1. Field of the Invention
The present invention relates to an electromagnetic relay and more particularly to the electromagnetic relay to be used as a vehicle-mounted electromagnetic relay or a like.
The present application claims priority of Japanese Patent Application No. 2005-114584 filed on Apr. 12, 2005, which is hereby incorporated by reference.
2. Description of the Related Art
Conventionally, an electromagnetic relay is used for electrical components of automobiles or a like. The general and conventional electromagnetic relay being used as a vehicle-mounted one is described below.
Moreover, the movable contact spring 3 is in contact with the armature 4 with a spool 8 and an iron core 9 being interposed between the movable contact spring 3 and the armature 4.
In
Generally, a very large amount of current flows through loads such as a lamp or a capacitor when a contact is closed. Therefore, the above-described contact bounce occurring at the time of closing the contact has much effect on a contact life of the electromagnetic relay 10.
If a contact bounce occurs in a state where a large amount of current is flowing, arc currents are produced and there is a danger of an occurrence of a failure such as welding of a contact or locking caused by a protrusion or hole formed on a contact surface.
In order to decrease the occurrence of the bounce at time of closing the contact, by making stiffness of the fixed contact member lower and by making the fixed contact member itself elastic, repulsion is suppressed at a time of collision of the movable contact, which enables the occurrence of the bounce to be reduced. This technology is disclosed in Patent Reference I (Japanese Utility Model Application Laid-open No. Hei05-83994).
As described above, in the Patent Reference 1, for example, in order to decrease the occurrence of arc currents, an electromagnetic relay is so configured that a fixed contact spring itself is made to have elasticity, however, to make the fixed contact member itself have elasticity, it is necessary to make a plate thickness be small, which causes a decrease in current-carrying capability due to reduction in a cross-sectional area for current carrying. Moreover, if a vibration-isolating material is to be mounted thereon, new problems of an increase in component counts accompanied by an increase in the number of man-hours or in costs arise.
In view of the above, it is an object of the present invention to provide an electromagnetic relay which is capable of reliably decreasing a contact bounce at time of closing a contact without causing a decrease in current-carrying capability and an increase in component counts.
According to a first aspect of the present invention, there is provided an electromagnetic relay including:
a fixed contact member having a normally closed fixed contact;
a fixed contact member having a normally open fixed contact;
a movable contact spring having a movable contact whose surface is opposed to each of a surface of the normally closed fixed contact and a surface of the normally open fixed contact;
an armature coupled to the movable contact spring; and
an iron core around which coils used to attract the armature are wound;
wherein, by interaction between a spring force of the movable contact and a magnetic force generated by an exciting current fed to the coils, either of the normally closed fixed contact or the normally open fixed contact does or does not come into surface-contact with the movable contact and wherein an opposed angle θ when viewed from a direction of sliding of the movable contact and the normally open fixed contact that is induced by bending of the normal contact spring, which the normally open fixed contact forms with the movable contact before either of the normal close contact or the normal open contact comes into surface-contact with the movable contact, is 0°<θ<45°.
In the foregoing aspect, a preferable mode is one wherein the opposed angle θ, when viewed from the direction of sliding of the movable contact and the normally open fixed contact that is induced by bending of the normal contact spring, which the normally open fixed contact forms with the movable contact before either of the normal close contact or the normal open contact comes into surface-contact with the movable contact, is θ°<0<20°.
Also, a preferable mode is one wherein the normally open fixed contact has a plate-shaped surface, and the movable contact has a plate-shaped surface.
Another preferable mode is one wherein the normally open fixed contact is formed to have an inclination angle θ being equal to the opposed angle θ in advance, such that the opposed angle θ, when viewed from the direction of sliding of the movable contact and the normally open fixed contact that is induced by bending of the normal contact spring, which the normally open fixed contact forms with the movable contact before either of the normal close contact or the normal open contact comes into surface-contact with the movable contact, is 0°<θ<45°.
Still another mode is one wherein the movable contact is formed to have an inclination angle θ being equal to the opposed angle θ in advance, such that the opposed angle θ, when viewed from the direction of sliding of the movable contact and the normally open fixed contact that is induced by bending of the normal contact spring, which the normally open fixed contact forms with the movable contact before either of the normal close contact or the normal open contact comes into surface-contact with the movable contact, is 0°<θ<45°.
By configuring as above, the surface of the plate-shaped normally open fixed contact and the surface of the plate-shaped movable contact are opposed to each other in a manner to form a specified angle and, when the normally open fixed contact comes into surface-contact with the movable contact, after part of one contact portion comes into contact with part of other contact portion, the movable contact is twisted, while sliding on the plate-shaped movable contact due to elasticity of an arm-shaped spring member supporting the movable contact, which causes a residual portion of the contact to come into contact and causes repulsion at a time of collision to be reduced, thus preventing an occurrence of a contact bounce.
With the above configuration, the contact bounce at the time of closing the contact is reduced, which enables the provision of the electromagnetic relay to have a long contact life.
The above and other objects, advantages, and features of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:
Best modes of carrying out the present invention will be described in further detail using various embodiments with reference to the accompanying drawings. According to the present invention, an inclination angle θ which a surface of a movable contact forms with a surface of a normally open fixed contact obtained by making a supporter of at least either of the movable contact or the normally open fixed contact be inclined in advance is preferably 0°<θ<45°. Also, the same effect as above can be achieved not by making the supporter be inclined, but by making the contact portion only be inclined so as to have a convex surface. Moreover, the reason why the inclination angle θ is set in the above range is that, if the inclination angle θ is more than 45°, a contact failure occurs. From a viewpoint of wearing-out of the contact, the inclination angle θ is set to be preferably 5°<θ<20°.
An electrical life test under lamp-loaded conditions was conducted, using a testing circuit shown in
Table 1 shows results from the electrical life test.
As shown in Table 1, the comparison between the conventional example (test sample 1) and samples (test samples 2 to 9) according to the first embodiment of the present invention shows that an initial bounce occurs and the electrical life was only about forty-thousand operations in the conventional example (test sample 1), whereas no initial bounce occurred in the test samples 2 to 9 according to the first embodiment of the present invention. Moreover, even if the number of times of operations exceeds one hundred thousand, no failure occurred. It is assumed that the occurrence of arc currents at the time of closing the contact can be prevented with the configurations of the first embodiment. Also, in the case of the test sample 10, in which the inclination angle θ=45°, though the initial bounce did not occur, when the number of times of operations exceeds seventy-thousand, a failure occurred. This was presumably attributable to a contact failure caused by excessive inclination of the normally open fixed contact 6a.
Though not shown in Table 1, when the test samples 2 to 9 were made to operate in a manner to exceed one hundred thousand times of operations, the test samples 2 to 5 showed excellent results in particular. This is presumably not only because the occurrence of arc currents caused by the bounce at time of operations was prevented but also because wearing-out of the contact caused by the occurrence of the arc currents at time of restoration was decreased. Therefore, when the inclination angle θ is more than 0° and is less than 45°, the occurrence of the initial bounce is prevented and the electromagnetic relay having an electrically long life can be obtained. The inclination angle θ is more preferably set to be more than 5° and 20° or less.
An electrical life test under lamp-loaded conditions was conducted, using a testing circuit shown in
As a result, almost the same effect obtained in the first embodiment was achieved in the second embodiment. Therefore, when the angle θ which the surface of the movable point 3a forms with the surface of the normally open fixed contact 6a is more than 0° and is less than 45°, occurrence of an initial bounce is prevented and the electromagnetic relay having an electrically long life can be obtained. The inclination angle θ is more preferably set to be more than 5° and 20° or less.
An electrical life test under lamp-loaded conditions was conducted, using a testing circuit shown in
As a result, almost the same effects obtained in the first and second embodiments were achieved in the third embodiment. Therefore, when the inclination angle θ of the inclined surface is more than 0° and is less than 45°, the occurrence of the initial bounce is prevented and the electromagnetic relay having an electrically long life can be obtained. The inclination angle θ is more preferably set to be more than 5° and 20° or less.
Moreover, even in cases other than the above embodiments, if the angle θ which the surface of the movable contact 3a forms with the surface of the normally open fixed contact 6a is substantially more than 0° and is less than 45°, the occurrence of the initial bounce is prevented and the electromagnetic relay having an electrically long life can be obtained. Moreover, setting the above angle θ to be more than 5° and 20° or less enables the electromagnetic relay having an electrically long life to be achieved.
It is apparent that the present invention is not limited to the above embodiments but may be changed and modified without departing from the scope and spirit of the invention. Additionally, by using the electromagnetic relay of the present invention, it is made possible to increase reliability of automobile parts and/or electrical components using electromagnetic relays.
Number | Date | Country | Kind |
---|---|---|---|
2005-114584 | Apr 2005 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
2490280 | Rees | Dec 1949 | A |
2671836 | Anger et al. | Mar 1954 | A |
2731527 | Marsh | Jan 1956 | A |
2805301 | Shaw | Sep 1957 | A |
2976379 | Rhodes | Mar 1961 | A |
3155804 | Stanley | Nov 1964 | A |
3242283 | Clements | Mar 1966 | A |
3272949 | Lawrence | Sep 1966 | A |
3317869 | Funke | May 1967 | A |
3344373 | Janninck | Sep 1967 | A |
3866092 | Burns | Feb 1975 | A |
3974468 | Ygfors | Aug 1976 | A |
4216358 | Brozille | Aug 1980 | A |
4401863 | Lemmer et al. | Aug 1983 | A |
4421959 | Chen et al. | Dec 1983 | A |
4453057 | Streich et al. | Jun 1984 | A |
4551660 | Suzuki | Nov 1985 | A |
4640998 | Sorenson | Feb 1987 | A |
4650935 | Ootsuka et al. | Mar 1987 | A |
4876493 | Suzuki | Oct 1989 | A |
4947146 | Ichimura et al. | Aug 1990 | A |
RE33457 | Ootsuka et al. | Nov 1990 | E |
5049845 | Yokoyama et al. | Sep 1991 | A |
5329163 | Satoh et al. | Jul 1994 | A |
5572176 | Heinzl et al. | Nov 1996 | A |
5757255 | Noda et al. | May 1998 | A |
5831502 | Kirsch | Nov 1998 | A |
6084488 | Macbeth et al. | Jul 2000 | A |
6300854 | Oberndorfer | Oct 2001 | B1 |
6837729 | Hogue et al. | Jan 2005 | B2 |
20040048521 | Hogue et al. | Mar 2004 | A1 |
Number | Date | Country |
---|---|---|
499 732 | May 1979 | AU |
91 17 155 | Aug 1991 | DE |
198 58 755 | Dec 1998 | DE |
0 326 116 | Jan 1989 | EP |
S51-148646 | May 1950 | JP |
2-18218 | Feb 1990 | JP |
3-58818 | Jun 1991 | JP |
3-124450 | Dec 1991 | JP |
5-120971 | May 1993 | JP |
5-83994 | Nov 1993 | JP |
06267390 | Sep 1994 | JP |
9-129108 | May 1997 | JP |
2001-23496 | Jan 2002 | JP |
2002-8506 | Jan 2002 | JP |
Number | Date | Country | |
---|---|---|---|
20060226935 A1 | Oct 2006 | US |