JP7702697B2 - electromagnetic relay - Google Patents

Description

The present disclosure relates generally to electromagnetic relays, and more specifically to an electromagnetic relay that includes a contact device that includes a fixed contact and a movable contact, and an electromagnetic device that includes a coil.

Patent Document 1 discloses an electromagnetic relay. This electromagnetic relay has an insulating member arranged between a coil and a yoke. The insulating member has engagement ends that respectively engage with the outer edges of the flanges on both sides of the coil spool (bobbin), and an insulating coating part that fits between the flanges on both sides and is located closer to the coil than the engagement ends to insulate the coil from the yoke.

JP 2017-27877 A

In electromagnetic relays, it is sometimes desirable to increase the insulation distance between the coil and the yoke.

The objective of this disclosure is to provide an electromagnetic relay that can increase the insulation distance between the coil and the yoke.

An electromagnetic relay according to one aspect of the present disclosure includes a coil, a bobbin, an iron core, a yoke, an insulating member, a fixed contact portion, and a movable spring. The coil is wound around the bobbin. The iron core is inserted vertically through the bobbin along a first axis. The yoke forms a magnetic circuit together with the iron core. The insulating member is disposed between the bobbin and the yoke. The fixed contact portion has a fixed contact. The movable spring has a movable contact. The movable spring moves between a closed position in which the movable contact contacts the fixed contact and an open position in which the movable contact is separated from the fixed contact in response to switching between excitation and de-excitation of the coil. The yoke includes a first yoke and a second yoke. The first yoke extends vertically along the first axis. The second yoke is connected to the first yoke and extends horizontally along a second axis intersecting the first axis . The bobbin includes a main body around which the coil is wound, an upper flange provided on an upper portion of the main body, and a lower flange provided on a lower portion of the main body. The insulating member includes a first cover portion that covers at least a portion of the second yoke, and a second cover portion that is a portion different from the first cover portion and covers at least a portion of an upper surface of the upper flange portion of the bobbin. The lower flange portion of the bobbin includes an opening into which the first cover portion and the second yoke of the insulating member can be inserted.

The present disclosure has the advantage of being able to provide an electromagnetic relay that can increase the insulation distance between the coil and the yoke.

FIG. 1 is a perspective view of an electromagnetic relay according to an embodiment. FIG. 2 is an exploded perspective view of the electromagnetic relay. FIG. 3 is an exploded perspective view of a relay body provided in the electromagnetic relay. FIG. 4 is an exploded perspective view of a main body block included in the relay main body. FIG. 5 is an exploded perspective view of an electromagnet block provided in the main body block. FIG. 6 is a top view of a bobbin provided in the electromagnet block. FIG. 7 is a perspective view of the bobbin. FIG. 8 is a perspective view of an insulating member provided in the electromagnet block. FIG. 9 is a cross-sectional view of the electromagnet block. Fig. 10A is a cross-sectional view of the relay body of the same embodiment, Fig. 10B is an enlarged view of a B1 portion of Fig. 10A, Fig. 10C is an enlarged view of a B2 portion of Fig. 10A, and Fig. 10D is an enlarged view of a B3 portion of Fig. 10A. FIG. 11 is an exploded perspective view of a movable block included in the main body block. FIG. 12 is an exploded perspective view of a fixing block provided in the relay body. FIG. 13 is a perspective view of a support stand provided on the fixed block. FIG. 14 is a perspective view of a case of the electromagnetic relay. FIG. 15 is a cross-sectional view of the electromagnetic relay. Fig. 16A is a cross-sectional view of a main part of the electromagnetic relay shown in Fig. 16. Fig. 16B is an enlarged view of a portion B4 of Fig. 16A. FIG. 17 is a top view of a bobbin provided in the electromagnetic relay of the first modified example. FIG. 18 is a cross-sectional view of the electromagnetic relay.

The electromagnetic relay of the embodiment of the present disclosure will be described using the drawings. Each figure described in the following embodiment is a schematic diagram, and the ratio of the size and thickness of each component in the figure does not necessarily reflect the actual dimensional ratio.

(1) Overview As shown in Figs. 2 to 5, the electromagnetic relay 100 of this embodiment includes a coil 21, a bobbin 22, an iron core 23, a yoke 25, an insulating member 24, a fixed contact portion 400, and a movable spring 31. The coil 21 is wound around the bobbin 22. The iron core 23 is inserted vertically through the bobbin 22 along the first axis A1. The yoke 25 forms a magnetic circuit together with the iron core 23. The insulating member 24 is disposed between the bobbin 22 and the yoke 25. The fixed contact portion 400 has a fixed contact F1. The movable spring 31 has a movable contact M1 (see Fig. 11). The movable spring 31 moves between a closed position and an open position in response to switching between excitation and non-excitation of the coil 21. The closed position is a position of the movable spring 31 where the movable contact M1 contacts the fixed contact F1. The open position is a position of the movable spring 31 where the movable contact M1 is separated from the fixed contact F1. The yoke 25 includes a first yoke 251 and a second yoke 252. The first yoke 251 extends vertically along the first axis A1. The second yoke 252 is connected to the first yoke 251 and extends horizontally along a second axis A2 intersecting the first axis A1. The insulating member 24 includes a cover portion 242 that covers at least a part of the second yoke 252. The bobbin 22 includes a main body portion 61 around which the coil 21 is wound, and a lower flange portion 63 provided at the lower portion of the main body portion 61. The lower flange portion 63 of the bobbin 22 includes an opening 630 into which the cover portion 242 and the second yoke 252 of the insulating member 24 can be inserted.

In the electromagnetic relay 100 of this embodiment, the insulating member 24 arranged between the bobbin 22 and the yoke 25 has a cover portion 242 that covers the second yoke 252 of the yoke 25, and the lower flange portion 63 of the bobbin 22 has an opening 630 into which the cover portion 242 and the second yoke 252 can be inserted. Therefore, in the electromagnetic relay 100 of this embodiment, it is possible to interpose the lower flange portion 63 and the cover portion 242 between the coil 21 and the second yoke 252, which has the advantage of making it possible to increase the insulation distance between the coil 21 and the yoke 25. In addition, when the yoke 25 is electrically connected to a contact device including a movable contact M1 and a fixed contact F1, it is possible to increase the insulation distance between the coil and the conductive parts electrically connected to the contact device.

(2) Details Hereinafter, the electromagnetic relay 100 of the present embodiment will be described in detail with reference to the drawings.

The electromagnetic relay 100 is a so-called hinge-type relay. The electromagnetic relay 100 includes a contact device including a movable contact M1 and a fixed contact F1, and a coil 21. The conductive parts electrically connected to the contact device and the conductive parts electrically connected to the coil 21 are electrically insulated.

The electromagnetic relay 100 is mounted, for example, on an electric vehicle. The electromagnetic relay 100 is used, for example, to turn on and off the electrical path of the charging cable of the electric vehicle. The contact device is inserted into the electrical path of the charging cable.

As shown in Figures 1 and 2, the electromagnetic relay 100 includes a relay body 1 and a case 9.

As shown in Figures 2 to 4, the relay body 1 is formed by joining multiple blocks. The relay body 1 comprises an electromagnet block 2, a movable block 3, and a fixed block 4, which are joined together. Below, the electromagnet block 2 joined to the movable block 3 may be referred to as the body block 10 (see Figure 3).

As shown in Figures 3 and 4, the main body block 10 includes a coil 21, an iron core 23 inserted inside the coil 21, and an armature 33.

Hereinafter, the imaginary axis along which the iron core 23 extends is also referred to as the first axis A1. The armature 33 is aligned with the iron core 23 along the first axis A1. The imaginary axis along which the main body block 10 and the fixed block 4 are aligned is also referred to as the second axis A2. The second axis A2 intersects with the first axis A1, and is orthogonal here. The imaginary axis that intersects with both the first axis A1 and the second axis A2 is also referred to as the third axis A3. Here, the third axis A3 is orthogonal to both the first axis A1 and the second axis A2. In addition, the side of the first axis A1 where the armature 33 is located as viewed from the iron core 23 is also referred to as the "upper", and the side of the first axis A1 where the iron core 23 is located as viewed from the armature 33 is also referred to as the "lower". In addition, on the second axis A2, the side on which the fixed block 4 is located when viewed from the main body block 10 is also referred to as the "left", and on the second axis A2, the side on which the main body block 10 is located when viewed from the fixed block 4 is also referred to as the "right". In addition, the two sides on the third axis A3 are also referred to as the "front" and "rear", respectively.

In addition, in this disclosure, "top view" refers to viewing from above along the first axis A1, "side view" refers to viewing from the right or left along the second axis A2, and "front view" refers to viewing from the front along the third axis A3.

As shown in FIG. 3, the fixing block 4 is assembled to the main body block 10 from the left side along the second axis A2 and fixed to the main body block 10. In this disclosure, "fixed" can mean both being fixed in a detachable manner by fitting or the like, and being fixed in an undetachable manner by adhesion, welding, or the like.

(2.1) Electromagnet Block As shown in FIGS. 4 and 5, the electromagnet block 2 includes a coil 21, a bobbin 22, an iron core 23, an insulating member 24, a yoke 25, and two coil terminals 26.

As shown in FIG. 5, the bobbin 22 has a main body 61, an upper flange 62 provided on the upper part of the main body 61, and a lower flange 63 provided on the lower part of the main body 61. The main body 61, the upper flange 62, and the lower flange 63 are integrally formed as a molded body of electrically insulating synthetic resin.

The main body 61 is a hollow cylinder whose axis is aligned along the first axis A1. The coil 21 is wound around the main body 61. The axis of the coil 21 (the imaginary axis around which the windings of the coil 21 are wound) approximately coincides with the axis of the main body 61.

As shown in Figures 5 and 6, the upper flange portion 62 has an upper flange body 621 that is a plate-like shape that is generally rectangular when viewed from above. The upper flange body 621 has a circular hole 622 that is connected to the internal space of the body portion 61 at a position to the left of the center. A circular support base portion 623 that protrudes upward is provided around the hole 622 on the upper surface of the upper flange body 621.

The upper flange portion 62 has a first wall portion 64, a second wall portion 65, and a third wall portion 66 on the upper surface of the upper flange body 621.

The first wall portion 64 is provided along a first side (front side) of the upper tsuba body 621 along the second axis A2. The first wall portion 64 protrudes upward from the top surface of the upper tsuba body 621. The first wall portion 64 is formed continuously along the second axis A2. The first wall portion 64 is provided at a position overlapping with an imaginary line extending forward along the third axis A3 from the center of the hole 622 of the upper tsuba body 621.

The first wall portion 64 comprises a base portion 641 formed on the upper surface of the upper flange body 621, and a protruding rib 642 formed on the upper surface of the base portion 641. The base portion 641 is a generally rectangular parallelepiped extending along the second axis A2. The protruding rib 642 is a generally protruding stripe extending along the second axis A2.

The thickness of the protruding rib 642 (the dimension along the third axis A3) is thinner than the thickness of the base 641. The front surface (outer surface) of the base 641 and the front surface of the protruding rib 642 are flush (in the same plane). Therefore, there is a step between the rear surface (inner surface) of the protruding rib 642 and the base 641.

The length of the protruding rib 642 (the dimension along the second axis A2) is shorter than the length of the base 641. On the second axis A2, the protruding rib 642 is located approximately in the center of the upper surface of the base 641. Therefore, there is a step between the left side surface of the protruding rib 642 and the base 641, and there is a step between the right side surface of the protruding rib 642 and the base 641. A recess (first recess 643) is formed in the step between the base 641 and the protruding rib 642. In this way, the first wall portion 64 has a first recess 643 recessed along the first axis A1. The first wall portion 64 has two first recesses 643 located at both ends (left end and right end) of the first wall portion 64 on the second axis A2.

The second wall portion 65 is provided along the second side (rear side) of the upper tsuba body 621 along the second axis A2. The second wall portion 65 protrudes upward from the upper surface of the upper tsuba body 621. The second wall portion 65 is formed continuously along the second axis A2. The second wall portion 65 is provided at a position overlapping with an imaginary line extending rearward along the third axis A3 from the center of the hole 622 of the upper tsuba body 621.

The second wall portion 65 faces the first wall portion 64 across the hole 622 on the third axis A3. When viewed from above, the first wall portion 64 and the second wall portion 65 are symmetrical.

The second wall portion 65 comprises a base portion 651 formed on the upper surface of the upper flange body 621, and a protruding rib 652 formed on the upper surface of the base portion 651. The base portion 651 is a generally rectangular parallelepiped extending along the second axis A2. The protruding rib 652 is a generally protruding stripe extending along the second axis A2.

The thickness of the protruding rib 652 (the dimension along the third axis A3) is thinner than the thickness of the base 651. The rear surface (outer surface) of the base 651 and the rear surface of the protruding rib 652 are flush (in the same plane). Therefore, there is a step between the front surface (inner surface) of the protruding rib 652 and the base 651.

The length of the protruding rib 652 (the dimension along the second axis A2) is shorter than the length of the base 651. On the second axis A2, the protruding rib 652 is located at approximately the center of the upper surface of the base 651. Therefore, there is a step between the left side surface of the protruding rib 652 and the base 651, and there is a step between the right side surface of the protruding rib 652 and the base 651. A recess (second recess 653) is formed in the step between the base 651 and the protruding rib 652. In this way, the second wall 65 has a second recess 653 recessed along the first axis A1. The second wall 65 has two second recesses 653 located at both ends (left end and right end) of the second wall 65 on the second axis A2 as the second recess 653.

The third wall portion 66 is provided on the upper surface of the upper tsuba body 621 along the third axis A3. The third wall portion 66 is provided along the third side (left side) of the upper tsuba body 621 along the third axis A3. The third wall portion 66 protrudes upward from the upper surface of the upper tsuba body 621. The third wall portion 66 is located to the left of the hole 622.

The third wall portion 66 is a generally rectangular parallelepiped extending along the third axis A3. The height of the third wall portion 66 (the dimension along the first axis A1) is generally equal to the height of the base 641 of the first wall portion 64 and generally equal to the height of the base 651 of the second wall portion 65.

The third wall portion 66 connects between the first end (left end) of the first wall portion 64 and the first end (left end) of the second wall portion 65. More specifically, the third wall portion 66 connects between the rear surface of the first end (left end) of the base portion 641 of the first wall portion 64 and the front surface of the first end (left end) of the base portion 651 of the second wall portion 65. The third wall portion 66 is formed continuously along the third axis A3. In the upper flange portion 62, the first wall portion 64, the second wall portion 65, and the third wall portion 66 form a C-shape when viewed from above.

As shown in Figures 5 and 6, the upper flange 62 further includes a protruding portion 624, a retaining protrusion 625, and a positioning portion 626.

The protruding plate portion 624 is a plate-like member that protrudes leftward along the second axis A2 from the third side (left piece) of the upper flange body 621. The protruding plate portion 624 is flush with the upper flange body 621.

The retaining protrusion 625 is provided on the upper surface of the protruding plate portion 624. The retaining protrusion 625 is a rib that extends along the second axis A2 at a position near the front end on the upper surface of the protruding plate portion 624. One end of the retaining protrusion 625 is connected to the left side surface of the third wall portion 66.

The positioning portion 626 is a protrusion provided on the upper surface of the upper flange body 621 along the third axis A3. The positioning portion 626 is provided along the fourth side (right side) of the upper flange body 621 along the third axis A3. The length of the positioning portion 626 (the dimension along the third axis A3) is shorter than the length of the fourth side (right side) of the upper flange body 621. The positioning portion 626 is provided in the center of the fourth side (right side) of the upper flange body 621 on the third axis A3. The first end (front end) of the positioning portion 626 is not connected to the second end (right end) of the first wall portion 64, and there is a gap between them. The second end (rear end) of the positioning portion 626 is not connected to the second end (right end) of the second wall portion 65, and there is a gap between them.

As shown in Figures 5 and 7, the lower flange 63 includes an upper wall portion 631, a lower wall portion 632, a front wall portion 633, a rear wall portion 634, and a left wall portion 635. The lower flange 63 is formed in a hollow rectangular box shape. The lower flange 63 is open on one side of the second axis A2 (the right side). In other words, the lower flange 63 includes an opening 630 on the right side.

The upper wall portion 631 is a generally rectangular plate when viewed from above. The upper wall portion 631 has a circular hole 636 in the center that connects the internal space of the main body portion 61 and the internal space of the lower flange portion 63.

The lower wall portion 632 is a generally rectangular plate-like shape when viewed from above. The lower wall portion 632 has a circular hole 637 in its center that connects the internal space of the lower flange portion 63 with the external space. When viewed from above, the center of the hole 637 in the lower wall portion 632 generally coincides with the center of the hole 636 in the upper wall portion 631.

The lower wall portion 632 is longer (dimension along the second axis A2) than the upper wall portion 631. When viewed from above, the right end of the lower wall portion 632 protrudes further to the right than the right end of the upper wall portion 631.

The lower surface of the lower wall portion 632 is provided with an engagement protrusion 638 that protrudes downward at the left end in the center of the third axis A3.

The front wall portion 633 and the rear wall portion 634 are generally rectangular plate-shaped when viewed from the front. The front wall portion 633 connects the front edge of the upper wall portion 631 to the front edge of the lower wall portion 632. The rear wall portion 634 connects the rear edge of the upper wall portion 631 to the rear edge of the lower wall portion 632.

The left wall portion 635 is a generally rectangular plate in side view. The left wall portion 635 connects the left edge of the upper wall portion 631 and the left edge of the lower wall portion 632.

The lower flange 63 has two retaining grooves 639 at both ends (front end and rear end) of the third axis A3 at the left end for respectively attaching two coil terminals 26. The retaining grooves 639 are formed across the upper wall portion 631, the left wall portion 635, and the lower wall portion 632.

As shown in Figures 4 and 5, the two coil terminals 26 are inserted into the two retaining grooves 639 of the lower flange 63, respectively, and are held by the lower flange 63. One of the two coil terminals 26 is connected to the first end of the coil 21, and the other is connected to the second end of the coil 21.

As shown in FIG. 5, the coil terminal 26 includes a first terminal portion 261 connected to the coil 21, a second terminal portion 262 connected to an external device, and a connecting portion 263 connecting the first terminal portion 261 and the second terminal portion 262. The first terminal portion 261 protrudes upward from the upper wall portion 631 of the lower flange portion 63. The second terminal portion 262 protrudes downward from the lower wall portion 632 of the lower flange portion 63. As shown in FIG. 1, the second terminal portion 262 is exposed downward from the case 9.

As shown in FIG. 5, the iron core 23 is formed in a cylindrical shape. The iron core 23 is inserted vertically into the bobbin 22 along the first axis A1. The iron core 23 is inserted into the body portion 61 of the bobbin 22. The iron core 23 has a disk-shaped magnetic pole portion 231 at one end (upper end) on the first axis A1. As shown in FIG. 4, the magnetic pole portion 231 is exposed above the bobbin 22. The lower surface of the magnetic pole portion 231 is supported by the support base portion 623 of the upper flange portion 62 of the bobbin 22. The iron core 23 has a relatively small diameter portion 232 at its lower end.

As shown in Figures 4 and 5, the coil 21 is wound around the bobbin 22. The coil 21 is wound around the body portion 61 of the bobbin 22. Therefore, the coil 21 is wound around the iron core 23.

The first end of the coil 21 is connected to one of the two coil terminals 26, and the second end of the coil 21 is connected to the other of the two coil terminals 26.

As shown in FIG. 5, the yoke 25 comprises a first yoke 251 and a second yoke 252.

The first yoke 251 is a rectangular plate extending along the first axis A1. The second yoke 252 is a rectangular plate extending along the second axis A2. The lower end of the first yoke 251 is connected to the right end of the second yoke 252, and the first yoke 251 and the second yoke form an inverted L-shape when viewed from the front.

The first yoke 251 has two fixing protrusions 253 for fixing the movable spring 31 at both ends (front end and rear end) of the third axis A3 on its right surface. The fixing protrusions 253 can be formed, for example, by pushing the portion of the left surface of the first yoke 251 that corresponds to the fixing protrusions 253 from the left side to the right.

The second yoke 252 has a through hole 254. The through hole 254 passes through the second yoke 252 along the first axis A1.

As shown in Figures 4 and 5, the first yoke 251 is disposed on the right side of the coil 21. The second yoke 252 is inserted from the right side through the opening 630 into the internal space of the lower flange portion 63 of the bobbin 22. Then, the iron core 23 (more specifically, the thin-diameter portion 232) is inserted from above into the through-hole 254 of the second yoke 252 (see Figures 9 and 10A). This fixes the iron core 23 to the yoke 25. The yoke 25 forms a magnetic circuit together with the iron core 23.

The length (dimension along the first axis A1) of the first yoke 251 is greater than the distance between the upper flange portion 62 (upper flange body 621) and the lower flange portion 63 (upper wall portion 631) of the bobbin 22. The width (dimension along the third axis A3) of the first yoke 251 is approximately the same as the diameter of the coil 21. In a side view from the right side, the first yoke 251 covers approximately the entire coil 21.

As shown in Figures 4 and 5, the insulating member 24 is disposed between the bobbin 22 and the yoke 25. The insulating member 24 is located between the coil 21 and the yoke 25. The insulating member 24 provides insulation between the coil 21 and the yoke 25. The insulating member 24 covers the coil 21 from the right side. The insulating member 24 is covered by the yoke 25 from the right side.

As shown in Figures 5 and 8, the insulating member 24 includes a main body 241, a cover portion (hereinafter also referred to as the "first cover portion") 242, a first connecting portion 243, a second covering portion 244, a second connecting portion 245, a pair of first protrusions 246, and a pair of second protrusions 247. The main body 241, the first covering portion 242, the first connecting portion 243, the second covering portion 244, the second connecting portion 245, the pair of first protrusions 246, and the pair of second protrusions 247 are integrally formed as a molded body of synthetic resin having electrical insulation properties.

The main body 241 has a plate shape with a substantially C-shaped cross section perpendicular to the first axis A1. The main body 241 faces the right side surface of the coil 21 and covers the coil 21 from the right side. The left surface of the main body 241 has a central portion that extends back and forth along the third axis A3 to match the curvature of the right side surface of the coil 21, and both end portions that extend diagonally forward and backward from both ends of the third axis A3 of the central portion so as to be inclined relative to the central portion. The main body 241 is also covered from the right side by the first yoke 251.

The first cover portion 242 is located below the main body portion 241. The first cover portion 242 is plate-shaped and has a width along the second axis A2.

The first cover portion 242 covers at least a part of the second yoke 252. The first cover portion 242 covers at least a part of the second yoke 252 from above. The first cover portion 242 covers a part of the second yoke 252 near the right end connected to the first yoke 251 (see FIG. 4). The first cover portion 242 integrally includes an upper cover portion 291 that covers the upper surface of the second yoke 252, a front cover portion 292 that covers the front side surface of the second yoke 252, and a rear cover portion 293 that covers the rear side surface of the second yoke 252. That is, the first cover portion 242 covers the second yoke 252 from three sides, namely, above and the front and rear. The part of the second yoke 252 where the through hole 254 is formed is not covered by the first cover portion 242 and is exposed from the first cover portion 242.

The first cover portion 242, together with the second yoke 252, is inserted from the right side through the opening 630 into the internal space of the lower flange portion 63 of the bobbin 22. For example, after the first cover portion 242 is inserted from the right side through the opening 630 into the internal space of the lower flange portion 63, the second yoke 252 is inserted from the right side through the opening 630 under the first cover portion 242 into the internal space of the lower flange portion 63. Here, the first cover portion 242 is pressed into the inside of the lower flange portion 63 through the opening 630. Also, the second yoke 252 is inserted into the internal space of the lower flange portion 63 through the opening 630 and pressed between the lower wall portion 632 of the lower flange portion 63 and the first cover portion 242. As a result, the insulating member 24 and the yoke 25 are fixed to the bobbin 22. Because the insulating member 24 and the yoke 25 are fixed to the bobbin 22, even if the electromagnetic relay 100 vibrates, defects such as wear on the bobbin 22 or insulating member 24 are unlikely to occur.

Figure 9 shows a horizontal cross-sectional view of the electromagnet block 2 on a virtual plane passing through the lower flange 63. As shown in Figure 9, the lower flange 63 of the bobbin 22 is provided with a bobbin side guide 69. The bobbin side guide 69 is an inclined surface formed on the right side surface of the front wall portion 633 and the rear wall portion 634 at the entrance of the opening 630 of the lower flange 63. The bobbin side guide 69 guides the first cover portion 242 of the insulating member 24. The lower flange 63 is provided with the bobbin side guide 69, which makes it easier to attach the insulating member 24 to the bobbin 22.

9, the first cover portion 242 of the insulating member 24 is provided with an insulating member side guide 240. The insulating member side guide 240 is an inclined surface formed on the rear side surface of the front cover portion 292 and the rear cover portion 293 of the first cover portion 242. The insulating member side guide 240 guides the second yoke 252. By providing the insulating member 24 with the insulating member side guide 240, it becomes easier to attach the yoke 25 to the insulating member 24, and therefore to attach the yoke 25 to the bobbin 22. In addition, the second yoke 252 has inclined surfaces 255 at both corners of its tip (left end). By providing the inclined surfaces 255, it becomes easier to attach the yoke 25 to the insulating member 24.

When the first cover portion 242 and the second yoke 252 are inserted into the opening 630, as shown in FIG. 10A, the lower wall portion 632 of the lower flange portion 63, the second yoke 252, the first cover portion 242 of the insulating member 24, the upper wall portion 631 of the lower flange portion 63, and the coil 21 are arranged in this order from below along the first axis A1. Therefore, the upper surface of the first cover portion 242 (the upper surface of the upper cover portion 291) is covered from above by the upper wall portion 631 of the lower flange portion 63. In addition, the lower surface of the second yoke 252 is covered from below by the lower wall portion 632 of the lower flange portion 63. That is, in the electromagnetic relay 100, the upper wall portion 631 of the lower flange portion 63 and the first cover portion 242 (upper cover portion 291) of the insulating member 24 are interposed between the coil 21 and the second yoke 252 on the first axis A1. Therefore, in a cross section perpendicular to the third axis A3, the shortest path between the coil 21 and the second yoke 252 is the path shown by the two-dot chain line L1 in FIG. 10B. This makes it possible to increase the insulation distance between the coil 21 and the yoke 25 compared to an electromagnetic relay of a comparative example in which the insulating member does not have a first cover portion. Note that in FIG. 10B, for convenience of explanation, a gap is drawn between the components. In addition, as described above, the first cover portion 242 covers the second yoke 252 from three sides (upper, front, and rear), so that the insulation distance between the coil 21 and the second yoke 252 can be further increased. In addition, since the first cover portion 242 does not cover the lower surface of the second yoke 252, it is possible to suppress an increase in the dimension of the electromagnet block 2 along the first axis A1.

As shown in FIG. 8, the first connecting portion 243 connects the main body portion 241 and the first cover portion 242. The first connecting portion 243 connects the lower edge of the right end of the main body portion 241 and the right end of the upper surface of the first cover portion 242.

The second cover portion 244 is located above the main body portion 241. The second cover portion 244 is plate-shaped and has a width along the second axis A2.

The second cover portion 244 covers at least a portion of the upper surface of the upper flange portion 62 (upper flange body 621) of the bobbin 22. As shown in FIG. 4, the second cover portion 244 covers the right end portion of the upper surface of the upper flange body 621. The magnetic pole portion 231 of the iron core 23 is exposed and not covered by the second cover portion 244.

The second cover portion 244 has steps at the left front end and the left rear end when viewed from above. The right end of the base 641 of the first wall portion 64 of the upper flange portion 62 and the right end of the base 651 of the second wall portion 65 fit into these steps. As shown in Figures 4 and 15, when viewed from above, the base 641 of the first wall portion 64 of the upper flange portion 62, the third wall portion 66, the base 651 of the second wall portion 65, and the second cover portion 244 of the insulating member 24 are connected in a rectangular frame shape.

As shown in FIG. 4, the upper surface of the second cover portion 244 has a height position (position on the first axis A1) that is substantially the same as the height position of the base 641 of the first wall portion 64 of the upper flange portion 62 and the height position of the base 651 of the second wall portion 65.

As shown in FIG. 8, a recess 248 is formed on the underside of the second cover portion 244 along the second axis A2. The positioning portion 626 of the upper flange portion 62 of the bobbin 22 is fitted into the recess 248 along the second axis A2, thereby positioning the insulating member 24 relative to the bobbin 22. As shown in FIG. 10A, with the positioning portion 626 fitted into the recess 248, the upper surface of the first cover portion 242 (the upper surface of the upper cover portion 291) is in contact with the lower surface of the upper wall portion 631 of the lower flange portion 63.

The second connecting portion 245 connects the main body portion 241 and the second cover portion 244. The second connecting portion 245 connects the upper edge of the right end of the main body portion 241 and the right end of the underside of the second cover portion 244.

A groove is formed along the third axis A3 between the second cover portion 244, the second connecting portion 245, and the main body portion 241. As shown in FIG. 10A, the right end portion of the upper flange main body 621 of the upper flange portion 62 of the bobbin 22 is fitted into this groove.

As shown in FIG. 8, the pair of first protrusions 246 protrude rightward along the second axis A2 from the right surfaces of the front cover portion 292 and the rear cover portion 293 of the first cover portion 242. The first protrusions 246 are generally rectangular parallelepiped shapes extending along the second axis A2. As shown in FIG. 4, the first protrusions 246 are placed on the upper surface of the lower wall portion 632 of the lower flange portion 63 of the bobbin 22. The pair of first protrusions 246 cover the front and rear sides of the lower end portion of the first yoke 251, respectively.

The pair of second protrusions 247 protrude rightward along the second axis A2 from the front and rear ends of the right surface of the second connecting portion 245. The pair of second protrusions 247 cover the front and rear sides of the upper end of the first yoke 251, respectively.

(2.2) Movable Block As shown in FIGS. 4 and 11, the movable block 3 includes a movable spring 31, a movable contact member 32, and an armature 33.

The movable spring 31 has a leg piece 35, a fixed piece 36, a spring piece 37, and a movable piece 38. The movable spring 31 has two leg pieces 35. The two leg pieces 35, the fixed piece 36, the spring piece 37, and the movable piece 38 are integrally formed from a conductive metal material.

The leg pieces 35 are rectangular plates extending along the first axis A1. The two leg pieces 35 are aligned along the third axis A3. The leg pieces 35 are terminals that are connected to external electrical equipment. As shown in FIG. 1, the leg pieces 35 are exposed downward from the case 9.

The fixed piece 36 is a plate extending upward from the upper end of the leg piece 35. The fixed piece 36 is a part that is fixed to the yoke 25, more specifically, the first yoke 251. The fixed piece 36 has two fixing holes 311 into which the two fixing protrusions 253 of the first yoke 251 are respectively inserted.

The spring piece 37 is a plate-like inverted L-shape when viewed from the front. The spring piece 37 is flexible. The spring piece 37 has a first plate-like spring portion 371 that extends upward from the upper end of the fixed piece 36, a curved portion 372 that curves leftward from the upper end of the first plate spring portion 371, and a second plate spring portion 373 that extends leftward from the left end of the curved portion 372.

The movable piece 38 is a plate extending leftward from the left end of the second leaf spring portion 373 of the spring piece 37. The joint between the movable piece 38 and the spring piece 37 (second leaf spring portion 373) is bent in a V-shape when viewed from the front. The movable piece 38 can move up and down along the first axis A1 in response to the bending of the spring piece 37. The movable piece 38 is inclined with respect to the normal direction of the fixed piece 36.

The movable piece 38 includes an armature holding portion 381 and a contact holding portion 382. The armature holding portion 381 is located relatively to the right of the movable piece 38. The contact holding portion 382 is located relatively to the left of the movable piece 38.

The armature 33 is held in the armature holding portion 381. Three fixing holes 313 are formed in the armature holding portion 381 and aligned along the third axis A3.

The movable contact M1 is held by the contact holder 382. The contact holder 382 has a through hole 314. The through hole 314 is provided relatively to the rear of the movable spring 31 on the third axis A3. Therefore, the center of the through hole 314 is located rearward of the center of the central fixing hole 313 among the three fixing holes 313.

As shown in FIG. 11, the armature 33 includes an armature body 331, a fixed protrusion 332, and a hook piece 333. The armature 33 includes three fixed protrusions 332. The armature 33 also includes two hook pieces 333. The armature body 331, the three fixed protrusions 332, and the two hook pieces 333 are integrally formed from a magnetic material.

The armature body 331 is a generally rectangular plate-like shape when viewed from above. Three fixed protrusions 332 are provided on the upper surface of the armature body 331. The three fixed protrusions 332 are arranged side by side along the third axis A3. The three fixed protrusions 332 of the armature 33 are inserted from below into the three fixing holes 313 of the armature holding portion 381 of the movable spring 31, and the tips of the fixed protrusions 332 are crushed, thereby fixing the armature 33 to the movable spring 31 (armature holding portion 381). The armature 33 is disposed below the movable spring 31 and fixed to the movable spring 31. In other words, the movable spring 31 is fixed to the upper surface of the armature 33.

As shown in Figures 2 and 3, when the movable block 3 is fixed to the electromagnet block 2, the lower surface of the armature 33 faces the upper surface of the iron core 23 (the upper surface of the magnetic pole portion 231).

When viewed from above, the armature 33 has a first end E1 and a second end E2 on a second axis A2 that intersects with the first axis A1 (see FIG. 11). In this embodiment, the first end E1 is the left end, and the second end E2 is the right end.

The two hook pieces 333 are located at the second end E2 (right end) of the armature 33. The two hook pieces 333 protrude downward from the front and rear ends, respectively, of the right side of the armature body 331. As shown in FIG. 3, the hook piece 333 hooks onto the upper end portion of the right side of the first yoke 251. Therefore, the armature 33 rotates with the hook piece 333 as a fulcrum depending on the presence or absence of an attractive force between the armature 33 and the iron core 23. The movable piece 38 of the movable spring 31 moves up and down along the first axis A1 together with the armature body 331.

As shown in FIG. 11, the movable contact member 32 includes a head portion 321 and a body portion 322.

The head 321 is shaped like a truncated cone. The axis of the head 321 is aligned with the first axis A1. The lower surface of the head 321 functions as the movable contact M1. The lower surface of the movable contact member 32 that functions as the movable contact M1 is made of, for example, a silver alloy (AgNi or AgSnO ₂ ). The portion of the movable contact member 32 other than the movable contact M1 is made of, for example, a copper alloy such as tough pitch copper. The surface (lower surface) of the movable contact member 32 that functions as the movable contact M1 is spherical. Note that the surface (lower surface) of the movable contact member 32 that functions as the movable contact M1 may be flat or dome-shaped.

The body 322 protrudes from the upper end of the head 321. The body 322 is inserted into the through hole 314 of the contact holder 382 of the movable spring 31. The movable contact member 32 is fixed to the movable spring 31 by crimping with the body 322 passing through the through hole 314 of the contact holder 382. In this way, the movable contact member 32 is electrically connected to the movable spring 31.

The movable contact M1 may be formed integrally with the movable spring 31. For example, a part of the metal plate constituting the movable spring 31 may be protruded downward, and the tip of the protruding part may be used as the movable contact M1.

In this way, the movable contact M1 is provided on the movable spring 31 on the side of the first end E1 (left end) of the armature 33 when viewed from above. The movable contact M1 moves up and down along the first axis A1 together with the armature body 331 in response to the movement of the armature 33 (rotation about the hook piece 333 as a fulcrum).

(2.3) Fixed Block As shown in FIGS. 3 and 12, the fixed block 4 includes a support base 41, a conductive member 42, a fixed contact member 43, and an auxiliary member 44.

The holding base 41 is a rectangular box-like shape with an opening on the right side. As shown in Figures 12 and 13, the holding base 41 has a left wall 45, a front wall 46, a rear wall 47, a lower wall 48, an upper wall 49, and an auxiliary wall 40. The left wall 45, the front wall 46, the rear wall 47, the lower wall 48, the upper wall 49, and the auxiliary wall 40 are integrally formed as a molded body of electrically insulating synthetic resin.

An engagement hole 411 is formed at the right end of the lower wall 48. A recess 412 recessed to the left along the second axis A2 is formed at the upper end of the right side of the front wall 46. A recess 413 recessed to the left along the second axis A2 is formed at the upper end of the right side of the rear wall 47. A retaining groove 414 extending along the second axis A2 is formed at the front end of the lower surface of the upper wall 49.

The front end and rear end of the protruding plate portion 624 of the upper flange 62 of the bobbin 22 are inserted into the recess 412 of the front wall 46 and the recess 413 of the rear wall 47, respectively. The holding protrusion 625 of the upper flange 62 of the bobbin 22 is inserted (pressed in here) into the holding groove 414 of the upper wall 49. The engaging protrusion 638 of the lower flange 63 of the bobbin 22 engages with the engaging hole 411 of the lower wall 48. This connects the fixed block 4 to the main body block 10. With the fixed block 4 connected to the main body block 10, the left wall 45 of the holding base 41 faces the left side surface of the coil 21 and covers the coil 21 from the left side (see FIG. 2).

A protruding wall portion 415 that protrudes upward along the first axis A1 is provided on the upper surface of the upper wall 49. The protruding wall portion 415 extends back and forth along the third axis A3.

As shown in FIG. 13, a retaining recess 416 recessed to the right is formed in the lower end of the left surface of the left wall 45. A retaining recess 417 recessed to the right is formed along the first axis A1 in the left surface of the rear wall 47.

The auxiliary wall 40 protrudes upward from the upper end of the front wall 46. A retaining groove 418 is formed on the left surface of the retaining base 41, extending along the first axis A1 from the auxiliary wall 40 to the upper portion of the front wall 46. The retaining groove 418 is used to retain the auxiliary member 44.

As shown in FIG. 12, the conductive member 42 has leg pieces 421, a center piece 422, a first fixed piece 423, a second fixed piece 424, and a holding piece 425. The conductive member 42 has two leg pieces 421. The two leg pieces 421, the center piece 422, the first fixed piece 423, the second fixed piece 424, and the holding piece 425 are integrally formed from a metal material having electrical conductivity.

The leg pieces 421 are plate-shaped and extend along the first axis A1. The two leg pieces 421 are aligned along the third axis A3. The leg pieces 421 are terminals that are connected to external electrical equipment. As shown in FIG. 1, the leg pieces 421 are exposed downward from the case 9.

The central piece 422 is a plate-like member that extends upward from the upper end of the leg piece 421. The right surface of the central piece 422 faces the left surface of the left wall 45 of the holding base 41.

The first fixed piece 423 is a plate extending rightward along the second axis A2 from the lower end of the central piece 422. The first fixed piece 423 extends from the portion between the two leg pieces 421 at the lower end of the central piece 422.

The second fixed piece 424 is a plate extending rightward along the second axis A2 from the rear edge of the central piece 422. The second fixed piece 424 extends from the center of the first axis A1 at the rear edge of the central piece 422.

The first fixed piece 423 is inserted from the left into the holding recess 416 of the holding base 41. The second fixed piece 424 is inserted from the left into the holding recess 417 of the holding base 41. This causes the conductive member 42 to be held on the holding base 41.

The left wall 45 and protruding wall portion 415 of the holding base 41 are interposed between the conductive member 42 and the coil 21. Therefore, the holding base 41 functions as an insulating member 7 that is disposed between the coil 21 and the conductive member 42 and insulates the coil 21 from the conductive member 42. The insulating member 7 has an insulating wall portion 70 (protruding wall portion 415) along the first axis A1 (see FIG. 3). The insulating wall portion 70 is between the fixed contact F1 and the center of the coil 21 on the second axis A2.

The holding piece 425 is a plate-like member whose thickness axis is aligned with the first axis A1. The holding piece 425 extends rightward from the upper end of the central piece 422. The holding piece 425 is located above the upper wall 49 of the holding base 41. The holding piece 425 has a through hole 426 in the center.

The conductive member 42 has a through hole 427 at the joint between the central piece 422 and the holding piece 425. Therefore, the current flowing through the holding piece 425 includes not only a component along the second axis A2 but also a component along the third axis A3. The current component along the third axis A3 applies a Lorentz force in a direction intersecting the first axis A1 to an arc that may occur along the first axis A1 between the movable contact M1 and the fixed contact F1, facilitating the extinguishing of the arc.

As shown in FIG. 12, the fixed contact member 43 includes a head portion 431 and a body portion 432, similar to the movable contact member 32. The fixed contact member 43, together with the conductive member 42, constitutes the fixed contact portion 400.

The head 431 is shaped like a truncated cone. The axis of the head 431 is aligned with the first axis A1. The upper surface of the head 431 functions as the fixed contact F1. The upper surface of the fixed contact member 43 that functions as the fixed contact F1 is made of, for example, a silver alloy (AgNi or AgSnO ₂ ). The portion of the fixed contact member 43 other than the fixed contact F1 is made of, for example, a copper alloy such as tough pitch copper. The surface (upper surface) of the fixed contact member 43 that functions as the fixed contact F1 is spherical. Note that the surface (upper surface) of the fixed contact member 43 that functions as the fixed contact F1 may be flat or dome-shaped.

The body 432 protrudes from the lower end of the head 431. The body 432 is inserted into the through hole 426 of the holding piece 425 of the conductive member 42. The fixed contact member 43 is fixed to the conductive member 42 by crimping with the body 432 passing through the through hole 426 of the holding piece 425. In this way, the fixed contact member 43 is electrically connected to the conductive member 42.

The fixed contact F1 may be formed integrally with the conductive member 42. For example, a part of the metal plate constituting the conductive member 42 may be protruded upward, and the tip of the protruding part may be used as the fixed contact F1.

As shown in Figures 2, 3, and 10A, when the fixed block 4 is fixed to the main body block 10, the fixed contact F1 faces the movable contact M1 along the first axis A1. The movable piece 38 of the movable spring 31 moves up and down, causing the movable contact M1 to move toward and away from the fixed contact F1. In addition, a protruding wall portion 415 is interposed between the fixed contact F1 and the iron core 23 (magnetic pole portion 231).

As shown in FIG. 12, the auxiliary member 44 includes a side piece 441 and an upper piece 442. The side piece 441 and the upper piece 442 are integrally formed from a conductive metal material.

The side piece 441 is a plate extending along the first axis A1. The side piece 441 has a recess 443 on its right side that is recessed to the left along the second axis A2. The recess 443 determines the position of the auxiliary member 44 relative to the holding base 41 on the first axis A1.

The upper piece 442 is a plate extending rearward from the upper end of the side piece 441 along the third axis A3. The lower surface of the upper piece 442 is provided with a protrusion 444 that protrudes downward further than other parts of the upper piece 442. The protrusion 444 can be formed, for example, by pushing a portion of the upper surface of the upper piece 442 that corresponds to the protrusion 444 downward from above. The lower surface of the protrusion 444 faces the upper surface of the body 322 of the movable contact member 32.

Since the upper piece 442 of the auxiliary member 44 is located above the movable contact member 32, even if the movable spring 31 vibrates when the movable contact M1 separates from the fixed contact F1 and the movable spring 31 moves upward, excessive vibration of the movable spring 31 is suppressed.

(2.4) Relay Body The relay body 1 is formed by combining an electromagnet block 2, a movable block 3, and a fixed block 4.

For example, as shown in FIG. 4, the movable block 3 is positioned to the right of the electromagnet block 2. Then, the movable block 3 is moved to the left along the second axis A2, and the two fixed protrusions 253 of the first yoke 251 are inserted into the two fixing holes 311 of the fixed piece 36 of the movable spring 31, respectively, and the tips of the fixed protrusions 253 are crushed. This fixes the movable block 3 to the electromagnet block 2. This forms the main body block 10 in which the electromagnet block 2 and the movable block 3 are joined (see FIG. 3).

As shown in FIG. 3, the fixed block 4 is positioned to the left of the main body block 10. Then, the fixed block 4 is moved to the right along the second axis A2, and the protruding plate portion 624 of the upper flange portion 62 of the bobbin 22 is inserted into the recesses 412, 413 of the holding base 41, the holding protrusion 625 of the upper flange portion 62 is inserted into the holding groove 414 of the holding base 41, and the engaging protrusion 638 (see FIG. 7) of the lower flange portion 63 is engaged with the engaging hole 411 of the holding base 41. This fixes the fixed block 4 to the main body block 10 (see FIG. 2). The bobbin 22 may be further fixed to the holding base 41 by adhesive or the like.

Thus, the electromagnetic relay 100 includes a main terminal block (bobbin 22 and insulating member 24) that includes the bobbin 22 and holds the movable spring 31, and a sub-terminal block (holding block 41) that holds the fixed contact F1. The sub-terminal block is separate from the main terminal block and is fixed to the main terminal block. In the electromagnetic relay 100 of this embodiment, the main terminal block and the sub-terminal block are separate. Therefore, it is possible to adjust the components held on one terminal block (e.g., the main terminal block) (aligning the components, adjusting the spring force, etc.) separately from the adjustment of the components held on the other terminal block (e.g., the sub-terminal block). This makes it possible to simplify the manufacturing process of the electromagnetic relay 100.

In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, an insulating member 7 (holding base 41) is arranged between the coil 21 and the fixed contact portion 400 (conductive member 42). Therefore, it is possible to increase the insulation distance between the coil 21 and the conductive parts (hereinafter also referred to as "main circuit parts") electrically connected to the contact device (movable contact M1 and fixed contact F1). In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, the main circuit parts include the movable spring 31, the conductive member 42, the iron core 23, the armature 33, and the yoke 25. In the electromagnetic relay 100, among the main circuit parts, the holding piece 425 of the conductive member 42, the fixed contact member 43 (fixed contact F1), and the movable piece 38 (movable contact M1) of the movable spring 31 are arranged above the bobbin 22. That is, in the electromagnetic relay 100, the fixed contact F1 and the movable contact M1 are provided above the bobbin 22.

In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, the insulating member 24 is provided with a first cover portion 242. Therefore, in a cross section perpendicular to the third axis A3, the shortest path between the coil 21 and the second yoke 252 is a path that goes around the first cover portion 242 as shown by the two-dot chain line L1 in FIG. 10B. This makes it possible to increase the insulation distance between the coil 21 and the second yoke 252, and further increase the insulation distance between the coil 21 and the main circuit components.

In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, the insulating member 24 is provided with a second cover portion 244. Therefore, in a cross section perpendicular to the third axis A3, the shortest path between the coil 21 and the armature 33 is the path that goes around the second cover portion 244 as shown by the two-dot chain line L2 in FIG. 10C. This makes it possible to increase the insulation distance between the coil 21 and the armature 33, and further increase the insulation distance between the coil 21 and the main circuit components. Note that, for ease of explanation, FIG. 10C shows a gap formed between the components.

In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, the third wall portion 66 of the upper flange portion 62 of the bobbin 22 is interposed between the magnetic pole portion 231 of the iron core 23 and the fixed contact F1 on the second axis A2. Therefore, in a cross section perpendicular to the third axis A3, the shortest path between the coil 21 and the iron core 23 is a path that goes around the third wall portion 66 as shown by the two-dot chain line L3 in FIG. 10D. This makes it possible to increase the insulation distance between the coil 21 and the iron core 23, and further increase the insulation distance between the coil 21 and the main circuit components. Note that, for convenience of explanation, FIG. 10D shows a gap formed between the components.

In addition, in the relay body 1 of the electromagnetic relay 100 of this embodiment, the protruding wall portion 415 of the holding base 41 (insulating wall portion 70 of the insulating member 7) is interposed between the magnetic pole portion 231 of the iron core 23 and the fixed contact F1 on the second axis A2. Therefore, in a cross section perpendicular to the third axis A3, the shortest path between the coil 21 and the fixed contact F1 is a path that goes around the insulating wall portion 70 as shown by the two-dot chain line L4 in FIG. 10D. This makes it possible to increase the insulation distance between the coil 21 and the fixed contact F1, and further increase the insulation distance between the coil 21 and the main circuit components.

Next, we will explain the operation of the relay main body 1 (operation of the electromagnetic relay 100).

In the relay body 1, when no voltage is applied between the two coil terminals 26 and the coil 21 is not energized (hereinafter also referred to as "non-energized"), as shown in FIG. 2, the spring force of the movable spring 31 keeps the movable contact M1 away from the fixed contact F1. Therefore, the electrical path between the leg 421 of the conductive member 42 and the leg 35 of the movable spring 31 is interrupted.

In the relay body 1, when a voltage is applied between the two coil terminals 26 and the coil 21 is energized (hereinafter also referred to as "when energized"), the armature 33 is attracted downward along the first axis A1 toward the magnetic pole portion 231 due to the attractive force generated between the armature 33 and the magnetic pole portion 231 of the iron core 23. As a result, the armature 33 rotates (counterclockwise when viewed from the front) with the hook piece 333 as a fulcrum, and the lower surface of the armature 33 comes into contact with the upper surface of the magnetic pole portion 231 of the iron core 23. When energized, the iron core 23, the yoke 25, and the armature 33 form a magnetic circuit through which the magnetic flux generated by the coil 21 passes. The yoke 25 and the armature 33, which constitute part of the magnetic circuit, are connected between both ends of the iron core 23 in an inverted C-shape when viewed from the front.

When electricity is applied, the movable contact M1 moves downward together with the armature 33 due to the rotation of the armature 33. As a result, when electricity is applied, the movable contact M1 comes into contact with the fixed contact F1. Therefore, an electric path is formed between the leg 421 of the conductive member 42 and the leg 35 of the movable spring 31.

When the current to the coil 21 is stopped in the relay body 1, the attractive force between the iron core 23 and the armature 33 disappears. Therefore, in the relay body 1, the spring force of the movable spring 31 causes the armature 33 to rotate (clockwise when viewed from the front) around the hook piece 333 as a fulcrum, and the armature 33 moves away from the iron core 23. As the armature 33 rotates, the movable contact M1 moves upward together with the armature 33 and moves away from the fixed contact F1. This breaks the electrical circuit.

As described above, in the electromagnetic relay 100 of this embodiment, the movable spring 31 can move between a closed position and an open position in response to switching between excitation and de-excitation of the coil 21. The closed position is a position of the movable spring 31 in which the movable contact M1 contacts the fixed contact F1. The open position is a position of the movable spring 31 in which the movable contact M1 is separated from the fixed contact F1.

In the relay body 1 (electromagnetic relay 100) of this embodiment, the movable contact M1 moves along the contact/separation axis X1 to contact or separate from the fixed contact F1. The contact/separation axis X1 is aligned with the first axis A1.

(2.5) Case As shown in Figures 1 and 2, the case 9 houses the relay body 1. Therefore, the case 9 houses the coil 21, the iron core 23, the armature 33, the fixed contact F1, and the movable spring 31. The case 9 also houses the main terminal block (bobbin 22 and insulating member 24) and the sub-terminal block (holding block 41). The case 9 is, for example, a molded body made of electrically insulating synthetic resin, and is insulating.

As shown in Figs. 2 and 14, the case 9 includes a case body 90. The case body 90 forms the outer shell of the case 9. The case body 90 is a rectangular box shape with an open bottom. The case body 90 includes an upper wall 91, a front wall 92, a rear wall 93, a right wall 94, and a left wall 95.

As shown in FIG. 14, the case 9 further includes a first protrusion 961 and two first connection parts 962 on the inside of the case body 90. The first protrusion 961 is plate-shaped and extends along the first axis A1. The first protrusion 961 extends along the second axis A2. The first protrusion 961 faces the front wall 92 on the third axis A3 with a gap between them. The two first connection parts 962 connect both ends of the first protrusion 961 on the second axis A2 to the rear surface of the front wall 92, respectively. The front wall 92 of the case body 90, the first protrusion 961, and the two first connection parts 962 form a first recess 96 with an open bottom surface.

The case 9 further includes a second protrusion 971 and two second connection parts 972 on the inside of the case body 90 (see FIG. 15). The second protrusion 971 is plate-shaped and extends along the first axis A1. The second protrusion 971 extends along the second axis A2. The second protrusion 971 faces the rear wall 93 on the third axis A3 with a gap between them. The two second connection parts 972 connect both ends of the second protrusion 971 on the second axis A2 to the front surface of the rear wall 93, respectively. The rear wall 93 of the case body 90, the second protrusion 971, and the two second connection parts 972 form a second recess 97 with an open bottom surface.

As shown in FIG. 15, the first wall portion 64 (more specifically, the protruding rib 642) of the upper flange portion 62 of the bobbin 22 is inserted into the first recess 96. Therefore, the first protrusion portion 961 faces the first wall portion 64 (more specifically, the protruding rib 642) on the third axis A3. The first connection portion 962 is inserted into the first recess 643. The two first connection portions 962 are inserted into the two first recesses 643, respectively. The first wall portion 64 (more specifically, the protruding rib 642) is surrounded on all four sides (front, back, left, right, and right) by the first protrusion portion 961, the two first connection portions 962, and the front wall 92.

As shown in FIG. 15, the second wall portion 65 (more specifically, the protruding rib 652) of the upper flange portion 62 of the bobbin 22 is inserted into the second recess 97. Therefore, the second protrusion portion 971 faces the second wall portion 65 (more specifically, the protruding rib 652) on the third axis A3. The second connection portion 972 is inserted into the second recess 653. Two second connection portions 972 are inserted into the two second recesses 653, respectively. The second wall portion 65 (more specifically, the protruding rib 652) is surrounded on all four sides (front, back, left, and right) by the second protrusion portion 971, the two second connection portions 972, and the rear wall 93.

Figure 16A shows a cross-sectional view of the electromagnetic relay 100 on an imaginary plane perpendicular to the second axis A2. In the electromagnetic relay 100 of this embodiment, an upper flange 62 is interposed between the armature 33 and the coil 21 on the first axis A1. Therefore, in a cross section perpendicular to the second axis A2, the shortest path between the armature 33 and the coil 21 is a path along the side surface of the upper flange 62. Here, in the electromagnetic relay 100 of this embodiment, the upper flange 62 has a first wall portion 64 and a second wall portion 65, and the first wall portion 64 and the second wall portion 65 are inserted into the first recess 96 and the second recess 97 of the case 9, respectively. Therefore, in a cross section perpendicular to the second axis A2, the shortest path between the armature 33 and the coil 21 is, for example, an S-shaped path including the space S1 between the first protrusion 961 of the case 9 and the first wall 64 (protrusion rib 642), as shown by the two-dot chain line L5 in FIG. 16B. This makes it possible to increase the insulation distance between the coil 21 and the armature 33 in the electromagnetic relay 100 of this embodiment, and further increase the insulation distance between the coil 21 and the main circuit components. Note that, for ease of explanation, FIG. 16B shows a gap between the components.

16A, in the electromagnetic relay 100 of this embodiment, on the first axis A1, the lower ends of the first protrusion 961 and the second protrusion 971 of the case 9 are located below the upper surface of the iron core 23 (the upper surface of the magnetic pole portion 231). In addition, the upper end of the first wall portion 64 (the upper end of the protrusion 642) and the upper end of the second wall portion 65 (the upper end of the protrusion 652) of the bobbin 22 are located above the upper surface of the iron core 23. The armature 33 moves up and down along the first axis A1, but cannot move below the upper surface of the iron core 23, so the armature 33 is always located above the upper surface of the iron core 23. By positioning the lower end of the first ridge 961 (the lower end of the second ridge 971) below the upper surface of the iron core 23, the shortest path (see the two-dot chain line L5) between the armature 33 and the coil 21 is a path that goes around the first ridge 961 (the second ridge 971). As a result, in the electromagnetic relay 100 of this embodiment, compared to the electromagnetic relay of the comparative example in which the lower end of the first ridge (the second ridge) is positioned above the upper surface of the iron core, it is possible to increase the insulation distance between the coil 21 and the armature 33, and to increase the insulation distance between the coil 21 and the main circuit components.

16A, in the electromagnetic relay 100 of this embodiment, the lower end of the first protrusion 961 of the case 9 contacts the upper surface of the upper flange 62 of the bobbin 22 (the upper surface of the base 641 of the first wall 64) on the first axis A1. The upper end of the first wall 64 of the upper flange 62 of the bobbin 22 is separated from the case 9 on the first axis A1. In addition, the lower end of the second protrusion 971 of the case 9 contacts the upper surface of the upper flange 62 of the bobbin 22 (the upper surface of the base 651 of the second wall 65) on the first axis A1. The upper end of the second wall 65 of the upper flange 62 of the bobbin 22 is separated from the case 9 on the first axis A1. In the electromagnetic relay 100, the lower end of the first protrusion 961 and the lower end of the second protrusion 971 contact the upper surface of the upper flange 62, which makes it possible to increase the insulation distance between the coil 21 and the armature 33, and therefore the insulation distance between the coil 21 and the main circuit components.

In the electromagnetic relay 100 of this embodiment, as shown in FIG. 15, the first protrusion 961 and the second protrusion 971 are provided at least at a position overlapping with a virtual line extending from the center of the iron core 23 along the third axis A3. The center of the iron core 23 approximately coincides with the center of the coil 21. Therefore, the first protrusion 961 and the second protrusion 971 are provided at least at a position overlapping with a virtual line extending from the center of the coil 21 along the third axis A3 in a top view. In addition, the first recess 643 and the second recess 653 are not provided at a position overlapping with the virtual line. Therefore, the shortest path between the armature 33 and the coil 21 is a path that goes around the first protrusion 961 and the protruding rib 642, or the second protrusion 971 and the protruding rib 652. This makes it possible to increase the insulation distance between the coil 21 and the armature 33, and further increase the insulation distance between the coil 21 and the main circuit component.

In addition, in the electromagnetic relay 100 of this embodiment, the protruding rib 642 (or the first recess 643) of the first wall portion 64 and the first connection portion 962 of the case 9 also serve to position the case 9 relative to the relay body 1. Similarly, the protruding rib 652 (or the second recess 653) of the second wall portion 65 and the second connection portion 972 of the case 9 also serve to position the case 9 relative to the relay body 1. In other words, the positioning parts also serve the function of increasing the insulation distance. This makes it possible to reduce the number of parts while improving insulation performance.

Furthermore, in the electromagnetic relay 100 of this embodiment, the first protrusion 961 and the second protrusion 971 are adjacent to the front and rear sides of the armature 33, respectively, making it possible to prevent the armature 33 from moving excessively due to an external impact. This makes it possible to prevent deformation of the movable spring 31 fixed to the armature 33. In other words, the positioning parts also serve the function of improving impact resistance. This makes it possible to improve impact resistance while reducing the number of parts.

As described above, the electromagnetic relay 100 of this embodiment can increase the insulation distance between the main circuit components and the coil 21 compared to the conventional one. In other words, it is possible to reduce the size of the electromagnetic relay 100 while maintaining the same insulation performance as the conventional one. Alternatively, it is possible to reduce the power consumption of the coil 21 by increasing the size of the coil 21 while maintaining the same insulation performance as the conventional one.

(3) Modifications The above embodiment is merely one of various embodiments of the present disclosure. The above embodiment can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved. Modifications of the embodiment are listed below. Hereinafter, the above embodiment may also be referred to as a "basic example." The above basic example and the modification examples described below can be applied in appropriate combination.

(3.1) First Modification An electromagnetic relay 100A according to this modification will be described with reference to Fig. 17 and Fig. 18. Descriptions of configurations similar to those of the electromagnetic relay 100 according to the basic example may be omitted as appropriate.

In the electromagnetic relay 100 of the basic example, as shown in FIG. 6, the hole 622 of the upper flange 62 of the bobbin 22 is formed at the center of the upper flange 62 on the third axis A3. In contrast, in the electromagnetic relay 100A of this modified example, as shown in FIG. 17, the hole 622A of the upper flange 62A of the bobbin 22A is formed relatively rearward of the center of the upper flange 62A on the third axis A3. Therefore, in the electromagnetic relay 100A of this modified example, the iron core 23A and the coil 21 are also located relatively rearward of the center of the upper flange 62A on the third axis A3.

In addition, in the electromagnetic relay 100A of this modified example, as shown in FIG. 17, the first wall portion 64A and the second wall portion 65A are asymmetrical in a top view. That is, the protruding rib 652A in the second wall portion 65A, which is relatively closer to the center of the hole 622A (the center of the coil 21), is longer in length (dimension along the second axis A2) than the protruding rib 642A in the first wall portion 64A, which is relatively farther from the center of the hole 622A (the center of the coil 21). As a result, the second wall portion 65A relatively increases the insulation distance between the armature 33 and the coil 21 at the rear side, where the insulation distance between the iron core 23A and the coil 21 is relatively short.

As shown in FIG. 18, in the electromagnetic relay 100A of this modified example, the first recess 96A and the second recess 97A are asymmetrical in a top view. That is, the length (dimension along the second axis A2) of the first protrusion 961A and the position along the second axis A2 of the first connection portion 962A are determined so that the protrusion rib 642A of the first wall portion 64A fits into the first recess 96A. Also, the length (dimension along the second axis A2) of the second protrusion 971A and the position along the second axis A2 of the second connection portion 972A are determined so that the protrusion rib 652A of the second wall portion 65A fits into the second recess 97A.

In this modified electromagnetic relay 100A, it is possible to increase the insulation distance between the coil 21 and the armature 33.

(3.2) Other Modifications In one modification, the method of fixing the sub-terminal block to the main terminal block is not limited to press-fitting. For example, the sub-terminal block may be fixed to the main terminal block by adhesive, resin welding, or the like.

In one modified example, the first cover portion 242 does not have to cover the second yoke 252 from three sides, and may, for example, only have an upper cover portion 291 and cover the second yoke 252 only from above.

In one variation, the first cover portion 242 may further include a lower cover portion that covers the second yoke 252 from below.

In one modified example, a liquid sealant (e.g., epoxy resin) may be poured onto the underside of the lower flange 63, and the lower flange 63 and the yoke 25 (second yoke 252) may be bonded together by the solidified sealant. The lower flange 63 has a lower wall portion 632 that is more wettable to the sealant than the second yoke 252, making it easier to seal with the sealant. In addition, the lower surfaces of the second yoke 252 and the core 23 (thin diameter portion 232) are exposed from the hole 637 in the lower wall portion 632 of the lower flange 63, making it even easier to seal with the sealant. At this time, the lower flange 63 of the bobbin 22 and the insulating member 24 are also bonded together by the sealant.

In one modified example, the thickness (dimension along the third axis A3) of the base 641 and the protruding rib 642 of the first wall portion 64 may be the same. The same is true for the second wall portion 65.

In one modified example, the first recess 643 does not have to be provided at both ends of the second axis A2 of the first wall portion 64. For example, the first recess 643 may be provided only at one end of the second axis A2 of the first wall portion 64, or may be provided in the center. The first connection portion 962 of the case 9 may be provided at a position corresponding to the first recess 643. In one example, when the protruding rib 642 is formed over the entire length of the second axis A2 of the base portion 641 and the first recess 643 is provided in the center of the second axis A2 of the protruding rib 642, the first protrusion portion 961 and the first connection portion 962 of the case 9 may be formed in a T-shape when viewed from above. The same applies to the second recess 653 of the second wall portion 65 and the second connection portion 972 of the case 9.

In one modified example, the lower end of the first protrusion 961 does not have to be in contact with the upper flange 62 (the upper surface of the base 641 of the first wall 64). In one modified example, the upper end of the protrusion rib 642 of the first wall 64 may be in contact with the bottom of the first recess 96 of the case 9.

In one modified example, the lower end of the second protrusion 971 does not have to be in contact with the upper flange 62 (the upper surface of the base 651 of the second wall 65). In one modified example, the upper end of the protrusion rib 652 of the second wall 65 may be in contact with the bottom of the second recess 97 of the case 9.

In one modified example, the movable contact M1 and the fixed contact F1 may be provided below the bobbin 22. In this case, for example, the second yoke 252 may be disposed above the bobbin 22, the first protrusion 961 and the first wall 64 may be provided to cover the front side of the second yoke 252, and the second protrusion 971 and the second wall 65 may be provided to cover the rear side of the second yoke 252.

In one modified example, the insulating member 24 may not have the second cover portion 244. In that case, the height of the insulating member 24 (the dimension along the first axis A1) can be reduced. Even in that case, since the insulating member 24 has the first cover portion 242, the insulating member 24 can be firmly fixed to the bobbin 22.

In one modified example, the height (dimension along the first axis A1) of the protruding rib 642 of the first wall portion 64, the height of the protruding rib 652 of the second wall portion 65, the height of the first protruding portion 961, and the height of the second protruding portion 971 may be adjusted according to the required insulation distance.

In the basic example above, the contact device is a so-called a-contact (normally open contact) that cuts off the electric circuit when no current is flowing, but is not limited to this. In one modified example, the contact device may be a so-called b-contact (normally closed contact) that forms an electric circuit when no current is flowing. In one modified example, the contact device may be a so-called c-contact that has two fixed contacts F1 and the movable contact M1 comes into contact with different fixed contacts F1 when current is flowing and when no current is flowing. When the contact device is a b-contact or a c-contact, the lower surface of the protrusion 444 of the auxiliary member 44 may be used as the fixed contact F1.

(4) Aspects As is apparent from the embodiment and modified examples described above, the present specification discloses the following aspects.

The electromagnetic relay (100, 100A) of the first aspect includes a coil (21), a bobbin (22), an iron core (23), a yoke (25), an insulating member (24), a fixed contact portion (400), and a movable spring (31). The coil (21) is wound around the bobbin (22). The iron core (23) is inserted vertically through the bobbin (22) along the first axis (A1). The yoke (25) forms a magnetic circuit together with the iron core (23). The insulating member (24) is disposed between the bobbin (22) and the yoke (25). The fixed contact portion (400) has a fixed contact (F1). The movable spring (31) has a movable contact (M1). The movable spring (31) moves between a closed position where the movable contact (M1) contacts the fixed contact (F1) and an open position where the movable contact (M1) is separated from the fixed contact (F1) in response to switching between excitation and de-excitation of the coil (21). The yoke (25) includes a first yoke (251) and a second yoke (252). The first yoke (251) extends vertically along the first axis (A1). The second yoke (252) is connected to the first yoke (251) and extends horizontally along a second axis (A2) that intersects with the first axis (A1). The insulating member (24) includes a cover portion (242) that covers at least a portion of the second yoke (252). The bobbin (22) has a main body (61) around which the coil (21) is wound, and a lower flange (63) provided at the bottom of the main body (61). The lower flange (63) of the bobbin (22) has an opening (630) into which the cover (242) of the insulating member (24) and the second yoke (252) can be inserted.

This embodiment has the advantage that it is possible to interpose the lower flange portion (63) and the cover portion (242) between the coil (21) and the second yoke (252), thereby making it possible to increase the insulation distance between the coil (21) and the yoke (25).

In the electromagnetic relay (100, 100A) of the second embodiment, in the first embodiment, the cover portion (242) of the insulating member (24) covers the second yoke (252) from three sides, namely, above and the front and rear.

This embodiment has the advantage that it is possible to increase the insulation distance between the coil (21) and the second yoke (252).

In the electromagnetic relay (100, 100A) of the third aspect, in the first or second aspect, the lower flange portion (63) of the bobbin (22) has an upper wall portion (631) that covers the upper surface of the cover portion (242) and a lower wall portion (632) that covers the lower surface of the second yoke (252).

According to this embodiment, it is possible to sandwich and hold the cover portion (242) and the second yoke (252) between the upper wall portion (631) and the lower wall portion (632). In addition, when a liquid sealing material is poured onto the underside of the lower flange portion (63) and the lower flange portion (63) and the yoke (25) are joined by the solidified sealing material, sealing with the sealing material becomes easier.

In the electromagnetic relay (100, 100A) of the fourth aspect, in any one of the first to third aspects, the lower wall portion (632) of the lower flange portion (63) of the bobbin (22), the second yoke (252), the cover portion (242) of the insulating member (24), the upper wall portion (631) of the lower flange portion (63) of the bobbin (22), and the coil (21) are arranged in this order along the first axis (A1).

This embodiment makes it possible to increase the insulation distance between the coil (21) and the second yoke (252).

In the fifth aspect of the electromagnetic relay (100, 100A), in any one of the first to fourth aspects, the second yoke (252) has a through hole (254). The iron core (23) is inserted into the through hole (254).

According to this embodiment, the second yoke (252) and the core (23) are fixed in the internal space of the lower flange portion (63), which makes it possible to improve the reliability of the fixation.

In the sixth aspect of the electromagnetic relay (100, 100A), in any one of the first to fifth aspects, the lower flange portion (63) of the bobbin (22) is provided with a bobbin side guide (69) that is provided at the entrance of the opening (630) and guides the cover portion (242) of the insulating member (24).

This aspect makes it easier to attach the insulating member (24) to the bobbin (22).

In the seventh aspect of the electromagnetic relay (100, 100A), in any one of the first to sixth aspects, the cover portion (242) of the insulating member (24) is provided with an insulating member side guide (240) that guides the second yoke (252).

This embodiment makes it easier to attach the yoke (25) to the insulating member (24).

In the electromagnetic relay (100, 100A) of the eighth aspect, in any one of the first to seventh aspects, the bobbin (22) further includes an upper flange portion (62) provided on the upper portion of the main body portion (61). The insulating member (24) further includes a second cover portion (244). The second cover portion (244) is a portion different from the first cover portion (242) which is a cover portion, and covers at least a portion of the upper surface of the upper flange portion (62) of the bobbin (22).

This embodiment makes it possible to increase the insulation distance between the coil (21) and the armature.

100, 100A electromagnetic relay 21 coil 22 bobbin 23 iron core 24 insulating member 240 insulating member side guide 242 cover portion (first cover portion)
244 Second cover portion 25 Yoke 251 First yoke 252 Second yoke 254 Through hole 31 Movable spring 400 Fixed contact portion 61 Main body portion 62 Upper flange portion 63 Lower flange portion 630 Opening portion 631 Upper wall portion 632 Lower wall portion 69 Bobbin side guide F1 Fixed contact M1 Movable contact A1 First shaft A2 Second shaft

Claims (7)

A coil and
a bobbin around which the coil is wound;
an iron core that is inserted vertically through the bobbin along a first axis;
a yoke that forms a magnetic circuit together with the iron core;
an insulating member disposed between the bobbin and the yoke;
A fixed contact portion having a fixed contact;
a movable spring having a movable contact and moving between a closed position where the movable contact contacts the fixed contact and an open position where the movable contact is separated from the fixed contact in response to switching between excitation and de-excitation of the coil;
Equipped with
The yoke is
a first yoke extending vertically along the first axis;
a second yoke connected to the first yoke and extending laterally along a second axis intersecting the first axis;
Equipped with
The bobbin is
a main body around which the coil is wound;
An upper flange portion provided on an upper portion of the main body portion;
A lower flange portion provided at a lower portion of the main body portion;
Equipped with
The insulating member is
A first cover portion that covers at least a portion of the second yoke;
a second cover portion that is a portion different from the first cover portion and covers at least a portion of an upper surface of the upper flange portion of the bobbin;
Equipped with
The lower flange portion of the bobbin has an opening into which the first cover portion and the second yoke of the insulating member can be inserted.
Electromagnetic relay. The first cover portion of the insulating member covers the second yoke from three sides, namely, above, front and rear.
2. An electromagnetic relay as claimed in claim 1. The lower flange of the bobbin is
An upper wall portion covering an upper surface of the first cover portion;
A lower wall portion covering a lower surface of the second yoke;
Equipped with
3. An electromagnetic relay according to claim 1 or 2. a lower wall portion of the lower flange portion of the bobbin, the second yoke, the first cover portion of the insulating member, an upper wall portion of the lower flange portion of the bobbin, and the coil are arranged in this order along the first axis.
The electromagnetic relay according to any one of claims 1 to 3. The second yoke has a through hole,
The iron core is inserted into the through hole.
5. An electromagnetic relay according to claim 1. the lower flange portion of the bobbin includes a bobbin side guide provided at an entrance of the opening portion and guiding the first cover portion of the insulating member;
6. An electromagnetic relay according to claim 1. The first cover portion of the insulating member includes an insulating member side guide that guides the second yoke.
7. An electromagnetic relay according to claim 1 .

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