Electromagnetic Contactor Plate Substrate Brazing
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Solution Overview
Problem
The existing electromagnetic contactor designs face challenges with low productivity due to the complex three-dimensional structure of the sealed receptacle, requiring complex brazing jigs and difficulty in controlling flatness and warpage during the metalizing process for brazing fixed terminals.
Innovation Solution
The design features a plate-like fixed contact support insulating substrate with a metal cylindrical body brazed to its outer edge, allowing for efficient screen printing and simplification of brazing jigs, enabling better control over flatness and warpage, and using ceramic insulating substrates for mass production and cost reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a box-form sealed receptacle is used for housing the contact mechanism, then the structural integrity and sealing are improved, but the productivity decreases due to the need for individual screen printing of each receptacle and complex brazing jigs
Solution Approach 1:
The invention divides the box-form sealed receptacle into two separate components: a plate-like fixed contact support insulating substrate and a separate case. The substrate serves as the base structure for mounting fixed contacts, while the case provides the enclosing housing. This segmentation allows the substrate to be screen-printed in a planar configuration enabling batch processing, while the case can be separately manufactured and assembled, thereby improving productivity without compromising structural integrity.
Solution Approach 2:
The invention transitions from a three-dimensional box-form receptacle to a two-dimensional plate-like substrate configuration. By flattening the structure into a planar form, multiple substrates can be arranged in rows and columns on a single screen printing board, enabling simultaneous screen printing of multiple units. This dimensional reduction resolves the productivity issue while the separate case component maintains the necessary three-dimensional enclosure for structural integrity.
2Reliability
If a box-form sealed receptacle is used, then the sealing and protection are improved, but the complexity of brazing jigs and assembly fixtures increases
Solution Approach 1:
By separating the fixed contact support function (handled by the plate-like substrate) from the enclosing function (handled by the case), the invention simplifies the brazing process. The substrate can be brazed to the case in a straightforward manner without requiring complex jigs to maintain the three-dimensional box structure, as the substrate's planar form naturally facilitates simpler fixture design for assembly.
3Shape
If a box-form sealed receptacle is used, then the housing structure is improved, but the control of flatness and warpage of the bottom portion becomes difficult
Solution Approach 1:
The invention separates the functions of providing housing structure (case) and supporting fixed contacts (plate-like substrate). The substrate, being planar and two-dimensional, is inherently easier to control for flatness and warpage during manufacturing compared to a three-dimensional box structure. The case then provides the necessary housing structure, allowing each component to be optimized for its specific function without compromising manufacturing precision.
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
This configuration significantly improves productivity, simplifies the fabrication and brazing process, and reduces fabrication costs by allowing for easier management of flatness and warpage, while enabling simultaneous brazing of fixed contacts and the metal cylindrical body.
Implementation Method 1
the metal cylindrical body brazed to the outer peripheral edge of one surface of the fixed contact support insulating substrate
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
There is provided an electromagnetic contactor such that it is possible to improve productivity, and simplify a brazing jig, and furthermore, it is possible to control the flatness and warpage of a plate portion supporting fixed contacts. An electromagnetic contactor includes an arc extinguishing chamber (102) inside which is mounted a contact mechanism (101) having a pair of fixed contacts (111) and (112) and a movable contact (130) in contact with the pair of fixed contacts, wherein the arc extinguishing chamber (102) has a plate-like fixed contact support substrate (105) wherein metal foils are each formed at least around through holes (105) and (106) in which are fixed the pair of fixed contacts and on an outer peripheral edge of one surface by a metalizing process, is such that the pair of fixed contacts (111) and (112) and a metal cylindrical body (104) are brazed and joined to the metal foils of the fixed contact support insulating substrate (105), and an insulating cylindrical body (140) is disposed on the inner peripheral surface of the metal cylindrical body (104).