that the sealing material 70 excessively flows into the inside from the gap of the lead-out portion (that is, the window portion 65) of the connection end portion 71 is more reliably prevented.
[0033]
Further, the presence of the convex portion 54a of the case 64 also has an advantage that the thickness T1 of the L-shaped plate portion 52f of the spool 52 located on both sides of the window portion 65 does not need to be excessively reduced. This is because the spool 52 needs to be made of an insulating material, and is usually manufactured as a molded product of a synthetic resin. On the technical level, it is usually about 0.4 mm, and less than 0.4 mm is very difficult. In order to make the production cost lower, it is necessary to make the dimension as large as possible. However, as described above, the thickness of the connection end of the terminal in this type of relay is as thin as 0.3 mm, for example. In other words, the thickness of the connection end portion 71 inserted into the window portion 65 is not more than the minimum dimension of the resin molding at present, and thus the thickness of the window portion 65 is not provisionally provided. When the thickness dimension is equal to the thickness T1 of the L-shaped plate-shaped portion 52f, a relatively large gap of, for example, about 0.1 mm is formed even if this T1 is set to the limit dimension. There is a risk that moderate management of the intrusion state may be difficult. Conversely, if the gap is reduced toward the optimum value, the thickness T1 of the L-shaped plate-shaped portion 52f needs to be close to or less than the minimum dimension of resin molding. Problems such as production becoming impossible occur. However, in this example, the thickness T1 of the L-shaped plate-like portion 52f can be set to be equal to or larger than the minimum dimension of the resin molding (or larger) by securing a considerable amount of the thickness of the convex portion 54a. is there.
[0034]
In this example, as shown in FIG. Vertical plate 54b In this case, the caulking projection 54c and the rotation preventing projection 54d formed on the outer surface of Vertical plate 54b Are arranged vertically on the center line of the notch, and the horizontal positions of these protrusions are set within the width dimension W1 of the notch 52e. Therefore, when the yoke 4 is linearly moved in the vertical direction and is attached as described above, the notch 52e also has a function of forming a space (escape) for avoiding interference between the projection and the spool 52. In addition, it is not necessary to separately provide a configuration such as the groove 32e (shown in FIG. 7) of the second conventional example, which has the effect of reducing costs. In addition, when such a groove 32e is provided, the sealing material may excessively enter the relay from the groove 32e and cause a malfunction such as a malfunction, and in some cases, some countermeasure is required. In the case of this example, there is also a feature that there is no fear of such a defect.
[0035]
The present invention is not limited to the above embodiment.
For example, the protrusion 54a (the protrusion fitted into the notch 52e) on the inner surface of the opening of the case 64 is not always necessary. This is because even if the thickness of the connection end of the terminal is larger than the minimum dimension of the resin molding described above, or even if the gap of the terminal lead-out portion is slightly increased due to the absence of such a protrusion, the sealing is performed. This is because it is not necessary when excessive penetration of the material does not occur (when the viscosity of the sealing material is high).
Further, the L-shaped plate-shaped portion 52f in the above-described embodiment is not always necessary. For example, when the width W0 of one end of the movable contact spring 56 that fits into the notch 52e (the base end of the connection end 71) is equal to the width of the yoke 54 (ie, the width of the notch 52e). When the dimension W1 is the same as the width dimension of the concave portion 52c), the L-shaped plate portion 52f eventually disappears, and in this case, even without the L-shaped plate portion 52f, excessive inflow of the sealing material is prevented. Can be blocked.
[0036]
Further, the movable contact spring (movable contact terminal) does not necessarily need to be attached by linear parallel movement as described above, and is not limited to automatic assembly by an automatic machine, but may be attached manually. When the connection end of the movable contact spring is arranged to be inserted into the notch as in the present invention, the movable contact can be easily fitted by fitting the connection end into the notch before assembling the case. Since the spring is attached, attachment is possible even if it is not necessarily a linear translation. In addition, since it is not necessary to perform a difficult and troublesome operation such as inserting the connection end portion into the slit-shaped window portion (narrow gap) as in the second conventional example, the assembling property is improved even when the assembly is performed manually. good.
Also, it goes without saying that other components other than the movable contact spring are not limited to automatic assembly by an automatic machine, and may be assembled manually. However, the relay according to the present invention does not have a problem that hinders automatic assembly. Therefore, for example, in a production country where labor costs are high, the production cost can be advantageously reduced by performing automatic assembly.
The above embodiment is an example in which the present invention is applied to a so-called c-contact type electromagnetic relay (a type having both a-contacts and b-contacts). However, an a-contact type having only a-contacts and a b-contact having only b contacts are provided. It goes without saying that the present invention can be similarly applied to a contact type.
[0037]
【The invention's effect】
In the electromagnetic relay of the present invention, a notch is formed on a side surface of one of the flanges of the spool so as to face a concave portion and an opening in which the yoke is fitted, and this notch is provided with a movable contact in a window portion surrounded by the case and the yoke. One end of the spring (the end for connection of the movable contact terminal) was inserted and inserted, and the window was filled with a sealing material. That is, according to the present invention, the lead-out portion of the connection end portion of the movable contact terminal is formed without providing the portion like the cover portion 2e (shown in FIG. 4) in the first conventional example described above, and this lead-out portion is sealed. I did it.
For this reason, the size of the entire relay in the height direction can be kept small as in the second conventional example. Moreover, when assembling the movable contact spring, it is not necessary to insert one end of the movable window into the slit-shaped window, which is a narrow gap, as in the second conventional example described above. Is much easier.
In the relay of the present invention, Claim 4 As in the assembling method described above, assembling of the movable contact spring before mounting the case can be easily performed by linearly moving in a horizontal direction, so that assembling can be automated and high productivity (low productivity) can be achieved. Production cost).
[0039]
Also, Claim 2 In the relay of (1), a convex portion that fits into the notch and abuts or faces the outer surface on one end side of the movable contact spring is formed on the inner surface of the opening of the case. Accordingly, when a plate-like portion of the spool (for example, a portion like the L-shaped plate-like portion 52f of the above embodiment) is formed on both sides of the window, the thickness T1 of this plate-like portion is excessively reduced. There is an advantage that it is not necessary.
This is because the spool must be made of an insulating material and is usually manufactured as a molded product of synthetic resin. At the level, it is usually about 0.4 mm, and below this is very difficult, and it is necessary to make this dimension as large as possible as much as possible to make the production cost lower. However, as described above, the thickness of the connection end of the terminal in this type of relay is as thin as 0.3 mm, for example. In other words, the thickness of the connection end portion inserted into the window portion is not more than the minimum dimension of the resin molding at present, and thus the thickness of the window portion is not provided in the provisional projection. If the dimension becomes equal to the thickness T1 of the plate-shaped portion, a relatively large gap of, for example, about 0.1 mm is formed even if this T1 is set to the above-mentioned limit dimension. Can be difficult. Conversely, if the gap is reduced toward an optimum value, the thickness T1 of the plate-shaped portion needs to be close to or less than the minimum dimension of the resin molding, which makes practical production impossible. Problems such as being possible arise. However, in the present invention, the thickness T1 of the plate-shaped portion can be set to be equal to or larger than the minimum dimension of resin molding (or larger) by securing a considerable amount of the thickness of the convex portion.
[0040]
Also, Claim 3 In the relay, at least one of a crimping projection for fixing the movable contact spring and a detent projection for preventing rotation of the movable contact spring is formed on the outer surface of the vertical plate-like portion of the yoke. Then, when the projections or the positions of these projections are fitted in the recesses formed in the end face of the one flange, the lateral plate-like portion of the L-shaped yoke is within the width dimension of the notch. It was set to such a position. Therefore, the movable contact spring can be easily fixed (or prevented from rotating) to the yoke, and the problem of interference at the time of assembling the projection can be easily eliminated.
That is, when the yoke is moved, for example, linearly in the vertical direction, and is fitted into the concave portion and the opening of one of the flanges of the spool and mounted, the notch functions as a space (escape) for avoiding interference between the projection and the spool. Therefore, it is not necessary to separately provide a configuration such as the groove 32e (shown in FIG. 7) of the second conventional example, and the cost can be reduced accordingly. If a space (gap) such as the groove 32e is provided, the sealing material may excessively enter the relay from this space and cause a malfunction such as malfunction, and in some cases, some countermeasure is required. However, the present invention has a feature that there is no fear of such a problem.
[Brief description of the drawings]
FIG. 1 is an exploded perspective view showing an electromagnetic relay.
FIG. 2 is a rear side plan view showing an electromagnetic relay.
FIG. 3 is a sectional view taken along line XX in FIG. 2;
FIG. 4 is an exploded perspective view showing a first conventional example of an electromagnetic relay.
FIG. 5 is a rear side plan view showing a first conventional example of an electromagnetic relay.
FIG. 6 is a sectional view taken along line AA in FIG.
FIG. 7 is an exploded perspective view showing a second conventional example of an electromagnetic relay.
FIG. 8 is a rear side plan view showing a second conventional example of an electromagnetic relay.
FIG. 9 is a sectional view taken along line BB in FIG. 8;
[Explanation of symbols]
51 Small electromagnetic relay
52 spool
52b One flange
52a The other flange
52c recess
52d opening
52e cutout
52f L-shaped plate
53 iron core
54 York
54a Horizontal plate
54b vertical plate
54c Protrusion for swaging
54d Non-rotating protrusion
55 Moving Iron Piece
56 Movable contact spring (movable contact terminal)
57 Moving contacts
62 1st coil terminal
63 Second coil terminal
64 cases
70 Sealing material
71 Connecting end of movable contact terminal (one end of movable contact spring)
72 Connection end of first fixed terminal
73 Connecting end of second fixed terminal
W1 Notch width dimension
W0 Width of base end side of connection end of movable contact terminal

Claims

One end of the spool, which is covered with a case whose one end side is open, and around which the coil of the electromagnet is wound, is disposed inside the opening of the case, and a recess formed on the end face of the one flange is provided with a side of the L-shaped yoke. The L-shaped yoke has a vertical plate-like portion which is inserted into an opening formed in the bottom surface of the concave portion of the one flange, and the side of the other flange of the spool along the coil axial direction of the spool. The movable contact spring is fixed to the outer surface of the vertical plate-like portion of the yoke, and one end of the movable contact spring extends from the opening of the case so as to protrude from the case. Part is formed, in an electromagnetic relay sealed by filling a sealing material on the opening side of the case,
A notch facing the recess and the opening is formed on a side surface of the one flange on the side where the vertical plate-shaped portion is arranged, and the notch is formed in a window portion surrounded by the case and the yoke. Arranged such that one end side of the movable contact spring is inserted therethrough,
An electromagnetic relay, wherein the window is filled with the sealing material.

The electromagnetic relay according to claim 1 , wherein a convex portion that fits into the notch and abuts or faces the outer surface on one end side of the movable contact spring is formed on the inner surface on the opening side of the case.

On the outer surface of the vertical plate portion of the yoke, at least one of a crimping protrusion for fixing the movable contact spring and a rotation preventing protrusion for preventing rotation of the movable contact spring is formed. The position in the direction orthogonal to the coil axis direction of the spool and in the direction along the surface on which the protrusion is arranged on the outer surface of the vertical plate-like portion of the yoke is set within the width dimension of the notch. claim 1 or 2 electromagnetic relay according to, characterized in that the set.

From the side of the spool with the yoke attached, the movable contact spring is linearly moved in a direction transverse to the coil axis direction and toward the outer surface of the notch and the vertical plate portion. The movable contact spring is attached by fixing the movable contact spring to an outer surface of the vertical plate-shaped portion while moving the movable contact spring in one end side into the notch while moving in parallel. Item 4. The method for assembling the electromagnetic relay according to any one of Items 1 to 3 .