Horizontal Twin Electromagnetic Relay for Compact Surface Mounting
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Solution Overview
Problem
Conventional twin-type electromagnetic relays face challenges in achieving reduced size and height due to increased coil length and terminal configuration, which affects reliability and surface mounting, and are prone to foreign matter incorporation and thermal stress during manufacturing and assembly.
Innovation Solution
The design features a base plate with side-by-side electromagnetic relay blocks having L-shaped yokes and integrally molded terminal blocks, with projections for thermocompression, bifurcated terminals, and a cover with a lib insertion hole to prevent foreign matter introduction and enhance reliability, allowing for reduced size and mounting height while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the coil length is increased to generate sufficient attractive force for high power control, then the electromagnetic relay can control higher power, but the size and mounting height of the electromagnetic relay are increased
Solution Approach 1:
The patent changes the spatial arrangement of the coil from a conventional vertical winding (perpendicular to base plate) to a horizontal winding configuration (parallel to base plate). This dimensional change allows the coil to generate sufficient magnetic force for high power control while reducing the vertical height of the electromagnetic relay, thereby resolving the contradiction between power control capability and mounting height.
Solution Approach 2:
The patent employs a composite structure combining a ferrite core with a horizontal coil arrangement. The ferrite core enhances magnetic flux density and directs the magnetic field efficiently, allowing the coil to achieve higher power control capability without requiring excessive coil length, thus reducing the overall size while maintaining power control.
2Adaptability or versatility
If terminals are arranged for surface mounting with bending work required, then surface mounting is enabled, but additional manufacturing steps and complexity are introduced
Solution Approach 1:
The patent integrates the terminal structure directly into the base plate as integral terminals, merging two previously separate components (base plate and terminals) into one. This eliminates the need for separate terminal bending operations and reduces manufacturing steps while maintaining surface mounting capability, thereby resolving the contradiction between adaptability and ease of manufacture.
3Length of stationary object
If the electromagnetic relay is designed for compact size, then the mounting height is reduced, but the coil length must be reduced which limits power control capability
Solution Approach 1:
The patent reduces mounting height by reorienting the coil winding from vertical to horizontal, placing it parallel to the base plate rather than perpendicular. This dimensional change allows the coil to maintain sufficient length for power control while keeping the vertical profile compact, effectively resolving the contradiction between compact size and power control capability.
Solution Approach 2:
The use of a ferrite core in combination with the horizontal coil creates a composite electromagnetic structure that increases magnetic flux density. This allows the coil to achieve higher power control capability with reduced coil length, enabling compact design without sacrificing power control.
4Ease of operation
If conventional terminal configurations are used, then connection to external wirings is possible, but bending work is required which complicates surface mounting
Solution Approach 1:
The patent merges the terminal function with the base plate structure by creating integral terminals that are directly formed as part of the base plate. This eliminates the need for separate terminal components and bending operations, simplifying both manufacturing and assembly while maintaining the capability to connect to external wirings for surface mounting applications.
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 enables a reliable, compact electromagnetic relay suitable for surface mounting with improved assembly accuracy and thermal stress resistance, minimizing foreign matter introduction and ensuring high reliability and reduced mounting height.
Implementation Method 1
an electromagnetic relay having, on a base plate, a plurality of electromagnetic relay blocks each provided with a movable contact swung by excitation current
Implementation Method 2
At least one projection provided in the spool of the coil assembly constituting each of the electromagnetic relay blocks is inserted into a projection insertion hole formed in the base plate so as to fix each of the electromagnetic relay blocks
Data Source
AI summary
To provide a twin-type power electromagnetic relay having high reliability, having a reduced size and low mounting height, and suitable for surface mounting.By inserting projections provided in a coil spool, which is a component constituting an electromagnetic relay block, into projection insertion holes 5a and 5b formed in a base plate 5, two electromagnetic relay blocks 4A and 4B are arranged side by side on the base plate 5 such that their central axes are nearly parallel to the base plate. A base protective wall 5c is provided on the base plate 5, and a coil wire winding terminal portion of a spool is covered by the base protective wall and by a fixed terminal protective wall on the fixed terminal block when assembled, preventing foreign matters such as flux from entering between the contacts from the winding terminal portion.