Switching Relay

The present invention relates to devices for switching a load current by movement of a movable switching member to effect making and breaking of a set of electrical contacts. The present invention relates particularly to switching devices of the type employing an electromagnetic actuator for effecting the movement of the movable switch member; and, particularly relates to relays having an armature magnetically moved by electrical energization of a coiled conductor such as a solenoid.

Where it is required to provide a relay for switching a substantial load current in association with an electronic control circuit, it has been desired for simplicity in high-volume manufacturing to provide the relay as part of the fabrication of the circuit as, for example, built up on a printed circuit board. For applications in which space or volume is limited, it has been desired to provide such a relay and base, such as a printed circuit board combination with a minimum volume for installation in appliances controlled by the electronic circuit. Such an arrangement is desirable from a manufacturing standpoint because it is less costly to fabricate the relay as part of the printed circuit board, thereby eliminating the handling and separate attachment and wiring of a relay to the printed circuit board.

It has further been desired to provide a built-up or base-mounted relay such as for a printed circuit with a minimum volume and generally flat configuration, yet provide sufficient switching power to the relay to enable making and breaking of a set of contacts capable of handling substantial load currents, yet requiring only a very small current to the relay coil for effecting switching. Heretofore, printed circuit board mounted relays have had an overall bulkiness and awkward configuration due to the amount of ferromagnetic pole material required to provide sufficient magnetic flux to produce adequate relay actuating force with the low electrical current as, for example, the current provided by low voltage solid state signal transistors, for driving the relay coil. It has thus been desirable to find a way or means of providing a compact, low current relay which may be built upon or fabricated on a base, such as a printed circuit board, and which is capable of switching a set of contacts for handling a substantial load current, and to provide such a device which is low in manufacturing cost, to facilitate high volume mass production.

The present invention provides a simple, compact, and economical low current relay built-up or fabricated integrally on a base structure as, for example, a printed circuit board, in which the relay has a compact, generally flat configuration with respect to the surface of the base upon which it is fabricated. The relay employs an electromagnetic actuator having a coil and movable armature for effecting movement of a movable switch blade which, upon energization and de-energization of the coil, causes making and breaking of a set of load current carrying contacts.

The relay has a stationary ferromagnetic pole piece attached to the base with an integrally formed core portion extending therefrom in a direction generally parallel to the surface of the base; and, a coil is received over the core portion. A generally flat U-shaped armature has the open ends thereof pivoted on the pole piece to complete a magnetic flux loop therewith. Upon energization of the coil, the closed end of the armature is movable about the end of the coil for effecting movement of a movable switch member cantilevered at the base.

The pole piece is formed of ferromagnetic material and has a layer of insulating material provided on a surface thereof electrical conductor strips formed of a relatively thin film of conductive material laid thereon which has the coil leads attached thereto; and, the conductive strips are adapted for external electrical connection. The construction of the relay of the present invention lends itself particularly to applications where the base comprises a printed circuit board. The pole piece including the core portion and the armature may be conveniently be formed of flat sheet stock, and upon build up on a printed circuit board, provide a compact, flat arrangement with sufficient ferromagnetic material to enable a small low current coil to effect the desired switching of a movable blade arm having relatively large load current contacts.

The relay of the present invention is particularly suitable for printed circuit board bases because the coil leads are attached directly to the pole piece, rather than on a printed circuit board, which provides for convenience of external electrical attachment to the printed circuit board and relay. The pole piece preferably has a ceramic coating of insulating material thereover, upon which a polymer film conductive strip is laid to provide for attachment of the coil leads thereto, and external lead attachment thereto. The construction of the present relay lends itself particularly to an arrangement whereby the pole piece has an elongated configuration, with a plurality of spaced core portions extending therefrom to permit a plurality of coils and U-shaped armatures to be disposed therealong, thus providing plural relays on a common base or printed circuit board. In such a plural coil arrangement, the conductive strip on the elongated pole piece serves conveniently as a bus bar for the plurality of coils.

FIG. 1 is a somewhat perspective view of the assembled relay on the base;

FIG. 2 is a sectional view taken through the axis of the coil of the relay of FIG. 1;

FIG. 3 is a plan view of the pole piece of the relay of FIG. 1; and,

FIG. 4 is a somewhat perspective view of an alternate arrangement of the armature of the relay of FIG. 1.

Referring to FIGS. 1 and 2, the assembled switching relay is indicated generally at 10 has having a base 12 formed of electrically non-conductive or insulating material such as, for example, the material from which printed circuit boards are made, and which has a generally flat upper surface 14 upon which the switching components are mounted, and which has a recess or depression 16 formed therein for accommodating the components of the relay as will hereinafter be described.

Referring to FIGS. 1, 2, and 3, a pole piece 18 composed of ferromagnetic material having a generally elongated configuration is provided with at least one, and preferably a plurality, of spaced core portions 20 formed integrally therewith and extending outwardly therefrom in planar arrangement in a direction transverse to the direction of elongation. The core portions are denoted by reference numerals 20,20', 20", and 20"' in FIG. 3. In the presently preferred practice of the invention, the pole piece 18 and core portions are formed integrally from sheet stock for ease of fabrication in high volume production. The pole piece has apertures 22,24 respectively provided adjacent opposite ends thereof for receiving therein suitable locating posts provided on the base, such as the post denoted by reference numeral 26 and 28 in FIG. 2.

Referring to FIGS. 1, 2, and 3, at least one, and preferably a plurality of electrical coils, two of which are shown and denoted by reference numerals 30,31, are received respectively over the core portions 20,20' with the axis of the coil thereby disposed generally parallel to the surface 14 of the base. The lower portion of each of the coils 20 is received in a groove 16 provided in the base 12, and one of these grooves is illustrated by reference numeral 16. It will be understood that a groove is provided in the base for each coil; and, that the coils for core portions 20" and 20"' have been omitted in FIG. 3 for brevity.

The pole piece or bus bar 18 has the upper surface thereof coated with a thin layer of insulating material as, for example, ceramic material denoted by reference numeral 32 in FIG. 3. In the presently preferred practice of the invention, the ceramic coating has a thickness on the order of 0.15 mm. The ceramic material provides a substrate or base for strips of thin conductive material which may comprise as, for example, polymeric conductive film material, and which are deposited on the insulating material 32 in the form of a common strip 34 having pad portions 36 and 38 provided thereon in longitudinally spaced arrangement respectively adjacent the coils 30 and 31. Additional pad portions 40,42 are provided in spaced arrangement and adjacent the coil core portions 20",20"' respectively. A separate strip 44 is provided in generally parallel relationship to the common strip 34; and, the strip 44 has a pad portion 46 formed at the end thereof adjacent the coil 30. Similarly, a separate strip 48 is provided and has a pad portion 50 provided adjacent coil 31 with the ends of the strips 44 and 48 turned at right angles to terminate adjacent the edge of the bus bar 18. A tying strip 52 extends from the common strip 34 and terminates adjacent the edge of the bus bar 18. Separate strips 54,56 are provided with end pads respectively 58,60 for core portions 20",20"' respectively. The strips 54,56 are also turned to terminate adjacent the edge of the bus bar 18 to facilitate external connection thereto.

It will be understood that the leads for the ends of the coil 20 are attached by suitable expedient as, for example, soldering respectively to the pads of electrically conducting material 36,46 to provide circuit connection to the coil. Similarly, the ends of the coil 31 are connected respectively to pads 38 and 50 to permit external electrical connection to the coil 31 via common strip 52 and strip 48.

A generally U-shaped ferromagnetic armature 62 is disposed with the open ends of the legs thereof pivoted on the pole piece 18. In the embodiment shown in FIGS. 1, 2, and 3 the open ends of the U-shape are registered pivotally against the edge 64 of the pole piece 18 for vertical pivotal movement thereabout. As shown in FIGS. 1 and 3, the opposite legs of the U-shaped armature 62 straddle the coil 30; and, the closed end portion 66 of the armature 62 clears the end of the coil 20.

Referring to FIGS. 1 and 2, a cover 68 formed of a suitable insulating material is received over the armature and has the edge thereof contacting the inside surface 70 of the upright portion of the base 12. The cover 68 has a depending rib 72, which registers against the upper surface of the pole piece 18 and retains the pole piece in position on the posts 22,24 provided on the base. Cover 68 has an elongated aperture 74 provided therein which has received therethrough an electrical terminal connector 76 which has a right angled portion 78 formed along the undersurface of the cover, and which is retained in position thereon by a riveted stud 80 which passes through an aperture formed in the portion 78 of the terminal. The right angle portion of the terminal also has a downwardly extending depending portion 82, which extends in close proximity to the pivoted end of armature 62.

The depending portion 82 of the terminal 76 has attached thereto, by any suitable expedient as, for example, weldment, a generally flat-spring switch blade arm 84, which has a cut-out 86 provided therein to permit passage of the coil thereinto. A pair of electrical contacts 88,90 are provided at the end of blade 84 with one contact disposed on each opposite side of the blade. The depending portion 82 of the electrical terminal 76 thus provides a suspension for locating and holding the switch contact arm in cantilever arrangement therefrom, and in juxtaposition to the armature 62.

The closed end of armature 62 is secured to blade arm 84 by any suitable expedient such as, for example, weldment. A second electrical connector terminal 92 extends upwardly through another aperture 94 provided in the cover. The terminal 92 has a tab portion 96 bent at right angles thereto and secured to the undersurface of cover 68 by an integrally formed stud 98 received through an aperture in the tab 96 and riveted thereover. Terminal 92 also has a flange 100 formed generally at right angles thereto along the undersurface of cover 68 and extending in a direction opposite to the tab 96. The flange 100 has mounted thereon stationary electrical contact 102, which is disposed and located directly above the contact 88 on the switch blade 84.

A third electrical connecting terminal 104 is provided and extends upwardly through an aperture 106 formed in the cover 68; and, terminal 104 is secured by a tab 108 formed at right angles thereto which is curled retained the upper surface of the cover 68 by integrally formed stud 110, which is received through an aperture therein and deformed thereover to provide a rivet. Terminal 104 extends downwardly through the aperture 106, and has a flange 112 formed at generally right angles thereto, and extending beneath the switch contact arm 84. Flange 112 has a stationary contact 114 provided thereon and disposed directly beneath and spaced from the contact 90 on the switch blade 84.

It will be understood that the switch contact blade 84 is biased to the upward position shown in solid outline in FIG. 2 such that contact 88 is closed against contact 102, thereby completing a circuit between terminals 76 and 92. Upon energization of the coil 30, armature 62 is attracted downwardly by the magnetomotive force developed in the core 20, and moves to the position shown in dashed outline in FIG. 2 causing contact arm 84 to move downwardly, breaking the circuit between contacts 102 and 88, and closing contact 90 against contact 114 to complete the circuit between electrical terminals 76 and 104. The operation of the relay illustrated is thus that of a single-pole double-throw switch.

It will be understood that although only a single coil and armature is illustrated in FIGS. 1 and 2, where a plurality of coils are employed as shown in FIG. 3, the switching terminal arrangement is repeated for each armature and contact blade arm.

Referring to FIG. 4, an alternate embodiment is illustrated, wherein the pole piece 118 has an elongated slot 119 formed therein, with a coil core portion 120 formed integrally therewith, and extending therefrom, in a manner similar to the core portion 20 of the pole piece 18. An armature 162 has a generally U-shaped configuration similar to that of armature 62, and has the open ends of the legs thereof offset, or "S" shaped in side view, and received in the slot 119 for retaining the armature on the pole piece 118 and permitting pivotal movement therein.

The present invention thus provides a unique and novel contact switching relay built up or fabricated on a base as, for example, a printed circuit board, which enables low current solid state switching devices to actuate an electromagnetically operated switch for switching heavy load currents, and yet provides a compact and easy to manufacture assembly on the base. The relay of the present invention has a compact low profile configuration, yet provides sufficient ferromagnetic material to enable adequate magnetomotive forces from a low current coil to actuate electrical contacts capable of carrying substantial load current.

Although the invention has been described hereinabove with respect to the illustrated embodiments, it will be understood that the invention is capable of modification and variation, and is limited only by the scope of the following claims.