Relay Contact Holder Structure for Spring Heat Dissipation

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Solution Overview

Problem

Existing contact devices in electromagnetic relays generate excessive heat and have durability issues due to the thermal conductivity and material properties of their components, leading to potential failure and reduced performance.

Innovation Solution

The contact device incorporates a holder made of a high thermal conductivity metal, such as SUS304, with an exposed portion that contacts a metal spring, enhancing heat dissipation and durability by improving thermal conductivity and resistance compared to resin-only contacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a resin member is used to cover the holder bottom, then insulation and ease of manufacture are improved, but thermal conductivity deteriorates leading to excessive heat accumulation

Engineering Contradiction:

Improveease of manufactureVSAvoidheat dissipation

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The holder is constructed as a composite structure combining a resin member with a metal plate having high thermal conductivity. The metal plate is positioned at the bottom surface to provide thermal conduction path while the resin member provides insulation and structural support. This composite approach resolves the contradiction by integrating materials with complementary properties.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a metal spring contacts the holder, then thermal conductivity and durability are improved, but device complexity increases compared to resin-only contact

Engineering Contradiction:

ImprovedurabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The holder structure is designed with localized metal components specifically at the contact areas where thermal conduction and mechanical durability are critical. The metal plate is positioned at the bottom surface to provide thermal conduction path while the resin member provides insulation and structural support. This localized use of metal resolves the contradiction by applying complex materials only where necessary rather than throughout the entire structure.

Inventive Principle:

Principle #3Local quality

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

The solution provides improved heat dissipation and durability by leveraging the higher thermal conductivity of metal components, reducing the risk of failure and enhancing the reliability of the electromagnetic relay.

Implementation Method 1

the holder has a higher thermal conductivity than a thermal conductivity of the resin member

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP4333016B1Contact device and electromagnetic relay

Publication Date: 2026.03.04 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

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AI summary

This contact device includes: a first fixed terminal; a movable contactor configured to contact the first fixed terminal and separate from the first fixed terminal; a spring disposed below the movable contactor and formed of a metal; a holder including a bottom and disposed to position the bottom below the spring; and a resin member configured to cover a portion of the bottom of the holder. The holder has a higher thermal conductivity than a thermal conductivity of the resin member. The upper surface of the bottom of the holder includes an exposed portion that is exposed from the resin member. The spring is in contact with the exposed portion of the bottom.