Axial Relay Contact Layout for Compact Pole Density
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Solution Overview
Problem
Existing relays face challenges in increasing the number of contact poles without enlarging the device, as adding more movable touch pieces requires a larger structure and increased manufacturing time when combining multiple relays.
Innovation Solution
A relay design featuring a first base substrate with side contact points and movable touch pieces arranged in the axial direction of a coil, where a movable member rotates to bring contacts into contact or separation, allowing for a dense arrangement of contact points within a compact space, inhibiting size enlargement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of movable touch pieces is increased to increase the number of contact poles, then the number of contact poles increases, but the structure for supporting the movable touch pieces is enlarged
Solution Approach 1:
Multiple movable touch pieces are integrated onto a single movable member, which rotates to simultaneously control multiple contacts. This merging approach allows multiple contact poles to be controlled without proportionally increasing the number of separate movable components and their supporting structures.
Solution Approach 2:
The movable member serves multiple functions by simultaneously controlling multiple movable touch pieces that correspond to different contact poles. One movable member performs the work of multiple independent components, reducing overall structural complexity while increasing contact pole count.
2Quantity of substance
If multiple relays are combined to increase the number of poles, then the number of contact poles increases, but manufacturing time increases due to soldering requirements
Solution Approach 1:
Multiple relay functions are merged into a single integrated device with one coil block and one movable member controlling multiple contact poles. This eliminates the need to manually assemble and solder multiple separate relay units, significantly reducing manufacturing time and complexity.
3Quantity of substance
If the number of movable touch pieces is increased, then the number of contact poles increases, but the relay becomes enlarged making layout difficult
Solution Approach 1:
The contact points are arranged in the axial direction of the coil rather than radially or in a planar expansion. This dimensional arrangement allows multiple contact poles to be packed along the coil axis, utilizing space more efficiently and preventing lateral enlargement of the relay.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables easy layout and increased contact poles without enlarging the relay, facilitating placement in narrow spaces and reducing manufacturing time by allowing more contact points within a smaller area.
Implementation Method 1
The coil block includes a coil and causes the movable member to rotate by electromagnetic force generated by energization of the coil
Data Source
AI summary
A movable member is configured to switch, by rotation, between a first state and a second state. In the first state, the movable member presses a plurality of first movable contact pieces to bring first contacts into contact with first substrate side contact points. When the movable member is in the second state, the first contacts are separated from the first substrate side contact points. A coil block includes a coil and causes the movable member to rotate by electromagnetic force generated by energization of the coil. A rotation axis of the movable member is parallel to an axis of the coil. The plurality of first substrate side contact points is arranged side by side in an axial direction of the coil on a first base substrate. The plurality of first movable contact pieces is arranged side by side in the axial direction.