Relay Spring Self-Locking Structure for Small Relay Assembly
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Solution Overview
Problem
Small relays face challenges in securing sufficient press-fitting strength due to their small size, leading to issues like spring deformation and increased production costs, and there is a risk of spring disengagement during the manufacturing process.
Innovation Solution
The relay design incorporates a self-locking mechanism using resilient springs with locked parts that lock onto the base, reducing the need for temporary bonding and enhancing press-fitting strength, while also featuring an adhesive layer between the base and cover to ensure proper sealing and a recessed insertion hole for terminals to manage adhesive flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If springs are made thicker to maintain press-fitting strength, then press-fitting strength is improved, but resilience deteriorates and deformation risk increases
Solution Approach 1:
The spring is designed with non-uniform thickness: the terminal portion is made thicker 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 press-fitting strength and resilience.
2Reliability
If springs are temporarily bonded after insertion, then reliability is improved, but production cost increases and spring displacement risk remains
Solution Approach 1:
The spring structure includes a locked part that automatically engages with a lock part on the base through the spring's own resilience, enabling self-locking without requiring temporary bonding processes. This self-service mechanism eliminates additional manufacturing steps while ensuring reliable spring retention.
Solution Approach 2:
The locked part is pre-formed on the spring during manufacturing, and the lock part is pre-formed on the base, enabling automatic locking upon spring insertion without requiring subsequent bonding operations. This preliminary preparation of locking structures prevents spring displacement.
3Volume of moving object
If small press-fitting allowance is used, then device size is reduced, but press-fitting strength deteriorates
Solution Approach 1:
The terminal portion of the spring is locally thickened to provide sufficient press-fitting strength even with small press-fitting allowance, while maintaining the overall compact size of the relay device.
4Reliability
If contact stiffness is lowered to accommodate contact wear, then contact reliability is improved, but energizing capacity deteriorates
Solution Approach 1:
The spring is designed with different thicknesses in different regions: the terminal portion is thicker to provide high stiffness for maintaining contact reliability under wear, while the spring portion is thinner to maintain adequate energizing capacity and flexibility.
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 enhances the reliability and cost-effectiveness of small relays by preventing spring disengagement and reducing manufacturing costs, while maintaining airtightness and improving contact reliability through the use of self-locking springs and strategic adhesive placement.
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.