Terminal connection structure and electromagnetic relay using same

Abstract

A terminal connection structure with a good material yield and high productivity, free of mounting failure. The terminal connection structure is provided with: a base including a terminal hole, a fixed contact terminal portion, a through hole passing through the fixed contact terminal portion along its shaft center and communicating with the terminal hole, and a conductive film formed in a continuous manner on an inner circumferential surface of the terminal hole, an inner circumferential surface of the through hole, and an exposed surface of the fixed contact terminal portion; and a touch piece press-fitted into the terminal hole and electrically connected to the fixed contact terminal portion via the conductive film.

Claims

1. A terminal connection structure comprising: a base comprising: a base body having a first surface and a second surface opposite to the first surface; a terminal hole opened on the first surface; a terminal projection projected from the second surface in a direction away from the first surface; a through hole passing through the terminal projection along a shaft center of the terminal projection, extending to the terminal hole and communicating with the terminal hole; and a conductive film formed in a continuous manner on an inner circumferential surface of the terminal hole, an inner circumferential surface of the through hole, and an exterior surface of the terminal projection; and a touch piece press-fitted into the terminal hole and electrically connected to the conductive film.

2. The terminal connection structure according to claim 1, wherein metal-plating is performed on a region where the inner circumferential surface of the terminal hole, the inner circumferential surface of the through hole, and the exterior surface of the terminal projection are irradiated with laser light and a metal powder is deposited, to form the conductive film.

3. The terminal connection structure according to claim 2, wherein the inner circumferential surface of the through hole has a tapered surface.

4. The terminal connection structure according to claim 2, wherein pre-solder is made to adhere to at least the exterior surface of the terminal projection.

5. The terminal connection structure according to claim 1, wherein the inner circumferential surface of the through hole has a tapered surface.

6. The terminal connection structure according to claim 5, wherein pre-solder is made to adhere to at least the exterior surface of the terminal projection.

7. The terminal connection structure according to claim 1, wherein pre-solder is made to adhere to at least the exterior surface of the terminal projection.

8. An electromagnetic relay comprising the terminal connection structure according to claim 1.

9. A terminal connection structure comprising a base comprising: a touch piece; a terminal projection; a through hole passing through the terminal projection along a shaft center of the terminal projection and being open to a basal portion of the touch piece; and a conductive film formed in a continuous manner on a front surface of the touch piece, an inner circumferential surface of the through hole, a region connecting from the front surface of the touch piece to the inner circumferential surface of the through hole, and an exposed surface of the terminal projection, wherein the touch piece integrally molded to the base is electrically connected to the terminal projection via the conductive film.

10. The terminal connection structure according to claim 9, wherein metal-plating is performed on a region where the front surface of the touch piece, the inner circumferential surface of the through hole, the region connecting from the front surface of the touch piece to the inner circumferential surface of the through hole, and the exposed surface of the terminal projection are irradiated with laser light and a metal powder is deposited, to form the conductive film.

11. The terminal connection structure according to claim 10, wherein the inner circumferential surface of the through hole has a tapered surface.

12. The terminal connection structure according to claim 10, wherein pre-solder is made to adhere to at least the exposed surface of the terminal projection.

13. The terminal connection structure according to claim 9, wherein the inner circumferential surface of the through hole has a tapered surface.

14. The terminal connection structure according to claim 9, wherein pre-solder is made to adhere to at least the exposed surface of the terminal projection.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of an electromagnetic relay, to which one or more embodiments of a terminal connection structure according to the present invention has been applied.

(2) FIG. 2 is a partial perspective view illustrating a base of the electromagnetic relay illustrated in FIG. 1.

(3) FIG. 3 is a longitudinal sectional view of the base illustrated in FIG. 2.

(4) FIG. 4 is a perspective view for describing a manufacturing process for the base according to the electromagnetic relay illustrated in FIG. 1.

(5) FIG. 5 is a longitudinal sectional view of the base illustrated in FIG. 4.

(6) FIG. 6 is a cross-sectional view of the base illustrated in FIG. 4.

(7) FIG. 7 is a perspective view for describing the manufacturing process subsequent to FIG. 4.

(8) FIG. 8 is a longitudinal sectional view of the base illustrated in FIG. 7.

(9) FIG. 9 is a cross-sectional view of the base illustrated in FIG. 7.

(10) FIG. 10 is a perspective view for describing the manufacturing process subsequent to FIG. 7.

(11) FIG. 11 is a longitudinal sectional view of the base illustrated in FIG. 10.

(12) FIG. 12 is a cross-sectional view of the base illustrated in FIG. 10.

(13) FIG. 13 is a perspective view for describing the manufacturing process subsequent to FIG. 10.

(14) FIG. 14 is a perspective view illustrating one or more embodiments of the terminal connection structure according to the present invention.

(15) FIG. 15 is a perspective view illustrating one or more embodiments of the terminal connection structure according to the present invention.

(16) FIG. 16 is a longitudinal sectional view of FIG. 15.

(17) FIG. 17 is a perspective view of an electromagnetic relay, to which one or more embodiments of the terminal connection structure according to the present invention has been applied.

(18) FIG. 18 is a partial plan view of the base illustrated in FIG. 17.

(19) FIG. 19 is a longitudinal sectional view of the base illustrated in FIG. 18.

(20) FIG. 20 is a partial perspective view of the base illustrated in FIG. 17.

(21) FIG. 21 is a front view of the base illustrated in FIG. 17.

(22) FIG. 22 is a longitudinal sectional view for describing a method to mount the base illustrated in FIG. 17 on a printed circuit board.

(23) FIG. 23 is a longitudinal sectional view for describing another method to mount the base illustrated in FIG. 17 on the printed circuit board.

(24) FIG. 24 is a perspective view for describing a manufacturing process for a base of an electromagnetic relay, to which one or more embodiments of the terminal connection structure according to the present invention has been applied.

(25) FIG. 25 is a perspective view for describing the manufacturing process subsequent to FIG. 24.

(26) FIG. 26 is a perspective view for describing the manufacturing process subsequent to FIG. 25.

(27) FIG. 27 is a perspective view illustrating a connector, to which one or more embodiments of the terminal connection structure according to the present invention has been applied.

(28) FIG. 28 is a longitudinally sectional perspective view of the connector illustrated in FIG. 27.

DETAILED DESCRIPTION

(29) Embodiments of a terminal connection structure according to the present invention will be described in accordance with the accompanied drawings of FIGS. 1 to 28.

(30) In the following description, in describing configurations represented in the drawings, terms showing directions such as up, down, left, and right, and other terms including those, will be used. It is noted that the purpose for using those terms is to facilitate understanding of the embodiments through the drawings. Accordingly, those terms do not necessarily show directions used at the time of actually using the embodiments of the present invention. A technical scope of the invention recited in the claims shall not be restrictively interpreted by using those terms.

(31) As illustrated in FIGS. 1 to 13, one or more embodiments are the case of applying a terminal connection structure according to the present invention to an electromagnetic relay.

(32) That is, as illustrated in FIG. 1, the electromagnetic relay is provided with: a base 10; an electromagnetic device 20; a movable iron piece 21 having a substantially L-shaped cross section and rotating based on excitation and demagnetization of the electromagnetic device 20; a card 22 that reciprocates and moves as the movable iron piece 21 rotates; a movable touch piece 23 that is pressed by the card 22; and a fixed touch piece 25 having a fixed contact 26, which a movable contact 24 provided in the movable touch piece 23 comes into contact with or separates from, the electromagnetic device 20, the movable iron piece 21, the card 22, the movable touch piece 23, and the fixed touch piece 25 being vertically provided on the base 10. The internal components such as the electromagnetic device 20 are covered by a cover 27 fitted to the base 10.

(33) Next, a description will be given of a connection process for the movable touch piece 23 and the fixed touch piece 25 which are vertically provided on the base 10 in accordance with the accompanied drawings of FIGS. 2 to 13.

(34) First, as illustrated in FIGS. 2 to 4, terminal holes 11, 12 are formed on the upper surface of the base 10. Further, a fixed contact terminal portion 13 and a movable contact terminal portion 14 are integrally molded with the lower surface of the base 10. The terminal holes 11, 12 are respectively communicated with through holes 15, 16 that pass through the fixed contact terminal portion 13 and the movable contact terminal portion 14.

(35) A molding material for the base 10 contains a base polymer, a filler, and a metal powder. Examples of the base polymer include a liquid crystal polymer (LCP) and polybutylene terephthalate (PBT).

(36) Note that each of the through holes 15, 16 is not restricted to a simple cylindrical form, but may have a tapered surface such as a truncated cone or a truncated square. This has the advantage of facilitating laser irradiation and improving the productivity.

(37) Then, the inner circumferential surfaces of the terminal holes 11, 12, the inner circumferential surfaces of the through holes 15, 16, and the exposed surfaces of the fixed contact terminal portion 13 and the movable contact terminal portion 14 are irradiated with laser light to deposit the metal powder contained in the molding material. Further, the base 10 is soaked into a plating tank, not illustrated, to plate the metal-powder deposited surface with copper and/or nickel, etc., to form a conductive film (FIGS. 7 to 9). Subsequently, the fixed contact terminal portion 13 and the movable contact terminal portion 14 are soaked into a molten solder tank to make pre-solder 18 adhere to the exposed surfaces of the fixed contact terminal portion 13 and the movable contact terminal portion 14 and the insides of the through holes 15, 16 (FIGS. 10 to 13).

(38) Note that the pre-solder 18 may be made to adhere after completion of assembly of the electromagnetic relay.

(39) Next, as illustrated in FIG. 13, the fixed touch piece 25, having a strip shape, is press-fitted into the terminal hole 11, to electrically connect between the fixed touch piece 25 and the outer circumferential surface of the fixed contact terminal portion 13. Similarly, the movable touch piece 23, having a strip shape, is press-fitted into the terminal hole 12, to electrically connect between the movable touch piece 23 and the outer circumferential surface of the movable contact terminal portion 14.

(40) As illustrated in FIG. 14, one or more embodiments are obtained by providing in a projecting manner a terminal projection 19 with a semicircular cross section on the bottom surface of the base 10, and forming a groove portion 19a with a semicircular cross section which communicates with the through hole 15. Since the others are similar to those in one or more embodiments, the same portions are provided with the same numerals, and descriptions thereof are omitted.

(41) Due to the exposure of the groove portion 19a communicating with the through hole 15, one or more embodiments have the advantage of facilitating etching by laser light and improving the productivity.

(42) As illustrated in FIGS. 15 and 16, one or more embodiments are obtained by integrally molding the terminal projection 19, which has a substantially L-shaped cross section, to the bottom surface of the base 10 and forming the groove portion 19a, which has a semicircular cross section and communicates with the through hole 15, on the lower surface of the terminal projection 19.

(43) One or more embodiments the advantage of being capable of surface-mounting on a printed circuit board and enhancing design freedom.

(44) As illustrated in FIGS. 17 to 23, one or more embodiments are the case of applying the terminal connection structure according to the present invention to an electromagnetic relay that can be mounted on the surface of the printed circuit board. Since a basic configuration is almost the same as one or more embodiments described above, the same portions are provided with the same numerals, and only different respects will be described.

(45) First, in the same manner as in one or more embodiments, a plate-like body to be a fixed touch piece 25a is integrally molded to the upper surface of the base 10 by using a molding material containing a base polymer, a filler, and a metal powder. The fixed contact terminal portion 13 is then integrally molded to the lower surface of the base 10. Simultaneously, the through hole 15 is provided in the basal portion of the fixed touch piece 25a, the through hole 15 passing through the fixed contact terminal portion 13 along its shaft center.

(46) Similarly, the terminal hole 12 for press-fitting of the movable touch piece 23 is provided on the upper surface of the base 10. The movable contact terminal portion 14 is then integrally molded to the lower surface of the base 10. Simultaneously, the through hole 16 is provided in a position adjacent to the terminal hole 12, the through hole 16 passing through the movable contact terminal portion 14 along its shaft center.

(47) Then, the front surface of the fixed touch piece 25a, the inner circumferential surface of the through hole 15, a region connecting from the front surface of the fixed touch piece 25a to the inner circumferential surface of the through hole 15, and the exposed surface of the fixed contact terminal portion 13 are etched by laser light to deposit a metal powder.

(48) Similarly, the inner circumferential surfaces of the terminal hole 12 and the through hole 16, a region connecting from the terminal hole 12 to the through hole 16, and the exposed surface of the movable contact terminal portion 14 are etched by laser light to deposit a metal powder.

(49) Naturally, the etching processing by laser light does not need to be performed on the entire surface of the fixed touch piece 25a, for example, but may be restrictively performed on a necessary region.

(50) The base 10 is then soaked into a plating tank, not illustrated, to plate the metal-powder deposited surface with copper and/or nickel, etc., to form a conductive film (FIGS. 18 and 19). Note that, if necessary, the fixed contact terminal portion 13 and the movable contact terminal portion 14 of the base 10 may be soaked in advance into a molten solder tank for adhesion of pre-solder.

(51) Next, when the electromagnetic relay having the base 10 is to be mounted on the surface of a printed circuit board 30, for example as illustrated in FIG. 22, the fixed contact terminal portion 13 of the base 10 is mounted on the surface of the printed circuit board 30. Then, solder 31 is made to adhere to a conductive film 17 exposed from the side surface of the base 10 to electrically connect between the printed circuit board 30 and the conductive film 17.

(52) Since the solder 31 is made to adhere to the conductive film 17 exposed from the side surface of the base 10 to electrically connect between the printed circuit board 30 and the conductive film 17, one or more embodiments have the advantage of facilitating the connecting operation and improving the productivity.

(53) The electromagnetic relay is not restricted to the foregoing connection structure. As illustrated in FIG. 23, the fixed contact terminal portion 13 of the base 10 may be fitted into a through hole 32 provided in the printed circuit board 30, and electric connection may be made by the solder 31.

(54) According to one or more embodiments, the base 10 hardly falls off the printed circuit board 30, and a highly reliable terminal connection structure is thus obtained.

(55) In any of the one or more embodiments, the fixed contact terminal portion 13 and the movable contact terminal portion 14 are not plastically deformed as in the conventional example, and any of the embodiments thus has the advantage of causing no mounting failure at the time of mounting the printed circuit board 30 on the electromagnetic relay. This also applies to a coil terminal portion.

(56) As illustrated in FIGS. 24 to 26, one or more embodiments are the case of applying the terminal connection structure according to the present invention to an electromagnetic relay made up of the fixed touch piece 25a integrally molded to the base 10 and the movable touch piece 23 press-fitted into the terminal hole 12 in the base 10 to be electrically connected.

(57) As in one or more embodiments, the fixed touch piece 25a according to the embodiment is electrically connected to the fixed contact terminal portion 13 via a through hole (not illustrated) provided in the base 10. Further, as in one or more embodiments, the movable touch piece 23 according to one or more embodiments is electrically connected to the movable contact terminal portion 14 provided in a projecting manner on the lower surface of the base 10.

(58) Since the others are similar to those in one or more embodiments, the same portions are provided with the same numerals, and descriptions thereof are omitted.

(59) The terminal connection structure according to one or more embodiments the present invention is not restricted to the foregoing electromagnetic relays, but may, for example, be applied to a connector 35 as in one or more embodiments illustrated in FIGS. 27 and 28.

(60) That is, the connector 35 is formed by integrally molding terminal holes 36 at both edges of the upper surface of the connector 35 with terminal projections 37 on the lower surface of the connector 35 by a resin material containing a metal powder. The terminal hole 36 communicates with a through hole 38 passing through the terminal projection 37 along its shaft center.

(61) Note that the operations of performing etching by laser light after resin molding, depositing the metal powder, and then performing metal-plating with copper or nickel to form a conductive film are similar to those in one or more embodiments, and hence the descriptions thereof are omitted.

(62) Although the disclosure has been described with respect to only a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that various other embodiments may be devised without departing from the scope of the present invention. Accordingly, the scope of the invention should be limited only by the attached claims.

INDUSTRIAL APPLICABILITY

(63) A terminal connection structure according to the present invention is not restricted to the one or more embodiments, but is also applicable to other relays, switches, IC sockets, and the like.

DESCRIPTION OF SYMBOLS

(64) 10 base 11 terminal hole 12 terminal hole 13 fixed contact terminal portion (terminal projection) 14 movable contact terminal portion (terminal projection) 15 through hole 16 through hole 17 conductive film 18 pre-solder 19 terminal projection 20 electromagnetic device 21 movable iron piece 22 card 23 movable touch piece 24 movable contact 25 fixed touch piece 25a fixed touch piece 26 fixed contact 27 cover 30 printed circuit board 31 solder 35 connector 36 terminal hole 37 terminal projection 38 through hole