Relay Terminal Side Projection for Compact Junction Box
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Solution Overview
Problem
Conventional relays and relay modules require a large receiving space due to the height of the relay main body and the holding member, resulting in a significant size increase in the fitting direction between terminals and terminal fittings.
Innovation Solution
The relay main body has terminals projected from its upper surface with bent tips opposite to the side surfaces, reducing the overall height and receiving space required, allowing for a more compact design in the relay module and electrical junction box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminals are projected from the bottom surface of the relay main body, then the relay can be fitted with terminal fittings, but the receiving space in the fitting direction becomes large
Solution Approach 1:
The patent changes the projection direction of terminals from the bottom surface (vertical direction) to the side surface (horizontal direction) of the relay main body. This dimensional change allows terminal fittings to be arranged horizontally rather than vertically, significantly reducing the receiving space height while maintaining terminal fitting capability
Solution Approach 2:
The patent employs asymmetric terminal arrangement where terminals are projected from specific side surfaces at different positions. This asymmetric configuration optimizes space utilization by placing terminals where they best fit the housing structure, reducing the overall receiving space requirements compared to symmetric bottom-projection designs
2Ease of operation
If the holding member is designed to accommodate bottom-projected terminals, then terminal fitting is enabled, but the overall height of the relay module increases
Solution Approach 1:
The holding member is redesigned to accommodate terminals projected from side surfaces rather than the bottom surface. This involves creating horizontal receiving chambers and positioning terminal fittings laterally, which transforms the vertical height requirement into a horizontal width requirement, thereby reducing the overall relay module height
Solution Approach 2:
Instead of having the holding member extend downward to accommodate bottom-projected terminals, the patent inverts the approach by having the holding member extend sideways to accommodate side-projected terminals. This inversion of the accommodation direction eliminates the need for excessive vertical space in the holding member structure
Data Source
AI summary
An object of the present invention is to provide a relay able to reduce a receiving space in a fitting direction between a terminal and a terminal fitting. A relay includes: a relay main body of which outer shape is in a rectangular parallelepiped shape; and four plate-shaped terminals projected from the relay main body and configured to be fitted with terminal fittings 4. The relay main body includes: an upper surface and a lower surface opposite to each other; two side surfaces opposite to each other; and two side surfaces opposite to each other. Four terminals are projected from the upper surface and bent at right angle two times so that tips of these terminals are opposite to the side surfaces. The tips of the two terminals are opposite to one side surface, and the tips of the remaining two terminals are opposite to the other side surface.