Electromagnetic Relay Terminal Fixing Structure for Crack-Free Resin Bases
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Solution Overview
Problem
High-capacity electromagnetic relays with thermosetting resin bases face challenges in securely fixing terminals without cracking or generating resin waste, and without press fitting, the terminal position becomes unstable.
Innovation Solution
Incorporating a separate fixing member with higher elasticity than the thermosetting resin, which includes support walls and recesses for adhesives to firmly attach the terminals, preventing cracking and resin waste while maintaining terminal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the terminal is fixed to the base made of thermosetting resin by press fitting, then the terminal position can be held stably, but the base is likely to be cracked or resin waste is likely to be generated
Solution Approach 1:
The patent introduces a fixing member as an intermediary component between the terminal and the base. This fixing member has higher elasticity than the thermosetting resin base, allowing it to deform during press fitting and then return to its original shape, thereby securing the terminal without cracking the base or generating resin waste.
Solution Approach 2:
The patent changes the material parameter of the fixing member to have higher elasticity compared to the thermosetting resin base. This parameter change enables the fixing member to undergo elastic deformation during assembly, absorbing the stress that would otherwise crack the rigid base, while maintaining stable terminal positioning.
2Object-affected harmful factors
If the terminal is fixed to the base without press fitting, then cracking of the base or generation of resin waste can be suppressed, but the position of the terminal cannot be held stably
Solution Approach 1:
The fixing member serves as a mediator that provides the necessary mechanical interference fit between the terminal and base without directly pressing the terminal against the rigid thermosetting resin base. The elastic fixing member deforms during assembly and then maintains constant pressure on the terminal, ensuring stable positioning without base damage.
3Object-affected harmful factors
If a fixing member with higher elasticity than thermosetting resin is used, then cracking of the base or generation of resin waste can be suppressed, but additional components and assembly steps are required
Solution Approach 1:
The patent segments the terminal fixation function into two separate components: the fixing member that provides elastic support and prevents base cracking, and the adhesive that provides permanent bonding. This segmentation allows each component to perform its specific function optimally while together solving the overall fixation problem.
Solution Approach 2:
The patent combines two fixation methods - elastic mechanical support from the fixing member and chemical bonding from the adhesive - into a unified terminal fixation system. The fixing member provides initial positioning and stress absorption, while the adhesive provides permanent bonding, creating a comprehensive solution that addresses both positioning stability and base protection.
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
The solution provides high heat resistance, stable terminal attachment, and reduced bounce during relay operation, enhancing assembly ease and reliability.
Implementation Method 1
The first adhesive is filled in the first recess. The first adhesive adheres the first terminal and the first support wall.
Data Source
AI summary
An electromagnetic relay includes a base, a first terminal, a fixing member, and a first adhesive. The base includes a first hole. The base is made of a thermosetting resin. The first terminal extends through the first hole. The fixing member is a separate body from the base. The fixing member has higher elasticity than the thermosetting resin. The fixing member fixes the first terminal to the base. The fixing member includes a first support wall and a first recess. The first support wall is disposed between an inner surface of the first hole and the first terminal. The first support wall extends upward along the first terminal. The first recess is disposed on an upper surface of the first support wall and faces the first terminal. The first adhesive is filled in the first recess. The first adhesive adheres the first terminal and the first support wall.