1. Field of the Invention
The present invention relates to an electromagnetic relay, and, more specifically, it relates to an electromagnetic relay having a sealed contact mechanism.
2. Description of the Related Art
Hitherto, a sealed relay apparatus disclosed in JP-T-9-510040 is one of switching apparatus for breaking direct current.
In other words, a plunger 9 touches and leaves a core center 4 based on excitation and demagnetization of coils 26 in a hollow cavity 40 so that an armature assembly 8 and armature shaft 10 integrated with the plunger 9 can slide toward the shaft center. Thus, a movable contact disk 21 touches and leaves fixed contacts 22 and 22.
However, the sealed relay apparatus has a problem that impact noise is caused when the plunger 9 touches the core center 4 and cannot be absorbed and mitigated, which is noisy.
The invention was made in view of the problem, and it is an object of the present invention to provide a silent electromagnetic relay, which can absorb and mitigate impact noise in switching contacts.
In order to achieve the object, an electromagnetic relay according to the invention includes an electromagnet block having coils wound about the bodies of spools through which iron cores are provided. The electromagnet block is accommodated in a concave part that opens upward of a box-shaped case such that the shaft centers of the iron cores can be orthogonal to the bottom surface of the box-shaped case. The electromagnet block is excited and demagnetized by the passage and break of electric current through the coils so that a contact mechanism can be driven by a movable iron piece that is absorbed to and leaves by magnetic pole portions at the upper ends of the iron cores. In this case, the electromagnet block is hung at the upper opening edge of the box-shaped case such that a space can be provided between the bottom surface of the box-shaped case and the electromagnet block.
According to the invention, an electromagnet block is hung at the upper opening edge of the box-shaped case, and the electromagnet block and the bottom surface of the box-shaped case do not directly touch each other. Thus, when the movable iron piece is abutted to the magnetic pole portions of the iron cores in driving the contact mechanism, vibration noise, which travels through a solid, does not travel from the iron cores to the bottom surface of the case directly. Therefore, a silent electromagnetic relay can be provided.
As an aspect of the invention, the electromagnet block may be hung at the upper opening edge of the box-shaped case through coil terminals at collars of the spools.
According to this aspect, when the movable iron piece is abutted to the magnetic pole portions of the iron cores, the coil terminals at the collars of the spools are elastically deformed so that the occurrence of traveling impact noise can be suppressed and a more silent electromagnetic relay having the advantage and the above-described advantages can be provided.
As another aspect of the invention, a sound-absorbing elastic material that absorbs and mitigates impact noise may be filled in the space between the bottom surface of the box-shaped case and the electromagnet block.
According to the aspect, a sound-absorbing elastic material can absorb vibration noise, which is caused when the movable iron piece is abutted to the magnetic pole portions of the iron cores and travels through a solid, and a much more silent electromagnetic relay can be provided.
As another aspect of the invention, the electromagnet block may have a pair of aligned iron cores connected by a yoke spanned across the lower ends of the iron cores.
According to the aspect, the traveling of vibration noise, which travels through a solid, can be suppressed since the yoke spanned across the lower ends of the iron cores is not directly abutted to the bottom surface of the box-shaped case. Thus, a silent electromagnetic relay can be provided.
An embodiment according to the invention will be described with reference to
This embodiment is a case that the invention is applied to a direct current load switching relay, and, as shown in
As shown in
The box cover 15 has a form that can be fitted into the box case 10 and can accommodate a sealing case block 40, which will be described later. Furthermore, the ceiling surface of the box cover 15 has connecting holes 16 and 16 through which the connecting terminals 75 and 85, which will be described later, of the relay body 20 project. Furthermore, projections 17 and 17, which can accommodate a venting pipe 21, project from the ceiling surface of the box cover 15. The projections 17 and 17 are connected through a partition 18, and they also function as an insulating wall. Associating holes 19 at the lower opening edges of the box cover 15 are associated with associating nails 14 at the upper opening edges of the box case 10 so that both of them can be bonded and integrated.
As shown in
As shown in
Relay terminals 34 and 35 are press-fitted from the sides to facing both end faces of lower collars 32a among collars 32a and 32b at both upper and lower ends of the spools 32. Moreover, one end of each of the coils 31 wound about the spools 32 is wound about and soldered to one end (winding portion) 34a of the one relay terminal 34 while the other end is wound about and soldered to one end (winding portion) 35a of the other relay terminal 35. The relay terminals 34 and 35 bend and raise the winding portion 34a as well as the other end (connecting portion) 35b. Then, between the relay terminals 34 and 35 assembled to the aligned spools 32 and 32, the connecting portion 35b of the one relay terminal 35 and the winding portion 34a of the other relay terminal 34 are joined adjacently and soldered to each other. Furthermore, the winding portion 35a of the one relay terminal 35 and the connecting portion 34b of the other relay terminal 34 are adjacently joined and soldered to each other. Thus, the two coils 31 and 31 are connected to each other. Then, coil terminals 36 and 36 are spanned across the upper and lower collars 32a and 32b of the spools 32 and are connected to the connecting portions 34b and 35b of the relay terminals 34 and 35 (see
The sealing case block 40 includes a sealing case 41 and a sealing cover 45. The sealing case 41 can accommodate the contact mechanism block 50, which will be described later. The sealing cover 45 seals an opening part of the sealing case 41. The bottom surface of the sealing case 41 has a pair of press-fit holes 42 into which iron cores 37 can be press-fitted (see
The electromagnet block 30 and the sealing case 40 can be assembled by following steps.
First of all, the relay terminals 34 and 35 are press-fitted into the one pair of collars 32a of the spool 32. Then, the coils 31 are wound about the spools 32, and the lead lines are wound about and soldered to the winding portions 34a and 35a of the relay terminals 34 and 35. Next, the spools 32 are aligned which bend and raise the winding portions 34a and 35a and connecting portions 34b and 35b of the relay terminals 34 and 35. Then, the winding portion 35a of the adjacent relay terminal 35 and the connecting portion 34b of the other relay terminal 34 are adjacently joined and soldered to each other. Furthermore, the connecting portion 35b of the adjacent relay terminal 35 and the winding portion 34a of the other relay terminal 34 are adjacently joined and soldered to each other. Thus, the coils 31 and 31 can be connected to each other.
On the other hand, as shown in
Since the sealing case 41 is made of a material having a higher thermal expansion coefficient, such as aluminum, than those of the iron cores 37 and pipes 38 according to this embodiment, the hermeticity is not deteriorated even at different temperatures, which is an advantage.
This is because the sealing case 41 is held between the heads 37c of the iron cores 37 and the pipes 38 more strongly even when a temperature increases and the parts expand since the expansion of the sealing case 41 in the thick direction is relatively larger than those of the other parts. This is also because the lower necks 37b of the iron cores 37 are fastened even when a temperature decreases and the parts contract since, on the other hand, the contraction of the press-fit holes 42 in the sealing case 41 is relatively larger than those of the other parts. Notably, in order to prevent the occurrence of thermal stress with the hermeticity maintained, the iron cores 37 and the pipes 38 preferably have thermal expansion coefficients, which are substantially equal.
When the sealing case 41 is made of aluminum, which is readily machinable, the sealing work can be performed easily, and hydrogen does not easily permeate therethrough, which is another advantages.
Furthermore, since the bottom surface of the sealing case 41 has a slit 43 according to this embodiment, the occurrence of eddy current can be prevented even when any changes occur in magnetic fluxes of the iron cores 37 as shown in
The occurrence of eddy current can be prevented not only by providing the slit 43 connecting the press-fit holes 42 and 42 as described above but also, for example, by providing at least one notch part around each of the press-fit holes 42 and 42 with the notch parts not connected to each other. Parts around the press-fit holes 42 of the bottom surface of the sealing case 41 may have concaves and convexes having different thickness to increase electrical resistance so that the occurrence of eddy current can be suppressed.
Then, as shown in
Next, the coil terminals 36 are spanned across the upper and lower collars 32a and 32b of the spools 32, respectively, and the lower ends of the coil terminals 36 are connected to the connecting portions 34b and 35b of the relay terminals 34 and 35 so that the work of assembling the electromagnet block 30 and the sealing case 41 can be finished. Then, a sealant 98 is injected and hardened on the bottom surface of the sealing case 41 and seals the slit 43 thereby. The sealant 98 contains alumina powder in an epoxy resin and has a linear expansion coefficient, which is substantially equal to that of aluminum when hardened.
As shown in
As shown in
The movable insulating base 61 has deep grooves 61b and 61b on both sides of a guide projection 61a that projects from the top surface at the center of the movable insulating base 61. The deep grooves 61b and 61b can accommodate the coil springs 63 not to fall off. Furthermore, the movable insulating base 61 has a foot 61 projecting from the center of the lower surface of the movable insulating base 61 and has concaves 61d and 61d (where the concave 61d at the back is not shown) in the ceiling surface on both sides of the movable insulating base 61. The foot 61c has a section in a substantially cross form. The concaves 61d and 61d position the return coil springs 65.
The movable contact piece 62 is a thick, band-shaped conductive material having half-round ends and has a guiding long hole 62a at the center. On the other hand, the coil springs 63 give contact pressure to the movable contact piece 62 and forces the movable contact piece 62 downward at all times.
Therefore, in order to assemble the movable contact block 60, the guiding long hole 62a in the movable contact piece 62 is fitted to the guiding projection 61a of the movable insulating base 61 first. Then, the pair of coil springs 63 and 63 is fitted to the deep grooves 61b and 61b and is positioned by mounting the lock 64 thereto. Furthermore, the rivets 68 and 68 extending through the crimp holes 66a in the movable iron piece 66 and through the crimp holes 67a in the magnet-shielding plate 67 are inserted into the return coil springs 65 and 65 positioned at the concaves 61d and 61d in the movable insulating base 61. Then, the rivets 68 through the crimp holes 61e and 61e in the movable insulating base 61 and the crimp holes 64a in the lock 64 are crimped and integrated so that the assembly work can be completed. According to this embodiment, the movable contact piece 62 is always forced downward by spring force of the coil springs 63 and does not shake.
As shown in
The fixed contact bases 71 and 81 have butt projections 72 and 73 and 82 and 83 at the upper and lower edges of facing surfaces. Especially, the projections 72 and 73 and 82 and 83 have fit projections 71a and 81a, which can be fitted to each other, and holes 71b and 81b in the distal surfaces. Furthermore, as shown in
As shown in
As shown in
Next, steps of assembling the contact mechanism block 50 will be described.
First of all, the fixed contact blocks 70 and 80 are assembled thereto from both sides of the movable insulating base 61 with the lower ends of the return springs 65 of the mounted movable contact block 60 lifted, and the hole 81b and projection 81a of the butt projections 82 and 83 are fitted to and butted against the projection 71a and hole 71b of the butt projections 72 and 73. Thus, the fixed contact bases 71 and 81 can have operating holes 51 and 52 therebetween. Furthermore, the insulating case 90 is fitted to the fixed contact blocks 70 and 80 so that the connecting terminals 75 and 85 can project from the terminal holes 91 and 91, respectively, and the contact mechanism block 50 can be finished. Here, the venting holes 92 and 92 and the operating holes 51 and 52 are coaxially positioned and communicated (see
Next, when the contact mechanism block 50 is inserted to the sealing case 41 mounted to the electromagnet block 30 (see
According to this embodiment, one of the venting holes 92 can be sealed by the venting pipe 21, and the other venting hole 92 is covered by the sealing cover 45. Thus, even when the sealant 99 is injected thereto, the sealant 99 does not invade into the insulating case 90. Furthermore, since the free-fit hole 47 into which the pipe 21 is to be inserted is evenly away from the connecting terminals 75 and 85, a good insulation characteristic can be advantageously attained.
Next, a liquid elastic material 97 containing an urethane resin is injected on the bottom surface of the concave part 11 of the case 10, and the relay body 20 is accommodated in the concave part 11. The coil terminals 36 are positioned at the connecting concaves 13, and the liquid elastic material 97 is hardened with the relay body 20 hung within the case 10. Then, the cover 15 is assembled to the case 10 so that the direct current breaking relay can be finished. While, according to this embodiment, the injected and hardened liquid elastic material 97 serves as a noise-absorbing elastic material, the invention is not always limited thereto. An elastic sheet may be used as a sound-absorbing elastic material. Alternatively, the collar 32b of the spool 32 may be extended and hung within the concave part 11 of the case 10.
Next, a relay operation in the above-described construction will be described.
First of all, when voltage is not applied to the coils 31 of the electromagnet block 30, the movable insulating base 61 can be pressed up by spring force of the return springs 65 and 65 (see
Then, when voltage is applied to the coils 31, the magnetic pole portions 37c of the iron cores 37 attracts the movable iron piece 66, and the movable iron piece 67 falls down against spring force of the return springs 65. Thus, after the movable insulating base 61 integrated to the movable iron piece 66 falls down and both ends of the movable contact pieces 62 touch the fixed contacts portions 78 and 88, the movable iron piece 66 is absorbed to the magnetic pole portions 37c of the iron cores 37.
According to this embodiment, the hardened liquid elastic materials 97 and the coil terminals 36 absorb and mitigate an impact force caused when the movable iron piece 66 abuts to the magnetic pole portions 37c of the iron cores 37, and the occurrence of impact noise can be suppressed. Thus, a silent electromagnetic relay can be advantageously provided.
Next, when the application of voltage to the coils 31 is stopped, the movable insulating base 61 is pressed up by spring forces of the return springs 65. Then, after the movable iron piece 66 integrated to the movable insulating base 61 leaves the magnetic pole portions 37c of the iron cores 37, both ends of the movable contact piece 63 leaves the fixed contact portions 78 and 88.
When both ends of the movable contact piece 62 touch and leave the fixed contact portions 78 and 88, the contact flying powder flies toward the inner surfaces of the fixed contact bases 71 and 81. However, since, according to this embodiment, the inner surfaces of the fixed contact bases 71 and 81 indicated by solid lines in
When both ends of the movable contact piece 62 leaves the fixed contact portions 78 and 88, arc current 100 is generated from the fixed contact portion 78 and is extended as shown in
In other words, as shown in
This embodiment is the case for breaking direct current, but the invention is not limited thereto. The invention may be applied to a case for breaking alternate current.
The invention is not limited to the above-described electromagnetic relay but is apparently applicable to other electromagnetic relays.
Number | Date | Country | Kind |
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P2003-425012 | Dec 2003 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
3238329 | Russo | Mar 1966 | A |
5519370 | Perreira et al. | May 1996 | A |
5680083 | Kogawa et al. | Oct 1997 | A |
20040066261 | Nishida et al. | Apr 2004 | A1 |
Number | Date | Country |
---|---|---|
9-510040 | Oct 1997 | JP |
WO 9524051 | Sep 1995 | WO |
Number | Date | Country | |
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20050151606 A1 | Jul 2005 | US |