Electromagnetic Relay Contact Support Recess for Compact Switching
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Solution Overview
Problem
Existing electromagnetic relays face a challenge in extending the length of the elastically deformable portion of the movable contact piece while maintaining a compact vertical size, as longer deformable portions increase the relay's vertical size.
Innovation Solution
Incorporating a recessed support portion on the movable terminal that overlaps the movable contact piece, allowing for increased deformation length without vertical expansion, along with optional protrusions and a bent shape to enhance rigidity and contact force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the elastically deformable portion of the movable contact piece is made longer to satisfy electrical switching performance, then the spring constant and contact force are improved, but the vertical size of the electromagnetic relay increases
Solution Approach 1:
The movable contact piece is nested within the recess of the movable terminal, allowing the elastically deformable portion to extend downward into the recess space rather than upward outward. This nesting arrangement enables the contact piece to achieve sufficient deformation length for reliable electrical switching while containing the overall vertical height of the relay component assembly.
Solution Approach 2:
Instead of extending the elastically deformable portion in the vertical dimension, the design redirects the deformation space into the horizontal recess area. The movable contact piece extends downward into the recess and utilizes lateral space for elastic deformation, transforming the problem from a vertical dimension constraint to a horizontal dimension solution.
2Length of stationary object
If the support portion of the movable terminal is reduced in vertical height to maintain compact size, then the vertical size is reduced, but the rigidity of the support portion deteriorates
Solution Approach 1:
The support portion combines multiple structural elements with different functional properties: a recessed region providing vertical clearance for the contact piece, upward protrusions providing lateral support and rigidity, and downward extensions providing mechanical connection to the base. This composite structure achieves both compact vertical size and sufficient rigidity through integrated design.
Solution Approach 2:
The support portion features localized protrusions at critical positions (sides and bottom) that provide rigidity and support where needed, while the central region remains recessed to accommodate the movable contact piece. This local differentiation of structural properties allows the support portion to be compact overall while maintaining local rigidity where structurally necessary.
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 increases the deformation length of the movable contact piece while keeping the relay's vertical size constant, ensuring the spring constant required for electrical switching performance and maintaining stable contact forces.
Implementation Method 1
The movable contact piece is made of an elastic conductive material such as copper. The movable contact piece is elastically deformed by being pressed by a pressing member such as a card.
Data Source
AI summary
An electromagnetic relay includes a fixed terminal, a base, a fixed contact, a movable contact, a movable contact piece, and a movable terminal. The base supports the fixed terminal. The fixed contact is connected to the fixed terminal. The movable contact faces the fixed contact. The movable contact is connected to the movable contact piece. The movable terminal is provided separately from the movable contact piece and supported by the base. The movable terminal includes a support portion. The support portion is connected to the movable contact piece below the movable contact and supports the movable contact piece. The support portion includes an upper edge and a recess. The recess has a shape recessed downward from the upper edge at a position overlapping the movable contact piece.