Monolithic Leaf Spring Contact Bridge Arrangement
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Solution Overview
Problem
Existing contact bridge arrangements for electrical switching elements are complex, difficult to assemble, require many parts, and have a large volume, making them costly and inefficient to manufacture.
Innovation Solution
A contact bridge arrangement with a monolithic leaf spring integrated into the contact bridge holder, featuring spacers to pretension the spring and a compact design that eliminates the need for additional spring holding elements, allowing for reduced part count and optimized spring properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate spring members are used in contact bridge arrangements, then the spring can exert pressure on contact surfaces, but the device complexity increases and assembly becomes difficult
Solution Approach 1:
The spring member is formed monolithically with the contact bridge holder as an integrated component, eliminating the need for separate spring parts and their associated mounting hardware. This merging of the spring function into the holder structure reduces the number of parts while maintaining the spring pressure function on the contact surfaces.
2Reliability
If traditional separate spring members are used, then the spring can compensate for length tolerances, but the volume of the arrangement increases
Solution Approach 1:
The spring member is integrated into the contact bridge holder structure, eliminating the need for additional space required by separate spring components and their mounting fixtures. This integration reduces the overall volume of the contact bridge arrangement while preserving the tolerance compensation function.
3Ease of manufacture
If traditional separate spring members are used, then the spring can be installed, but additional holding tools and elements are required for assembly
Solution Approach 1:
The spring member and contact bridge holder are formed as a single integrated component, eliminating the need for separate holding tools, clips, or mounting elements that would be required to attach a separate spring to the holder. This integration simplifies the assembly process and reduces the complexity of assembly tools and elements.
4Adaptability or versatility
If separate spring members are used from different manufacturers, then production flexibility exists, but production differences cause variations in length and spring strength
Solution Approach 1:
The spring member is formed as an integrated part of the contact bridge holder in the same manufacturing process, eliminating variations that arise from sourcing springs from different manufacturers. This integration ensures consistent length and spring strength characteristics, improving manufacturing precision while maintaining design flexibility.
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 more compact and cost-effective design with reduced assembly complexity, improved spring tensioning, and enhanced adaptability, while compensating for tolerances and ensuring reliable electrical contact.
Implementation Method 1
the at least one spring member is formed as a leaf spring which extends substantially transverse to the actuating direction
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a contact bridge arrangement (1) for an electrical switching element such as a contactor or a relay, with a contact bridge holder (5), and a contact bridge (3), which is held on the contact bridge holder (5) in a movable manner along an actuating direction (B), and which is pressed against at least one stop (15) of the contact bridge holder (5) by at least one spring member (13). In order to provide a contact bridge arrangement (1) which has a small size, consists of few parts, and which has defined spring properties, it is intended according to the invention that the at least one spring member (13) is formed monolithically with the contact bridge holder (5).