An arc-proof relay with increased contact surface

Abstract

The utility model relates to an anti -electric arc relay of increasing contact point contact area, including shell and setting in the electromagnetic part and contact subassembly of shell inner chamber, the electromagnetic part includes the coil fixed in the shell inner chamber, increases product coil power consumption, makes the springback effect of moving contact piece increase, the utility model relates to relay technical field. This anti -electric arc relay of increasing contact point contact area, the contact area of contact point and electrical life are improved greatly: the contact surface of static contact point adopts 10 degree bevel design, forms stable surface contact when cooperating with moving contact point, and the effective conductive area is increased significantly. In combination with 5-20mu m uniform micro -convex point array formed by laser micro -fusion treatment of moving contact point surface and static contact point surface, the micro -convex point is contacted and generates local plastic deformation in the moment of closure, further compacts the contact interface, makes the contact resistance reduce greatly, effectively restraines the temperature rise of contact area. This directly brings the substantial improvement of electrical life of product under the normally closed state.

Description

Technical Field

[0001] This utility model relates to the field of relay technology, specifically to an anti-arc relay with increased contact surface. Background Technology

[0002] Relays, as crucial electronic control switching components, are widely used in various electrical control systems. When a relay disconnects a high-current load, the electric arc generated between the contacts is a key factor leading to contact erosion, welding, shortened electrical life, and even failure. Current technologies often employ increasing the contact gap, optimizing the arc-extinguishing structure, or using high-melting-point contact materials to suppress the arc, but significant shortcomings remain. First, traditional planar contact structures are mostly point or line contacts when closed, resulting in a limited effective conductive area, leading to high contact resistance and temperature rise. This not only exacerbates contact material wear but also limits the improvement of current-carrying capacity and electrical life. Second, at the moment of contact disconnection, if the moving contact's rebound force is insufficient, the contact separation speed is slow, and the gap does not increase rapidly, easily generating a strong and continuous electric arc. This severely erodes the contact surface and may cause insulation degradation or even breakdown, affecting the product's withstand voltage performance. Furthermore, if the Joule heat generated during contact operation cannot be effectively conducted away in a timely manner, it will accumulate in the contact area, further accelerating material oxidation and degradation, and reducing contact reliability. Therefore, there is an urgent need for a relay structure that can simultaneously solve problems such as small contact area, strong breaking arc, and low heat dissipation efficiency, in order to improve its electrical life, withstand voltage and operational reliability. Utility Model Content

[0003] To address the shortcomings of existing technologies, this utility model provides an arc-proof relay with increased contact surface area, thus solving the aforementioned problems.

[0004] To achieve the above objectives, this utility model is implemented through the following technical solution: an anti-arc relay with increased contact surface, comprising a housing and an electromagnetic part and a contact assembly disposed in the inner cavity of the housing. The electromagnetic part includes a coil fixed in the inner cavity of the housing, which increases the power consumption of the coil, enhances the rebound effect of the moving contact piece, increases the gap between the contacts, reduces the arc generated when the contacts are disconnected, and improves the pressure resistance of the product. The contact assembly includes a moving contact and a stationary contact fixed in the inner cavity of the housing. The moving contact has a moving contact fixedly connected to its inner cavity, and the stationary contact has a stationary contact fixedly connected to its inner cavity above the moving contact. The contact surface of the stationary contact has a 10° inclined structure to form a surface contact with the moving contact. The inclination ensures that the stationary contact and the moving contact are in complete contact, which greatly improves the electrical life of the normally closed test of the product. It also includes heat dissipation components for cooling stationary contacts.

[0005] As a further embodiment of this utility model: the heat dissipation component includes an upper heat-conducting copper block fixed in the inner cavity of the housing and a lower heat-conducting copper block fixedly connected to the top of the stationary contact. Thermal grease is filled between the upper and lower heat-conducting copper blocks. The high thermal conductivity copper alloy extends to the mounting surface of the relay housing and directly adheres to the thermal grease to form an efficient heat conduction path and quickly dissipate the Joule heat of the contact.

[0006] As a further embodiment of this utility model: the upper heat-conducting copper block and the lower heat-conducting copper block are insulated from the outer shell.

[0007] As a further aspect of this invention: a first laser micro-melting layer is provided on the surface of the moving contact, and a second laser micro-melting layer is provided on the surface of the stationary contact. The contact surfaces are subjected to laser micro-melting treatment to form a uniformly distributed array of 5-20μm micro-bumps. When closed, the micro-bumps preferentially contact and undergo local plastic deformation, further increasing the effective conductive area and reducing the contact resistance temperature rise.

[0008] Compared with the prior art, the present invention has the following advantages: Significantly improved contact area and electrical life: The stationary contact surface features a 10° bevel design, forming a stable surface contact when mated with the moving contact, significantly increasing the effective conductive area. Combined with a 5-20μm uniform micro-bump array formed by laser micro-melting of the moving and stationary contact surfaces, the micro-bumps preferentially contact and undergo localized plastic deformation at the moment of closure, further compacting the contact interface. This results in a significant reduction in contact resistance and effectively suppresses temperature rise in the contact area. This directly leads to a substantial improvement in the product's electrical life under normally closed conditions.

[0009] Effective suppression of breaking arc and improved withstand voltage: By appropriately increasing the coil power consumption, the driving force of the electromagnetic system is enhanced, allowing the moving contact to obtain greater rebound force at the moment of power failure. This drives the moving contact to separate from the stationary contact quickly and forcefully, significantly increasing the gap at the moment of contact disconnection. The larger initial gap can more effectively lengthen and cool the arc, accelerating its extinguishing, thereby significantly reducing the arc energy generated during the breaking process and mitigating contact erosion. At the same time, the larger contact gap also directly improves the product's dielectric recovery strength and withstand voltage performance in the disconnected state.

[0010] High-efficiency heat dissipation ensures stable operation: A unique heat dissipation component design features a lower thermally conductive copper block tightly fitted to the stationary contact, and an upper thermally conductive copper block extending to the relay housing mounting surface. High thermal conductivity thermal grease is filled between the two, creating a highly efficient heat conduction path from the heat source at the contact to the relay housing. This design quickly dissipates the Joule heat generated during contact operation, preventing heat accumulation in the contact area, effectively reducing the contact's operating temperature, further ensuring contact stability and material durability, and extending the overall product lifespan. Attached Figure Description

[0011] Figure 1 This is a cross-sectional view of the structure of this utility model; Figure 2 This is a schematic diagram of the coil structure of this utility model; Figure 3 This is a side view of the structure of the coil of this utility model; Figure 4 This is a schematic diagram of the static contact of this utility model; Figure 5 This is a schematic diagram of the structure of the moving contact of this utility model.

[0012] In the diagram: 1. Outer shell; 2. Coil; 3. Moving contact; 4. Stationary contact; 5. Moving contact; 6. Stationary contact; 7. Lower thermally conductive copper block; 8. Thermal grease; 9. Upper thermally conductive copper block; 11. First laser micro-melting layer; 12. Second laser micro-melting layer. Detailed Implementation

[0013] To further illustrate the technical means and effects adopted by this utility model in order to achieve the intended utility model purpose, the following detailed description of the specific implementation methods, structure, features and effects of this utility model is provided in conjunction with the accompanying drawings and preferred embodiments.

[0014] Please see Figure 1-5 This utility model provides a technical solution: an anti-arc relay with increased contact surface, including a housing 1 and an electromagnetic part and a contact assembly disposed in the inner cavity of the housing 1. The electromagnetic part includes a coil 2 fixed in the inner cavity of the housing 1, which increases the power consumption of the coil 2, increases the rebound effect of the moving contact piece 3, increases the gap between the contacts, reduces the arc generated when the contacts are disconnected, and can improve the pressure resistance of the product. The contact assembly includes a moving contact 3 and a stationary contact 6 fixed in the inner cavity of the housing 1. The moving contact 3 is fixedly connected to a moving contact 5 in the inner cavity, and the stationary contact 6 is fixedly connected to a stationary contact 4 located above the moving contact 5 in the inner cavity. The contact surface of the stationary contact 4 is a 10° inclined structure that forms a surface contact with the moving contact 5. The inclination allows the stationary contact 4 to make complete contact with the moving contact 5, which greatly improves the electrical life of the normally closed test of the product. It also includes a heat dissipation component for dissipating heat from stationary contact 4.

[0015] The heat dissipation assembly includes an upper thermally conductive copper block 9 fixed in the inner cavity of the housing 1 and a lower thermally conductive copper block 7 fixedly connected to the top of the stationary contact 4. Thermally conductive silicone grease 8 is filled between the upper thermally conductive copper block 9 and the lower thermally conductive copper block 7. The high thermal conductivity copper alloy extends to the mounting surface of the relay housing 1 and directly adheres to the thermally conductive silicone grease 8 to form an efficient heat conduction path and quickly dissipate the Joule heat of the contact.

[0016] The upper heat-conducting copper block 9 and the lower heat-conducting copper block 7 are insulated from the outer casing 1.

[0017] The surface of the moving contact 5 is provided with a first laser micro-melting layer 11, and the surface of the stationary contact 4 is provided with a second laser micro-melting layer 12. The contact surfaces are laser micro-melted to form a uniformly distributed array of 5-20μm micro-bumps. When closed, the micro-bumps preferentially contact and undergo local plastic deformation, further increasing the effective conductive area and reducing the contact resistance temperature rise.

[0018] When this utility model is in use, the coil is excited and the contacts are closed: when the coil is energized, the generated electromagnetic force attracts the moving contact to overcome its own elasticity and move downwards. The moving contact drives the moving contact at its end to disconnect from the stationary contact.

[0019] The interaction between the beveled contact and the micro-bumps: During contact closure, the moving contact comes into contact with the stationary contact, which has a 10° bevel. The beveled structure guides the two from an initial point / line contact to a stable surface contact state. Simultaneously, the 5-20μm micro-bumps uniformly distributed on the first laser-melted layer of the moving contact surface and the second laser-melted layer of the stationary contact surface preferentially contact and undergo localized plastic deformation under contact pressure. This deformation not only fills in microscopic unevenness but also increases the actual contact area between the metals, significantly reducing contact resistance and lowering power consumption and temperature rise in the conducting state.

[0020] Efficient heat dissipation: The Joule heat generated when the contacts close and conduct current is primarily transferred through the stationary contacts to the lower thermally conductive copper block, which is fixedly connected to it. Heat is then rapidly conducted to the upper thermally conductive copper block via highly thermally conductive silicone grease filled between the lower and upper thermally conductive copper blocks. The upper thermally conductive copper block extends to the inner wall mounting surface of the relay housing, and the heat is ultimately dissipated to the external environment through the housing, typically in contact with an external mounting plate or heat sink, forming an efficient thermal management path.

[0021] Coil de-energization and contact separation: When the coil is energized, an electromagnetic force is generated. The increased coil power consumption in the design means a higher ampere-turns or magnetic field strength, and the electromagnetic force generated at the moment of energization gives the moving contact a stronger rebound force. This rebound force drives the moving contact, along with the moving contact point, to move downwards rapidly and violently, quickly separating it from the stationary contact.

[0022] Increasing the gap to suppress arcing: The strong rebound of the moving contact results in a significantly larger gap between the moving and stationary contacts at the moment of separation compared to traditional designs. This rapidly increasing gap effectively lengthens the arc path, reduces the electric field strength between the gaps, and promotes contact between the arc plasma and the surrounding cooling medium, thereby accelerating the dissipation and extinguishing of arc energy and minimizing the ablation damage to the contacts caused by the arc. Simultaneously, the resulting larger contact gap also improves the relay's ability to withstand high voltages in the open state.

[0023] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Although the present utility model has been disclosed above with reference to a preferred embodiment, it is not intended to limit the present utility model. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present utility model. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present utility model without departing from the scope of the present utility model shall still fall within the scope of the present utility model.

Claims

1. An arc-resistant relay with increased contact surface, comprising a housing (1) and an electromagnetic portion and a contact assembly disposed within the cavity of the housing (1), characterized in that: The electromagnetic component includes a coil (2) fixed inside the housing (1); The contact assembly includes a moving contact (3) and a stationary contact (6) fixed in the inner cavity of the housing (1). The inner cavity of the moving contact (3) is fixedly connected to a moving contact (5), and the inner cavity of the stationary contact (6) is fixedly connected to a stationary contact (4) located above the moving contact (5). The contact surface of the stationary contact (4) is a 10° inclined structure that forms a surface contact with the moving contact (5). The inclined surface allows the stationary contact (4) and the moving contact (5) to be in complete contact, which greatly improves the electrical life of the normally closed test of the product. It also includes a heat dissipation component for dissipating heat from the stationary contact (4).

2. The arc-resistant relay with increased contact surface according to claim 1, characterized in that: The heat dissipation assembly includes an upper thermally conductive copper block (9) fixed in the inner cavity of the housing (1) and a lower thermally conductive copper block (7) fixedly connected to the top of the stationary contact (4), with thermally conductive silicone grease (8) filling the space between the upper thermally conductive copper block (9) and the lower thermally conductive copper block (7).

3. An arc-resistant relay with increased contact surface according to claim 2, characterized in that: The upper heat-conducting copper block (9) and the lower heat-conducting copper block (7) are insulated from the outer shell (1).

4. An arc-resistant relay with increased contact surface as described in claim 1, characterized in that: The surface of the moving contact (5) is provided with a first laser micro-melting layer (11), and the surface of the stationary contact (4) is provided with a second laser micro-melting layer (12).

Images