CONNECTING STRUCTURE OF COIL IN ELECTROMAGNETIC RELAY

Abstract: According to the invention, a pair of pockets (13) are formed in one flange (12). A pair of almost L-shaped connecting terminals (14) are fitted into the pocket with a pressure. The starting and terminating sides (10a, 10b) of a coil core wire (10) are respectively wound around the connecting terminals. Thus, the cutting-out of the coil core wire is prevented and the connecting work can be easily performed.

Description: The present invention relates to an electromagnetic relay and a method for manufacturing thereof according to the pre-characterizing part of claims 1 and 2, respectively. A conventional electromagnetic relay corresponding to the features of the preamble of claim 1 is shown in Figs. 5 and 6. That is, a coil core wire 1 is wound around the outer periphery of a bobbin 2 to which a pair of flanges 3 are attached on both sides of the bobbin so as to face each other. A pair of receiving portions 5 consisting of slots which are notched from both side portions of the flange 3 are formed in one of the flanges 3. Coil lead wires 1a and 1b each of which is formed by extracting the coil core wire 1 or by twisting a plurality of coil core wires 1 and extracting the twisted wire are inserted into the receiving portions 5. The coil lead wire 1a on the starting side is inserted into one of the receiving portions 5 from the upper direction and its end portion is wound around the upper surface of a coil terminal 7a implanted onto a terminal base 6 and is soldered to the terminal 7a (refer to Figs. 7 and 8). The coil lead wire 1b on the terminating side is inserted into the other receiving portion 5 and its end portion is wound around the upper surface of another coil terminal 7b implanted onto the terminal base 6 and is soldered in a manner similar to the coil lead wire 1a on the starting side (refer to Fig. 7). The insulation between the starting side 1a and the terminating side 1b of the coil lead wire 1 is accomplished by a barrier portion 4 formed on the upper surfaces of the receiving portions 5. In the above coil connecting structure, the coil core wire 1 is connected with the coil terminals 7a and 7b by using the coil lead wires 1a and 1b each of which is an end portion of the coil core wire 1 or formed by twisting a plurality of coil core wire end portions. Therefore, there is a problem such that when a repetitive bending force due to the tension or vibration is applied to the coil lead wires 1a and 1b, they can be easily fatigued and may break by the concentration of the stresses. On the other hand, even in the case where the coil lead wires 1a and 1b are come into contact with the corner portions of the receiving portions 5 and the tension is applied to them, the coil lead wires 1a and 1b can be easily cut by the pointed corner portions. Moreover, since the coil lead wires 1a and 1b have the flexibility, there is also a problem such that the twisted core wires are projected and the good insulating property is not held. Further, assuming that the end portions of such coil lead wires 1a and 1b were melted and bonded to the coil terminals 7a and 7b, the cross sections of the coil lead wires 1a and 1b decrease due to the dissolution and their strengths are weakened. Therefore, it is improper to connect the coil lead wires by the melt bonding method. Consequently, hitherto, the coil lead wires 1a and 1b are generally connected with the coil terminals 7a and 7b by soldering. In the case of connecting the coil lead wires 1a and 1b with the coil terminals 7a and 7b by soldering, there are problems such that the flux produced upon soldering is diffused and deposited onto contacts (not shown) of the electromagnetic relay, so that a defective contact is caused and the like. Furthermore, US-A-4,347,493 discloses per se a coil assembly comprising a bobbin on both sides of which a flange is provided and around the outer periphery of which a coil core wire is wound. In both side portions of one of the flanges a pair of slots are provided to receive connecting terminals therein. The starting side and the terminating side of the coil core wire are connected to respective ears of the connecting terminals by soldering. Such coil assemblies, however, are used in synchronous motors. The present invention is made in consideration of the foregoing problems and it is an object of the invention to provide an electromagnetic relay having a coil connecting structure which has such toughness that it will not be cut even if a repetitive bending force due to a tension or vibration is applied and in which a melt bonding with coil terminals can be performed. The object is solved by the electromagnetic relay and the method of claims 1 and 2, respectively. That is, according to the invention, the connection with the coil terminals implanted onto the terminal base is not directly performed by the coil lead wires extracted from the coil core wire as in the conventional relay but is accomplished by a connecting structure such that an almost L-shaped connecting terminal having a thickness which is almost equal to a width of the slot of the receiving portion and also having a projecting portion is provided and the connecting terminal is fitted into the receiving portion with pressure. Therefore, the connecting terminal is inserted into the first slot and the second slot of the receiving portion and can be fixedly attached. At the same time, even if a repetitive bending force due to a tension or vibration is applied, the fatigue and breaking-out of the connecting terminal can be prevented. On the other hand, since the connecting terminal is formed like a plate, its lower portion can come into area contact with the upper surface of the coil terminal and the connection with the coil terminal can be executed by melt bonding. Thus, the connecting work can be easily performed and it is possible to eliminate such a problem that the diffused flux is deposited onto the connecting surface and a defective contact is caused as in the case of the soldering. Therefore, according to the invention, it is possible to provide a coil connecting structure in which the reliability upon operation of a contact can be improved and the connecting work can be easily executed. An embodiment of the present invention will be described in detail hereinbelow with reference to the drawings, in which; Fig. 1 is a perspective view showing a coil according to the present invention; Fig. 2 is a perspective view showing an attaching state of a starting side connecting terminal according to the invention; Fig. 3 is a cross sectional view taken along the line III-III in Fig. 2; Fig. 4 is a side elevational view showing an electromagnetic relay having a coil connecting structure according to the invention; Figs. 5 and 6 are perspective views showing an example of a coil according to a conventional electromagnetic relay; Fig. 7 is a front view showing an example of a coil connecting structure of a conventional electromagnetic relay; and Fig. 8 is a side elevational view of Fig. 7. In Figs. 1 and 2, a coil core wire 10 is wound around the outer periphery of a bobbin 11 to which a pair of flanges 12 are attached on both sides of the bobbin. On both sides of the coil core wire 10, relatively short coil lead wires 10a and 10b on the starting and terminating sides are extracted directly from the coil core wire 10 or are extracted after a plurality of coil core wires 10 were twisted. A pair of receiving portions 13 are formed on the inside of one of the flanges 12. The receiving portions 13 are constructed by first slots 13a notched in parallel with the flange from both side surfaces of the flange 12. On the other hand, as shown in Fig. 3, a second slot 13b communicating with the first slot 13a is formed at a part of the bottom of the first slot 13a. Further, the upper portion, lower portion, and side portion of the first slot 13a are opened. Reference numeral 14 denotes a connecting terminal inserted into the receiving portion 13. The connecting terminal 14 comprises: a rectilinear portion 14a which is inserted into the first slot 13a; and a projecting portion 14b which is projected from the upper portion of the rectilinear portion 14a and is inserted into the second slot 13b. That is, as will be understood from Fig. 3, the connecting terminal 14 is formed into an almost L-shape. The coil lead wires 10a on the starting side and the coil lead wires 10b on the terminating side are respectively wound around the rectilinear portions 14a of the connecting terminals 14. On the other hand, as shown in Fig. 4, the lower portions of the connecting terminals 14 around which the coil lead wire 10a on the starting side and the coil lead wire 10b on the terminating side are respectively wound are joined to coil terminals 16a (and 16b) implanted onto a terminal base 15 and are melted and bonded by a high frequency melt bonding method or the like. In Fig. 4, an electromagnetic coil is fixed to the terminal base 15. An iron core 17 is inserted and fixed into the bobbin 11. When a current is supplied through the coil core wire 10, an arm 21 is attracted to the iron core 17 against a force of a spring 24. Thus, a movable contact member 22 having a movable contact 22a attached to the arm 21 is swung and the movable contact 22a is away from a fixed contact 23a and is come into contact with a fixed contact 23b. The fixed contacts 23a and 23b are provided for terminals 24a and 24b. On the other hand, the movable contact 22a is connected to a terminal 24c through the movable contact member 22. Since the invention is constructed as mentioned above, the starting side coil lead wire 10a and terminating side coil lead wire 10b of the coil core wire 10 are respectively wound around the connecting terminals 14, the connecting terminals 14 are fitted into the receiving portions 13 with pressure and are area-joined with the upper portions of the coil terminals 16a(and 16b) and both surfaces of the terminals 14 and 16a (16b) can be connected by the melt bonding method. As described above, according to the coil connecting structure of the invention, the second slot is formed in the receiving portion and the almost L-shaped connecting terminal having the projecting portion is fitted into the receiving portion with pressure. Therefore, the connecting terminal can be fixedly attached into the receiving portion. Even if a repetitive bending force due to the tension or vibration is applied, the fatigue and breaking-out of the connecting terminal do not occur. On the other hand, since the connecting terminal can be easily joined with the coil terminal by the melt bonding method, the connecting terminal can be certainly easily attached. Moreover, since the flux which is used upon soldering is not used, there are advantages such that the contacting function is not deteriorated by the corrosion of the contact surfaces, and the like.

Claims: An electromagnetic relay comprising: a bobbin (11) on both sides of which a flange (12) is provided and around the outer periphery of which a coil core wire (10) is wound; a pair of first slots (13a) arranged opposite to each other in both side portions of one of said flanges (12); and coil terminals (16a, 16b) implanted onto a base (15) supporting said bobbin (11); characterized in that a further slot (13b) is provided at a part of the bottom of each first slot (13a); that a pair of connecting terminals (14)is provided each of which has a thickness almost equal to the gap in the direction of thickness of said slots (13a, 13b) and a projecting portion (14b) adapted to be fitted into said further slot (13b) when the respective connecting terminal is fitted into the first slot (13a) with pressure; that a starting side (10a)of the coil core wire (10) is wound around one of said connecting terminals (14) and a terminating side (10b) of the coil core wire is wound around the other connecting terminal (14); and that said connecting terminals (14) are connected to the end portions of said coil terminals (16a, 16b) by melt bonding. A method for manufacturing an electromagnetic relay comprising the steps of: providing a bobbin (11) on both sides with a flange (12); winding a coil core wire (10) around an outer periphery of said bobbin; providing in both side portions of one of said flanges (12) a pair of first slots (13a); and implanting coil terminals (16a, 16b) onto a base (15) supporting said bobbin (11); characterized by the following steps: providing a further slot (13b) at a part of the bottom of each first slot (13a); providing a pair of connecting terminals (14) each of which has a thickness almost equal to a gap in the direction of thickness of said slots (13a, 13b) and a projecting portion (14b) adapted to be fitted into said further slot (13b) when the respective connecting terminal is fitted into the first slot (13a) with pressure; winding a starting side (10a) of said coil core wire (10) around one of said connecting terminals (14) and a terminating side (10b) of said coil core wire around the other connecting terminal (14); fitting said connecting terminals (14) into said first slots (13a) with pressure; and connecting said connecting terminals (14) to the end portions of said coil terminals (16a, 16b) by melt bonding.

Inventors: TUJI, HIDEAKI
Applicants: OMRON CORPORATION
Application year: 1989
Main classification: H01H50
IPC codes: H01H50