Relay Contact Spring Holder Structure for Better Heat Dissipation
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Solution Overview
Problem
Existing contact devices in electromagnetic relays generate excessive heat due to electrical conduction, leading to reduced durability and efficiency.
Innovation Solution
Incorporating a metal holder with higher thermal conductivity than the resin member, where the spring is in contact with an exposed metal portion of the holder, enhancing heat dissipation and durability.
Engineering Contradictions & Design Principles
Engineering 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
Solution Approach 1:
The patent applies local quality by creating a composite structure where the holder bottom has different material properties in different regions: a metal portion with high thermal conductivity for heat dissipation and a resin portion with insulation properties. This allows each region to perform its specific function optimally - the metal portion dissipates heat from the spring while the resin portion provides electrical insulation.
Solution Approach 2:
The patent uses composite materials by combining metal and resin materials in the holder bottom structure. The metal portion (e.g., aluminum or stainless steel) provides thermal conductivity for heat dissipation, while the resin portion provides electrical insulation. This composite approach resolves the contradiction between needing good heat dissipation and maintaining insulation properties.
2Reliability
If the spring contacts the resin member, then insulation is improved, but heat dissipation and durability deteriorate
Solution Approach 1:
The patent applies local quality by designating specific regions of the holder bottom with different material properties. The metal portion is specifically positioned where the spring makes contact to provide thermal conductivity and durability, while the resin portion is positioned in areas where electrical insulation is needed. This localized differentiation resolves the contradiction between insulation needs and heat dissipation requirements.
3Temperature
If the spring contacts the metal holder, then heat dissipation and durability are improved, but insulation deteriorates
Solution Approach 1:
The patent uses composite materials by combining metal and resin in the holder bottom structure. The metal portion provides thermal conductivity for heat dissipation and mechanical durability where the spring contacts, while the resin portion provides electrical insulation where needed. This composite construction resolves the contradiction between heat dissipation/durability and insulation requirements.
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
Improves heat dissipation and durability by effectively dissipating heat away from the spring, reducing the likelihood of electric arcs and enhancing the operational reliability of the contact device.
Implementation Method 1
the holder has a higher thermal conductivity than a thermal conductivity of the resin member
Data Source
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.