Electromagnetic Relay Terminal Orientation and Segmentation
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Solution Overview
Problem
Existing electromagnetic relays have long current flow paths and high internal resistance, which reduce their performance and limit the permissible current due to the length of terminal legs and the need to maintain spring resiliency.
Innovation Solution
The electromagnetic relay design includes a base with a receiving space, an electromagnet unit, an armature unit, and terminal units with a movable terminal member that reduces current flow path length by increasing the thickness of conductive legs and terminal units, while maintaining spring resiliency through a two-piece movable terminal structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the length of terminal legs is increased, then the permissible current is increased, but the current flow path becomes longer and internal resistance increases
Solution Approach 1:
The patent changes the orientation of terminal legs from vertical (top-bottom direction) to horizontal (front-rear direction), allowing current flow paths to be shortened in the vertical dimension while maintaining adequate current carrying capacity through horizontal extension. The terminal legs extend along the front-rear direction of the base rather than the top-bottom direction, fundamentally changing the spatial arrangement.
Solution Approach 2:
The patent employs asymmetric arrangement of terminal units, with first and second terminal units positioned at opposite sides of the base and a third terminal unit positioned between them. The terminal legs have different lengths and orientations, with first and second terminal legs extending along the front-rear direction while the third terminal leg extends along the left-right direction, creating an optimized current distribution pattern.
2Quantity of substance
If the thickness of terminal leg is increased, then the permissible current is increased, but the spring plate resiliency deteriorates
Solution Approach 1:
The movable terminal unit is segmented into a terminal leg and a spring plate as separate components. The terminal leg extends along the left-right direction with sufficient thickness for current conduction, while the spring plate extends along the top-bottom direction with optimized thickness for resiliency. This segmentation allows each component to be independently optimized for its specific function without compromising the other.
Solution Approach 2:
Different parts of the terminal structure have different thicknesses optimized for their specific functions. The terminal leg has greater thickness in the left-right direction for current conduction, while the spring plate has optimized thickness in the top-bottom direction for maintaining resiliency. The magnetically attractive plate is positioned at a specific location to provide local magnetic attraction without affecting overall spring performance.
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 minimizes current flow path length, reduces internal resistance, and increases permissible current, enhancing the relay's performance and safety by allowing thicker terminal units and maintaining spring resiliency.
Implementation Method 1
an electromagnet unit (3) mounted to the base (21) in proximity to the second base wall (212) and outside of the receiving space (200)
Implementation Method 2
an armature unit (4) disposed on the base (21) and connected to the electromagnetic unit (3), the armature unit (4) including a magnetically attractive member (42) magnetically attractable by the electromagnet unit (3)
Data Source
AI summary
An electromagnetic relay includes a base having a receiving space, an electromagnetic unit disposed outside of the receiving space, a magnetically attractive member magnetically attractable by the electromagnet unit, a first stationary contact disposed in the receiving space, a second stationary contact, a movable terminal member and a movable contact. When the electromagnetic unit is energized, the movable terminal member is pushed by the magnetically attractive member and the movable contact contacts one of the first and second stationary contacts. When the electromagnetic unit is de-energized, the movable contact contacts the other one of the first and second stationary contacts.