Resistive Coupler Terminal for Electromagnetic Relay Surge Absorption
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Solution Overview
Problem
Conventional electromagnetic relays with pre-fabricated resistors limit design flexibility and size reduction due to fixed resistor shapes and placements, making it difficult to accommodate design changes such as size reduction.
Innovation Solution
A coil terminal with a coupler formed from resistive material, featuring a resistance regulator that can be bent and raised, allowing for adjustable resistance without the constraints of pre-fabricated resistors, enabling flexible design and size reduction of the electromagnetic relay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ready-made resistor is used to absorb surge voltage, then the surge voltage is absorbed, but the shape and placement of the coil terminal are limited
Solution Approach 1:
The patent merges the resistor with the coil terminal structure by forming the resistance regulator directly from the coupler material. The coupler that connects terminal portions is made of resistive material, integrating the surge absorption function into the terminal structure itself, eliminating the need for separate ready-made resistors and thereby enabling design freedom.
Solution Approach 2:
The coupler serves multiple functions: it mechanically connects terminal portions and simultaneously provides surge voltage absorption through its resistive material property. This multi-functionality allows the same component to fulfill both structural and protective roles, enhancing adaptability without compromising reliability.
2Reliability
If a ready-made resistor is mounted, then surge voltage is absorbed, but size reduction is difficult
Solution Approach 1:
By combining the resistor function with the coil terminal structure, the patent eliminates the need for additional space-consuming ready-made resistors. The resistance regulator is formed from the same material as the coupler, integrating surge protection into the existing terminal structure and enabling compact design.
Solution Approach 2:
The resistance regulator is nested within the coupler structure itself. The coupler that connects terminal portions contains the resistive material, effectively nesting the surge absorption function within the existing structural component, thereby minimizing overall device volume.
3Stability of the object's composition
If the resistance regulator is made rigid, then the structure is stable, but it interferes with coil winding
Solution Approach 1:
The resistance regulator is designed with flexibility, allowing it to be bent and deformed during the coil winding process. After winding, the regulator can be raised to its operational position. This dynamic characteristic enables the component to adapt to manufacturing requirements while maintaining its surge absorption function.
Solution Approach 2:
The resistance regulator is positioned and shaped in advance to accommodate the coil winding process. By planning its initial configuration to be flexible and bendable, the manufacturing process can proceed without interference, and the regulator is subsequently adjusted to its final operational position.
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 solution provides enhanced design freedom and facilitates size reduction of the electromagnetic relay by allowing adjustable resistance settings, preventing interference during coil winding and enabling more compact device designs.
Implementation Method 1
The coupler is formed by a resistive material, and includes a resistance regulator formed by bending at least part of the coupler
Data Source
AI summary
A coil terminal includes: first to third terminal portions configured to supply a current to a coil; a coupler configured to couple these first to third terminal portions; and connectors provided in the coupler and connected with a lead wire of the coil. The coupler is formed by a resistive material, and includes a resistance regulator formed by bending at least part of the coupler.