Linear-Actuated Double-Throw Relay for Compact Circuit Switching

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Solution Overview

Problem

Existing electrical relay systems are bulky and costly due to the need for multiple relays to control different circuits, particularly in applications like HVAC, power supply, and aerospace, where double throw relays are complicated and inefficient.

Innovation Solution

A double pole-double throw relay design utilizing a linear actuator and movable contact assembly within a housing, allowing for two outputs per input with a single relay, enabling efficient switching between multiple circuits through a plunger's linear movement between retracted and advanced positions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple relays are used to control different circuits, then circuit control capability is improved, but system cost and weight increase

Engineering Contradiction:

Improvecircuit control capabilityVSAvoidsystem weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The patent combines multiple relay functions into a single integrated relay device. The relay includes a common input terminal connected to a movable contact that can switch between multiple output terminals, allowing one relay to control multiple circuits simultaneously. This merging approach eliminates the need for multiple separate relays, thereby reducing system weight while maintaining circuit control capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The relay is designed with multi-functionality to control different circuits through a single device. The movable contact can be positioned to connect the common input to different output terminals based on actuation state, enabling one relay to perform the functions of multiple relays. This universal design improves adaptability while reducing overall system weight.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If a rotary contact is used in double throw relays, then circuit switching capability is improved, but device complexity and size increase

Engineering Contradiction:

Improvecircuit switching capabilityVSAvoidrelay complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces the traditional rotary mechanical contact system with a linear actuation system. Instead of using a rotary contact that pivots between contacts, the invention employs a movable contact that travels linearly between terminal positions. This substitution simplifies the mechanical structure, reduces device complexity, and decreases overall relay size while maintaining the double-throw switching capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention transitions from a rotary (circular) contact movement to a linear (straight-line) contact movement. By changing the dimension of contact actuation from rotational to linear, the relay achieves the same switching functionality with a simpler, more compact structure, thereby reducing device complexity and size.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Adaptability or versatility

If a rotary contact is used in double throw relays, then circuit switching capability is improved, but relay size increases

Engineering Contradiction:

Improvecircuit switching capabilityVSAvoidrelay volume

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent replaces the rotary mechanical contact system with a linear actuation system. Instead of using a rotary contact that pivots between contacts, the invention employs a movable contact that travels linearly between terminal positions. This substitution simplifies the mechanical structure, reduces device complexity, and decreases overall relay size while maintaining the double-throw switching capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 design reduces system weight and cost by enabling multiple circuit control within a single, compact relay, enhancing reliability and efficiency in various electrical applications.

Implementation Method 1

When the relay receives an electrical signal, the relay is energized to introduce a magnetic field to drive a movable contact to mate with fixed contacts

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS20240282538A1Double throw relay

Publication Date: 2024.08.22 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A relay includes fixed contacts in a cavity of a housing including an input contact and first and second output contacts. The relay includes a relay actuator in the cavity having a plunger movable in a linear actuation direction between a retracted position and an advanced position. The relay includes a movable contact coupled to the plunger and movable with the plunger between first and second mated positions. The movable contact is electrically connected to the input contact in both the first mated position and the second mated position. The movable contact is electrically connected to the first output contact and is disconnected from the second output contact in the first mated position. The movable contact is electrically connected to the second output contact and is disconnected from the first output contact in the second mated position.