Electromagnetic Relay Terminal Fixing with Adhesive Inflow Suppression
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Solution Overview
Problem
Conventional electromagnetic relays face challenges in securely fixing terminals while preventing adhesive from entering the case, which can hinder the operation of contacts and lead to unreliable performance.
Innovation Solution
The electromagnetic relay incorporates an adhesive fixer applied to the outer surface of the case and an inflow suppressor, such as an intersection wall part on the terminal, to prevent adhesive from entering the case and ensure secure terminal fixation, even with varying plate thicknesses of contact units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to fix the terminal to the case, then terminal fixation strength is improved, but adhesive may enter the case through gaps and hinder contact operation
Solution Approach 1:
The terminal is divided into functional segments: the insertion portion for mechanical fitting, the plate portion for electrical connection, and the intersection wall portion that acts as a barrier. This segmentation allows the intersection wall to specifically prevent adhesive intrusion while the other portions maintain their respective functions.
Solution Approach 2:
The intersection wall portion acts as an intermediary barrier between the adhesive (harmful substance) and the case interior (protected space). It mediates by physically blocking the adhesive flow path without interfering with the terminal's electrical or mechanical functions.
2Reliability
If the case structure is modified to prevent adhesive inflow, then contact operation reliability is improved, but device complexity increases
Solution Approach 1:
The terminal serves multiple functions: electrical connection through the plate portion, mechanical fixation through the insertion portion, and adhesive prevention through the intersection wall portion. This multi-functionality eliminates the need for separate adhesive barriers, maintaining case structure simplicity.
Solution Approach 2:
The terminal structure provides its own adhesive prevention function through the intersection wall portion, without requiring external modifications to the case. The terminal serves itself by incorporating the barrier function directly into its design.
3Adaptability or versatility
If terminals with different plate thicknesses are used, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The insertion hole is designed with differentiated local qualities: the upper portion has a larger diameter to accommodate various plate thicknesses, while the lower portion maintains a consistent, smaller diameter for precise positioning. This local quality variation enables both adaptability and precision.
Solution Approach 2:
The solution moves the precision constraint from the horizontal dimension (plate thickness variation) to the vertical dimension (insertion hole depth and lower diameter). By controlling the lower portion diameter and depth, precise positioning is achieved regardless of plate thickness variations.
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 configuration firmly fixes the terminal while securely suppressing hindrance of contact operation and allows for the use of contact units with different plate thicknesses without replacing the case, enhancing the reliability and adaptability of the electromagnetic relay.
Implementation Method 1
The adhesive fixer is made of an adhesive applied onto an outer surface of the case and cured
Data Source
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AI summary
An electromagnetic relay includes a first contact, a second contact configured to contact the first contact and be separated from the first contact, a case accommodating the first and second contacts therein and having an insertion hole provided therein, a terminal inserted into the insertion hole of the case, an adhesive fixer, and an inflow suppressor. The terminal is electrically connected to the first and second contacts while the first contact contacts the second contact. The adhesive fixer is made of an adhesive applied onto an outer surface of the case and cured. The inflow suppressor is configured to suppress inflow of the adhesive to an inside of the case through a gap between the terminal and an inside surface of the insertion hole of the case. In this electromagnetic relay, the terminal is firmly fixed while securely suppressing hindrance of operation.