# Patent

## Title
Electromagnetic relay

## Abstract

An electromagnetic relay includes a contact part including a fixed contact and a movable contact, and a drive part including a fixed core and a movable core. The movable core is connected to the movable contact via an axial core. The fixed core includes a plate member, which is positioned between the contact part and the drive part and includes a through hole through which the axial core is inserted. The movable core includes a convex part protruding in a direction opposing the plate member. The plate member includes a concave part opposing the convex part and having a shape corresponding to the convex part.

## Background
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electromagnetic relay.
2. Description of the Related Art
In electromagnetic relays, passage and blockage of a current in an electric circuit is realized by opening/closing a contact part including a fixed contact and a movable contact. A drive unit for moving the movable contact of the contact part toward and away from the fixed contact includes a fixed core and a movable core. The fixed core includes a cylindrical fixed core part that is arranged opposite the movable core. In order to adjust the attraction force and optimize operating characteristics, the side of the movable core opposing the cylindrical fixed core part is arranged into a conical shape, and the side of the cylindrical fixed core part opposing the movable core is arranged to have a stepped hole corresponding to the conical shape of the movable core (See e.g. Japanese Patent No. 4840533).
In the electromagnetic relay disclosed in Japanese Patent No. 4840533, for example, the cylindrical fixed core part is arranged to have a stepped hole corresponding to the conical shape of the movable core. Thus, the cylindrical fixed core part constitutes one part of the fixed core, and as a result, the number of components is increased and manufacturing costs are increased.
In light of the above, there is a demand for an electromagnetic relay that is capable of optimizing operating characteristics without causing a cost increase.
SUMMARY OF THE INVENTION
According to one embodiment of the present invention, an electromagnetic relay is provided that includes a contact part including a fixed contact and a movable contact, and a drive part including a fixed core and a movable core. The movable core is connected to the movable contact via an axial core. The fixed core includes a plate member, which is positioned between the contact part and the drive part and includes a through hole through which the axial core is inserted. The movable core includes a convex part protruding in a direction opposing the plate member. The plate member includes a concave part opposing the convex part and having a shape corresponding to the convex part.
According to another embodiment of the present invention, an electromagnetic relay is provided that includes a contact part including a fixed contact and a movable contact, and a drive part including a fixed core and a movable core. The movable core is connected to the movable contact via an axial core. The fixed core includes a plate member, which is positioned between the contact part and the drive part and includes a through hole through which the axial core is inserted. The movable core includes a concave part opposing the plate member. The plate member includes a convex part opposing the concave part.
According to an aspect of the present invention, operating characteristics may be optimized while preventing an increase in the number of components of the fixed core and avoiding a cost increase.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of an electromagnetic relay according to an embodiment of the present invention along a central axis line of a shaft;
FIG. 2 is a perspective view of a convex part of a plunger of the electromagnetic relay according to an embodiment of the present invention;
FIG. 3 is a perspective view of a concave part of a yoke of the electromagnetic relay according to an embodiment of the present invention;
FIG. 4 schematically illustrates a concave part of the plunger, a convex part of the yoke, and a backside concave part of the yoke of the electromagnetic relay according to an embodiment of the present invention;
FIG. 5 is an external perspective view of the electromagnetic relay according to an embodiment of the present invention;
FIG. 6 schematically illustrates a fixed contact and a movable contact of the electromagnetic relay according to an embodiment of the present invention;
FIG. 7 is a graph illustrating stroke and attraction force characteristics of the electromagnetic relay according to an embodiment of the present invention;
FIG. 8 schematically illustrates a convex part of the plunger, a concave part of the yoke, and a backside convex part of the yoke of the electromagnetic relay according to an embodiment of the present invention;
FIG. 9 schematically illustrates an arc-extinguishing grid arranged in the electromagnetic relay according to an embodiment of the present invention;
FIG. 10 schematically illustrates an arc runner arranged in the electromagnetic relay according to an embodiment of the present invention;
FIG. 11 schematically illustrates extension parts of the yoke holding permanent magnets in the electromagnetic relay according to an embodiment of the present invention;
FIG. 12 schematically illustrates a sloped surface and a flat surface of a connection housing in the electromagnetic relay according to an embodiment of the present invention; and
FIG. 13 schematically illustrates the connection housing in a case where the yoke includes a backside convex part in the electromagnetic relay according to an embodiment of the present invention.



DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following, embodiments of the present invention will be described with reference to the accompanying drawings.
As illustrated in FIG. 1, an electromagnetic relay 1 according to an embodiment of the present invention includes a contact part including a pair of fixed contacts 2 and a pair of movable contacts 3 each corresponding to one of the fixed contacts 2. The movable contacts 3 are displaceable in directions toward and away from the fixed contacts 2. The electromagnetic relay 1 also includes a movable element 4 that holds the pair of movable contacts 3. The movable element 4 is configured to be movable in the directions toward and away from the fixed contacts 2. The electromagnetic relay 1 further includes a shaft 5 (axial core) and a plunger 6 (movable core). The shaft 5 is connected to the movable element 4. The plunger 6 is connected to the shaft 5 and is displaceable. Note that in the following descriptions, with respect to the displacement directions of the movable element 4, a moving direction of the movable contact 3 moving closer to the fixed contact 2; namely, the moving direction of the movable contact 3 toward the fixed contact 2 is referred to as “approaching direction”, and a moving direction of the movable contact 3 moving away from the fixed contact 2 or the direction opposite the approaching direction is referred to as “separating direction”.
The electromagnetic relay 1 further includes a drive part 7 configured to drive the plunger 6 in the approaching direction (upward direction in FIG. 1), a return spring 8 configured urge the shaft 5 in the separating direction (downward direction in FIG. 1), and a pressure spring 9 configured to urge the movable element 4 in the approaching direction.
As illustrated in FIG. 1, the drive part 7 includes a yoke 10 (second plate member), a yoke 11, and a yoke 12 (first plate member) as magnetic members making up a fixed core. The drive part 7 also includes an insulation barrier 14 for securing insulation between the yoke 10 and a coil 13. The yoke 10 is formed by bending one piece of plate member into a U-shaped configuration. The yokes 10-12 are yoke components of a magnetic circuit. The electromagnetic relay 1 also includes a reel-shaped bobbin 15 to which the coil 13 is wound. The bobbin 15 and the insulation barrier 14 may be made of synthetic resin, for example.
The electromagnetic relay 1 of the present embodiment includes a drive part housing 16, a contact part housing 17, and a connection housing 18, as illustrated in FIG. 1. The drive part housing 16 may be made of molded resin, for example. The drive part housing 16 may be arranged into a box structure having a bottom to accommodate the drive part 7 described above. The connection housing 18 and the contact part housing 17 may also be made of molded resin, for example.
A substantially cylindrical protruding part 16a is arranged at the bottom of the drive part housing 16, and a hole 10a with a diameter greater than the diameter of the protruding part 16a is formed at the bottom of the yoke 10. Also, the yoke 10 has a notch 10b for engaging the yoke 12, and a pair of extension parts 10c that extend toward the contact part from the yoke 12 upon being assembled. The pair of extension parts 10c holds a corresponding pair of plate-shaped permanent magnets 19 by magnetic force. The permanent magnets 19 are polarized in directions perpendicular to the approaching/separating directions of the contact part.
As illustrated in FIG. 2, the plunger 6 has convex part 6a with a truncated cone configuration arranged at a side facing the yoke 12. As illustrated in FIG. 3, the yoke 12 has a concave part 12a corresponding to the shape of the convex part 6a. A through hole 121 through which the shaft 5 is inserted is formed at the center of the concave part 12a. Also, as illustrated in FIG. 3, the yoke 12 has an engagement piece 12b for engaging the notch 10b of the yoke 10. Note that in an alternative embodiment, the concave and convex configurations of the plunger 6 and the yoke 12 may be reversed as illustrated in FIG. 4. That is, the plunger 6 may have a concave part 6aa and the yoke 12 may have a convex part 12aa, for example. Note that the convex part 6a or the concave part 6aa of the plunger 6 may be formed through a cutting operation, for example. Also, the concave part 12a or the convex part 12aa may be formed by pressing the yoke 12, for example.
When the yoke 10 and the yoke 11 are mounted to the drive part housing 16, the protruding part 16a penetrates through the hole 10a and is inserted into the inner peripheral side of the yoke 11. The yoke 11 is arranged into a cylindrical shape and is positioned by the protruding part 16a. The yoke 10 is held between and positioned by the side walls of the drive part housing 16.
After mounting the yokes 10 and 11, the bobbin 15 having the insulation barrier 14 attached thereto is inserted into the drive part housing 16 from the upper side, and an assembly of the plunger 6 and the shaft 5 is inserted into the yoke 11. Then, the engagement piece 12b is inserted into the notch 10b of the yoke 10 so that the yoke 12 may be positioned at the top, and the shaft 5 is inserted through the through hole 121 to assemble the drive part 7. Further, the connection housing 18 corresponding to a plate including a configuration for enabling engagement with the contact part housing 17 is mounted on top of the yoke 12.
Further, the upper side of the shaft 5 is inserted through the pressure spring 9 and is fit into a hole 4a of the movable element 4. Also, an end part of the shaft 5 that protrudes from the upper side of the movable element 4 is inserted into the return spring 8 so that a separating direction side end (lower end in FIG. 1) of the return spring 8 comes into contact with the upper face of the movable element 4.
The contact part housing 17 is configured to fix in place a pair of substantially cylindrical fixed terminals 21 having the fixed contacts 2 arranged at their ends. The contact part housing 17 is inserted from the opening of the drive part housing 16 and is fit into the drive part housing 16. In this way, the contact part housing 17 arranges the fixed contacts 2 to face the movable contacts 3. Further, the contact part housing 17 includes a hole 17a for holding and fixing in place an approaching direction side end (upper end) of the return spring 8. The contact part housing 17 holds the outer faces of the extension parts 10c and the inner faces of the permanent magnets 19. Further, engaging portions of the contact part housing 17 may be bonded, welded, or brazed to the drive part housing 16 after which a sealing process may be conducted as is necessary.
FIG. 5 illustrates an exemplary external view of the electromagnetic relay 1 after being assembled in the above-described manner. In FIG. 5, two terminals S1 and S2 for inserting the electromagnetic relay 1 of the present embodiment into a DC circuit are exposed from the contact part housing 17.
Note that the fixed terminals 21 each correspond to one of the fixed contacts 2. The fixed contacts 2 are arranged at the separating direction side ends (lower ends in FIG. 1) of the fixed terminals 21 at positions facing opposite the movable contacts 3. In the present embodiment, the fixed contacts 2 and the movable contacts 3 are both arranged to have spherical curvature surfaces such that their points of contact are limited to their centers as illustrated in FIG. 6. The fixed contacts 2 and the movable contacts 3 may both be made of a copper-based material or a precious metal material, for example. The movable element 4 is arranged into a plate shape extending in the radial directions of the shaft 5, and the movable contacts 3 are arranged at side ends of the plate-shaped movable element 4.
As described above, the electromagnetic relay 1 according to the present embodiment is a plunger type relay having a pair of contacts arranged at the left and right hand sides. In the present embodiment, the fixed terminals 21 arranged at the left and right hand sides as illustrated in FIG. 1 are inserted at corresponding locations of a DC circuit that is to be connected/disconnected. A terminal part of the coil 13 of the drive unit 7 may be connected to an input/output (I/O) interface of a PWM control circuit (not shown), for example, and in this way, an excitation current applied to the terminal part of the coil 13 may be controlled as desired.
In a state where no excitation current is applied to the terminal part of the coil 13, the shaft 5 is urged toward the lower side of FIG. 1 by an urging force of the return spring 8 such that the fixed contact 2 and the movable contact 3 transition to an open state or are maintained in the open state. In the state illustrated in FIG. 1, the shaft 5 pushes the plunger 6 from the upper side toward the lower side of FIG. 1 by the urging force of the return spring 8 such that the bottom part of the plunger 6 is held in contact with the protruding part 16a of the drive part housing 16.
When an excitation current is applied to the terminal part of the coil 13, the coil 13 and the yokes 10-12 generate an attraction force that draws the plunger 6 toward the upper side of FIG. 1, and as a result, the plunger 6 is pushed toward the upper side causing the shaft 5 and the movable element 4 to move toward the upper side. In this way, the movable contact 3 may come into contact with the fixed contact 2 to thereby transition to a closed state, or the closed state of the movable contact 3 and the fixed contact 2 may be maintained in such a state.
If an arc occurs during the opening and closing operations of the contacts, the arc is blown away in the direction in which a Lorentz force acts, such direction being determined based on the direction of the current flowing in the approaching/separating directions as described above and the polarity direction of the permanent magnets 19. In the present embodiment, the direction in which the Lorentz force acts corresponds to the parallel alignment direction of the contacts and a direction perpendicular to the polarity direction of the permanent magnets 19.
As illustrated in FIG. 7, the stroke and attraction force characteristics of the movable core (plunger) may vary depending on the configuration of the convex part of the movable core. That is, the above characteristics may vary depending on whether the truncated cone configuration of the convex part of the movable core is arranged into an obtuse cone, whether the convex part of the movable core is arranged into an acute cone with a smaller top surface and a larger side surface compared to the obtuse cone (i.e., closer to a triangle in side view), or whether the movable core has no convex part and is arranged to be flat. As can be appreciated from FIG. 7, when the movable core has a convex part that is arranged into an obtuse cone or an acute cone configuration, the attraction force is smaller in a lower stroke region compared to the case where the movable core is flat. Also, with respect to the spring load characteristics illustrated in FIG. 7, the movable core with the obtuse cone configuration has a higher load following capability compared to the movable core with the acute cone configuration in a high stroke region, and the movable core with the acute cone configuration has a higher load following capability compared to the movable core with the obtuse cone configuration in the low stroke region. Note that the above principle similarly applies to a case where the movable core is arranged to have a concave part and the yoke 12 is arranged to have a convex part.
In the electromagnetic relay 1 according to the present embodiment, the attraction force with respect to the stroke may be adjusted by adjusting the ratio of the side surface to the top surface of the truncated cone configuration of the convex part 6a or the concave part 12a. That is, in the electromagnetic relay 1 according to the present embodiment, the fixed core does not need to have a cylindrical fixed core part corresponding to the convex part 6a of the plunger 6. In this way, operating characteristics may be optimized while reducing the number of components and reducing costs, for example.
Note that in the case where the plunger 6 has the concave part 6aa and the yoke 12 has the convex part 12aa as illustrated in FIG. 4, a backside concave part 12ca may be arranged at the backside of the convex part 12aa so that the depths of the convex part 12aa and the concave part 6aa in the stroke direction may be increased. In this way, greater flexibility may be provided in optimizing the operating characteristics of the electromagnetic relay 1 of the present embodiment, for example. Similarly, in the case where the plunger 6 has the convex part 6a and the yoke 12 has the concave part 12a, a backside convex part 12cb may be arranged at the backside of the concave part 12a as illustrated in FIG. 8.
As illustrated in FIG. 9, in certain embodiments, an arc extinguishing grid 22 including a plurality of flat plates made of ferrous material stacked on each other may be arranged according to the direction of the Lorentz force in the electromagnetic relay 1, for example. In this way, an arc may be divided up and absorbed by the plurality of plates to realize arc extinction. Also, as illustrated in FIG. 10, a horn-shaped arc runner 23 made of a copper-based material, for example, may be arranged in the electromagnetic relay 1, and arc extinction may be performed by gradually increasing the spatial distance of the arc, for example.
Note that in the above embodiment, to have the fixed core hold the permanent magnets 19, the extension parts 10c extending from the yoke 10 are arranged to hold the permanent magnets 19. However, in other embodiments, as illustrated in FIG. 11, extension parts 12c extending from the yoke 12 may be arranged to hold two pairs of the permanent magnets 19, for example. Note that the yoke 12 may be formed by bending a yoke plate material into a desired shape, for example. In this case, as illustrated in FIG. 11, the extension parts 12c may be formed such that the permanent magnets 19 may be polarized in a direction perpendicular to the direction in which the pairs of the fixed contacts 2 and the movable contacts 3 are aligned, for example.
By having extension parts of a yoke hold the permanent magnets 19, a separate yoke does not have to be provided in the embodiments described above. In this way, an increase in the number of components may be avoided. Note that where two pairs of permanent magnets 19 are used as in the embodiment illustrated in FIG. 11, for example, the permanent magnets 19 facing each may be polarized in opposite directions so that when a direction of a voltage applied between the terminals S1 and S2; that is, the direction of the current flowing in the DC circuit as described above, is reversed, an arc may be prevented from being blown inward in a direction toward a contact as a result of the Lorenz force acting in an inward direction toward the contact, for example.
Further, as illustrated in FIG. 12, in the electromagnetic relay 1 according to a preferred embodiment, the connection housing 18 (resin molded member) is arranged at the contact part side of the yoke 12, and the connection housing 18 has a hole 181 corresponding to the through hole 121, a sloped surface 18a sloping toward the drive part 7 from the outer edge of the hole 181, and a flat surface 18b that extends outward from the outer edge of the sloped surface 18a in a direction perpendicular to the shaft 5.
In the embodiment of FIG. 12, even when wear particles of the fixed contact 2 and the movable contact 3 fall onto the flat surface 18b, the sloped surface 18a may prevent the wear particles from moving in a radially inward direction, and the wear particles may be prevented from entering the hole 181 and the through hole 121 to interfere with the operation of the shaft 5.
Note that although the contact part side of the yoke 12 is arranged to be planar in the embodiment illustrated in FIG. 12, the present invention is not limited to such an embodiment. For example, as illustrated in FIG. 13, in the case where the yoke 12 includes the backside convex part 12cb, the thickness of the connection housing 18 at the sloped surface 18a and its surrounding area may be arranged to be thinner, and the connection housing 18 may be arranged to have a concave part 18c corresponding to the backside convex part 12cb, for example.
According to an aspect of the present invention, the structure of a fixed core of an electromagnetic relay may be simplified to thereby reduce costs and enable downsizing of the electromagnetic relay, for example. Embodiments of the present invention may be applied to various electromagnetic relays used in industrial and domestic settings, for example.
Further, the present invention is not limited to the embodiments described above, and various variations and modifications may be made without departing from the scope of the present invention.
The present application is based on and claims priority to Japanese Patent Application No. 2013-174995 filed on Aug. 26, 2013, the entire contents of which are hereby incorporated by reference.

## Claims

1. An electromagnetic relay comprising:
a contact part including a fixed contact and a movable contact; and
a drive part including a fixed core and a movable core which is connected to the movable contact via an axial core;
wherein the fixed core includes a plate member which is positioned between the contact part and the drive part and includes a through hole through which the axial core is inserted;
wherein the movable core includes a convex part protruding in a direction opposing the plate member;
wherein the plate member includes a concave part opposing the convex part and having a shape corresponding to the convex part; and
wherein the convex part has a truncated cone configuration, a part of the truncated cone including a protrusion formed around a perimeter of the movable core, and wherein the concave part corresponds to the truncated cone including the protrusion.

2. The electromagnetic relay as claimed in claim 1, wherein the plate member includes a backside convex part at a backside of the concave part.

3. An electromagnetic relay comprising:
a contact part including a fixed contact and a movable contact; and
a drive part including a fixed core and a movable core which is connected to the movable contact via an axial core;
wherein the fixed core includes a plate member which is positioned between the contact part and the drive part and includes a through hole through which the axial core is inserted;
wherein the movable core includes a concave part opposing the plate member;
wherein the plate member includes a convex part opposing the concave part; and
wherein the concave part includes a protrusion formed around a perimeter of the movable core, and wherein the concave part including the protrusion corresponds to the convex part.

4. The electromagnetic relay as claimed in claim 3, wherein the plate member includes a backside concave part at a backside of the concave part.