Abstract:
A method of making a relay includes: preparing a relay core member; coupling first, second and third terminals to the relay core member by moving the same horizontally relative to the relay core member such that terminal portions of the first, second and third terminals enter notches formed in the relay core member in a horizontal direction; and enclosing the relay core member, the first terminal, the second terminal, and the third terminal within a housing, and sealing the housing with resin.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to a method of making a relay. 
     2. Description of the Related Art 
     As shown in  FIG. 1 , a conventional method of making a relay  10  (see  FIG. 9 ) comprises steps  21  to  26 . 
     As shown in  FIGS. 1 and 2 , the step  21  is to prepare a relay core member  11  including a base plate  111  that extends in a horizontal direction (X) and that is formed with a through hole  116 , a top plate  112  that extends in the horizontal direction (X) and that is spaced apart from the base plate  111  in a vertical direction (Y), a coil unit  110  that extends in the vertical direction (Y) and that is disposed between the base and top plates  111 ,  112 , and a connecting plate  114  that interconnects the base and top plates  111 ,  112  and that is disposed between the coil unit  110  and the through hole  116 . The coil unit  110  includes a core  113 , a coil  12  wound on the core  113 , and a pair of rods  115 , each of which is coupled to the coil  12  and extends through the base plate  111 . 
     As shown in  FIGS. 1 ,  3 , and  4 , the step  22  is to prepare a first terminal  13  that has a first terminal portion  131  formed with a plate engaging notch  1310 , a first fixed portion  132  extending perpendicularly from one edge of the first terminal portion  131 , and a first contact  133  disposed on the first fixed portion  131 , and to couple the first terminal  13  to the relay core member  11  by moving the first terminal  13  horizontally relative to the relay core member  11  such that the plate engaging notch  1310  engages the base plate  111  of the relay core member  11 , that a portion of the first terminal portion  131  extends downwardly relative to the base plate  111 , and that the first fixed portion  132  extends horizontally above the top plate  112  of the relay core member  11 . 
     As shown in  FIGS. 1 ,  5 , and  6 , the step  23  is to prepare a second terminal  14  that has a second terminal portion  141 , a resilient portion  142  extending perpendicularly from one edge of the second terminal portion  141 , a second contact  143  disposed on the resilient portion  142 , a pair of opposite wing portions  144  formed at two sides of the second terminal portion  141 , and a pair of tongue pieces  145  formed respectively at the wing portions  144 , and to couple the second terminal  14  to the relay core member  11  by moving the second terminal  14  vertically relative to the relay core member  11  such that the second terminal portion  141  extends downwardly through the through hole  116  in the base plate  111 , that the resilient portion  142  extends horizontally above the top plate  112  and the first fixed portion  132  of the first terminal  13 , and that the second contact  143  is registered with the first contact  133  of the first terminal  13 . After the second terminal  14  is coupled to the relay core member  11 , an operator has to fold each of the wing portions  144  manually toward the connecting plate  114  with the use of a tool (not shown) such that the tongue pieces  145  engage respectively opposite sides of the connecting plate  144 , thereby positioning the second terminal  14  relative to the relay core member  11 . 
     As shown in  FIGS. 1 ,  7 , and  8 , the step  24  is to prepare a third terminal  15  that has a third terminal portion  151  formed with plate engaging notches  1510 ,  1511 , a second fixed portion  152  extending perpendicularly from one edge of the third terminal portion  151 , and a third contact  153  disposed on the second fixed portion  152 , and to couple the third terminal  15  to the relay core member  11  by moving the third terminal  15  horizontally relative to the relay core member  11  such that the plate engaging notches  1510 ,  1511  respectively engage the top and base plates  112 ,  111  of the relay core member  11 , that a portion of the third terminal portion  151  extends downwardly relative to the base plate  111 , that the second fixed portion  152  extends horizontally above the resilient portion  142  of the second terminal  14 , and that the third contact  153  is registered with the second contact  142 . 
     The step  25  is to test the resiliency of the resilient portion  142  of the second terminal  14  via a testing instrument (not shown). If the testing result does not fall within the standard range, the operator has to adjust manually the resilient portion  142  with the use of a tool so as to meet the standard requirement. 
     As shown in  FIGS. 1 and 9 , the step  26  is to enclose the relay core member  11 , the first terminal  13 , the second terminal  14 , and the third terminal  15  within a housing  16 , and to seal the housing  16  with resin  17  filled between the housing  16  and the base plate  111  of the relay core member  11 . 
     In use, the second contact  143  of the second terminal  14  contacts the third contact  153  of the third terminal  15  to form a first circuit when current does not flow through the coil unit  110 . When current flows through the coil unit  110 , an electromagnetic field is generated to attract the resilient portion  142  of the second terminal  14  such that the second contact  143  is separated from the third contact  153  and contacts the first contact  133  of the first terminal  13 , thereby forming a second circuit. 
     However, since the second terminal  14  is vertically coupled to the relay core member  11 , and since the tongue pieces  145  will affect vertical movement of the second terminal  14  if the wing portions  144  are folded prior to coupling the second terminal  14  to the relay core member  11 , the second terminal  14  has to be assembled manually. Moreover, since the resiliency of the resilient portion  142  of the second terminal  14  may deviate from the standard range during manual assembly of the second terminal  14 , the step  25  of testing the resiliency of the resilient portion  142  of the second terminal  14  after coupling to the relay core member  11  is required. Therefore, the conventional assembling method results in a relatively high cost of manufacture. Furthermore, if the tolerance range of the through hole  116  in the base plate  111  of the relay core member  11  is too large, the second terminal portion  141  of the second terminal  14  may not be properly assembled relative to the relay core member  11  since the second terminal portion  141  extends loosely through the through hole  116 , such that the operator has to spend more time to assemble properly the second terminal  14 , thereby resulting in higher manufacturing costs. 
     SUMMARY OF THE INVENTION 
     Therefore, the object of the present invention is to provide a method of making a relay with a higher efficiency and a lower cost of manufacturing. 
     Accordingly, a method of making a relay of the present invention comprises the steps of: (A) preparing a relay core member that includes a base plate extending in a horizontal direction and formed with first, second, and third notches, a top plate extending in the horizontal direction and spaced apart from the base plate in a vertical direction, a coil unit extending in the vertical direction and disposed between the base and the top plates, and a connecting plate interconnecting the base and top plates and disposed between the second notch in the base plate and the coil unit; (B) preparing a first terminal that has a first terminal portion, a first fixed portion extending perpendicularly from one edge of the first terminal portion, and a first contact disposed on the first fixed portion, and coupling the first terminal to the relay core member by moving the first terminal horizontally relative to the relay core member such that the first terminal portion enters the first notch in the horizontal direction and extends downwardly through the base plate, and that the first fixed portion extends horizontally above the top plate of the relay core member; (C) preparing a second terminal that has a second terminal portion, a resilient portion extending perpendicularly from one edge of the second terminal portion, a second contact disposed on the resilient portion, a pair of opposite wing portions formed at two sides of the second terminal portion, and a pair of tongue pieces formed respectively at the wing portions, and coupling the second terminal to the relay core member by moving the second terminal horizontally relative to the relay core member such that the second terminal portion enters the second notch in the horizontal direction and extends downwardly through the base plate, that the resilient portion extends horizontally above the first fixed portion of the first terminal, that the second contact is registered with the first contact, and that the tongue pieces engage the connecting plate; (D) preparing a third terminal that has a third terminal portion, a second fixed portion extending perpendicularly from one edge of the third terminal portion, and a third contact disposed on the second fixed portion, and coupling the third terminal to the relay core member by moving the third terminal horizontally relative to the relay core member such that the third terminal portion enters the third notch in the horizontal direction and extends downwardly through the base plate, that the second fixed portion extends horizontally above the resilient portion of the second terminal and is supported thereat by the top plate of the relay core member, and that the third contact is registered with the second contact; and (E) enclosing the relay core member, the first terminal, the second terminal, and the third terminal within a housing, and sealing the housing with resin filled between the housing and the base plate of the relay core member. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiment with reference to the accompanying drawings, of which: 
         FIG. 1  is a flow chart of a conventional method of making a relay; 
         FIG. 2  is a perspective view of a relay core member used in the conventional method; 
         FIG. 3  is a fragmentary exploded perspective view, illustrating a first terminal before being coupled to the relay core member according to the conventional method; 
         FIG. 4  is a fragmentary assembled perspective view, illustrating the first terminal after being coupled to the relay core member according to the conventional method; 
         FIG. 5  is a fragmentary exploded perspective view, illustrating a second terminal before being coupled to the relay core member according to the conventional method; 
         FIG. 6  is a fragmentary assembled perspective view, illustrating the second terminal after being coupled to the relay core member according to the conventional method; 
         FIG. 7  is a fragmentary exploded perspective view, illustrating a third terminal before being coupled to the relay core member according to the conventional method; 
         FIG. 8  is a fragmentary assembled perspective view, illustrating the third terminal after being coupled to the relay core member according to the conventional method; 
         FIG. 9  is an assembled perspective view, illustrating the relay core member enclosed in a housing with sealant filled therebetween according to the conventional method; 
         FIG. 10  is a flow chart of a preferred embodiment of a method of making a relay according to the invention; 
         FIG. 11  is a perspective view of a relay core member used in the preferred embodiment; 
         FIG. 12  is a fragmentary exploded perspective view, illustrating a first terminal before being coupled to the relay core member according to the preferred embodiment; 
         FIG. 13  is a fragmentary assembled perspective view, illustrating the first terminal after being coupled to the relay core member according to the preferred embodiment; 
         FIG. 14  is a fragmentary exploded perspective view, illustrating a second terminal before being coupled to the relay core member according to the preferred embodiment; 
         FIG. 15  is a fragmentary assembled perspective view, illustrating the second terminal after being coupled to the relay core member according to the preferred embodiment; 
         FIG. 16  is a fragmentary exploded perspective view, illustrating a third terminal before being coupled to the relay core member according to the preferred embodiment; 
         FIG. 17  is a fragmentary assembled perspective view, illustrating the third terminal after being coupled to the relay core member according to the preferred embodiment; 
         FIG. 18  is an assembled perspective view, illustrating the relay core member enclosed in a housing with sealant filled therebetween according to the preferred embodiment; 
         FIG. 19  is an assembled sectional view of the relay made according to the preferred embodiment when forming a first circuit; and 
         FIG. 20  is a view similar to  FIG. 19 , but illustrating the relay when forming a second circuit. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Before the present invention is described in greater detail, it should be noted that the relative positional terminology used in the following description, e.g., “horizontal direction (X)” and “vertical direction (Y)”, are based on the directions illustrated in the accompanying drawings, and that the horizontal direction (X) is perpendicular to the vertical direction (Y). 
     As shown in  FIG. 10 , the preferred embodiment of a method of making a relay according to the present invention comprises steps  31  to  35 . 
     As shown in  FIGS. 10 to 12 , the step  31  is to prepare a relay core member  40  including a base plate  41  that extends in a horizontal direction (X), a top plate  42  that extends in the horizontal direction (X) and that is spaced apart from the base plate  41  in a vertical direction (Y), a coil unit  49  that extends in the vertical direction (Y) and that is disposed between the base and top plates  41 ,  42 , and a connecting plate  44  that interconnects the base and top plates  41 ,  42 . The coil unit  49  includes a core  43 , a coil  46  wound on the core  43 , and a pair of rods  45 , each of which is coupled to the coil  46  and extends through the base plate  41 . 
     The base plate  41  of the relay core member  40  has one edge formed with a first notch  411  and a third notch  413  that extend in the horizontal direction (X) and that are spaced apart from each other, and has an opposite edge formed with a second notch  412  that extends in the horizontal direction (X). The connecting plate  44  is disposed between the second notch  412  and the coil unit  49 . Preferably, the second notch  412  has a flaring opening  414 . The top plate  42  is formed with a pair of spaced apart first and second engaging blocks  421 ,  422  at one edge above the first and third notches  411 ,  413 . 
     As shown in  FIGS. 10 ,  12 , and  13 , the step  32  is to prepare a first terminal  60  that has a first terminal portion  61 , a first fixed portion  62  extending perpendicularly from one edge of the first terminal portion  61 , and a first contact  63  disposed on the first fixed portion  61 , and to couple the first terminal  60  to the relay core member  40  by moving the first terminal  60  horizontally relative to the relay core member  40  such that the first terminal portion  61  enters the first notch  411  in the horizontal direction (X) and extends downwardly through the base plate  41 , and that the first fixed portion  62  engages the first engaging block  421  on the top plate  42  and extends horizontally above the top plate  42  of the relay core member  40 . 
     As shown in  FIGS. 10 ,  14 , and  15 , the step  33  is to prepare a second terminal  70  that has a second terminal portion  71 , a resilient portion  72  extending perpendicularly from one edge of the second terminal portion  71 , a second contact  73  disposed on a distal end part  721  of the resilient portion  72 , a pair of opposite wing portions  74  formed at two sides of the second terminal portion  71 , and a pair of tongue pieces  75  formed respectively at the wing portions  74 , and to couple the second terminal  70  to the relay core member  41  by moving the second terminal  70  horizontally relative to the relay core member  41  such that the second terminal portion  71  enters the second notch  412  in the horizontal direction (X) and extends downwardly through the base plate  41 , that the resilient portion  72  extends horizontally above the top plate  42  and the first fixed portion  62  of the first terminal  60 , and that the second contact  73  is registered with the first contact  63  of the first terminal  60 . Preferably, the wing portions  74  are folded respectively at an angle relative to the second terminal  70  prior to coupling the second terminal portion  71  to the relay core member  40 , such that the tongue pieces  75  of the second terminal  70  engage simultaneously opposite sides of the connecting plate  44  of the relay core member  40  when the second terminal portion  71  is inserted in the second notch  412 . 
     As shown in  FIGS. 10 ,  16 , and  17 , the step  34  is to prepare a third terminal  80  that has a third terminal portion  81 , a second fixed portion  82  extending perpendicularly from one edge of the third terminal portion  81 , and a third contact  83  disposed on the second fixed portion  82 , and to couple the third terminal  80  to the relay core member  40  by moving the third terminal  80  horizontally relative to the relay core member  40  such that the third terminal portion  81  enters the third notch  413  in the horizontal direction (X), and extends downwardly through the base plate  41 , that the second fixed portion  82  extends horizontally above the resilient portion  72  of the second terminal  70  and is supported thereat by the second engaging block  422  on the top plate  42  of the relay core member  40 , and that the third contact  83  is registered with the second contact  73 . 
     As shown in  FIGS. 10 ,  18 , and  19 , the step  35  is to enclose the relay core member  40 , the first terminal  60 , the second terminal  70 , and the third terminal  80  within a housing  90 , and to seal the housing  90  with resin  100  filled between the housing  90  and the base plate  41  of the relay core member  40 . Preferably, the housing  90  includes a block  91  extending into the second notch  412  in the base plate  41  so as to prevent the resin  100  from flowing into the relay core member  40 . 
     In use, the second contact  73  of the second terminal  70  contacts the third contact  83  of the third terminal  80  to form a first circuit (see  FIG. 19 ) when current does not flow through the coil unit  49 . When current flows through the coil unit  49 , an electromagnetic field is generated to attract the resilient portion  72  of the second terminal  70  such that the second contact  73  is separated from the third contact  83  and contacts the first contact  63  of the first terminal  60 , thereby forming a second circuit (see  FIG. 20 ). 
     Since the second terminal  70  is coupled horizontally to the relay core member  40  with the second terminal portion  71  entering the second notch  412  in the base plate  41  via the opening  414 , and since the tongue pieces  75  of the second terminal  70  engage simultaneously the connecting plate  44  when the second terminal portion  71  is inserted in the second notch  412 , the step of coupling the second terminal  70  to the relay core member  40  can be automated as well as those of the first and third terminals  60 ,  80 . Moreover, the aforementioned assembling process does not result in deviation of the resiliency of the resilient portion  72  of the second terminal  70 . Compared to the prior art, the manual assembling and the manual adjustment of the second terminal can be eliminated in this invention, thereby resulting in a higher efficiency and a lower cost of manufacturing. 
     While the present invention has been described in connection with what is considered the most practical and preferred embodiment, it is understood that this invention is not limited to the disclosed embodiment but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.