Relay Contact Spring Assembly for Multi-Variant Switching Force

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Solution Overview

Problem

The production of specific relay components for various applications increases production and storage costs due to differing size and weight constraints, necessitating a wide variety of components to meet diverse application requirements.

Innovation Solution

A stationary contact spring design with a base section, contact area, and spring section that includes abutting latches and bending zones to manage contact force and biasing force, allowing for adjustable biasing force and contact force balance, enabling the same contact spring to be used in different relay variants with distinct switching characteristics.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If specific components are produced for each application, then application-specific requirements are met, but production and storage costs increase

Engineering Contradiction:

Improveapplication-specific requirementsVSAvoidproduction and storage costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The contact spring is designed with a universal base section that can be used across multiple relay applications, while allowing customization in the spring section to achieve different switching characteristics. This multi-functionality approach reduces the need for completely different components for each application, thereby lowering production and storage costs while still meeting diverse application requirements.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The contact spring is divided into distinct functional sections: a base section that remains constant across applications, and a spring section that can be varied to meet different application-specific requirements. This segmentation allows the common base section to be produced in large quantities for cost efficiency, while only the variable spring sections need to be customized for different applications.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple contact spring variants are produced, then different switching characteristics are achieved, but device complexity increases

Engineering Contradiction:

Improveswitching characteristicsVSAvoidnumber of contact spring variants

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single contact spring design with a universal base section can achieve multiple switching characteristics by modifying only the spring section parameters. This reduces the overall device complexity by eliminating the need for entirely different contact spring variants, while still providing the necessary adaptability for different switching requirements through controlled variations in the spring section.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Use of energy by moving object

If relay size and weight are reduced, then power consumption decreases, but component variety requirements increase

Engineering Contradiction:

Improvepower consumptionVSAvoidcomponent variety

Core Design Contradiction:

Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The contact spring's universal base section enables small, low-power relays to be designed with a common platform that can serve multiple applications. This reduces the need for component variety while maintaining the ability to achieve different switching characteristics through variations in the spring section, thereby supporting low power consumption requirements without increasing component diversity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 the need for multiple contact spring variants, minimizing production costs and allowing for efficient assembly of relays with low power consumption and reduced contact bouncing, suitable for both low and high inrush loads.

Implementation Method 1

a spring section (6) extending along a longitudinal axis (L) from the base section (2) to the contact area (4)

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

an abutting latch (16) abutting the housing (54) with a biasing force (56) directed against the contact force (53)

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS11776783B2Kit and method for the assembly of at least two variants of a relay and contact spring for a relay

Publication Date: 2023.10.03 TE CONNECTIVITY AUSTRIA GMBH

AI summary

A stationary contact spring for a relay includes a base section fixed in a housing of the relay, a contact area opposite the base section adapted to perform an electric switching with a contact force, a spring section extending between the base section and the contact area, and an abutting latch abutting the housing with a biasing force directed against the contact force.