Relay Spring Lock Structure for Miniature Press-Fit Retention
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Solution Overview
Problem
Small relays face challenges in securing sufficient press-fitting strength due to their compact size, leading to issues like insufficient resilience and increased production costs.
Innovation Solution
The relay design incorporates a locked part on the spring that utilizes its resilience to lock onto the base, and a base with a lock part to secure the locked part, enhancing press-fitting strength and preventing disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the springs are made thicker to maintain press-fitting strength, then press-fitting strength is improved, but resilience deteriorates
Solution Approach 1:
The spring is designed with non-uniform thickness: the terminal portion is made thick to ensure sufficient press-fitting strength, while the spring portion remains thin to maintain resilience. This local differentiation of structural properties resolves the contradiction between strength and resilience.
2Stability of the object's composition
If the springs are made thinner to maintain resilience, then resilience is improved, but press-fitting strength deteriorates
Solution Approach 1:
The spring structure implements local quality by concentrating thickness at the terminal portion where press-fitting strength is critical, while keeping the spring portion thin to preserve resilience. This spatial differentiation allows both requirements to be satisfied simultaneously.
3Reliability
If temporary bonding is applied to secure springs, then reliability is improved, but production cost increases
Solution Approach 1:
The spring structure is designed to be self-retaining through its geometric configuration. The thick terminal portion fits into the base cavity with interference fit, creating self-retention without requiring additional temporary bonding processes. This eliminates extra manufacturing steps and reduces production cost while maintaining reliability.
4Volume of moving object
If the relay size is reduced, then miniaturization is achieved, but press-fitting allowance deteriorates
Solution Approach 1:
The spring design concentrates material at the terminal portion where press-fitting occurs, providing sufficient local thickness for press-fitting allowance even in miniaturized relays. The spring portion remains thin to maintain flexibility, enabling the overall relay size to be reduced while preserving manufacturing feasibility.
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 reduces the risk of spring disengagement, lowers production costs by eliminating temporary bonding, and maintains resilience even with thin springs.
Implementation Method 1
at least one of the plurality of springs has a locked part which is locked on the base using resilience of the spring
Data Source
AI summary
A relay includes an electromagnet, a plurality of springs having contacts which open and close in accordance with operation of the electromagnet and terminals, and a base which supports the springs, wherein at least one of the plurality of springs has a locked part which is locked on the base using resilience of the spring, and the base has a lock part which locks the locked part.