Electromagnetic Relay Base Block with Vertical Terminal Retention
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Solution Overview
Problem
Conventional electromagnetic relays face challenges in miniaturization, contact drive performance, insulation, and reliability due to reduced coil capacity, increased resistance, and insufficient insulation distance between terminals, leading to potential short-circuits and malfunction.
Innovation Solution
The design includes a base block with vertically extending fixed contact terminal retaining portions and a T-shaped backstop, allowing for increased insulation distance and reduced thickness, preventing heat conduction issues and press-fit complications, while maintaining miniaturization and improving conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electromagnetic relay is miniaturized, then the size is reduced, but the insulation distance between terminals decreases leading to insulation performance degradation
Solution Approach 1:
The patent transitions from a planar arrangement of contacts to a three-dimensional configuration where fixed contact terminals are positioned at different vertical levels (heights) relative to the movable contact spring. This vertical stacking in the height dimension allows sufficient insulation distance to be maintained while keeping the horizontal footprint compact, thus achieving miniaturization without sacrificing insulation performance.
Solution Approach 2:
The patent divides the contact structure into separate functional segments: fixed contact terminals mounted on the base block at specific positions, and a movable contact spring with distinct contact portions. This segmentation allows optimized spatial arrangement where insulation distances can be independently controlled for each terminal pair, enabling compact overall design while maintaining required insulation clearances.
2Volume of moving object
If the coil capacity is reduced for miniaturization, then the size is reduced, but the contact drive performance deteriorates
Solution Approach 1:
The patent optimizes the local mechanical properties of the movable contact spring by carefully designing its thickness, width, and elastic modulus distribution. The spring portion is engineered to provide sufficient elastic restoring force to ensure reliable contact closure and opening, compensating for the reduced electromagnetic force from the smaller coil. This localized optimization of mechanical characteristics maintains contact drive performance despite miniaturization.
3Reliability
If the resistance of current carrying path is increased, then the insulation is improved, but the energization performance deteriorates
Solution Approach 1:
The patent separates the current carrying functions into distinct pathways: the coil winding current path and the contact current path. By providing dedicated low-resistance conductive paths for each function and avoiding shared high-resistance routes, the design maintains excellent energization performance for the coil while ensuring high insulation between different circuits. Each current path is independently optimized for its specific function.
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 enhances insulation performance, reduces failure factors, and ensures high reliability of electric contacts, achieving a compact, high-conductivity electromagnetic relay with improved contact stability and reduced risk of malfunction.
Implementation Method 1
an electromagnetic relay body 100 including an electromagnetic block 1 having a coil 11 and a movable contact spring 14 swung by current flowing in the coil 11
Data Source
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AI summary
To provide an electromagnetic relay having a reduced size, high conductivity, a high insulating performance between two fixed contact terminals and between each of the fixed contact terminals and backstop, a small number of factors causing a failure, and high reliability of electric contact. An electromagnetic relay has an electromagnetic block provided with a movable contact spring 14 swung by current flowing in a coil, two fixed contact terminals 22 and 22' each having a fixed contact, a backstop 23 having two movable contact abutment portions, and a base block 2 for retaining the above components. The base block 2 has a base portion 20 having substantially a rectangular shape, fixed contact terminal retaining portions 21 and 21' extending vertically from two opposing sides of the rectangle so as to retain the two fixed contact terminals, and a backstop retaining portion 24 extending vertically from the center portion of one of the remaining two opposing sides of the rectangle.