US3128355A - Plastic relay structure and method of making - Google Patents

Description

April 7, 1964 FULLER 3,128,355

PLASTIC RELAY STRUCTURE AND METHOD OF MAKING Filed Oct. 19, 1959 I II mvll. vlim'llz III I INVENTOR -E EVANDER K FULLER ATTORNEY United States Patent 3,128,355 PLASTIC RELAY STRUQTURE AND METHGD 9F MAKING Evander K. Fuller, Greenshoro, N.C., assignor to Western Electric Company, Incorporated, New York, N.Y., a corporation of New York Filed Oct. 19, 195?, Ser. No. 847,247 9 Claims. (Cl. 260-87) This invention relates to an electromagnetic relay and a method of making the relay. More particularly this invention relates to an electromagnetic relay having an integral resilient insulating support and armature and a method of forming the support and armature.

An object of the present invention is to provide a new and improved electromagnetic relay and a method of making the relay.

Another object is the provision of an electromagnetic relay having an integral resilient insulating support, and a method of forming the support.

A method of making a relay from an integral sheet of resilient insulating material illustrating certain aspects of the invention may include the steps of fixing contacts and an armature to the sheet and deforming the sheet to align the contacts in space opposition. A coil is secured on the sheet adjacent the armature whereby attraction of the armature by the coil flexes the resilient sheet to operate the contacts.

A relay illustrating certain aspects of this invention may include a support formed of an integral sheet of resilient insulating material, contacts fixed to the resilient support in space opposition, and an armature positioned within the support responsive to the energization of a relay coil flexing the resilient support to operate the contacts.

A complete understanding of the invention may be had from the following detailed description of several embodiments thereof when read in conjunction with the appended drawings, in which:

FIG. 1 is a side sectional view of a relay embodying the principles of the invention;

FIG; 2 is a perspective view of a preformed sheet of resilient insulating material to be formed into the shape of the relay support shown in section in FIG. 1;

FIG. 3 is a side sectional view of a make-break contact type relay exemplifying another embodiment of the invention;

FIG. 4 is a front sectional view of the relay taken along the line 44 of FIG. 3; and

FIG. 5 is a perspective view of a preformed sheet of resilient insulating material to be formed into the shape of the relay support shown in FIGS. 3 and 4.

Referring now to the drawing, wherein like reference characters designate like or corresponding parts throughout the several views, there is shown in FIG. 1 a relay, generally designated by the numeral 11, having an integral resilient insulating support 12 of a material such as the plastic, sold under the trade name Plexiglas. The desired configuration may be formed by any well known technique, such as molding, stamping, cutting, or the like. Securely embedded within or fixed to the support 12 is an armature 13 of a paramagnetic material of high permeability, such as soft iron. Contacts 14 having terminal leads 15 are fixed to the support 12 to form a switch gap 16, the contacts 14 being disengaged to maintain the switch gap 16 open when the relay 11 is not operated.

A relay-operating coil 17 having leads 18 is positioned fixedly within a recess 19 which is formed within the support 12. The coil 17 is positioned such that its core 21 is in space opposition with the armature 13 to form an air gap 22 when the relay 11 is in an unoperated condition. The relay 11, as shown in FIG. 1, is of the ice type referred to as normally open; i.e., the relay contacts 7 14 are disengaged forming the switch gap 16 when there is no electrical current applied to the leads 18 of the coil 17.

In operation when an electrical current is applied by leads 18 to the coil 17, it creates a strong magnetic field causing the armature 13 to be attracted to and held in engagement with the core 21. Such attraction causes the resilient support 12 to flex or to temporarily distort so as to bring contacts 14 into mutual engagement with a predetermined pressure. This pressure is primarily dependent upon the width of the switch gap 16 with respect to that of the air gap 22, which may be slightly wider, and the flexibility or elasticity of the support 12. Hence, when the coil 17 is energized, a circuit, not shown, connected by leads 15 to the contacts 14, is closed, and upon the removal of electrical current from the coil 17, the contacts 14 disengage to open the circuit, not shown, connected to them.

In making the relay 11 of FIG. 1, the armature 13 and contacts 14 are fixed to a preformed integral sheet of resilient insulating material by any of the conventional methods of joining metal and resilient material, such as heating and embedding, plastic deformation, utilization of fasteners, gluing, cementing, or the like. If the heating-and-embedding joining method is used, it may be desirable, for example, to first remove some of the material of the support 12 before embedding the heated armature 13. After the armature 13 and contacts 14 are so fixed, the sheet is deformed to align the contacts 14 in space opposition. Such deformation may be achieved simply by bending or folding the sheet past its elastic limit. It may be desirable, depending on the physical and chemical characteristics of the sheet, to heat the sheet at locations where the bending is to be performed to aid in the bending operation. Such heating, for example, may be concentrated along lines 23, FIG. 2, and while the sheet is in a heated condition, it may be bent along lines 23 to form the support 12.

A second embodiment of the relay is shown in FIGS. 3, 4, and 5. The methods of making the second embodiment are somewhat similar to the methods of making the first embodiment. A sheet of resilient insulating material is fabricated into the configuration of a T, FIG. 5 having a stem, an upper crossbar, and a lower crossbar. Both the upper and the lower crossbars have two portions of unequal length extending laterally at right angles from the stem. Also, the upper crossbar is parallel to and spaced from the lower crossbar. Contacts 24 are positioned within the upper edge of the upper crossbar and in the base of the T of the sheet as shown in FIG. 5. Armature 13 is fixed to the stem intermediate the lower crossbar and the base. Apertures 26 are then formed through the lower crossbar at each side of the stem.

As shown in FIG. 5, the spacing of folding lines 23 of the upper crossbar is unequal so that when it is folded into the shape of FIGS. 3 and 4, the contacts 24 of the upper crossbar are vertically aligned in space opposition. Also, the spacing of the folding lines 23 of the lower crossbar is unequal so that when it is folded into the shape shown in FIGS. 3 and 4, the apertures 26 are spaced in vertical alignment above the stem.

An operating coil 17 is secured within the vertically aligned apertures 26 of the folded lower crossbar by gluing, cementing, or the like. Next, the portion of the stem extending below the lower crossbar is folded to place the armature 13 in vertical space alignment above the coil 17 and to place the contact 24 fixed to the base of the T in sandwiched relationship between the vertically aligned contacts 24 of the upper crossbar such that attraction of the armature 13 by the coil 17 causes the contact 24 of 3 the stem to move from one of the vertically aligned contacts 24 to the other.

The second embodiment, FIGS. 3 and 4, differs in structure from that shown in FIG. 1 in that three cooperating contacts 24 are secured to support 25 instead of the two cooperating contacts 14 of the embodiment of FIG. 1. Hence, the second embodiment constitutes a make-break relay. Also, the support 25 is provided with apertures 26 for fixedly locating the coil 17.

As another embodiment of the relay shown in FIGS. 3, 4, and 5, one of the portions of the upper crossbars of the resilient sheet could be omitted. The sheet would be fabricated into the configuration of an L having a stern and an upper crossbar extending laterally from one edge of the stern and a lower crossbar extending laterally from both edges of the stem. Contacts 24 and an armature 13 would be fixed in the same or similar manner as in the second embodiment. Also, the folding would be accomplished in the same or similar manner to form a relay similar to that shown in FIGS. 3 and 4, except that there would be only two cooperating contacts (instead of three cooperating contacts) that is, either normally open or normally closed, depending upon which portion of the crossbar of the second embodiment was omitted.

It should be understood that the above-described embodiments and methods are merely illustrative and that numerous modifications may be made within the spirit and scope of the invention. Further, the particular relays and methods of making them are not limited solely to the above-described embodiments and methods.

What is claimed is:

l. A method of making a relay from an integral sheet of resilient electrically insulating material comprising the steps of heating a pair of electrical contacts and an armature, fixing by plastic deformation the heated contacts and armature to the sheet, deforming the sheet to align the contacts in space opposition, and supporting a coil on the sheet sufficiently near the armature that energizing the coil attracts the armature and flexes the resilient sheet to operate the contacts.

2. A method of making a relay comprising the steps of fabricating a sheet of resilient electrically insulating material into the configuration of a T having a stem and an upper and a lower crossbar, positioning electrical contacts in the upper crossbar of the T-shaped sheet, fixing another electrical contact to the base of the stem of the T, fixing an armature to the stem intermediate the lower crossbar and the base of the stem, forming apertures through the lower crossbar at each side of the stern, folding the upper crossbar to align the contacts thereon in vertical space opposition, folding the lower crossbar at the juncture of each side of the lower crossbar with the stem to space the apertures in vertical alignment above the stem, securing a coil within the vertically aligned apertures of the lower crossbar, and then folding the portion of the stem extending below the lower crossbar to place the armature in vertical space alignment above the coil and to place the contact fixed to the base of the T in sandwiched relationship between the vertically aligned contacts of the upper crossbar such that attraction of the armature by the coil causes the contact on the stem to move from one of the vertically aligned contacts to the other.

3. A method of making a relay comprising the steps of fabricating a sheet of resilient electrically insulating material into the configuration of an L having a stem and an upper crossbar extending laterally from one edge of the stem and a lower crossbar extending laterally from opposite edges of the stem, the upper crossbar being parallel to and spaced from the lower crossbar, positioning an electrical contact on the upper crossbar of the L-shaped sheet, folding the upper crossbar to align the contact in vertical spaced relationship to the stem, fixing another electrical contact to the base of the stem of the L, fixing an armature to the stem intermediate the lower crossbar and the base of the stem, forming apertures through the lower crossbar at each side of the stem, folding the lower crossbar at the juncture of each side of the lower crossbar with the stem to space the apertures in vertical alignment above the stem, securing a coil within the vertically aligned apertures of the lower crossbar, and then folding the portion of the stern extending below the lower crossbar to place the armature in vertical space alignment above the coil and to place the contact fixed to the base of the L in opposition with contact of the upper crossbar such that attraction of the armature by the coil causes the contact of the stem to operate.

4. A relay structure comprising a strip of resilient, insulating material formed in a loop with the ends thereof spaced from each other, a pair of contacts attached to said ends to form a switch gap, an armature secured to the inside of the strip, and a coil secured to the inside of the strip and spaced from said armature for attracting the armature to flex the resilient loop and move the contacts through the switch gap and into engagement with each other.

5. A relay comprising an operating coil having a magnetizable core, an integral resilient electrically insulating support made from a strip of material formed into substantially a rectangle having a gap formed in one side by the ends of the strip, the ends of said strip having cooperating metal contacts fixed thereto so as to form a switch gap, an operating coil fixed within the support, an armature fixed within the support opposite the magnetizable core to form an air gap between the core and the armature, said air gap having a width slightly larger than the width of the switch gap so that upon operation of the relay, the contacts thereof will close with a predetermined pressure.

6. A relay which comprises a support of a block-C configuration, the open part of the block 0 forming a gap, said block-C configuration having an inner surface and an outer surface and composed of resilient electrically insulating material, electrical contacts fixed to the support adjacent the gap of the block-0, an armature fixed to the support inner surface at the top of the block-C configuration, and an operating coil fixed to the inner surface of the support at the bottom of the block-C configuration in operating spaced relation with the armature.

7. A relay comprising an integral resilient electrically insulating support having an inner surface and an outer surface and a bottom with a recess formed in the inner surface thereof, a first side folded upwardly from the bottom, a top folded from the first side parallel and equal in size to the bottom, and a second side formed by folding a portion of the top downwardly and a portion of the bottom upwardly to form a gap, the second side being parallel and equal in size to the first side; a pair of cooperating, normally open electrical contacts fixed respectively to the outer ends of the gap to form a switch gap; an operating coil having a magnetizable core secured within the recess of the bottom; and an armature fixed to the inner surface of the top directly over the operating coil to form an air gap between the core and the armature so that upon energization of the relay the armature will be attracted to and held by the core, thereby closing the relay contacts.

8. A relay comprising an integral resilient electrically insulating support having an inner surface and an outer surface and a bottom with a recess formed in the inner surface thereof, a first side folded upwardly from the all...

fixed to the inner surface of the top in spaced alignment with the operating coil to form an air gap between the core and the armature, said air gap having a width slightly larger than the Width of the switch gap so that upon the energization of the relay the contacts thereof will close with a predetermined pressure.

9. A relay comprising an integral resilient electrically insulating support having an inner surface and an outer surface and a bottom, a side folded upwardly from the bottom, a top folded from the side parallel and equal in size to the bottom, a pair of apertured tabs extending laterally at right angles from the bottom, the tabs being adjacent the side and the apertures being aligned along an axis perpendicular to the bottom; an operating coil having a magnetizable core, the coil being fixed in the apertures so that the base of the coil is supported by the bottom; an armature fixed to the top in aligned spaced opposition with the core; a first electrical contact fixed to the outer end of the top; a pair of laterally extending projections spaced from and parallel to the tabs; and a second and a third electrical contact fixed to the projections such that said contacts are axially aligned in space opposition, the first contact being sandwiched between said contacts whereby attraction of the armature by the core of the coil causes the first contact to move from the second to the third contact.

References Cited in the file of this patent UNITED STATES PATENTS 1,664,212 Hawkinson Mar. 27, 1928 2,174,355 Sundstrom Sept. 26, 1939 2,377,604 Belden June 5, 1945 2,529,212 Coulter Nov. 7, 1950 2,549,323 McMullen Apr. 17, 1951 2,576,856 Robertson Nov. 27, 1951 2,587,568 Eisler Feb. 26, 1952 2,632,071 Rinke Mar. 17, 1953 2,856,674 Hill Oct. 21, 1958 2,877,324 Oshry Mar. 10, 1959 2,878,348 Haydon et al Mar. 17, 1959 2,880,378 Lindseth Mar. 31, 1959 2,884,574 Jaidinger Apr. 28, 1959 2,916,580 Seele Dec. 8, 1959 2,918,547 Titus Dec. 22, 1959 2,943,167 Hughes et a1 June 28, 1960

Claims (1)

1. 4. A RELAY STRUCTURE COMPRISING A STRIP OF RESILIENT, INSULATING MATERIAL FORMED IN A LOOP WITH THE ENDS THEREOF SPACED FROM EACH OTHER, A PAIR OF CONTACTS ATTACHED TO SAID ENDS TO FORM A SWITCH GAP, AN ARMATURE SECURED TO THE INSIDE OF THE STRIP, AND A COIL SECURED TO THE INSIDE OF THE STRIP AND SPACED FROM SAID ARMATURE FOR ATTRACTING THE ARMATURE TO FLEX THE RESILIENT LOOP AND MOVE THE CONTACTS THROUGH THE SWITCH GAP AND INTO ENGAGEMENT WITH EACH OTHER.

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