Relay Spring Self-Locking Mechanism for Press-Fit Strength

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Solution Overview

Problem

Small relays face challenges in securing sufficient press-fitting strength due to their size, leading to issues like spring deformation, increased processing costs, and risks of spring disengagement, especially when using thin springs.

Innovation Solution

The relay design incorporates self-locking mechanisms for springs using resilience, adhesive layers to secure covers, and structured insertion holes to prevent disengagement and improve airtightness, while allowing for rolling and sliding contact operations to enhance contact reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If springs are made thinner to maintain resilience, then spring flexibility is improved, but press-fitting strength deteriorates and deformation risk increases

Engineering Contradiction:

Improvespring flexibilityVSAvoidpress-fitting strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The spring is divided into functionally distinct segments: a thin spring portion for maintaining resilience and flexibility, and a thick terminal portion for ensuring press-fitting strength. This segmentation allows each part to be optimized for its specific function without compromise.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different thicknesses are applied to different parts of the spring based on local requirements. The spring portion remains thin for flexibility, while the terminal portion is made thick for press-fitting strength, creating local quality variations that resolve the contradiction.

Inventive Principle:

Principle #3Local quality

2Strength

If springs are made thicker to ensure press-fitting strength, then press-fitting strength is improved, but spring resilience deteriorates

Engineering Contradiction:

Improvepress-fitting strengthVSAvoidspring resilience

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The spring structure is segmented into a thick terminal portion for press-fitting and a thin spring portion for resilience, allowing both requirements to be satisfied simultaneously in different locations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal portion is locally thickened to provide sufficient press-fitting strength, while the spring portion maintains thin dimensions to preserve resilience, applying local quality changes to resolve the contradiction.

Inventive Principle:

Principle #3Local quality

3Reliability

If temporary bonding is applied to prevent spring disengagement, then spring retention is improved, but production cost increases and bonding timing risks arise

Engineering Contradiction:

Improvespring retentionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The spring structure is designed to be self-retaining through its own resilience and the mechanical interlocking with the base, eliminating the need for external temporary bonding processes and reducing manufacturing complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The mechanical retention system replaces the chemical bonding system. The thick terminal portion mechanically interlocks with the base through press-fitting, substituting the need for adhesive bonding and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If sliding contact is used between contacts, then contact cleaning effect is improved, but contact wear increases requiring higher pressing force

Engineering Contradiction:

Improvecontact cleaning effectVSAvoidpressing force

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The contact mechanism transitions from static or simple sliding contact to dynamic rolling contact, where the contact point continuously changes as the spring rotates. This dynamic motion provides cleaning action while reducing wear and required pressing force.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rolling contact creates periodic motion between the spring and contact surface, with the contact point continuously changing position. This periodic action maintains cleaning effectiveness while reducing the average pressing force required compared to continuous sliding contact.

Inventive Principle:

Principle #19Periodic action

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 press-fitting stress, prevents spring disengagement, lowers production costs, and maintains contact reliability by incorporating rolling and sliding movements, thus improving the operational performance and sealing of small relays.

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

Methodology Applied

Scientific EffectResilience: Elasticity

Data Source

PatentEP4718492A2relay

Publication Date: 2026.04.01 FCL COMPONENTS LTD

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AI summary

The present invention relates to a relay having 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.