Importance

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Abstract

An improved power-switching relay especially designed for mounting on printed circuit boards together with a method for manufacturing such a relay. The relay includes a number of features designed to properly position the various relay components relative to one another and to help ensure that they remain in the proper position at all times. To this end, the relay includes a unitary bobbin (22) and stationary contact support header (33) together with means (64) for firmly retaining the stationary contacts (34, 36) and their terminals (63, 73) in place in the header. The relay also provides means to prevent rotation of the armature relative to the movable contact assembly (53, 54) and to prevent rotation of the coil assembly relative to the frame (35). According to a further aspect of the invention, the core and coil assembly is attached to the relay frame by extending the core through the coil assembly and press-fitting the core into an extruded hole (14) in the frame. This procedure not only provides a very strong, rigid attachment, but permits the core to be accurately positioned relative to the movable contact arm assembly by simply pressing the core into the extruded aperture by the required amount. This capability, for the most part, eliminates the need for any final adjustments after the relay has been assembled and, thus, helps reduce manufacturing costs. The bobbin is additionally provided with deformable members (38) to take up any space between the core head and bobbin, ensuring a tight assembly.

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First Claim