ELECTROMAGNETIC RELAY

Abstract

The present invention is relating to an electromagnetic relay (100) comprising a bobbin assembly (10) a comprising a bobbin (12) wound with an annular coil (14), a core (16) insertable into said bobbin (12) and plurality of yolks (18). Further, the electromagnetic relay (100) comprises a plurality of contacts (20) that includes at least one fixed contact (20a) and at least one movable contact (20b) are configured to open and close the electromagnetic relay (100). In addition, a floating type pusher (30) configured to transfer armature (22) movement to the movable contact (20b) upon activation of said coil (14). Accordingly, the electromagnetic relay (100) is formed integrally enclosed in a moulded plastic casing (40) as a monobloc, and the casing (40) is configured to provide electric isolation in the electromagnetic relay (100).

Claims

1. An electromagnetic relay (100) comprising: a bobbin assembly (10), comprising: a bobbin (12) wound with an annular coil (14); and a core (16) insertable into said bobbin (12) and plurality of yolks (18), wherein the coil (14) is configured to move an armature (22) upon activation by means of voltage application; a plurality of contacts (20) configured to open and close the electromagnetic relay (100), wherein the plurality of contacts (20) comprises at least one fixed contact (20a) and at least one movable contact (20b); and a floating type pusher (30) configured to transfer armature (22) movement to the movable contact (20b) upon activation of said annular coil (14), wherein the electromagnetic relay (100) is formed integrally enclosed in a moulded casing (40) as a monobloc, and wherein the moulded casing (40) is configured to provide electric isolation in the electromagnetic relay (100).

2. The electromagnetic relay (100) as claimed in claim 1, wherein a clearance and creepage distance ranging between 10 mm to 12 mm is provided in the electromagnetic relay (100) to provide the electric isolation, and wherein the isolation between the coil and contact is more than 8 KV VAC (rms).

3. The electromagnetic relay (100) as claimed in claim 1, wherein the moulded casing (40) is a formed using at least one of plastic, polycarbonate, thermoplastic or other non-conductive materials.

4. The electromagnetic relay (100) as claimed in claim 1, wherein the plurality of yolks (18), include a first upper yolk (18a) and second lower yolk (18b).

5. The electromagnetic relay (100) as claimed in claim 1, wherein the casing (40) is formed by insert-molding to enclose the bobbin assembly (10), the plurality of contacts (20) and the pusher (30), and wherein a portion (22a, 24a) of the plurality of contacts (20) are arranged outside of the casing (40).

6. The electromagnetic relay (100) as claimed in claim 1, wherein the electromagnetic relay (100) comprises a flag indicator configured to indicate internal feature in the electromagnetic relay (100).

7. The electromagnetic relay (100) as claimed in claim 1, wherein the electromagnetic relay (100) comprises at least one pin (50) configured to be mounted on a socket.

8. The electromagnetic relay (100) as claimed in claim 6, wherein at least one pin (50) includes Printed Circuit Board (PCB) pin configured to be mounted on a PCB, and wherein the PCB are straight OR 90 degree bent.

9. The electromagnetic relay (100) as claimed in claim 1, wherein the electromagnetic relay (100) comprises at least one test button that includes at least one of a manual test button or a lockable push button.

10. The electromagnetic relay (100) as claimed in claim 1, wherein the electromagnetic relay (100) comprises a sealing member configured to prevent ingress of foreign material inside the electromagnetic relay (100).

Description

BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS

[0019] The invention will now be described in relation to the accompanying drawings in which

[0020] FIG. 1 shows an electromagnetic relay in accordance with one embodiment of present invention;

[0021] FIG. 2 shows the electromagnetic relay of FIG. 1 with partial casing in accordance with one embodiment of present invention;

[0022] FIGS. 3 shows an exploded view of a bobbin assembly of the electromagnetic relay of FIG. 1 in accordance with an embodiment of present invention;

[0023] FIG. 4 shows a plurality of contacts of the electromagnetic relay of FIG. 1 in accordance with one embodiment of present invention;

[0024] FIGS. 5 shows the electromagnetic relay of FIG. 1 enclosed in a housing in accordance with one embodiment of present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0025] The embodiments herein, the various features, and advantageous details thereof are explained with reference to the non-limiting embodiments. Descriptions of well-known components and processing techniques are omitted to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0026] Embodiments of the present invention will be described and illustrated hereinafter with reference to the accompanying drawings. However, the solutions disclosed herein may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein.

[0027] The present invention pertains to electromagnetic relay used in applications such as in household appliances, aviation, aerospace, rail transit, communication and control devices, electromechanical integration, power electronic equipment etc. In industry application there is a need to improve the clearance and creep age of the electromagnetic relays to attain better electronic insulations. Further, it is paramount that the electromagnetic relay should be of compact size to be able to be integrated in different components.

[0028] FIG. 1 illustrates an electromagnetic relay according to the embodiments of the present invention. The electromagnetic relay 100 of the present invention comprises a bobbin assembly 10, plurality of contacts 20 and a floating type pusher 30. Accordingly, the bobbin assembly 10 (shown in FIG. 3) comprises of a bobbin 12 that is generally made of a plastic material, and usually includes a hollow section in the middle. The bobbin assembly 10 further comprises a core 16 that is insertable into said hollow section of the bobbin 12. The bobbin assembly 10 further includes a plurality of yolks 18 arranged in proximity to the bobbin 12. In addition, the bobbin 12 is wound with an annular coil 14, the annular coil is metallic coil usually made of copper. In accordance with the embodiment of present invention the core 16 and plurality of yolks 18 are made of soft magnetic iron. Accordingly, the bobbin assembly 10 forms a magnetic circuit, that is capable of turning the soft magnetic iron parts namely the core 16 and the plurality of yolks 18 into a temporary magnet when power is supplied to said coil 14. Generally, the yolks 18 are arranged near the coil 14 such that the magnetic flux is transferable between the coil and the yolks 18. In addition, the bobbin assembly 10 is configured to move an armature 22 upon said activation by means of voltage application.

[0029] In an embodiment of the present invention, the electromagnetic relay 100 further comprises a plurality of contacts 20. The plurality of contacts 20 are configured to open and close the electromagnetic relay 100. Accordingly, the plurality of contacts 20 includes at least one fixed contact 20a, 20c and at least one movable contact 20b. The fixed contact 20a, 20c and the movable contact 20b generally include an elongated section and are generally disposed in a holder. The fixed contact 20a, 20c and the movable contact 20b are arranged to face each other at predetermined intervals, as shown in FIG. 4, and include a contact mechanism 22 at one end of said elongated section. The contact mechanism 22 may be provided in form of rivets that are riveted with said elongated section. Further, the electromagnetic relay 100 comprises a floating type pusher 30 configured to transfer armature 22 movement to the movable contact 20b upon activation of said coil 14. The floating type pusher is able to provide high contact pressure to the existing electromagnetic relays. Additionally, a manual pusher 32 may be provided to the electromagnetic relay 100, the manual pusher 32 may be configured to be in contact with the pusher 30 (refer FIG. 1).

[0030] FIG. 2 shows an electromagnetic relay 100 of the present invention in an assembled state without the casing 40. The electromagnetic relay 100 includes a bobbin assembly 10 and plurality of yolks that include a first upper yolk 18a and second lower yolk 18b are arranged in proximity to the bobbin assembly 10. Further, the armature 22 is arranged near the first upper yolk 18a and the second lower yolk 18b. The electromagnetic relay 100 is assembled such that the fixed contact 20a, the movable contact 20b, and the coil terminal (not marked in Figures) extend outwards. Further, the electromagnetic relay 100 includes a pusher 30 assembled on top of the electromagnetic relay 100. The pusher 30 is arranged in working contact with the armature 22 and the fixed contact 20a, 20c and moving contact 20b.

[0031] In an embodiment of the present invention as shown in FIG. 1, the electromagnetic relay 100 is formed integrally enclosed in a moulded plastic casing 40 as a monobloc. The casing 40 is configured to provide electric isolation in the electromagnetic relay 100. Accordingly, the casing 40 is formed by insert molding the electromagnetic relay and includes the bobbin assembly 10, the plurality of contacts 20 and the pusher 30. The electromagnetic relay 100 is integrated in the casing 40 such that the height of the casing surrounding the plurality of contacts 20 is lower than the positions of the fixed contact 20a, 20c and the movable contact 20b, so that the casing 40 does not interfere with the motion of the movable contact 20b toward the fixed contact 20a. The electromagnetic electromagnetic relay 100 according to the embodiment of present invention includes a clearance and creepage distance ranging between 10 mm to 12 mm to provide the electric isolation. According to the embodiment of the present invention, the electric isolation between the coil and contact is more than 8 KV VAC (rms), preferably ranging between 8 KV VAC (rms) to 12 KV VAC (rms). The above-disclosed effect of the present invention is achieved by enclosing the live components in plastic, a non-conductive material, or an insulating material.

[0032] In an alternate embodiment of the present invention, the electromagnetic relay 100 comprises a flag indicator that is configured to indicate internal feature in the electromagnetic relay 100. In addition, the electromagnetic relay 100 comprises at least one pin 50 configured to be mounted on a socket. Further, at least one pin 50 includes PCB pins configured to be mounted on a PCB. Accordingly, the PCB pins may be straight OR 90 degree bent as per the requirement of the device where the electromagnetic relay 100 is to be used. The pins 50 may be configured to complete the circuit and provide a connection. Additionally, the electromagnetic relay 100 comprises at least one test button that includes at least one of a manual test button or a lockable push button.

[0033] In an alternate embodiment of the present invention, the electromagnetic relay 100 comprises a sealing member configured to prevent ingress of foreign material inside the electromagnetic relay 100. The sealing member may be provided at the base of the casing near the pins. The sealing member allows the electromagnetic relay 100 can be used in various applications where the electromagnetic relays has to be used in the closed environment and with this sealing member penetration of flux vapours and the other gases inside the electromagnetic relay may be avoided. Accordingly, the sealing member 60 may be an O-ring, a rubber gasket, an epoxy or similar materials that may provide air tight seal and further may be having insulating properties so that they are not affected by the magnetic flux generated in the electromagnetic relay 100.

[0034] FIG. 5, shows the electromagnetic relay 100 according to an embodiment of the present invention, where the electromagnetic relay 100 along with the casing is placed inside a housing 42. Said housing 42 may be provided to enable additional protection to the electromagnetic relay from external disturbances. Alternatively, the housing 42 may be designed based on the application and design requirement.

[0035] Although the present invention has been described in considerable detail with reference to certain preferred embodiments and examples thereof, other embodiments and equivalents are possible. Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with functional and procedural details, the disclosure is illustrative only, and changes may be made in detail, especially in terms of the procedural steps within the principles of the invention to the full extent indicated by the broad general meaning of the terms. Thus, various modifications are possible of the presently disclosed system and process without deviating from the intended scope of the present invention.