Sintered Relay Lead-Out Pin Structure for Compact Insulated Yoke Mounting
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Solution Overview
Problem
The existing connecting structures between lead-out pins of auxiliary stationary contacts and yoke plates in DC relays have complex structures, large volumes, and high manufacturing difficulties, which hinder miniaturization and increase production costs.
Innovation Solution
A connecting structure that integrates a lead-out pin, a glass material body, and a kovar alloy part, connected through sintering, with insulation provided by the glass material, and fixed to the yoke plate via the kovar alloy part, featuring a multiple bending design to reduce stress concentration and enable direct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the lead-out pin, glass material body and kovar alloy part are connected through sintering to form an integrated assembly, then the manufacturing complexity is reduced and production efficiency is improved, but the manufacturing precision requirements increase due to the sintering process
Solution Approach 1:
The patent merges the lead-out pin, glass material body, and kovar alloy part into a single integrated assembly through sintering, combining multiple components into one unified structure. This reduces the number of separate parts and assembly steps, thereby improving production efficiency while maintaining reliable electrical insulation and mechanical connection.
Solution Approach 2:
The patent employs composite materials by combining metal (lead-out pin and kovar alloy part) with glass material body through sintering. This creates a hybrid structure that leverages the conductive properties of metal and the insulating properties of glass, achieving both electrical functionality and structural integrity in a single manufacturing process.
2Reliability
If the glass material body is used for insulation between lead-out pin and kovar alloy part, then the insulation reliability is improved, but the volume of the connecting structure increases
Solution Approach 1:
The glass material body is strategically positioned only where electrical insulation is required - between the lead-out pin and kovar alloy part. This localized application of insulating material provides reliable electrical isolation while minimizing the overall volume of the connecting structure, avoiding unnecessary bulk in other areas.
Solution Approach 2:
The glass material body is nested within the compact assembly of the lead-out pin and kovar alloy part, with the insulating material integrated into the internal structure rather than added as an external component. This nesting approach ensures insulation reliability while minimizing the external dimensions of the connecting structure.
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 structure achieves miniaturization by reducing height occupation, simplifies manufacturing processes, and ensures reliable insulation and soldering, thereby lowering production costs and enhancing product reliability.
Implementation Method 1
the lead-out pin and the kovar alloy part are insulated from each other by glass material
Implementation Method 2
the lead-out pin, the glass material body and the kovar alloy part are connected into a whole by sintering
Data Source
AI summary
A connecting structure between lead-out pins of auxiliary stationary contacts and a yoke plate of a DC relay, includes a yoke plate and an auxiliary stationary contact lead-out terminal assembly mounted on the yoke plate; the auxiliary stationary contact lead-out terminal assembly includes a lead-out pins, a glass material body and a kovar alloy part; the lead-out terminal, the glass material body and the kovar alloy part are connected into a whole by sintering, and the lead-out terminal and the kovar alloy part are insulated from each other by glass material; the auxiliary stationary contact lead-out terminal assembly is welded and fixed to the yoke plate through the kovar alloy part.