JPH11353999A - Manufacture of electromagnet device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase yield and enhance productivity by welding a part far from the base part of a holding connecting piece and positioned outside a housing to a lead frame for supporting. SOLUTION: A common terminal, a fixed contact terminal, and a coil terminal 24 are cut out and bent, and a supporting piece 51 is also cut out and bent in a lead frame 50. Fixed contacts 22a, 23a are previously formed in the fixed contact terminal. A relay terminal 17 of an electromagnet block 10 is welded to the free end of the coil terminal 24. A tip part 18a of a connecting piece 18 is welded to the supporting piece 51, they are positioned in a mold, then secondary molding is performed. The specified differential step is formed between a binding up part 17a and the connecting piece 18. The connecting piece 18 is cut out from the lead frame 50, and each terminal is also cut out and bent to complete a base block.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an electromagnet device, and more particularly to a method for manufacturing an electromagnet device incorporated in an electromagnetic relay.

[0002]

2. Description of the Related Art Conventionally, as an electromagnet device, for example, a pair of flanges formed integrally with one of flanges of a spool located at both ends of an iron core around which a coil is wound. After the coil relay terminal and the two holding connection pieces integrally formed so as to protrude from the other flange portion are welded and integrated to the lead frame, respectively,
There is a method of manufacturing an electromagnet device in which a housing is formed by subsequent molding.

However, in the above-described manufacturing method, when the holding connecting piece and the lead frame are welded and integrated, the base of the connecting piece is welded and integrated with the lead frame. For this reason, the coil was easily broken during welding, and the yield was poor. Also, since the relay terminal and the connecting piece were arranged at substantially the same height, if they were integrated on the production line before the secondary molding, the relay terminal and the connecting piece would collide,
There was a case that I got on. For this reason, there was a problem that continuous production was hindered and productivity was low.

[0004] A method of manufacturing an electromagnet device according to the present invention comprises:
In view of the above problems, it is an object of the present invention to provide a method of manufacturing an electromagnet device having a high yield and high productivity.

[0005]

According to the present invention, there is provided a method of manufacturing an electromagnet apparatus, wherein at least one of flanges of a spool located at both ends of an iron core around which a coil is wound to achieve the above object. After a pair of coil relay terminals integrally formed on the lead frame and at least one holding connection piece integrally formed so as to protrude from the other flange portion are welded and integrated to the lead frame, respectively, and then subjected to secondary molding. In the method for manufacturing an electromagnet device that forms a housing, a part that is separated from a base of the holding connecting piece and that is located outside the housing is welded and integrated with the lead frame to be supported. Further, the relay terminal and the connecting piece may be arranged so that a step is formed vertically.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment according to the present invention will be described with reference to FIGS. That is, the method of manufacturing an electromagnet device according to the present embodiment is applied to an electromagnetic relay.
A base block 20 formed by performing secondary molding on the base block 20;
It comprises a movable block 30 and a case 40. Incidentally, the outer dimensions (width × length × height) of this electromagnetic relay are 10 mm × 6.5 mm × 5 mm.

As shown in FIGS. 3 (b) and 4, the electromagnet block 10 has a coil 1 attached to a substantially U-shaped iron core 11.
6 is wound. As shown in FIGS. 5 (a) and 5 (b), a method of manufacturing the electromagnet block 10 is as follows.
Form 2 The spool 12 includes flanges 13 and 14 formed on both ends of the iron core 11, respectively.
A pair of connecting pieces 18 protruding from both side surfaces of the flange 14 extend along the axial direction. Further, a coil 16 is wound around an intermediate portion of the iron core 11, and a lead wire of the coil 16 is connected to a connecting portion 17a of the relay terminal 17 which is insert-molded to the flange portion 13 and soldered (FIG. 6).
(A), (b)). In addition, the electromagnet block 10 has a step between the bent portion 17 a of the relay terminal 17 and the pair of connecting pieces 18. For this reason, as shown in FIG. 7, even if a plurality of electromagnet blocks 10 are integrated on a production line, the advantage that the tying portion 17a does not ride on the connecting piece 18 and that the production activity can be performed smoothly. is there.

The base block 20 is shown in FIGS.
As shown in FIG. 5, the electromagnet block 10 connected to the lead frame 50 is formed by performing secondary molding. In the lead frame 50, the common terminal 21, the fixed contact terminals 22, 23, and the coil terminal 24 are cut out and bent, and the support piece 51 is cut out and bent. However, the fixed contact terminals 22 and 23 are provided with fixed contacts 22a and 23a, respectively.

The relay terminal 1 of the electromagnet block 10
7 is welded and integrated with the free end of the coil terminal 24 of the lead frame 50 (FIG. 9B). Further, the connecting piece 1
After welding and integrating the tip 18a of the lead 8 with the support piece 51 of the lead frame 50, these are positioned in a mold and subjected to secondary molding. At this time, there is a predetermined step between the barb 17a and the connecting piece 18. Then, the lead frame 50
The connecting piece 18 is cut from each of the terminals 21 to 24.
The base block 20 is cut off and bent.
Is completed. At this time, the bases of the terminals 21 to 24 are substantially flush with the outer surface of the base block 20.

Each of the terminals 21 to 24 protruding from the side surface of the base block 20 has narrow portions 21b, 22b, 23 at its base as shown in FIGS. 8 (b) and 8 (c), for example.
b, 24b (the narrow portions 21b, 24b are not shown). Therefore, when the terminals 21 to 24 are bent downward, the terminals 21 to 24 can be bent with high dimensional accuracy from a predetermined position without using a mold for forming a reference surface, and the bending positions do not vary. As a result, the terminals 21 to 24 are fitted into the shallow grooves provided on the outer surface of the base block 20, and these outer surfaces are substantially flush. When the thickness of each of the terminals 21 to 24 is, for example, 0.15 mm, each of the narrow portions 21 b to 24 from the side surface of the base block 20 before bending.
The distance to b may be 0 to 0.05 mm.

As shown in FIG. 1, the base block 20 obtained by the above-described secondary molding has a shallow recess 25 on its upper surface, and a pair of Protrusions 26a and 26b are protruded. One convex part 26
“a” has a long ridgeline such that the top thereof is in line contact with a movable block 30 described later. The other convex portion 26b is
In order to absorb variations in dimensional accuracy in the width direction, the protrusion 26
It has a ridge top that is shorter than a.

A fixed contact terminal 2 is provided at the corner of the recess 25.
2, 23 fixed contacts 22a and 23a are respectively exposed. The magnetic pole portions 11a and 11b of the iron core 11 are exposed between the adjacent fixed contacts 22a and 22a and between the adjacent fixed contacts 23a and 23a, respectively.
Further, the magnetic pole portions 11a and 11b of the iron core 11 are separated from the fixed contacts 22a and 23a by insulating walls 27 having a substantially U-shaped plane. The outer side surface of the insulating wall 27 facing itself is a tapered surface (FIG. 4). The connection receiving portion 21a of the common terminal 21 is exposed from the corner of the opening edge of the base block 20 substantially at the center of the side.

As shown in FIGS. 1 and 2, a projection 28 projects from the center of both end faces of the base block 20. As shown in FIG. As shown in FIG. 3B, the protrusion 28
The connecting piece 18, the fixed contact terminal 23, and the coil terminal 24 protrude forward from the uncut ends 18a, 23c, and 24c. This is to prevent, for example, the end portion 23c and the end portion 24c from climbing over or catching with each other when the base block 20 is continuously transported.

The movable block 30 is shown in FIG.
As shown in (b), the movable contact pieces 32, 32 are arranged on both sides of the permanent magnet 31 and the movable iron piece 33 is overlapped on one surface of the permanent magnet 31, and then the insulating table 34 is formed by resin molding. And integrated.

The permanent magnet 31 is narrower than the movable iron piece 33, and is superposed on a so-called drooping surface of the movable iron piece 33. This is to prevent the permanent magnet 31 from contacting the so-called burr generated when the movable iron piece 33 is subjected to press working, so that no gap is generated between the two.

Further, after partially joining the edge of the joint surface between the permanent magnet 31 and the movable iron piece 33, resin molding may be performed. As the temporary fixing method, for example, an existing method such as laser welding, welding with a gas burner, spot welding, or the like can be used. Alternatively, a joining metal thin film formed on a joining surface of both may be melted and integrated. As a metal thin film for bonding,
For example, a simple substance such as nickel, zinc, cadmium, tin, copper, chromium, lead, silver, gold, and palladium or an alloy thereof may be used. In addition, as a method for forming the bonding metal thin film, existing methods such as plating, vapor deposition, and coating can be selected. Further, the bonding metal thin film may be formed on the entire bonding surface, or may be formed only on the edge of the bonding surface or only on the center. Examples of the method for melting the bonding metal thin film include laser irradiation, heating using a gas burner, and an existing heating method using electric resistance.

The movable contact piece 32 is formed by punching a conductive thin plate spring material. Movable contacts 32a and 32b are provided on each of the divided pieces at both ends formed by dividing in the width direction. . Further, the movable contact piece 32 has a substantially T-shaped connecting portion 32c extending laterally from a substantially central portion of the side.

As a method of forming the movable block 30, for example, after the movable contacts 32a and 32b are provided, the movable contact pieces 32 and 32 cut out from a lead frame (not shown) by press working are positioned in a mold. Next, there is a method in which the temporarily fixed permanent magnet 31 and the movable iron piece 33 are positioned in the mold, and then integrated by an insulating table 34 formed of a resin mold. The movable iron piece 33 has the same configuration as that of the iron core 11 except for a portion in contact with the magnetic pole portions 11a and 11b.
The entire surface may be resin-molded to enhance the insulating properties.

Then, the movable block 30 is dropped into the base block 20 from above, and a pair of recesses 34a and 34b (FIG. 2) provided on the lower surface of the insulating table 34 are formed on the upper surface of the base block 30 by projecting protrusions 26a. , 26b are automatically positioned. Further, the connection portion 32c of the movable contact piece 32 is connected to the connection receiving portion 2 of the common terminal 21.
The movable block 30 is rotatably supported by welding to 1a.

In the present embodiment, the concave portions 34 a and 34 b provided on the lower surface of the insulating table 34 are connected to the convex portions 26 of the base block 20.
a and 26b to be fitted and supported. For example, even if the distance between the convex portions 26a and 26b has a variation due to the processing tolerance, the ridgeline at the top of the convex portion 26b is shorter than that of the convex portion 26a, and the variation in the processing tolerance can be absorbed. Therefore, it is possible to avoid a malfunction due to a variation in processing tolerance. Also, the concave portion 34 of the insulating table 34
a, 34b and the convex portions 26a, 26 of the base block 20.
The contact portion with b is located on substantially the same plane as the connecting portion 32c serving as the rotation axis. For this reason, there is no play due to the variation of the rotation axis, and a smooth rotation can be obtained.

In this embodiment, two convex portions 26 are provided.
Although the case where a and 26b are formed has been described, the present invention is not limited to this, and one or two or more may be formed. The shape of the projections 26a and 26b is not limited to the above-described one, and the top may be a triangular prism, a cone, or a hemisphere. Furthermore, while the tops of the protrusions 26a and 26b are formed to have an acute angle, and the bottoms of the recesses 34a and 34b are formed to have an obtuse angle, it is possible to provide a structure in which the rotation fulcrum hardly rattles.

In this electromagnetic relay, the spatial distance between the movable contact piece 32 and the movable iron piece 33 is about 0.9 mm. However, as shown in FIGS. 4 and 15, as a result of assembling the movable block 30 to the base block 20, the substantially U-shaped insulating wall 27 separates the movable iron piece 33 and the movable contact piece 32. For this reason, the creepage distance between the two becomes long, and the insulation characteristics are high. Then, both ends 34 of the insulating table 34
c and 34 d extend long and overlap the insulating wall 27. For this reason, the extension distance between the two becomes even longer,
There is an advantage that the insulation characteristics are improved.

As shown in FIG. 1, the case 40 has a box shape that can be fitted to the base block 20, and has a notch 41 for fitting formed at the opening edge thereof. Also,
The case 40 has a gas vent hole 42 at the edge of the ceiling surface. Further, as shown in FIG. 2, the case 40 has an insulating rib 43 protruding from a ceiling surface thereof. One end of the insulating rib 43 is continuous with the inner surface of the case 40, and the joining surface joining the insulating wall 27 of the base block 20 is a tapered surface.

Then, the case 40 is attached to the base block 20 to which the movable block 30 is attached, and the terminal 2
The notches 41 are fitted to the respective 1 to 24. As a result, as shown in FIG.
Abuts against the outer surface of the insulating wall 27 provided on the base block 20. For this reason, the creepage distance between the two becomes longer,
The insulation properties are improved. Also, since the joining surfaces of both the insulating wall 27 and the insulating rib 43 are tapered surfaces,
There is an advantage that smooth assembling is possible and the assembling work is facilitated. Note that the insulating ribs 43 may be in contact with the opposing inner surfaces of the insulating wall 27.

Next, the base block 20 and the case 40
After sealing the joint surface with the gas vent hole 4 of the case 40,
2 (FIG. 4) to release the internal gas from the gas vent hole 42.
By heat sealing, the assembly operation is completed.

Next, the operation of the electromagnetic relay having the above-described structure will be described. First, when no voltage is applied to the coil 16 of the electromagnet block 10, one end 33a of the movable iron piece 33 is attracted to the magnetic pole part 11a of the iron core 11 by the magnetic force of the magnetic flux of the permanent magnet 31, and the magnetic circuit is closed. And the movable contact 32a of the movable contact piece 32 is in contact with the fixed contact 22a.

When a voltage is applied to the coil 16 of the electromagnet block 10 so that a magnetic flux for canceling the magnetic flux of the permanent magnet 31 is generated, the movable iron piece 33 rotates against the magnetic force of the permanent magnet 31, and The movable contact piece 32 rotates. For this reason, after the movable contact 32a is separated from the fixed contact 22a, the movable contact 32b contacts the fixed contact 23a, and the other end 33b of the movable iron piece 33 is connected to the magnetic pole 1 of the iron core 11.
Adsorb to 1b. And even if the application of the above-mentioned voltage is released, the movable block 30
Hold that state.

Further, when a voltage in a direction opposite to the above-described application direction is applied to the coil 16, the coil 16 resists the magnetic force of the permanent magnet 31,
The movable iron piece 33 rotates in the direction opposite to the above-described rotation direction, and accordingly, the movable contact piece 32 also rotates. Therefore, the movable contact 32b is separated from the fixed contact 23a, and the movable contact 32a
After contacting with the fixed contact 22a, one end 33a of the movable iron piece 33 is attracted to the magnetic pole portion 11a of the iron core 11 and returns to the original state.

In the above embodiment, the self-holding type electromagnetic relay has been described. However, the present invention is not limited to this.
Needless to say, the present invention may be applied to a self-recovering type electromagnetic relay.

[0030]

As is apparent from the above description, according to the electromagnet apparatus according to the first aspect of the present invention, the holding connecting piece protruding from the flange of the spool is separated from the base thereof and the housing. Is supported by being welded integral with the lead frame. For this reason, the portion of the connecting piece welded and integrated with the lead frame is separated from the coil wound around the iron core. As a result, the coil does not break during welding, and the yield is improved.
Further, the portion of the connecting piece to be welded and integrated is located outside the housing formed by the secondary molding. Therefore, the welded portion is not separated by the resin pressure, and the yield is further improved. According to the second aspect, a step is formed between the coil relay terminal and the holding connection piece. For this reason, for example, even if the iron core on which the coil is wound for the secondary molding is integrated in the molding machine, the relay terminal does not collide with the connecting piece and does not run over. As a result,
There is an effect that the secondary molding operation proceeds smoothly and the productivity is improved.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view of an electromagnetic relay showing an embodiment of the present invention.

FIG. 2 is an exploded perspective view of the electromagnetic relay of FIG. 1 when viewed from below.

3A and 3B show a state after assembling the electromagnetic relay shown in FIG. 1, wherein FIG. 3A is a partial plan view and FIG. 3B is a partial front view.

FIG. 4 is a side sectional view of the electromagnetic relay shown in FIG.

5A and 5B show an iron core in which a spool is integrally formed. FIG. 5A is a perspective view seen from above, and FIG. 5B is a perspective view seen from below.

6A and 6B show an electromagnet block, wherein FIG. 6A is a perspective view seen from above, and FIG. 6B is a perspective view seen from below.

FIG. 7 is a perspective view showing a state where electromagnet blocks are integrated.

8A and 8B show a secondary molding method of an electromagnet block, wherein FIG. 8A is a plan view, and FIGS. 8B and 8C are enlarged plan views of a main part.

FIG. 9 shows a secondary molding method of the electromagnet block, wherein FIG. 9 (a) is a side view and FIG. 9 (b) is a front view.

FIG. 10 is a perspective view of the electromagnet block as viewed from above before secondary molding.

FIG. 11 is a perspective view of the electromagnet block as viewed from below before performing secondary molding.

FIG. 12 is a perspective view of the electromagnet block viewed from above after secondary molding.

FIG. 13 is a perspective view seen from below after the electromagnet block has been subjected to secondary molding.

14 (a) is an exploded perspective view seen from above, and FIG. 14 (b) is an exploded perspective view seen from below.

FIG. 15 is a perspective view showing a state where a movable block is assembled to a base block.

[Explanation of symbols]

10: electromagnet block, 11: iron core, 11a, 11b ...
Magnetic pole part, 12 ... Spool, 13, 14 ... Flange part, 16 ... Coil, 17 ... Relay terminal, 17a ... King part, 18 ... Connecting piece, 18a ... Tip, 20 ... Base block, 21 ... Common terminal, 21a ... connection receiving part, 21b ... narrow part, 22,
23: fixed contact terminal, 22a, 23a: fixed contact, 22
b, 23b narrow part, 22c, 23c end part, 24 coil terminal, 24b narrow part, 24c end part, 25 concave part, 26a, 26b convex part, 27 insulating wall, 28 ... Projection, 30 movable block, 31 permanent magnet, 32 movable contact piece, 32a, 32b movable contact, 32c connection part,
33: movable iron piece, 34: insulating stand, 34a, 34b: concave portion, 34c, 34d: end portion, 40: case, 41: notched portion, 42: gas vent hole, 43: insulating rib, 50 ...
Lead frame, 51 ... support piece.

Claims (2)

[Claims] 1. A pair of coil relay terminals integrally formed on one of flanges of a spool located at both ends of an iron core around which a coil is wound, and integrated with each other so as to protrude from the other flange. The method for manufacturing an electromagnet device, in which at least one molded holding connection piece and a lead frame are welded and integrated to a lead frame, respectively, and then a housing is formed by secondary molding, separating from the base of the holding connection piece, A method for manufacturing an electromagnet device, wherein a portion located outside the housing is welded integrally to the lead frame and supported. 2. The device according to claim 1, wherein the relay terminal and the connecting piece are arranged so that a step is formed vertically.
3. The method for manufacturing an electromagnet device according to claim 1.