Bi-Stable Relay Core Assembly Using Magnetic Shell Retention

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Solution Overview

Problem

Conventional relay disconnect switches require complex assembly processes due to fixed shells that are secured using screws or rivets, increasing assembly time and part complexity.

Innovation Solution

A bi-stable relay assembly utilizing a core assembly with a coil support structure, magnets, and electromagnetic shell components held in place by magnetic forces, reducing the need for fastening components and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional shells are fixed to core structures using screws or rivets, then the structural strength and reliability are improved, but the assembly complexity and assembly time increase

Engineering Contradiction:

Improvestructural reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical fastening system (screws, rivets) with a magnetic field-based retention system. The coil assembly generates a magnetic field that holds the shell components in place, substituting mechanical connections with electromagnetic forces. This reduces assembly complexity while maintaining structural reliability through the magnetic retention mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the retention mechanism from mechanical (physical fasteners) to electromagnetic (magnetic field). By utilizing the magnetic field generated by the coil assembly, the shell components are retained without mechanical fasteners. This parameter change from mechanical to electromagnetic retention simplifies the assembly process while maintaining structural integrity.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional shells are fixed to core structures using screws or rivets, then the structural strength and reliability are improved, but the assembly time and productivity decrease

Engineering Contradiction:

Improvestructural reliabilityVSAvoidassembly productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the mechanical fastening system (screws, rivets) with a magnetic field-based retention system. The coil assembly generates a magnetic field that holds the shell components in place, substituting mechanical connections with electromagnetic forces. This substitution eliminates the need for fastening operations, significantly improving assembly productivity while maintaining structural reliability through the magnetic retention mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Device complexity

If magnetic forces are used to hold shell components in position, then the assembly complexity and assembly time are reduced, but the structural reliability may be compromised

Engineering Contradiction:

Improveassembly complexityVSAvoidstructural reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The coil assembly serves multiple functions: it generates the magnetic field for retaining shell components during assembly and operation, and it performs its primary function of actuating the relay switch. This multi-functionality ensures that the magnetic retention system does not compromise structural reliability, as the same component that provides magnetic retention is also the active element of the relay mechanism.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces the mechanical fastening system (screws, rivets) with a magnetic field-based retention system. The coil assembly generates a magnetic field that holds the shell components in place, substituting mechanical connections with electromagnetic forces. This substitution reduces assembly complexity while maintaining structural reliability through the magnetic retention mechanism.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution simplifies the assembly process by using magnetic forces to maintain the shell components in position, thereby reducing the time and complexity required for assembly while ensuring stable switch positions.

Implementation Method 1

When current flows through the coil, a magnetic field is created proportional to the current flow

Methodology Applied

Scientific EffectMagnetic field generation: Electromagnetic Induction

Implementation Method 2

the magnetic field is sufficiently strong to pull the switch's movable contact from its rest, or de-energized position, to its actuated, or energized position

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Implementation Method 3

a first electromagnetic shell component and a second electromagnetic shell component each extending between the first and second magnets

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS11769646B2Magnetic core of a relay disconnect switch

Publication Date: 2023.09.26 LITTELFUSE INC

AI summary

Provided herein is an improved bi-stable relay. In some embodiments, the bi-stable relay assembly may include a housing, and a core assembly within the housing. The core assembly may include a coil support structure, a first coil and a second coil along a central section of the coil support structure, a first magnet at a first end of the coil support structure, a second magnet at a second end of the coil support structure, and a first electromagnetic shell component and a second electromagnetic shell component each extending between the first and second magnets.