A high insulation dielectric strength relay structure

Abstract

The application discloses a high-insulation dielectric strength relay structure, which comprises a first shell and a second shell, the second shell is installed above the first shell, the first shell and the second shell are communicated, a coil holder is arranged in the first shell, driving coils are arranged on both sides of the coil holder, a contact mechanism is arranged between the middle cavity position of the coil holder and the second shell, and the contact mechanism is used for realizing the communication or disconnection of the relay; the relay structure is suitable for extreme working conditions of spaceflight, has the characteristics of super-high insulation dielectric strength, spaceflight-level sealing, miniaturization and light weight, realizes 75kV / 120kV DC super-high dielectric voltage resistance, and meets the requirements of spaceflight-level environment, service life, installation and wiring in all dimensions.

Description

Technical Field

[0001] This invention relates to the field of high voltage DC relay technology, and specifically to a relay structure with high insulation dielectric strength. Background Technology

[0002] With the development of aviation and aerospace technology, high-voltage DC control systems for spacecraft are placing complex requirements on core control components, including high insulation dielectric strength, adaptability to harsh environments, long lifespan, high reliability, and lightweight design. A 1000V DC 0.1A high-voltage DC relay used in the drive system of a certain project is required to meet ultra-high dielectric withstand voltage requirements of 75kV DC between main contacts and 120kV DC between contacts and the coil under special operating conditions.

[0003] The core technical flaw of existing traditional high-voltage DC relays is that they cannot adapt to high dielectric withstand voltage applications. 1) Insufficient dielectric strength: Traditional structures use plastic potting and metal base plate design, resulting in small creepage distance. Conventional high-voltage relays have difficulty exceeding the insulation withstand voltage requirement of 30kV DC and are prone to external conductor breakdown under AC 11kV conditions, failing to meet the dielectric withstand voltage index of 75kV DC and above. 2) Unreasonable electrical layout design: The coil wiring is arranged on the same side as the load, and the insulation distance is insufficient. Under high voltage conditions, it is very easy to cause electrical breakdown, creepage failure and low safety margin. 3) Excessive redundancy in volume and weight: Traditional high-voltage dielectric equipment (such as high-voltage insulation equipment used in power grids) is far from meeting the quality and volume control requirements of aviation and aerospace, exceeding the onboard installation limits and failing to meet the compact installation requirements.

[0004] 4) Inadequate sealing performance: Ordinary sealing processes have a high leakage rate, cannot adapt to the aerospace vacuum environment, and the insulation performance deteriorates rapidly over time. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides a high-insulation dielectric strength relay structure.

[0006] The present invention is achieved through the following technical solutions.

[0007] The technical solution of the present invention is as follows: A high-insulation dielectric strength relay structure includes a first housing and a second housing, the second housing is installed above the first housing, and the first housing and the second housing are connected. A coil frame is provided inside the first housing, and a drive coil is installed on both sides of the coil frame. A contact mechanism is provided between the second housing and the middle cavity of the coil frame. The contact mechanism is used to realize the connection or disconnection of the relay.

[0008] Preferably, the contact mechanism includes a trigger component, an insulating frame, and a driving component. One end of the insulating frame is placed in a first housing, and the other end is placed in a second housing. The trigger component is located at the upper end of the insulating frame, and the driving component is located at the lower end of the insulating frame. The driving component, in conjunction with the driving coil, drives the trigger component to achieve closure or opening.

[0009] Preferably, the driving assembly includes a first driving core, a second driving core, and a reaction spring. The first driving core is installed in the middle cavity of the coil frame. One end of the second driving core is slidably inserted into the first driving core, and the other end is fixedly connected to the insulating frame. One end of the reaction spring is installed on the first driving core, and the other end is installed on the insulating frame.

[0010] Preferably, the triggering assembly includes a connecting core rod, an insulating bushing, a contact spring, a moving contact, and a stationary contact. The lower end of the connecting core rod is fixedly mounted on the upper end of the insulating frame. The insulating bushing is sleeved on the upper end of the connecting core rod. The moving contact abuts against the upper end of the insulating bushing. The contact spring is sleeved on the insulating bushing, with one end of the contact spring connected to the moving contact and the other end connected to the insulating frame. The stationary contact is mounted on the upper end of the first housing, and the moving contact corresponds to the stationary contact.

[0011] Preferably, a sealing base is installed at the bottom of the first drive core.

[0012] Preferably, the sealing base has an air inlet installed through it.

[0013] Preferably, the gaps on both sides of the coil frame are filled with a potting layer.

[0014] Preferably, a Kovar sealing base plate is provided between the first housing and the second housing, and a Kovar ring is provided at the connection between the Kovar sealing base plate and the second housing.

[0015] Preferably, the lower end of the coil frame is provided with lead wires.

[0016] Preferably, the second housing is made of A99 alumina ceramic material.

[0017] The beneficial effects of this invention are: 1. By optimizing the electrical layout of the drive coil and contact mechanism, the electrical path between the coil and the load is completely isolated, eliminating the risk of high-voltage breakdown; 2. By using an insulating frame, the triggering component and the drive coil are completely isolated from each other. 3. By setting up a first housing, a second housing, a Kovar sealing base plate, and a Kovar ring; and by providing an air inlet and filling the first drive core with inert gas before sealing, and by using a potting layer to fully fill and reinforce both sides of the coil frame, the overall structure's sealing performance is enhanced, with a maximum air leakage rate ≤1×10⁻⁶. -9 Pa·m 3 / s, meeting aerospace sealing requirements; 4. Adaptable to extreme aerospace conditions, featuring ultra-high insulation dielectric strength, aerospace-grade sealing, miniaturization, and lightweight design, achieving 75kV / 120kV DC ultra-high dielectric withstand voltage while meeting all requirements for aerospace-grade environment, lifespan, installation, and wiring. Attached Figure Description

[0018] Figure 1 This is a cross-sectional structural schematic diagram of the present invention; Figure 2 This is a schematic diagram of a portion of the contact mechanism used in this invention. Figure 3 This is a partial structural schematic diagram used in this invention to mainly illustrate the second shell and its internal structure; Figure 4 This is a schematic diagram of the structure of the first housing in this invention; Figure 5 This is a schematic diagram of a portion of the coil frame used to demonstrate the main structure of this invention.

[0019] Reference numerals: 1-First housing; 2-Second housing; 3-Coil frame; 4-Coil; 5-Insulating frame; 6-First driving core; 7-Second driving core; 8-Reaction spring; 9-Connecting core rod; 10-Insulating bushing; 11-Contact spring; 12-Moving contact; 13-Static contact; 14-Sealing base; 15-Air inlet; 16-Pouring layer; 17-Kovar sealing base plate; 18-Kovar ring; 19-Lead lead; 20-Mounting hole; 21-Lead lead hole; 22-Pouring hole. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0022] In this embodiment, refer to Figure 1It includes a first housing 1 and a second housing 2. The second housing 2 is installed above the first housing 1 and the first housing 1 and the second housing 2 are connected. The first housing 1 is made of non-metallic material and the second housing 2 is made of A99 alumina ceramic material. The corners of the outer surface of the second housing 2 are rounded, which maximizes the creepage distance of the relay and also improves the dielectric strength of the insulation.

[0023] In this embodiment, refer to Figure 1 and Figure 3 The upper surface of the first housing 1 is equipped with a Kovar sealing base plate 17, which is installed by laser welding. The Kovar sealing base plate 17 is also connected to the second housing 2. A Kovar ring 18 is installed at the connection between the Kovar sealing base plate 17 and the second housing 2. The Kovar sealing base plate 17 and the Kovar ring 18 are fixedly connected to the second housing 2 by laser welding to enhance the sealing performance of the external structure.

[0024] In this embodiment, refer to Figure 1 and Figure 5 The first housing 1 contains a coil frame 3, with coils 4 mounted on both sides of the coil frame 3. The coils 4 are mounted using an integrated coil frame, with a rated voltage of 28V DC, a maximum voltage of 32V DC, a coil resistance of 80Ω±8Ω, a coil current ≤0.5A, and a suppression voltage ≤42V DC. It also includes a yoke, a flange, a yoke ring, and a bushing (the yoke, flange, yoke ring, and bushing are conventional technologies and are not shown in the figure). The yoke, flange, and yoke ring are made of DT4C high-permeability magnetic material, and the bushing is made of non-magnetic brass material. The pull-in / release characteristics are optimized: cold pull-in voltage ≤20V DC, release voltage 2V~9V DC, and pull-in / release time ≤30ms.

[0025] In this embodiment, refer to Figure 1 A contact mechanism is provided between the middle cavity of the coil frame 3 and the second housing 2. The contact mechanism is used to connect or disconnect the relay.

[0026] In this embodiment, refer to Figure 1 and Figure 2The contact mechanism includes a trigger component, an insulating frame 5, and a drive component. A connecting cavity is provided in the middle of the Kovar sealing base plate 17. The insulating frame 5 passes through the connecting cavity. One end of the insulating frame 5 is placed in the first housing 1, and the other end is placed in the second housing 2. The trigger component is located at the upper end of the insulating frame 5, and the drive component is located at the lower end of the insulating frame 5. The drive component, in conjunction with the coil 4, drives the trigger component to achieve closure or opening. The insulating frame 5 achieves insulation isolation between the drive component and the trigger component. At the same time, by placing the drive component and the coil 4 in the first housing 1 and the trigger component in the second housing 2, the circuit layout is optimized, the two are isolated, and the risk of high voltage breakdown is eliminated.

[0027] In this embodiment, refer to Figure 1 and Figure 2 The drive assembly includes a first drive core 6, a second drive core 7, and a reaction spring 8. The first drive core 6 is installed in the middle cavity of the coil frame 3. One end of the second drive core 7 is slidably inserted into the first drive core 6, and the other end is fixedly connected to the insulating frame 5. The first drive core 6 and the insulating frame 5 are respectively provided with a first groove and a second groove at opposite ends. The reaction spring 8 is sleeved on the second drive core 7. One end of the reaction spring 8 is fixedly installed in the first groove, and the other end is fixedly installed in the second groove.

[0028] The trigger assembly includes a connecting core rod 9, an insulating bushing 10, a contact spring 11, a moving contact 12, and a stationary contact 13. The lower end of the connecting core rod 9 is fixedly installed on the upper end of the insulating frame 5. The insulating bushing 10 is sleeved on the upper end of the connecting core rod 9. A limiting platform is provided on the upper end of the insulating bushing 10. The moving contact 12 abuts against the lower end face of the limiting platform. A first limiting groove is installed on the lower end face of the moving contact 12. A second limiting groove is opened on the upper end face of the insulating frame 5. The contact spring 11 is sleeved on the insulating bushing 10. One end of the contact spring 11 is fixedly installed in the first limiting groove, and the other end is fixedly installed in the second limiting groove. The contact spring 11 provides support and buffer for the moving contact 12. The stationary contact 13 is fixedly installed on two opposite side walls on the upper end of the first housing 1. The two ends of the moving contact 12 correspond to the two stationary contacts 13 respectively.

[0029] Under the magnetic force of coil 4, the second driving core 7 is driven upward, and the reaction spring 8 is in a stretched state, thereby driving the insulating frame 5 upward, driving the connecting core rod 9 upward, and causing the moving contact 12 to move upward and contact the stationary contact 13, realizing the connection of the main contacts; when coil 4 no longer generates magnetic force, the reaction spring 8 pulls the second driving core 7 downward, so that the moving contact 12 and the stationary contact 13 no longer contact, the main contacts are in an open state, and the second driving core 7 returns to its initial state. The rated load of the contacts is 1000V DC 0.1A, the inrush current is 100A / 1μs, the contact bounce time is ≤5ms, and the initial contact voltage drop is ≤125mV; the rated load life is 10,000 cycles, and the mechanical life is 50,000 cycles.

[0030] In this embodiment, refer to Figure 1 and Figure 2 A sealing base 14 is installed at the bottom of the first drive core 6. The sealing base 14 is fixed to the bottom of the first drive core 6 by welding. An air inlet 15 is installed through the sealing base 14. After filling the structure with inert gas, the air inlet 15 is then sealed with glue to achieve an overall seal inside the structure. The maximum air leakage rate is ≤1×10. -9 Pa·m 3 / s, meeting aerospace sealing requirements.

[0031] In this embodiment, refer to Figure 1 The gaps on both sides of the coil frame 3 are filled with a potting layer 16 to enhance the internal insulation performance of the structure.

[0032] In this embodiment, refer to Figure 1 and Figure 5 The lower end of the coil frame 3 is provided with lead wire pins 19, and there are two lead wire pins 19. The bottom of the second housing 2 is provided with lead wire holes 21. The two lead wire pins 19 pass through the lead wire holes 21 and are placed outside the first housing 1. The lead wires on the coil 4 are led out of the first housing 1 through the lead wire pins 19.

[0033] In this embodiment, refer to Figure 4 The bottom of the second housing 2 is provided with a glue-filling hole 22 to facilitate glue filling into the structure; the upper edge of the first housing 1 is provided with a mounting hole 20 for connecting with the Kovar sealing base plate 17.

[0034] The working principle of this invention is as follows: Under the magnetic force of the coil 4, the second driving core 7 is driven to move upward, and the reaction spring 8 is in a stretched state, thereby driving the insulating frame 5 to move upward, driving the connecting core rod 9 to move upward, and causing the moving contact 12 to move upward and contact the stationary contact 13, realizing the connection of the main contacts; when the coil 4 no longer generates magnetic force, the reaction spring 8 pulls the second driving core 7 to move downward, so that the moving contact 12 and the stationary contact 13 no longer contact each other, the main contacts are in a disconnected state, and the second driving core 7 returns to the initial state. This structure has the characteristics of ultra-high insulation dielectric strength, aerospace-grade sealing, miniaturization and lightweight, and achieves ultra-high dielectric withstand voltage of 75kV DC / 120kV DC.

[0035] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural transformations made under the concept of the present invention using the description and drawings of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A high-insulation dielectric strength relay structure, characterized in that: It includes a first housing (1) and a second housing (2). The second housing (2) is installed above the first housing (1). The first housing (1) and the second housing (2) are connected. A coil frame (3) is provided inside the first housing (1). A coil (4) is installed on both sides of the coil frame (3). A contact mechanism is provided between the middle cavity of the coil frame (3) and the second housing (2). The contact mechanism is used to realize the connection or disconnection of the relay.

2. The high insulation dielectric strength relay structure according to claim 1, characterized in that: The contact mechanism includes a trigger component, an insulating frame (5) and a drive component. One end of the insulating frame (5) is placed in the first housing (1) and the other end is placed in the second housing (2). The trigger component is located at the upper end of the insulating frame (5) and the drive component is located at the lower end of the insulating frame (5). The drive component works with the coil (4) to drive the trigger component to achieve closing or opening.

3. The high insulation dielectric strength relay structure according to claim 2, characterized in that: The drive assembly includes a first drive core (6), a second drive core (7), and a reaction spring (8). The first drive core (6) is installed in the middle cavity of the coil frame (3). One end of the second drive core (7) is slidably inserted into the first drive core (6), and the other end is fixedly connected to the insulating frame (5). One end of the reaction spring (8) is installed on the first drive core (6), and the other end is installed on the insulating frame (5).

4. The high insulation dielectric strength relay structure according to claim 2, characterized in that: The triggering assembly includes a connecting core rod (9), an insulating bushing (10), a contact spring (11), a moving contact (12), and a stationary contact (13). The lower end of the connecting core rod (9) is fixedly installed on the upper end of the insulating frame (5). The insulating bushing (10) is sleeved on the upper end of the connecting core rod (9). The moving contact (12) abuts against the upper end of the insulating bushing (10). The contact spring (11) is sleeved on the insulating bushing (10). One end of the contact spring (11) is connected to the moving contact (12), and the other end is connected to the insulating frame (5). The stationary contact (13) is installed on the upper end of the first housing (1), and the moving contact (12) corresponds to the stationary contact (13).

5. The high insulation dielectric strength relay structure according to claim 3, characterized in that: A sealing base (14) is installed at the bottom of the first drive core (6).

6. The high insulation dielectric strength relay structure according to claim 5, characterized in that: The sealing base (14) is fitted with an air inlet (15).

7. The high insulation dielectric strength relay structure according to claim 1, characterized in that: The gaps on both sides of the coil frame (3) are filled with a potting layer (16).

8. The high insulation dielectric strength relay structure according to claim 1, characterized in that: A Kovar sealing base plate (17) is provided between the first housing (1) and the second housing (2), and a Kovar ring (18) is provided at the connection between the Kovar sealing base plate (17) and the second housing (2).

9. The high insulation dielectric strength relay structure according to claim 1, characterized in that: The lower end of the coil frame (3) is provided with lead wires (19).

10. The high insulation dielectric strength relay structure according to claim 1, characterized in that: The second housing (2) is made of A99 alumina ceramic material.

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