Curved Fixed Terminal Electromagnetic Relay for High Current
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Solution Overview
Problem
Existing electromagnetic relays face a challenge in achieving a higher current carrying capacity while maintaining a compact size without compromising performance.
Innovation Solution
The design incorporates a unique configuration with a fixed terminal main body, a curving fixed terminal arm portion, and a backstop with a leg portion positioned away from the fixed terminal, allowing for increased surface area and efficient heat dissipation, along with a backstop that enhances insulation and stability, enabling higher current carrying capacity and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sizes of the fixed terminal and other components are increased to achieve higher current carrying capacity, then the current carrying capacity is improved, but the size of the electromagnetic relay as a whole becomes larger
Solution Approach 1:
The fixed terminal arm portion is designed to curve in a specific direction, transitioning from a linear arrangement to a three-dimensional configuration. This curvature allows the terminal to extend into additional spatial dimensions, effectively increasing the current carrying surface area without proportionally increasing the overall relay volume. The leg portion of the backstop similarly curves to optimize spatial arrangement, enabling better current distribution across multiple dimensions while maintaining compact packaging.
Solution Approach 2:
The leg portion of the backstop is positioned to be located between the movable contacts when viewed from the first direction, creating a nested arrangement where components are interlaced in three-dimensional space. This nesting allows the backstop to provide structural support and current carrying pathways without occupying additional external volume, as it fits within the existing spatial envelope defined by the movable contacts and fixed terminal.
2Volume of stationary object
If the size is reduced to achieve compactness, then the size is decreased, but the current carrying capacity deteriorates
Solution Approach 1:
By curving the fixed terminal arm portion and leg portion of the backstop, the design utilizes three-dimensional spatial arrangement to maximize the current carrying surface area within a reduced volume. The curved configurations allow current pathways to extend in multiple directions rather than linearly, effectively packing more current carrying capacity into a smaller footprint by exploiting volumetric space efficiency.
Solution Approach 2:
The fixed terminal arm portion and leg portion of the backstop are designed with curved geometries rather than straight lines. These curvatures increase the surface area available for current conduction within a compact volume, as curved paths can enclose more surface area than linear paths of the same endpoint distance. The curved shapes also improve heat dissipation surface area relative to the enclosed volume.
3Volume of stationary object
If the fixed terminal and backstop are positioned closer to reduce size, then the size is reduced, but the insulation between fixed terminals and backstop deteriorates
Solution Approach 1:
The leg portion of the backstop is positioned to be located between the movable contacts when viewed from the first direction, creating a three-dimensional spatial separation that maintains insulation distances. This positioning utilizes the vertical and lateral dimensions to ensure adequate clearance between the backstop and fixed terminals, preventing electrical breakdown while minimizing the overall envelope size of the relay.
Solution Approach 2:
The fixed terminal arm portion curves in a specific direction rather than symmetrically, creating an asymmetric arrangement that optimizes the spacing between the backstop and fixed terminals. This asymmetric curvature allows the design to maintain sufficient insulation clearance in critical areas while minimizing the overall dimensions in other directions, achieving compactness without compromising electrical isolation.
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 allows for a higher current carrying capacity and a decrease in size simultaneously, while maintaining performance and ensuring efficient heat dissipation and insulation, thus addressing the need for compact and efficient electromagnetic relays.
Implementation Method 1
an electromagnetic device including a coil
Data Source
AI summary
An electromagnetic relay includes: a fixed terminal including a fixed terminal main body extending in a first direction, a fixed terminal arm portion, and two fixed contacts; a movable spring including two movable contacts, and extending in a second direction; a backstop; and a fixed terminal retainer. One of the fixed terminal main body and the fixed terminal arm portion is a first side terminal portion facing in the second direction, and the other is a second side terminal portion curving from a first edge of the first side terminal portion in a direction opposite to the second direction. A leg portion of the backstop is provided away from the first side terminal portion in the direction opposite to the second direction, and is provided between the two movable contacts on a projection plane with a perpendicular extending in the second direction when viewed from the first direction.