Electromagnetic relay

BACKGROUND OF THE INVENTION
1. Technical Field

The present disclosure relates to an electromagnetic relay.

2. Related Art

An electromagnetic relay is an electronic part which turns on or off an electric current by closing or opening a set(s) of movable and fixed contacts housed in its cover. In recent years, there has been a demand for electromagnetic relays to have a higher current carrying capacity.

In response, Japanese Patent Application Publication No. 2009-289678 discloses an electromagnetic relay which enhances its compactness, current carrying capacity, and insulation between fixed terminals and a backstop by devising things such as the shape of the backstop which comes in contact with a movable spring including movable contacts.

SUMMARY OF THE INVENTION

The electromagnetic relay according to Japanese Patent Application Publication No. 2009-289678 can obtain a certain high level of current carrying capacity. If the electromagnetic relay according to Japanese Patent Application Publication No. 2009-289678 is employed in order to obtain a higher current carrying capacity, the sizes of the fixed terminal and the like need to be increased. As a result, the size of the electromagnetic relay as a whole becomes larger. In recent years, there has been a demand for not only a higher current carrying capacity but also a decrease in the size while avoiding deterioration in performance of the electromagnetic relay. In this context, a further improvement to the electromagnetic relay is awaited.

The present disclosure has been made in view of the above problem. An object of the present disclosure is to provide an electromagnetic relay which is advantageous to achieve a higher current carrying capacity and a reduction in the size at the same time.

One aspect of the present disclosure is an electromagnetic relay including: an electromagnetic device including a coil; a fixed terminal including a fixed terminal main body extending in a first direction, a fixed terminal arm portion curving and continuing from an edge of the fixed terminal main body, and two fixed contacts; a movable spring including two movable contacts which come into or out of contact with the two fixed contacts, extending in a second direction, and being movable by drive of the electromagnetic device; a backstop including a restraint portion provided contactable to a surface opposite from a contact abutment-side surface, an arm portion provided with the restraint portion, and a leg portion curving from the arm portion to a contact-abutment side in the first direction; and a fixed terminal retainer which retains the fixed terminal and the backstop. One of the fixed terminal main body and the fixed terminal arm portion is a first side terminal portion facing in the second direction. Another of the fixed terminal main body and the fixed terminal arm portion is a second side terminal portion curving from a first edge of the first side terminal portion in a direction opposite to the second direction. The leg portion of the backstop is provided away from the first side terminal portion in the direction opposite to the second direction, and provided between the two movable contacts on a projection plane with a perpendicular extending in the second direction when viewed from the first direction.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The figures depict one or more implementations in accordance with the present teaching, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.

FIG. 1 is a view illustrating an external appearance of an electromagnetic relay according to an embodiment.

FIG. 2 is a view illustrating an internal configuration of the electromagnetic relay according to the embodiment.

FIG. 3 is a cross-sectional view of the electromagnetic relay taken along the A-A line in FIG. 1.

FIG. 4 is an exploded perspective view of the electromagnetic relay according to the embodiment.

FIG. 5 is a side view illustrating the internal configuration of the electromagnetic relay according to the embodiment.

FIG. 6 is a view illustrating a shape of a fixed terminal in the embodiment.

FIG. 7 is a view of the internal configuration illustrated in FIG. 2, exclusive of the fixed terminals.

FIG. 8 is a view illustrating a shape of a backstop in an embodiment.

FIG. 9 is a view illustrating an internal configuration of an electromagnetic relay according to an embodiment.

FIG. 10 is a view illustrating a shape of a fixed terminal in the embodiment.

FIG. 11 is a view of the internal configuration illustrated in FIG. 9, exclusive of the fixed terminals.

FIG. 12 is a view illustrating an internal configuration of the electromagnetic relay according to an embodiment.

FIG. 13 is view illustrating a shape of a fixed terminal in the embodiment.

FIG. 14 is a view of the internal configuration illustrated in FIG. 12, exclusive of the fixed terminals.

DETAILED DESCRIPTION

Embodiments of the present disclosure will be described below with reference to the drawings. In the following descriptions, as an example, a first direction, a second direction and a third direction are defined as follows. First of all, the first direction in which connecting terminals extend is defined as a Z direction. The Z direction is a direction toward the inside of the electromagnetic relay from a side of the electromagnetic relay from which the connecting terminal is exposed to the outside of the electromagnetic relay. The direction in which the distal end of the connecting terminal is exposed to the outside of the electromagnetic relay is the lower side. Furthermore, an X direction and a Y direction are defined as being perpendicular to each other on a plane perpendicular to the Z direction. Particularly, a second direction in which a later-discussed movable spring 30b extends is defined as the X direction. In addition, a third direction in which later-discussed two movable contacts 33 or two fixed contacts 44 are arranged side-by-side is defined as the Y direction.

First Embodiment

To begin with, descriptions will be provided for an electromagnetic relay according to a first embodiment. FIG. 1 is a perspective view illustrating an external appearance of the electromagnetic relay 1 according to this embodiment. FIG. 2 is a perspective view illustrating an internal configuration of the electromagnetic relay 1, exclusive of a cover 10. FIG. 3 is a cross-sectional view of the electromagnetic relay 1 taken along the A-A line in FIG. 1. FIG. 4 is an exploded perspective view of the electromagnetic relay 1.

The electromagnetic relay 1 is an electronic part which is installed in various electronics, and which turns on or off an electric current. The electromagnetic relay 1 includes the cover 10, an electromagnetic device 12, a movable contact unit 13, a fixed contact unit 14 and a yoke 15.

The cover 10 is made of, for example, a resin. The cover 10 houses various components such as the electromagnetic device 12. The cover 10 is a box body shaped like a rectangular prism, and includes a ceiling wall 10a and side walls 10b surrounding the ceiling wall 10a. The ceiling wall 10a of the cover 10 is provided with a ventilation hole 10c through which air can flow between an inner space and an outer space of the cover 10.

The ventilation hole 10c inhibits an increase in pressure inside the cover 10 while, as discussed later, the inner space is sealed off using a sealing material, and discharges heat generated in the inner space by an energizing operation to the outside of the cover 10. Incidentally, descriptions will be later provided for where to place the ventilation hole 10c.

The electromagnetic device 12 displaces the movable spring 30b included in the movable contact unit 13 each time the electromagnetic device 12 is excited or de-excited based on energization from the outside depending on the necessity. The electromagnetic device 12 includes: an iron core 22 having an attraction piece 22a in its distal end; a coil bobbin 23 supporting the iron core 22; a coil 24 of wire wound around the coil bobbin 23; and two coil terminals 25. Each coil terminal 25 is a connecting terminal. One end of the coil terminal 25 is connected to the coil 24, and the other end of the coil terminal 25 projects to the outside. The coil bobbin 23 is made of a synthetic resin-made insulating material.

The base of the electromagnetic relay 1 is formed from: a support 42b of a fixed terminal retainer 42 which will be discussed later; and a flange 11 of the coil bobbin 23. When viewed from the Z direction, the base is rectangular. The base is attached to the cover 10 with the peripheral portion of the base in engagement with the inner peripheral portion of an opening portion 10d of the cover 10. In this state, as illustrated in FIG. 3, the coil 24 of the electromagnetic device 12, the movable contacts 33 of the movable contact unit 13, the fixed contacts 44 of the fixed contact unit 14, and the yoke 15 are housed in the inner space of the cover 10. Each connecting terminal projects from the inner space to the outside. The inner space of the cover 10 is sealed off by, although not illustrated, filling a sealing material made of a liquid curable resin, such as an epoxy seal, into a gap in the lower surface of the base. This makes it possible to make the inner space more dustproof, and to increase the strength of support for the each connecting terminal.

The movable contact unit 13 includes a main body 30, movable terminals 31, and an armature 32.

The main body 30 includes: a fixed portion 30a connected to the yoke 15; and a movable spring 30b continued to the fixed portion 30a, and being movable. The fixed portion 30a is a flat plate portion extending in the Z direction. The movable spring 30b is a flat plate portion extending to the plus side in the X direction. An X-direction plus-side distal end part of the movable spring 30b is divided into two portions. Of the two movable divided portions, one situated on the plus side in the Y direction is a first movable divided portion 30c, and the other situated on the minus side in the Y direction is a second movable divided portion 30d. The first and second movable divided portions 30c, 30d, respectively, have the movable contacts 33 on first surfaces 30e which correspond to Z-direction minus-side parts of the X-direction plus-side distal end areas of the first and second movable divided portions 30c, 30d. The two movable contacts 33 change their positions in the Z direction when the movable spring 30b swings on its opposite end which continues to the fixed portion 30a.

Each movable terminal 31 is a connecting terminal with its one end connected to the fixed portion 30a of the main body 30, and with its opposite end projecting to the outside. This embodiment has two movable terminals 31.

The armature 32 is a flat plate-shaped conductor set on the movable spring 30b. One surface of the armature 32 faces the surface of the attraction piece 22a of the iron core 22.

Each of the main body 30 and the movable terminals 31 can be formed by curving a conductive sheet metal material which is blanked in a predetermined shape. Incidentally, the main body 30 and the movable terminals 31 may be separately-formed components to be connected together when produced, or may be formed integrally from the beginning.

The fixed contact unit 14 includes fixed terminals 41, the fixed terminal retainer 42, and a backstop 43.

Each fixed terminal 41 is a connecting terminal which has a fixed contact 44 on its one end, and whose opposite end projects to the outside. The fixed terminal 41 can be formed by curving a conductive sheet metal material which is blanked in a predetermined shape. This embodiment has two fixed terminals 41.

FIG. 5 is a side view of the internal configuration of the electromagnetic relay 1 from the plus side in the X direction. The two fixed terminals 41 have their respective shapes which are symmetrical with respect to a center line C in the Y direction. The two fixed terminals 41 are placed adjacent to each other with the center line C interposed in between. Of the two fixed terminals 41, hereinafter, one situated on the plus side in the Y direction is referred to as a first fixed terminal 41a, and the other situated on the minus side in the Y direction is referred to as a second fixed terminal 41b.

FIG. 6 is a view illustrating the shape of the first fixed terminal 41a. FIG. 6 includes a top view, a side view from the plus side in the Y direction, a front view of the first fixed terminal 41a from the plus side in the X direction, a side view from the minus side in the Y direction, a back view and a bottom view. Incidentally, the directions indicated by the X, Y and Z axes in FIG. 6 are the same as those in the other drawings. The first fixed terminal 41a includes the following four flat plate portions.

A fixed terminal main body 400 is a flat plate portion whose main plane is a YZ plane facing in the X direction, and which extends in the Z direction. The fixed terminal main body 400 is a flat plate portion which is among the flat plate portions of the first fixed terminal 41a, and which includes a terminal portion 400a projecting to the outside. Incidentally, in the example illustrated in FIG. 6, the terminal portion 400a of the fixed terminal main body 400 is slightly offset in the X direction compared with the other portions of the fixed terminal main body 400 in light of the stability of the electromagnetic relay 1 after assembled or the like.

A fixed contact retainer 401 is a flat plate portion whose main plane is an XY plane, which continues to the Z-direction plus-side edge of the fixed terminal main body 400, and which curves to the minus side in the X direction, that is to say, a direction opposite to the direction in which the movable spring 30b extends. The fixed contact 44 is placed on the first surface corresponding to the Z-direction plus-side part of the fixed contact retainer 401. Thus, as illustrated in FIG. 5, the two fixed contacts 44 included in the fixed contact unit 14 and the two movable contacts 33 included in the movable contact unit 13 are arranged along the Z direction, respectively, facing each other in pairs.

A fixed terminal arm portion 402 is a flat plate portion whose main plane is an XZ plane, which continues to a Y-direction plus-side first edge of the fixed terminal main body 400, and which curves to the minus side in the X direction. In contrast to the fixed terminal main body 400, the fixed terminal arm portion 402 is a flat plate portion which is among the flat plate portions of the first fixed terminal 41a, but which does not include the terminal portion 400a.

A terminal arm portion 403 is a flat plate portion whose main plane is an XZ plane, which continues to a Y-direction minus-side second edge of the fixed terminal main body 400, and which curves to the minus side in the X direction.

Here, of the flat plate portions of the first fixed terminal 41a, for example, one facing in the second direction, or the X direction is defined as a first side terminal portion, and another one curving from the first edge of the first side terminal portion in a direction opposite to the second direction is defined as a second side terminal portion. When these definitions are applied to this embodiment, the fixed terminal main body 400 corresponds to the first side terminal portion, and the fixed terminal arm portion 402 corresponds to the second side terminal portion.

In addition, as illustrated in FIG. 6, a Z-direction length L1 of the fixed terminal arm portion 402 is greater than a Z-direction length L2 of the terminal arm portion 403. Meanwhile, both an X-direction length of the fixed terminal arm portion 402 and an X-direction length of the terminal arm portion 403 are L3. Furthermore, the length L3 is approximately equal to an X-direction length L4 of the fixed contact retainer 401.

Because of the existence of the fixed terminal arm portion 402 and the terminal arm portion 403, the first fixed terminal 41a has a space between the fixed terminal arm portion 402 and the terminal arm portion 403. A Y-direction width of this space is denoted by W1.

It should be noted that: as discussed above, the shape of the second fixed terminal 41b is just symmetrical to that of the first fixed terminal 41a with respect to the center line C in the Y direction illustrated in FIG. 5; and the two fixed terminals may be regarded as having the same shape. For this reason, detailed descriptions for the second fixed terminal 41b will be omitted.

FIG. 7 is a perspective view illustrating the internal configuration of the electromagnetic relay 1 illustrated in FIG. 2, from which the first fixed terminal 41a and the second fixed terminal 41b are excluded for the explanation sake.

The fixed terminal retainer 42 retains the first fixed terminal 41a and the second fixed terminal 41b. The fixed terminal retainer 42 is made of an insulating material. The fixed terminal retainer 42 includes: a fixed terminal fixation portion 42a in contact with the first fixed terminal 41a and the second fixed terminal 41b; and the support 42b which continues to the fixed terminal fixation portion 42a, and which is combined with the flange 11 of the coil bobbin 23.

The fixed terminal fixation portion 42a is a rectangular prism-shaped member which is installed upright from the support 42b, a part of the base, to the plus side in the Z direction.

The fixed terminal fixation portion 42a includes a first side portion 42a₁which faces the first fixed terminal 41a or the second fixed terminal 41b in the X direction. The first side portion 42a₁includes the following three hole portions formed therein.

Terminal hole portions 42c, 42d, respectively, house at least parts of the terminal arm portions 403. Of these terminal hole portions 42c, 42d, the terminal hole portion 42c houses the terminal arm portion 403 of the first fixed terminal 41a when the first fixed terminal 41a is combined with the fixed terminal fixation portion 42a. Similarly, the terminal hole portion 42d houses the terminal arm portion 403 of the second fixed terminal 41b when the second fixed terminal 41b is combined with the fixed terminal fixation portion 42a. In other words, for the purpose of realizing the above-discussed housing, the terminal hole portions 42c, 42d are arranged in a Y-direction center area of the fixed terminal fixation portion 42a. Here, the terminal hole portions 42c, 42d are not in contact with each other. Thus, after the first fixed terminal 41a and the second fixed terminal 41b are combined with the fixed terminal fixation portion 42a, too, the first fixed terminal 41a and the second fixed terminal 41b are separate away from each other with a width W2 in between, as illustrated in FIG. 5.

As illustrated in FIG. 3, a backstop hole portion 42e houses a backstop end portion 43d provided in a part of the later-discussed backstop 43, and thereby supports the backstop 43. The backstop hole portion 42e is located in the Y-direction center area of the fixed terminal fixation portion 42a, and to the plus side in the Z direction from the terminal hole portions 42c, 42d.

Moreover, the fixed terminal fixation portion 42a includes two second side surfaces 42a₂which continue to the first side portion 42a₁, one of which faces to the plus side in the Y direction, and the other of which faces to the minus side in the Y direction. When the first fixed terminal 41a is combined with the fixed terminal fixation portion 42a, one second side surface 42a₂comes into contact with an inner surface of the fixed terminal arm portion 402 of the first fixed terminal 41a, or faces the inner surface of the fixed terminal arm portion 402 of the first fixed terminal 41a with a space in between. Thereby, as illustrated in FIG. 2, the second side surface 42a₂is covered with the fixed terminal arm portion 402 of the first fixed terminal 41a. Similarly, when the second fixed terminal 41b is combined with the fixed terminal fixation portion 42a, the other second side surface 42a₂comes into contact with an inner surface of the fixed terminal arm portion 402 of the second fixed terminal 41b, or faces the inner surface of the fixed terminal arm portion 402 of the second fixed terminal 41b with a space in between. Thereby, as illustrated in FIG. 2, the second side surface 42a₂is covered with the fixed terminal arm portion 402 of the second fixed terminal 41b.

In this respect, for the purpose of realizing the above-discussed housing and covering, a length L11 between a Y-direction plus-side inner surface of the terminal hole portion 42c and the Y-direction plus side-situated second side surface 42a₂is approximately equal to a width W1 of the first fixed terminal 41a. Similarly, the length L11 between a Y-direction minus-side inner surface of the terminal hole portion 42d and the Y direction minus side-situated second side surface 42a₂is approximately equal to the width W1 of the second fixed terminal 41b.

In addition, an X-direction length L12 of the second side surface 42a₂is equal to or slightly longer than the X-direction length L3 of the fixed terminal arm portion 402.

Furthermore, a Z-direction length L13 of the fixed terminal fixation portion 42a is set at a length which, after all the internal components are assembled together as illustrated in FIG. 5, does not allow the fixed contacts 44 and the movable contacts 33 to be too away from each other when the movable contacts 33 are detached from the fixed contacts 44, and which causes no abnormal current flow while the movable contacts 33 are away from the fixed contacts 44.

The backstop 43 is a restraint member which inhibits displacements of the first and second movable divided portions 30c, 30d with the movable contacts 33 set thereon. The backstop 43 can be formed by curving a conductive sheet metal member which is blanked in a predetermined shape.

The backstop 43 includes restraint portions 43a, an arm portion 43b, a leg portion 43c and a backstop end portion 43d.

As illustrated in FIG. 5, so as to agree with the locations of the movable contacts 33, the restraint portions 43a face second surfaces 30f corresponding to Z-direction plus-side parts of X-direction plus-side distal areas of the first and second movable divided portions 30c, 30d. To put it specifically, this embodiment has two restraint portions 43a. Incidentally, the second surfaces 30f are located on the opposite sides of the first and second movable divided portions 30c, 30d from the first surfaces 30e. While the movable contacts 33 are away from the fixed contacts 44, the restraint portions 43a are contactable to parts of the second surfaces 30f which are on the opposite sides of the first and second movable divided portions 30c, 30d from the contact abutment-side first surfaces 30e.

The arm portion 43b is a flat plate portion extending in the Y direction. The arm portion 43b includes a first surface 43b₁which faces the movable contacts 33. The two restraint portions 43a are placed on the first surface 43b₁.

The leg portion 43c is a flat plate portion which continues from the arm portion 43b, and which, as illustrated in FIG. 5, curves from the center of a Y-direction length L21 between the two restraint portions 43a to the contact-abutment side, that is to say, to the minus side in the Z direction.

The backstop end portion 43d is a flat plate portion which, as illustrated in FIG. 3, curves from an end of the leg portion 43c in the direction opposite to the X direction, that is to say, to the minus side in the X direction. The backstop end portion 43d is housed in the backstop hole portion 42e in the fixed terminal fixation portion 42a, as discussed above.

Here, a Y-direction length L22 of the leg portion 43c is shorter than the length L21 between the two restraint portions 43a, as illustrated in FIG. 5. In addition, while the first and second fixed terminals 41a, 41b are retained by the fixed terminal retainer 42, at least part of the leg portion 43c overlaps the terminal arm portions 403 of the respective first and second fixed terminals 41a, 41b when viewed from an axis extending in the Y direction which intersects the Z direction and the X direction. In FIG. 5, a width of the Y-direction overlap between the leg portion 43c and the terminal arm portion 403 of the first fixed terminal 41a is denoted by W3. Furthermore, while the first and second fixed terminals 41a, 41b are retained, the Y-direction length L22 of the leg portion 43c (the width of the leg portion 43c) is less than a width W4 between the first and second fixed terminals 41a, 41b on the plus side in the Z direction of the terminal arm portions 403.

Besides, as illustrated in FIG. 3, the leg portion 43c curves in the X direction from a position in the restraint portions 43a-placing area which is set back inward from the X-direction plus-side end portion of the arm portion 43b, that is to say, a position which is offset to the minus side in the X direction by a width W5. In addition, a backstop hole portion 42e-forming surface of the fixed terminal fixation portion 42a is offset to the minus side in the X direction by a width W6 from a terminal hole portions 42c, 42d-forming surface of the fixed terminal fixation portion 42a. Thus, while the first and second fixed terminals 41a, 41b are retained, a space with a width W7 occurs in the X direction between the surface of the fixed terminal main body 400 and the surface of the leg portion 43c of the backstop 43. In other words, a space S with a Y-direction dimension of W4, and with a Z-direction dimension of W8 is formed between the leg portion 43c and the side wall 10b of the cover 10 adjacent to the leg portion 43c.

Moreover, as illustrated in FIG. 5, while the first and second fixed terminals 41a, 41b are retained, the backstop end portion 43d and the terminal arm portion 403 are away from each other in the Z direction with a width W9 in between. Meanwhile, a lower surface 43d₁of the backstop end portion 43d is lower in the Z direction by a width W10 than a Z-direction plus-side distal end of the fixed terminal arm portion 402. In other words, the backstop end portion 43d is placed in Z-direction between fixed contact 44-side end portions of the fixed terminal arm portions 402 and fixed contact 44-side end portions of the terminal arm portions 403.

In addition, the yoke 15 is a plate member which is made, for example, of a magnetic steel, and which is curved so that its cross section is formed in the shape of the letter L. As described above, one flat plate portion of the yoke 15 retains the fixed portion 30a included in the main body 30 of the movable contact unit 13. The other flat plate portion of the yoke 15 is connected to the iron core 22 included in the electromagnetic device 12. Thus, when the electromagnetic device 12 is driven, a magnetic circuit is formed by the iron core 22, the armature 32 and the yoke 15.

Next, descriptions will be provided for how the contacts in the electromagnetic relay 1 work. The movable contacts 33 and the fixed contacts 44 are arranged facing each other in the Z direction, respectively. When the coil 24 of the electromagnetic device 12 is de-energized, the sets of movable and fixed contacts 33, 44 are opened. On the other hand, when the coil 24 is energized, the movable contacts 33 come closer to and into contact with the fixed contacts 44. In this respect, the de-energization of the coil 24 means de-excitation of the electromagnetic device 12. When the electromagnetic device 12 is de-excited, a biasing force of the movable spring 30b to the minus side in the Z direction holds the armature 32 away from the attraction piece 22a. Meanwhile, the energization of the coil 24 means excitation of the electromagnetic device 12. When the electromagnetic device 12 is excited, a magnetic force of the attraction piece 22a is greater than the biasing force of the movable spring 30b, and the armature 32 comes into contact with the attraction piece 22a. The above swing movement of the fixed contacts 44 makes the movable contacts 33 come into or out of contact with the fixed contacts 44, and thus the sets of contacts are opened or closed. In other words, the electromagnetic relay 1 works such that when the electromagnetic device 12 is switched to be energized or de-energized, the movable contacts 33 come into contact or out of contact with the fixed contacts 44. Incidentally, in this embodiment, the fixed terminal 41 includes two fixed terminals: the first fixed terminal 41a and the second fixed terminal 41b which are independent from each other. Accordingly, when the sets of fixed and movable contacts 44, 33 are opened, the first and second fixed terminal 41a, 41b are not electrically connected to each other.

Next, descriptions will be provided for how the electromagnetic relay 1 works, and what effects the electromagnetic relay 1 brings about.

In this embodiment, each fixed terminal 41 includes not only the fixed terminal main body 400 including the terminal portion 400a and the fixed contact retainer 401 including the fixed contact 44, but also the fixed terminal arm portion 402 and the terminal arm portion 403. The fixed terminal main body 400 and the fixed contact retainer 401 extend in the first direction as the Z direction, for example. The fixed terminal arm portion 402 curves from the first edge of the fixed terminal main body 400 in the direction opposite to the second direction as the X direction, for example, and covers the side surface of the fixed terminal retainer 42. The terminal arm portion 403 curves from the second edge of the fixed terminal main body 400 in the direction opposite to the second direction, and is housed in one of the terminal hole portions 42c, 42d formed in the fixed terminal retainer 42. This configuration makes it possible to further increase the surface area of the fixed terminal 41 by those of the fixed terminal arm portion 402 and the terminal arm portion 403, as well as to accordingly inhibit an increase in the size of the fixed terminal 41, and an increase in the external dimensions of the electromagnetic relay 1. Thus, a higher current carrying capacity of the electromagnetic relay 1 and a decrease in the size thereof can be achieved at the same time.

In addition, like the fixed terminal arm portion 402, the terminal arm portion 403 has a long plate shape with a wide surface area. The terminal arm portion 403 is housed in one of the terminal hole portions 42c, 42d formed in the fixed terminal retainer 42. This makes it possible to arrange the entirety of the fixed terminal main body 400 to face the cover 10, and accordingly to radiate heat efficiently. Furthermore, the terminal arm portion 403 makes it possible for the fixed terminal retainer 42 to retain the fixed terminal 41 more stably and firmly. Particularly, because the surface area of the fixed terminal arm portion 402 facing the cover 10 can be large, heat can be efficiently radiated from the fixed terminal 41, as well as a higher current carrying capacity and a decrease in the size can be achieved at the same time. Moreover, because the surface area of the fixed terminal arm portion 402 is wide enough to cover the second side surface 42a₂of the fixed terminal retainer 42, heat can be efficiently radiated from the fixed terminal 41, and the insulation from the electromagnetic device 12 can be secured. Here, that the surface area of the fixed terminal arm portion 402 is wide enough to cover the second side surface 42a₂of the fixed terminal retainer 42 means that, for example, the second direction length L3 of the fixed terminal arm portion 402 is set approximately equal to the second direction length L12 of the second side surface 42a₂.

Besides, in the inside of the electromagnetic relay 1, the fixed terminal arm portion 402 is arranged to cover the second side surface 42a₂. Meanwhile, since the terminal arm portion 403 is housed in one of the terminal hole portions 42c, 42d formed in the fixed terminal retainer 42, the terminal arm portion 403, after assembled, is contained in the fixed terminal retainer 42. In other words, although the surface area of the fixed terminal 41 increases by those of the fixed terminal arm portion 402 and the terminal arm portion 403, the fixed terminal 41 is compactly contained in the internal configuration of the electromagnetic relay 1. This makes it possible to inhibit an increase in the size of the electromagnetic relay 1.

Furthermore, as for the backstop 43, as indicated with the width W7 in FIG. 3, the leg portion 43c of the backstop 43 is away from the fixed terminal main body 400 as the first side terminal portion of this embodiment in the direction opposite to the second direction. What is more, on a projection plane with the perpendicular extending in the second direction, the leg portion 43c of the backstop 43 is provided between the two movable contacts 33 when viewed from the first direction. This is advantageous to increase insulation between the fixed terminal 41 and the backstop 43.

Moreover, on the projection plane with the perpendicular extending in the second direction, the backstop end portion 43d and the backstop hole portion 42e are provided between the two movable contacts 33 when viewed from the first direction. This is advantageous to secure the insulation between the fixed terminal 41 and the backstop 43, as well as to reduce the size. Furthermore, in connection with this, it is desirable that the opening of the backstop hole portion 42e be placed off the openings of the terminal hole portions 42c and 42d in which to house the terminal arm portions 403, in the first direction. In addition, at least part of the leg portion 43c of the backstop 43 may overlap the terminal arm portion 403 when viewed from an axis extending in the third direction which intersects the first and second directions.

Here, both the terminal arm portion 403 included in the fixed terminal 41 and the backstop end portion 43d included in the backstop 43 curve to the minus side in the X direction, that is to say, in the direction opposite to the second direction. Thus, from the plus side in the X direction, the terminal arm portion 403 and the backstop end portion 43d are housed, respectively, into the terminal hole portion 42c or 42d and the backstop hole portion 42e which are formed in the fixed terminal retainer 42. Accordingly, when it comes to a process of assembling the electromagnetic relay 1, all the components illustrated in FIG. 4, except the cover 10, can be sequentially assembled into the electromagnetic relay 1 in one direction, that is to say, in the X direction in this case. For example, the assembling sequence starting with the movable contact unit 13 may be such that the movable contact unit 13 is combined with the yoke 15, subsequently with the electromagnetic device 12, thereafter with the fixed terminal retainer 42, and finally followed by engaging the terminal arm portion 403 and the backstop end portion 43d. Like this, the shapes of the respective terminal arm portion 403 and the backstop end portion 43d are advantageous to make the process of assembling the electromagnetic relay 1 simpler and easier. Thus, the fixed terminal retainer 42 retains the electromagnetic device 12 and the coil terminals 25.

In addition, as indicated with the width W3 in FIGS. 3 and 5, on the projection plane with the perpendicular extending in the second direction, the backstop hole portion 42e may overlap the fixed terminal main body 400 as the first side terminal portion of this embodiment when viewed from the first direction. This makes it possible to make particularly a third direction dimension of the electromagnetic relay 1 smaller, and is advantageous to make the electromagnetic relay 1 compact in size.

In addition, as illustrated in FIG. 6, the Z-direction length L1 of the fixed terminal arm portion 402 may be greater than the Z-direction length L2 of the terminal arm portion 403. In other words, the fixed terminal arm portion 402 is longer in the first direction than the terminal arm portion 403. Thus, the length L1 of the fixed terminal arm portion 402 can be set as long as possible, so that the radiation of heat from the fixed terminal 41 can be accordingly facilitated. On the other hand, since the length L2 of the terminal arm portion 403 is set less than the length L1 of the fixed terminal arm portion 402, the position in which to place the leg portion 43c of the backstop 43 can be allocated in a way to make the internal configuration of the electromagnetic relay 1 compact in size. In this respect, it is particularly desirable that, as indicated with the width W10 in FIG. 5, the backstop end portion 43d be arranged between the fixed contact 44-side end portions of the fixed terminal arm portion 402 and the fixed contact 44-side end portion of the terminal arm portion 403, when viewed from the Z direction.

The foregoing descriptions have shown an example of the configuration in which the electromagnetic relay 1 includes two fixed terminals 41, that is to say, the first fixed terminal 41a and the second fixed terminal 41b. In the present disclosure, however, the electromagnetic relay 1 may include one fixed terminal 41. The operation and effects of this case are the same as those obtained from the electromagnetic relay 1 which includes the two fixed terminals 41.

Meanwhile, in the case where the electromagnetic relay 1 includes the two fixed terminals 41, that is to say, the first fixed terminal 41a and the second fixed terminal 41b, the movable spring 30b may include the first and second movable divided portions 30c, 30d on which the respective movable contacts 33 are placed. In this case, it is desirable that the leg portion 43c of the backstop 43 curve from the center between the two restraint portions 43a provided to the arm portion 43b, and be arranged between the first fixed terminal 41a and the second fixed terminal 41b. Thus, as illustrated in FIG. 5, one part of the single leg portion 43c overlaps the terminal arm portion 403 of the first fixed terminal 41a, and an opposite part of the same leg portion 43c overlaps the terminal arm portion 403 of the second fixed terminal 41b, when viewed from the Y direction. This is advantageous to make particularly the Y-direction dimension of the electromagnetic relay 1 smaller in the case where the electromagnetic relay 1 includes the first and second fixed terminals 41a, 41b.

Furthermore, in the case where the electromagnetic relay 1 includes the first and second fixed terminals 41a, 41b, the leg portion 43c of the backstop 43 may be arranged between the first and second movable divided portions 30c, 30d when viewed from the first direction, in addition to the above-discussed configuration. This is advantageous to make particularly the X- and Z-direction dimensions of the electromagnetic relay 1 smaller.

Furthermore, as for the cover 10, as illustrated in FIGS. 1 and 3, the ventilation hole 10c may be provided between the leg portion 43c of the backstop 43 and the side wall 10b of the cover 10 adjacent to the leg portion 43c. In other words, when viewed from the first direction, the ventilation hole 10c may be provided between the leg portion 43c of the backstop 43 and the side wall 10b of the cover 10 adjacent to the leg portion 43c. First, when the cover 10 is provided with the ventilation hole 10c, its ventilation hole 10c-forming area projects to the inside of the cover 10. With this taken into consideration, the ventilation hole 10c is provided at a position in the cover 10 which corresponds to the space S formed between the leg portion 43c and the side wall 10b, as illustrated in FIG. 3. Thus, the space S accommodates the projecting portion of the ventilation hole 10c into the inside of the cover. For this reason, it is possible to inhibit an .increase in the size of the electromagnetic relay 1. Second, since the space S is adjacent to both of the first and second fixed terminals 41a, 41b, heat from the first and second fixed terminals 41a, 41b can be easily guided to the space S. For this reason, the arrangement of the ventilation hole 10c to face the space S makes it possible to efficiently discharge heat produced in the inside of the electromagnetic relay 1 to the outside.

As discussed above, this embodiment can provide the electromagnetic relay which is advantageous to achieve a higher current carrying capacity and a reduction in the size at the same time.

Second Embodiment

Next, descriptions will be provided for an electromagnetic relay according to a second embodiment. In the first embodiment, as for the backstop 43, one backstop end portion 43d and one corresponding backstop hole portion 42e are provided to fit the shape of the leg portion 43c. In other words, on the projection plane with the perpendicular extending in the X direction, the backstop hole portion 42e is arranged between the terminal hole portions 42c, 42d with which the terminal arm portions 403 of the respective first and second fixed terminals 41a, 41b come into engagement, when viewed from the Z direction. However, the present disclosure is not limited to this. Multiple backstop end portions and multiple corresponding backstop hole portions may be provided.

FIG. 8 is a perspective view illustrating a shape of a backstop 53 of the second embodiment. Incidentally, FIG. 8 corresponds to FIG. 7 which draws the backstop 43 of the first embodiment. Particularly, the backstop 53 illustrated in FIG. 8 corresponds to the backstop 43 illustrated in FIG. 7. In addition, a fixed terminal retainer 52 illustrated in FIG. 8 corresponds to the fixed terminal retainer 42 illustrated in FIG. 7.

The shape of an arm portion 53b included in the backstop 53 is the same as that of the arm portion 43b illustrated in FIG. 7. Meanwhile, the backstop 53 includes: one leg portion 53c; and three backstop end portions 53d₁, 53d₂, 53d₃arranged along a line in which two restraint portions placed on the arm portion 53b stands side by side in the Y direction. The shapes of a fixed terminal fixation portion 52b and terminal hole portions 52c, 52d in the fixed terminal retainer 52 are substantially the same as those of the support 42b and the terminal hole portions 42c, 42d illustrated in FIG. 7, respectively. Meanwhile, a fixed terminal fixation portion 52a in the fixed terminal retainer 52 includes three backstop hole portions 52e₁, 52e₂, 52e₃formed therein to come into engagement with the three backstop end portions 53d₁, 53d₂, 53d₃, respectively.

Here, it is desirable that, as illustrated in FIG. 8, a pair consisting of the backstop end portion 53d₂and the backstop hole portion 52e₂be aligned with the leg portion 53c in the Y direction. Furthermore, it is desirable that a pair consisting of the backstop end portion 53d₁and the backstop hole portion 52e₁and a pair consisting of the backstop end portion 53d₃and the backstop hole portion 52e₃be placed symmetrically to each other with respect to the position of the leg portion 53c in the Y direction. Thus, while the backstop 53 is retained by the fixed terminal fixation portion 52a, stability of the backstop 53 to restrain the displacement of the movable spring 30b is greater than when the backstop 43 illustrated in FIG. 7 is used instead of the backstop 53. Accordingly, for example, even when the electromagnetic relay 1 receives an impact from the outside, the backstop 53 can inhibit the occurrence of a trouble such as a tilt of the arm portion 53b relative to the leg portion 53c.

In addition, even in the case where the backstop 53 is employed, arrangement of the three backstop hole portions 52e₁, 52e₂, 52e₃relative to the fixed terminal fixation portion 52a particularly in the X direction and in the Z direction is the same as the arrangement of the backstop hole portion 42e in the case where the backstop 43 is employed.

It should be noted that in the case where, as discussed above, there are multiple backstop hole portions 52e, at least one of these backstop hole portions 52e may overlap the fixed terminal main body 400 as the first side terminal portion of this embodiment on the projection plane with the perpendicular extending in the second direction, when viewed from the first direction. For example, a configuration provided with no backstop end portion 53d₂of the three backstop end portions 53d₁, 53d₂, 53d₃may be employed. To put it specifically, the configuration may be provided with no backstop end portion 53d₂, and use two backstop hole portions 52e₁, 52e₃which are respectively brought into engagement with the two symmetrically arranged backstop end portions 53d₁, 53d₃.

Third Embodiment

Next, descriptions will be provided for an electromagnetic relay according to a third embodiment. In the first embodiment, as for each fixed terminal 41, the fixed terminal main body 400 including the .terminal portion 400a is defined as the first side terminal portion facing in the second direction, and the fixed terminal arm portion 402 is defined as the second side terminal portion. In other words, in the first embodiment, the terminal portion 400a of the fixed terminal 41 is formed in a way that its main plane is the projection plane with the perpendicular extending in the X direction. The present disclosure, however, is not limited to this. The fixed terminal main body including the terminal portion may be defined as the second side terminal portion, while the fixed terminal arm portion may be defined as the first side terminal portion facing in the second direction.

FIG. 9 is a perspective view illustrating an internal configuration of the electromagnetic relay according to the third embodiment. Incidentally, FIG. 9 corresponds to FIG. 2 which illustrates the internal configuration of the electromagnetic relay 1 according to the first embodiment. In FIG. 9, the same components as those in the electromagnetic relay 1 according to the first embodiment are denoted by the same reference signs. Descriptions for such components will be omitted. To put it specifically, the shapes of fixed terminals 61 and a fixed terminal retainer 62 in the electromagnetic relay according to the third embodiment are different from those of the fixed terminals 41 and the fixed terminal retainer 42 in the electromagnetic relay 1 according to the first embodiment.

FIG. 10 is a view illustrating a shape of a first fixed terminal 61a. Incidentally, the drawings in FIG. 10 correspond to the drawings in FIG. 6 which illustrates the shape of the first fixed terminal 41a according to the first embodiment. The first fixed terminal 61a includes the following four flat plate portions.

A fixed terminal main body 602 is a second side terminal portion in this embodiment. The fixed terminal main body 602 is a flat plate portion whose main plane is the XZ plane, which continues to a Y-direction plus-side first edge of a fixed terminal arm portion 600, and which curves to the minus side in the X direction. In addition, in this embodiment, the fixed terminal main body 602 includes a terminal portion 602a projecting to the outside.

The fixed terminal arm portion 600 is the first side terminal portion of this embodiment. The fixed terminal arm portion 600 is a flat plate portion whose main plane is the YZ plane facing in the X direction, and which extends in the Z direction. In addition, in this embodiment, the fixed terminal arm portion 600 includes no terminal portion which projects to the outside.

A fixed contact retainer 601 is a flat plate portion whose main plane is the XY plane, which continues to a Z-direction plus-side edge of the fixed terminal arm portion 600, and which curves to the minus side in the X direction. Like the fixed contacts 44 in the first embodiment, each fixed contact 64 is placed on a first surface which corresponds to a Z-direction plus-side part of the fixed contact retainer 601.

A terminal arm portion 603 is a flat plate portion whose main plane is the XZ plane, which continued to a Y-direction minus-side second edge of the fixed terminal arm portion 600, and which curves to the minus side in the X direction.

It should be noted that the dimensions of the flat plate portions included in the first fixed terminal 61a are equal to those of the flat plate portions included in the first fixed terminal 41a in the first embodiment. For example, as illustrated in FIG. 10, a Y-direction width of a space between the fixed terminal main body 602 and the terminal arm portion 603 is equal to W1 illustrated in FIG. 6. On the other hand, an X-direction length L3a of the terminal arm portion 603 may be shorter than an X-direction length L3b of the fixed terminal main body 602, which is approximately equal to an X-direction length L4 of the fixed contact retainer 601. In addition, the shape of a second fixed terminal 61b is only symmetrical to that of the first fixed terminal 61a, like in the first embodiment.

FIG. 11 is a perspective view illustrating the internal configuration of the electromagnetic relay illustrated in FIG. 9, from which the first and second fixed terminals 61a, 61b are excluded for the explanation sake.

The basic shape of the fixed terminal retainer 62, inclusive of the dimensions of its various portions, is the same as that of the fixed terminal retainer 42 in the first embodiment. In this embodiment, too, a first side portion 62a₁includes terminal hole portions 62c, 62d formed therein to house at least parts of the terminal arm portions 603, respectively. Positions at which to place the terminal hole portions 62c, 62d are the same as the positions at which to place the terminal hole portions 42c, 42d in the first embodiment. Furthermore, a backstop hole portion which houses the backstop end portion 43d is formed in the first side portion 62a₁. A position at which to place the backstop hole portion is the same as the position at which to place the backstop hole portion 42e in the first embodiment.

One second side surface 62a₂of the fixed terminal fixation portion 62a comes into contact with an inner surface of the fixed terminal main body 602, or faces the inner surface of the fixed terminal main body 602 with a space in between, when the first fixed terminal 61a is combined with the fixed terminal fixation portion 62a. Thereby, as illustrated in FIG. 9, the second side surface 62a₂is covered with the fixed terminal main body 602 of the first fixed terminal 61a. This is the case with the other second side surface 62a₂as well.

Furthermore, the shape of a support 62b which continues to the fixed terminal fixation portion 62a, and which is combined with the flange 11 of the coil bobbin 23, is changed from the shape of the support 42b in the first embodiment, in accordance with the positions of the terminal portions 602a.

The positions at which to place the terminal portions 602a in this embodiment are different from that in the first embodiment. However, the basic shapes of the fixed terminals 61, the configuration of the backstop 43, and the like in this embodiment are not largely changed from those in the first embodiment. For this reason, this embodiment brings about the same effects as does the first embodiment.

Fourth Embodiment

Next, descriptions will be provided for an electromagnetic relay according to a fourth embodiment. In the third embodiment, the first and second fixed terminals 61a, 61b include their respective terminal arm portions 603, and are fixed to the fixed terminal fixation portion 62a by letting the terminal arm portions 603 housed into the terminal hole portions 62c, 62d formed in the fixed terminal fixation portion 62a. Here, the terminal hole portions 62c, 62d are adjacent to each other, and are placed in a Y-direction center area of the fixed terminal fixation portion 62a. In addition, the openings of the terminal hole portions 62c, 62d each have the shape which is elongated in the Z direction while matching the shape of the terminal arm portion 603. However, the present disclosure is not limited to these. The shapes of the terminal arm portions of the fixed terminals, and the shapes of the terminal hole portions in the fixed terminal fixation portion into which the terminal arm portions are housed may be further modified.

FIG. 12 is a perspective view illustrating an internal configuration of the electromagnetic relay according to the fourth embodiment. Incidentally, FIG. 12 corresponds to FIG. 9 which illustrates the internal configuration of the electromagnetic relay according to the third embodiment. In FIG. 12, the same components as those in the electromagnetic relay according to the third embodiment are denoted by the same reference signs. Descriptions for such components will be omitted. To put it specifically, the shapes of second terminal arm portions 703 of fixed terminals 71 and terminal hole portions 72c, 72d of a fixed terminal fixation portion 72a in the electromagnetic relay according to the fourth embodiment are different from those of the terminal arm portion 603 and the terminal hole portions 62c, 62d in the electromagnetic relay according to the third embodiment.

FIG. 13 is a view illustrating a shape of a first fixed terminal 71a. Incidentally, the drawings in FIG. 13 correspond to the drawings in FIG. 10 which illustrates the shape of the first fixed terminal 61a according to the third embodiment. Like the first fixed terminal 61a according to the third embodiment, the first fixed terminal 71a includes four flat plate portions. In the first fixed terminal 61a, the fixed terminal arm portion 600 includes the terminal arm portion 603 whose main plane is the XZ plane, and which continues to the Y-direction minus-side second edge of the fixed terminal arm portion 600. In contrast to this, a fixed terminal arm portion 700 of this embodiment includes a second terminal arm portion 703 instead of the terminal arm portion 603. The second terminal arm portion 703 is a flat plate portion whose main plane is an XY plane, and which curves from the lower edge of the fixed terminal arm portion 700 as a first side terminal portion to the minus side in the X direction. Incidentally, the dimensions of the flat plate portions included in the first fixed terminal 71a are the same as those of the flat plate portions included in the first fixed terminal 61a of the third embodiment.

FIG. 14 is a perspective view illustrating the internal configuration of the electromagnetic relay illustrated in FIG. 12, from which the first and second fixed terminals 71a, 71b are excluded for the explanation sake.

The basic shape of a fixed terminal retainer 72, inclusive of the dimensions of its various portions, is the same as that of the fixed terminal retainer 62 of the third embodiment. However, terminal hole portions 72c, 72d in which to house the second terminal arm portions 703 are adjacent to each other, and are placed in a Y-direction center area of a fixed terminal fixation portion 72a. In addition to this, the openings of the terminal hole portions 72c, 72d each have a shape which is elongated in the Y direction while matching the shape of the second terminal arm portion 703.

The shapes of the second terminal arm portions 703 and the terminal hole portions 72c, 72d in this embodiment are different from those in the third embodiment. However, the basic shapes of the fixed terminals 71, the configuration of the backstop 43, and the like in this embodiment are not largely changed from those in the first embodiment. For this reason, this embodiment brings about the same effects as does the first embodiment.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present teachings.

The entire contents of Japanese Patent Application No. 2016-242262 (filed on Dec. 14, 2016) and Japanese Patent Application No. 2017-200183 (filed on Oct. 16, 2017) are incorporated herein by reference.

Number	Date	Country	Kind
2016-242262	Dec 2016	JP	national
2017-200183	Oct 2017	JP	national

Electromagnetic relay

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

Field of Search

CPC

International Classifications

Term Extension

Abstract

Description

Claims

Priority Claims (2)

US Referenced Citations (1)

Foreign Referenced Citations (1)

Related Publications (1)