Electricity: magnetically operated switches – magnets – and electr – Electromagnetically actuated switches – Polarity-responsive
Utility Patent
1998-10-28
2001-01-02
Gellner, Michael L. (Department: 2832)
Electricity: magnetically operated switches, magnets, and electr
Electromagnetically actuated switches
Polarity-responsive
C335S080000, C335S202000, C335S203000, C335S261000, C335S275000, C335S299000
Utility Patent
active
06169469
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention relates to relays and, more particularly, to a subminiature relay made up by stacking generally plate-shaped component parts.
BACKGROUND ART
As a subminiature relay made up by stacking generally plate-shaped component parts, there has conventionally been a relay described in Japanese Patent Laid-Open Publication HEI 1-292725.
This relay is characterized by comprising a substrate which has two fitting holes and at least two print coil portions formed by printing into a generally spiral form around these fitting holes, an iron core which has a generally U-shaped cross section and which has both end portions fitted to the fitting holes so as to be protruded, respectively, and a movable contactor whose one end portion is fixedly secured to the projecting one end portion of the iron core and whose intermediate portion is placed so as to be contactable with and separable from the projecting other end portion of the iron core and moreover in which a movable contact provided at a free end portion of the movable contactor is contactably and separably opposed to a fixed contact provided on the substrate.
However, in this relay, because the iron core and the movable contactor must be assembled to the substrate in different directions, respectively, not only the positioning and assembling processes are time-consuming but also variations in accuracy of the assembling are more likely to occur. As a result, the relay is low in productivity and prone to variations in operating characteristics.
Also, because electrical conduction part and magnetic conduction part are constituted independently of each other, the relay is difficult to miniaturize.
Further, because the relay has a single contact, there is a problem that the contact reliability is low.
In view of these and other problems, an object of the present invention is therefore to provide a miniature relay which is high in contact reliability and productivity and which is free from variations in operating characteristics.
SUMMARY OF THE INVENTION
In order to achieve the above object, a first feature of the present invention exists in a relay comprising: a coil plate having at least one layer of spiral flat coil formed around each of a pair of holes and electrically connected to each other; and fixed contacts and movable contacts which are opposed to each other contactably and separably via the respective holes in the coil plate, wherein the fixed contacts are provided on one side of each of a pair of flat core blocks juxtaposed and insulated from one another, while the movable contacts are provided on one movable contactor which is supported so as to be drivable along a direction of plate thickness via at least one hinge portion extending from a support member for a movable contact plate.
According to the first feature of the present invention, since the movable contactor makes contact with the two fixed contacts, the relay becomes the so-called double break contact type. Moreover, since these contacts operate on magnetic force caused by the flat coils formed around the respective contacts, each contact force is stable and the contact reliability is improved.
Also, since the relay has a layer structure that the flat core block, the coil plate and the movable contact plate are stacked one on another, the relay is easy to assemble and high in assembling accuracy. As a result, a thin, miniature relay which is high in productivity and free from variations in operating characteristics can be obtained.
In particular, since the magnetic conduction part is shared by the electrical conduction part, the number of component parts and the number of assembling man-hours are small so that even higher productivity results.
Further, since a pair of flat core blocks are juxtaposed in an insulated state, the so-called double break contact is constituted. As a result, the contact-to-contact distance becomes substantially long, so that a relay excellent in insulating characteristic can be obtained.
A second feature of the present invention is that the fixed contacts are placed at fore end portions of iron cores which are of protrusions, also insertable into the holes in the coil plate. Also, a third feature is that the movable contacts are placed at fore end portions of protrusions protrusively provided on one side of the movable contactor and which are also insertable into the holes in the coil plate.
According to the second and third features of the present invention, since both the movable contact and the fixed contact are placed at fore ends of the protruding portions, magnetic fluxes are concentrated so that a relay of high magnetic efficiency can be obtained.
A fourth feature is that the flat core block is electrically connected to a connecting end portion of a contact terminal exposed from a bottom face of a box-shaped base.
According to the fourth feature, since the flat core blocks are electrically connected to the connecting terminals of the contact terminals exposed from the bottom face of the box-shaped base, the assembling work is not time-consuming and the productivity is high.
A fifth feature is that in the movable contact plate, a slit of a roughly C-like planar shape is provided in a thin plate made of an electrically conductive magnetic material, whereby a hinge portion is formed and whereby the annular support member and the movable contactor are partitioned from each other.
According to the fifth feature, since the movable contact plate is formed of a thin plate comprising one electrically conductive magnetic material, a relay low in unit price of component parts and high in parts accuracy and assembling accuracy can be obtained.
A sixth feature is that the movable contact plate is fitted to an annular step portion formed at an opening edge portion of the box-shaped base.
According to the sixth feature, since the movable contact plate is fitted and assembled to the annular step portion formed at the opening edge portion of the base, the assembling work of the movable contact plate becomes easier.
A seventh feature is that the flat core block is fixed in close contact to an insulating film provided on a lower surface of the coil plate, while the support member for the movable contact plate is fixed in close contact to an insulating film provided on an upper surface of the coil plate.
According to the seventh feature, since the flat core block and the movable contact plate are make close contact with the coil plate, an even thinner type relay can be obtained.
An eighth feature is that a pair of flat core blocks electrically connected to connecting end portions of a pair of contact terminals cut out from a lead frame are integrally molded with the base. Also, a ninth feature is that both a pair of flat core blocks electrically connected to connecting end portions of a pair of contact terminals cut out from a lead frame, and a coil plate electrically connected to connecting end portions of a pair of coil terminals cut out from the lead frame are integrally molded with the base.
According to the eighth and ninth features, since the flat core block and the coil plate connected via the lead frame can be integrally molded with the base, continuous production of the relay is enabled, offering an advantage that the productivity is remarkably improved.
A tenth feature exists in a relay comprising: a coil plate having at least one layer of spiral flat coil formed around each of a pair of holes and electrically connected to each other; and fixed contacts and movable contacts which are opposed to each other contactably and separably via the respective holes in the coil plate, wherein the fixed contacts are provided on one side of one flat core block, while the movable contacts are provided on one movable contactor which is supported so as to be drivable along a direction of plate thickness via at least one hinge portion extending from a support member for a movable contact plate.
According to the tenth feature, since the movable contactor makes contact with the two fixed contacts, the relay becomes
Kawai Mitsuhiro
Misumi Shuichi
Yamada Takaaki
Barrera Raymond
Gellner Michael L.
Morrison & Foerster / LLP
Omron Corporation
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