Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-01-11
2001-08-14
Shoap, Allan N. (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S622000, C029S606000, C029S827000, C335S080000, C335S083000, C335S152000, C264S272190, C264S272200
Reexamination Certificate
active
06272734
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to a method for producing an electromagnetic relay having
a coil through which a core passes and which has a winding and connecting pins, the core forming pole plates at both ends outside the coil,
an armature which bridges the pole plates forming air gaps, and
a contact arrangement having a contact spring which is operated by the armature and having at least one fixed contact element which interacts with the contact spring.
EP 0 531 890 A1 describes a switching relay as well as a method for its production, the relay elements being arranged in the manner mentioned above in a twopart housing. There, the two housing parts in fact do not form a closed housing, but merely a base which is preferably a printed circuit board with an integrally formed side wall and a cover part, between which a housing gap remains open even after the parts have been joined together. The relay there is preferably designed as a multiple relay with a row of magnet systems located alongside one another, a common core pole plate resting on the base and forming a row of vertically projecting core sections, onto each of which a coil is fitted. Each system also has a U-shaped armature, which is mounted on the core pole plate and, with the contact spring, encloses the coil like a frame. The cover part has slits with mating contact elements and spring supports inserted therein, and these slits are likewise not sealed. In general in the case of the relay there, a conventional manufacturing technique is used, the individual elements subsequently being mounted on one or the other housing part by plugging-on, riveting or in a similar way.
SUMMARY OF THE INVENTION
The aim of the present invention is cost-effective production of relays of the type mentioned initially for different sizes and applications. The aim in this case is to achieve high manufacturing accuracy for the mechanical relay characteristics without any specific operation being required for adjustment.
This aim is achieved according to the invention by a method which comprises the following steps:
the coil which is provided with the core is embedded in plastic with its connecting pins forming a first housing half-shell,
a spring support for the contact spring and at least one fixed contact element are embedded in plastic forming a second housing half-shell,
the armature is inserted into one of the two half-shells, and
the two half-shells are connected by their edges such that they rest on one another forming a seal.
The production of the relay housing, which is envisaged according to the invention, in the form of two plastic half-shells in which the functional elements are anchored by embedding, results not only in all the parts being accurately fixed in position, but at the same time also results in a simple and effective sealing of the housing, since the connecting elements of the relay are sealed in tight just by the embedding process, and the edges of the two half-shells just rest on one another in the form of plastic surfaces which can easily be sealed. All the parts are preferably produced and joined to one another by an injection-molding assembly. This results in a high level of manufacturing accuracy, since the accurate injection mold governs the position tolerance of the individual parts. These individual parts are preferably manufactured from flat sheet-metal strips and are extrusion coated successively or simultaneously. This injection-molding assembly is particularly well suited to manufacture by means of the cyclic extrusion coating of parts which are attached to the strip, by which means large quantities can be produced in a correspondingly cost-effective manner.
Refinements and developments of this general production method are specified in the dependent claims.
The invention will be explained in more detail in the following text using exemplary embodiments.
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Schiff & Hardin & Waite
Shoap Allan N.
Tugbang A. Dexter
Tyco Electronics Logistics AG
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