DC Relay Movable Contact Assembly With Multi-Point Holder Coupling
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Solution Overview
Problem
Existing direct current relays face challenges in manufacturing complexity due to different insertion and fixing directions of movable contacts and housings, leading to assembly errors and instability in the coupled state.
Innovation Solution
A movable contact part with a structure featuring upper and lower holders that include coupling protrusions and grooves, allowing for easy assembly and stabilization through insert injection molding, enabling coupling at multiple positions and improving design freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the housing is coupled by insert injection at a single location, then the manufacturing process is simplified, but the coupled state becomes unstable and difficult to maintain
Solution Approach 1:
The housing coupling is divided into multiple locations: the lower holder has coupling protrusions at multiple positions, and the upper holder has corresponding coupling grooves at multiple positions. This segmentation distributes the coupling load across multiple points, maintaining stable coupling while keeping the insert injection process simple.
2Ease of operation
If the movable contact is inserted through an opening of the housing, then the assembly process is simplified, but the insertion and fixing directions become different, resulting in manufacturing complexity
Solution Approach 1:
The movable contact is inserted through the housing opening and directly coupled to the lower holder in the same vertical direction. The coupling protrusions and grooves are positioned such that both insertion and fixing occur along the same axis, unifying the operation direction and simplifying the manufacturing process.
3Strength
If a member for fixing the movable contact is inserted and coupled in the vertical direction, then the fixing strength is improved, but the insertion and fixing directions become different, resulting in assembly complexity
Solution Approach 1:
The coupling protrusions are designed with asymmetric positioning relative to the housing opening, allowing the movable contact to be inserted and fixed in the same vertical direction. The asymmetric design ensures proper alignment and maintains fixing strength while simplifying the assembly process.
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
Facilitates easy and stable assembly of movable contact parts within direct current relays, reducing manufacturing complexity and assembly errors while enhancing coupling accuracy and stability.
Implementation Method 1
allowing for easy assembly and stabilization through insert injection molding
Data Source
AI summary
Disclosed are a movable contact part and a direct current relay including the same. The movable contact part according to an embodiment of the present disclosure includes an upper holder and a lower holder. One holder among the upper holder and the lower holder has a coupling protrusion that protrudes toward the other holder. The other holder among the upper holder and the lower holder has a coupling groove into which the coupling protrusion is inserted and coupled. The lower holder is coupled to the inside of a housing, and the upper holder is coupled to each of the lower holder and the housing. Accordingly, the coupling between the upper holder and the lower holder is facilitated, and the coupled state can be stably maintained.