Relay Coil Support Structure with Biasable Fasteners
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Solution Overview
Problem
Current relay assembly methods require complex fastening processes, increasing part complexity and assembly time, particularly for coil support structures and printed circuit board assemblies (PCBAs).
Innovation Solution
A bi-stable relay assembly featuring a coil support structure with biasable fasteners having sloped engagement surfaces and retention slots, allowing for simplified assembly by winding coils around the support structure and coupling the PCBAs within the retention slots, reducing the need for multiple fastening components and leveraging magnetic forces for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If PCBAs are fixed to the coil support by screwing, riveting and similar methods, then the connection strength is improved, but the device complexity and assembly time increase
Solution Approach 1:
The patent integrates the PCBA directly into the coil support structure by forming the PCBA as an integral part of the support, eliminating the need for separate fastening components. The support structure includes a body with a recess that receives and retains the PCBA, creating a unified component that reduces part complexity while maintaining connection strength through the integrated design.
Solution Approach 2:
The patent removes traditional fastening elements (screws, rivets) from the assembly by extracting their function entirely. Instead of using separate fastening components, the design uses the structural geometry of the support body and recess to provide retention, eliminating unnecessary parts and simplifying the overall device.
2Reliability
If traditional screwing or riveting methods are used to fix PCBAs to coil support, then the connection reliability is improved, but the assembly time increases
Solution Approach 1:
The PCBA is designed with pre-formed engagement features that fit into the recess of the coil support structure. The retention slots and engagement surfaces are built into the design, allowing the PCBA to be snapped or pressed into place during assembly without requiring time-consuming fastening operations, thus reducing assembly time while maintaining reliable connection.
3Strength
If multiple fastening components are used to secure the PCBA, then the connection strength is improved, but the ease of manufacture decreases
Solution Approach 1:
The coil support structure and PCBA are designed as integrated components where the support body includes a recess that directly receives the PCBA. This merging of functions eliminates the need for multiple separate fastening components, simplifying the manufacturing process and making assembly easier while maintaining adequate connection strength through the integrated structural design.
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 approach simplifies the assembly process by minimizing the number of fastening components required, reducing assembly time and complexity while maintaining stability through magnetic forces, allowing for efficient operation of the relay.
Implementation Method 1
a set of biasable fasteners extending from the first end section and the second end section, each of the set of biasable fasteners including a sloped engagement surface and a retention slot
Data Source
AI summary
Provided herein are coil support structures and methods of retaining a printed circuit board assembly (PCBA) of a relay. In some embodiments, a bi-stable relay assembly may include a coil support structure, having a central section extending between a first end section and a second end section, and set of biasable fasteners extending from the first end section and the second end section, wherein each of the set of biasable fasteners includes a sloped engagement surface and a retention slot. The coil support structure may further include a PCBA coupled to the first and second end sections of the coil support structure, wherein the coil support structure extends within the retention slot of each of the set of biasable fasteners.