DE102006042194A1 - Electromagnetic relays and method for its manufacture - Google Patents

Abstract

In an electromagnetic relay, the pins 12, 14 of a contact system 10 are embedded in a block 18 of laser-absorbent plastic. This plastic block 18 is arranged on a relay base plate 40 so that the pins 12, 14 pass through openings 41 in the base plate 40, and connected by laser welding tightly with the base plate 40. The openings 41 are larger than the cross sections of the terminal pins 12, 14, so that they are not touched by these. During the welding process, the contact system 10 and the coil system 20 of the relay are in an alignment gauge, which positions the parts relative to each other, so that the otherwise required adjustment can be largely eliminated.

Description

electromagnetic Relays are usually mounted so that fixed contacts, spring contacts and solenoid coil with their pins through corresponding openings or slots of a Plastic body stuck through and then be fixed by gluing and sealed. After assembly the rest Relay components, adjustment and testing the assembly becomes a housing cap placed and connected in a further gluing process with the body.

at the main body produced by injection molding is damaged by uneven shrinkage, caused by different orientation of the glass fibers, too a default. Change it the positions of the openings for the Pins. The openings are designed so that they surround the pins tightly to to achieve a precise positioning. The mentioned position changes As a result, they affect the contacts and, if necessary, their effects the response and waste behavior and the electrical life of the Relay off and must in a complex adjustment process Getting corrected. The two bonding processes also cause changes the desired arrangement of the components to each other, the last change, which by the final Bonding of the cap is caused, is no longer correctable. A corresponding Vorhaltung when adjusting is required.

Out DE 24 54 967 A It is known to embed fixed contact and spring contact in a common contact carrier and to use this in recesses on the bobbin. Although this determines the mutual assignment between the two contacts; However, the problems arising from a distortion of the bobbin and the bonding processes for sealing the pins in a relay base plate and closing with the housing cap, but also exist here.

Of the Invention is based on the general object disadvantages, as they occur in comparable relays according to the prior art, at least partially avoided. A more specific object of the invention can be seen in it, an electromagnetic relay with each other preferably to create precisely positioned relay parts.

The solution This object is achieved with the measures of claims 1 and 6. Thereafter, an essential feature of the invention in the Application of laser welding as replacement for the previous bonding. The welds generated by laser welding are gas-tight, of high strength and can be carried out precisely. simultaneously eliminates all contaminants caused by the previously used Adhesives and their outgassing could be caused. Further away the connections the contact system is not attached directly to the relay base body and sealed, but first be encapsulated with plastic and the plastic block thus formed welded are not just the mutual alignment of contacts and a perfect weld guaranteed but also simplifies handling during assembly.

The Development of the invention according to claim 2 is insofar favorable as Error in the positions of the openings in the body, about as a result of delay, no influence on the contacts themselves and theirs Position to each other and a correction of the contact position over a Adjustment possible is.

A subsequent Adjustment should be unnecessary if the laser welding according to claim 7 using a plastic block with the connection elements across from aligning the main body Teaching takes place.

According to claim 3 and 8 is preferably also the coil system in the area of his Connection elements with plastic encapsulated and the thus formed Plastic block together with the contact terminal elements containing Plastic blocks in the same operation and, where appropriate, using a common alignment gauge attached to the body.

In in the claims 4 and 9 specified embodiment of the invention is also the housing cap by laser welding at the relay base tightly fastened. For mutual isolation of the different, in the relay existing assemblies, the housing cap in the development according to claims 5 and 10 provided with partitions be, which are also connected by laser welding to the body. This is from the creepage distances or air gaps between adjacent conductive parts according to the associated Product standard a solid insulation, which meets the requirements of dielectric strength fulfill got to. Thus, further miniaturization is made possible.

at Use of in the claims 11 and 13 indicated plastic materials for the main body, the the connecting elements containing plastic blocks and the housing cap is a perfect weld guaranteed because the laser beam is the outer, out laser-transparent plastic existing part without major losses interspersed and its energy on the underlying, made of laser-absorbent Plastic part gives off, leaving the actual weld supplied the required energy becomes.

One embodiment The invention is explained below with reference to the drawings. In this demonstrate

1 a schematic perspective view of a single contact system,

2 several of the contact systems 1 and a coil system in an arrangement as it is inside a finished relay,

3 the arrangement after 2 in an end view with an alignment gauge,

4 the arrangement after 3 after insertion into the alignment gauge,

5 the arrangement after 4 with a relay base plate drawn above,

6 a perspective view of the arrangement according to 5 after welding with the transparent base plate and removing the alignment gauge, and

7 a perspective view of completed with a housing cap finished relay.

This in 1 shown contact system comprises a fixed contact element 11 with a pin 12 and a spring contact element 13 with a pin 14 , On the spring contact element 13 is a contact spring 15 riveted to the fixed contact element 11 cooperates. Both contact elements 11 . 13 are at their feet 16 . 17 with a plastic block 18 encapsulated, from which the pins 12 . 14 sticking out.

In the 2 The arrangement shown comprises a coil system 20 with a one coil 21 carrying plastic bobbin, with its two end flanges 22 . 23 out of the coil 21 protrudes. In the end flange 23 are two pins 24 the coil 21 embedded.

In the 2 The arrangement shown further comprises a total of six of the in 1 shown contact systems 10 of which five on one side and the sixth on the other side of the coil system 20 are arranged and run parallel to this.

In 3 is the in 2 shown arrangement of coil system 20 and contact systems 10 in side view above an alignment gauge 30 shown. The alignment doctrine 30 is designed comb-like overall, the width of the Zin ken 31 the distances between the contact systems prescribed for the finished relay 10 with each other and with respect to the coil system 20 certainly.

In 4 are the contact systems 10 and the coil system 20 in the alignment 30 used.

5 shows a base plate above this arrangement 40 , In the base plate 40 are breakthroughs 41 for the passage of the pins 12 . 14 the contact systems 10 and the pins 24 of the coil system 20 intended. The in 5 section shown lies in a plane in which the in the 2 front pins 13 the contact systems 10 are located. Therefore, those are in the base plate 40 existing breakthroughs for the other pins 14 the contact systems 10 and for the pins 24 of the coil system 20 not to be seen

Furthermore, in 5 wells 42 shown for receiving the unused and truncated end stub 19 (Comp. 1 ) serve. (In the 5 over the breakthroughs 41 visible elevations 43 arise from the material offset above the wells 42 .)

6 shows the arrangement after 5 in a perspective view, wherein the base plate shown here only with contour lines 40 on the arrangement of contact systems 10 and coil system 20 is up. For clarification is the Ausrichtlehre 30 in 6 not shown.

As shown, the breakthroughs 41 in the base plate 40 larger than the pins passing through them 12 . 14 the contact systems 10 , and that much, that usually no contact between the pins 12 . 14 and the walls breakthroughs 41 takes place.

Except the already mentioned depressions 42 for the connection stub 19 the contact systems 10 has the base plate 40 a larger recess 44 for receiving one over the upper level of the end flanges 22 . 23 of the coil system 20 protruding part of the coil 21 on.

The welding process between the base plate 40 on the one hand and the plastic blocks 18 the contact systems 10 and the bobbin end flanges 22 . 23 of the coil system 20 takes place while all components in the Ausrichtlehre 30 are located. The welding is done so that all pins 12 . 14 and 24 each completely surrounded by a weld and also a firm connection of the plastic blocks 18 the contact systems 10 and the end flanges 22 . 23 of the coil system 20 is reached.

While the base plate 40 from lasertrans parentem plastic, are the plastic blocks 18 the contact systems 10 and the bobbin with its end flanges 22 . 23 made of laser-absorbent plastic. With this choice of material a reliable laser welding is achieved.

In 7 is the in 6 shown arrangement (without the Ausrichtlehre 30 ) in a housing cap 50 inserted, the parallel to their side walls extending partitions 51 having. The side walls of the housing cap 50 and the partitions 51 are also sealed by laser welding to the base plate.

In 7 are the laser welding areas between the base plate 40 on the one hand and the contact systems 10 , the coil system 20 and the side walls of the housing cap 50 and the partitions 51 shown in black. The illustration is only schematic. In fact, the weld areas do not extend all the way to the pins 12 . 14 and 24 because of the breakthroughs that they enforced 41 are larger than their cross sections.

10

Contact system

11

Fixed contact element

12 14

pins

13

Spring contact element

15

contact spring

16 17

footboards

18

Plastic block

19

connection stub

20

coil system

21

Kitchen sink

22 23

end flanges

24

pins

30

Alignment

31

prong

40

baseplate

41

breakthroughs

42

wells

43

surveys

44

recess

50

housing cap

51

partitions

Claims (12)

Electromagnetic relay with one with breakthroughs ( 41 ) provided basic body ( 40 ), a coil system ( 20 ), a contact system ( 10 ) and a surrounding the coil system and the contact system and with the body tightly connected housing cap ( 50 ), wherein connection elements ( 12 . 14 . 24 ) of the contact system and the coil system are led out through the openings in the base body, characterized in that the connection elements ( 12 . 14 ) of the contact system ( 10 ) in a plastic block ( 18 ), which is laser-welded to the base body ( 40 ) is tightly connected. Relay according to claim 1, wherein each breakthrough ( 41 ) in the main body ( 40 ) larger than the cross section of the contact element of the contact system ( 10 ) is dimensioned. Relay according to Claim 1 or 2, whereby the connecting elements ( 24 ) of the coil system ( 20 ) in a plastic block ( 23 ), which is laser-welded to the base body ( 40 ) is tightly connected. Relay according to one of claims 1 to 3, wherein the housing cap ( 50 ) by laser welding to the base body ( 40 ) connected is. Relay according to claim 4, wherein the housing cap ( 50 ) with partitions ( 51 ) provided by laser welding to the base body ( 40 ) are tightly connected. Method for the production of an electromagnetic relay, one with breakthroughs ( 41 ) provided basic body ( 40 ), a coil system ( 20 ), a contact system ( 10 ) and a surrounding the coil system and the contact system and with the main body tightly connected housing cap ( 50 ), characterized in that the connection elements ( 12 . 14 ) of the contact system ( 10 ) in a plastic block ( 18 ) embedded on the body ( 40 ) is arranged, that the connection elements the breakthroughs ( 41 ) enforce in the body, and is tightly connected by laser welding to the body. The method of claim 6, wherein the laser welding using one of the plastic blocks ( 18 ) relative to the main body ( 40 ) Aligning teaching takes place. Method according to claim 6 or 7, wherein also the connecting elements ( 24 ) of the coil system ( 20 ) in a plastic block ( 23 ) and this by laser welding to the main body ( 40 ) is tightly connected. Method according to one of claims 6 to 8, wherein the housing cap ( 50 ) by laser welding to the base body ( 40 ) is connected. The method of claim 9, wherein the housing cap ( 50 ) with partitions ( 51 ) provided by laser welding to the base body ( 40 ) are tightly connected. Relay according to one of claims 1 to 6 or Method according to one of claims 8 to 10, wherein the base body ( 40 ) consists of a laser-transparent plastic and the connecting elements ( 12 . 14 . 24 ) of contact system ( 10 ) and coil system ( 20 ) embedding plastic blocks ( 18 . 23 ) are laser absorbent. Relay according to one of claims 4 to 6, 9 to 11 or method according to one of claims 9 to 11, wherein the housing cap ( 50 ) consists of laser-absorbent plastic.