Modular Relay Sub-Assembly with Split Conductor

Solution Overview

Problem

Existing relay systems require specialized or individual devices for different functionalities like current sensing and dimming, leading to increased complexity and costs due to the need for various dedicated relay configurations and add-on equipment.

Innovation Solution

A modular relay sub-assembly with a split conductor design that allows for interchangeable configurations, enabling the use of a base relay with additional modules for enhanced functionality, such as current sensing and dimming, while maintaining a common form-factor and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If specialized or individual devices are used for different functionalities (current sensing, phase dimming, 0-10V dimming), then the functionality and versatility of the relay system is improved, but the device complexity and manufacturing costs increase due to the need for various dedicated relay configurations and add-on auxiliary equipment

Engineering Contradiction:

ImprovefunctionalityVSAvoidcomplexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent applies universality by designing a single relay housing that can accommodate multiple different functionalities through interchangeable modules. The housing includes a cavity that can receive various modules such as current sensing modules, phase dimming modules, and 0-10V dimming modules, allowing one base relay to perform multiple functions without requiring separate dedicated devices for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies segmentation by dividing the relay system into a base housing and separate interchangeable modules. Each module is a self-contained unit that can be independently manufactured and then assembled into the housing, allowing for simplified manufacturing of individual components and easier customization of the complete system based on specific functionality requirements.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If specialized or individual devices are used for different functionalities, then the functionality and versatility of the relay system is improved, but the manufacturing costs increase due to the need for various dedicated relay configurations and add-on auxiliary equipment

Engineering Contradiction:

ImprovefunctionalityVSAvoidmanufacturing costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a single relay housing that can accommodate multiple different functionalities through interchangeable modules. The housing includes a cavity that can receive various modules such as current sensing modules, phase dimming modules, and 0-10V dimming modules, allowing one base relay to perform multiple functions without requiring separate dedicated devices for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent applies segmentation by dividing the relay system into a base housing and separate interchangeable modules. Each module is a self-contained unit that can be independently manufactured and then assembled into the housing, allowing for simplified manufacturing of individual components and easier customization of the complete system based on specific functionality requirements.

Inventive Principle:

Principle #1Segmentation

3Device complexity

If sensing elements are positioned inside the relay housing, then the relay structure is simplified, but the sensing elements may be damaged and measurement accuracy is reduced

Engineering Contradiction:

ImprovestructureVSAvoidsensing element durability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies segmentation by dividing the relay system into a base housing and separate interchangeable modules. Each module is a self-contained unit that can be independently manufactured and then assembled into the housing, allowing for simplified manufacturing of individual components and easier customization of the complete system based on specific functionality requirements.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9196441B2Modular relay sub-assembly

Publication Date: 2015.11.24 ABL IP HLDG LLC

AI summary

A modular relay sub-assembly is provided. The modular relay sub-assembly can include a first housing portion, a second housing portion, a conductor having a first contact, and a split conductor. The second housing portion may be attached to a surface of the first housing portion. The conductor may be disposed inside a cavity formed by the two housing portions. The first contact may be accessible through a first opening in the first housing portion. The split conductor may include a first portion, a second portion, and a contact. The split conductor being disposed inside the cavity formed by the first and second housing portions. The second portion may be disposed at a position electrically isolated from the first portion. The contact of the split conductor can be accessible through a second opening in the first housing portion. The split conductor can be positioned to selectively contact the conductor.