Bent Fixed Terminal Relay Structure for Heat Dissipation
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Solution Overview
Problem
Existing electromagnetic relays face challenges in improving heat dissipation without increasing the size of the device when high currents are handled, as enlarging the fixed terminal to enhance surface area leads to a larger relay.
Innovation Solution
The electromagnetic relay incorporates fixed terminals with a bent shape that protrude outside the housing, increasing the surface area for heat dissipation while maintaining a compact size, with the bent portion being integrally formed with a flat portion to facilitate easy manufacturing and enhance air convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the fixed terminal is enlarged to increase the surface area for heat dissipation, then the heat dissipation performance is improved, but the size of the electromagnetic relay is increased
Solution Approach 1:
The fixed terminal is designed with a bent shape that extends in multiple directions, utilizing three-dimensional space more efficiently. The terminal portion bends at approximately 90 degrees to form an L-shape or similar configuration, increasing the effective surface area for heat dissipation without proportionally increasing the overall footprint of the relay device. This dimensional approach allows heat dissipation surface area to increase while keeping the bounding box volume relatively constant.
Solution Approach 2:
The bent configuration of the fixed terminal allows it to nest within or alongside other components of the relay assembly. The terminal can be positioned to utilize space between the housing and other internal components, effectively nesting the heat dissipation structure within the existing form factor rather than requiring additional external space.
2Temperature
If the fixed terminal is enlarged to increase the surface area, then the heat dissipation is improved, but the compactness of the relay is reduced
Solution Approach 1:
The fixed terminal employs a bent geometry that exploits vertical and lateral dimensions simultaneously. By bending the terminal at approximately 90 degrees, the design increases surface area in the vertical direction while minimizing lateral expansion, thereby maintaining compactness in the horizontal plane while achieving enhanced heat dissipation through increased surface exposure.
3Temperature
If air convection is utilized to improve heat dissipation, then the heat dissipation performance is improved, but the design complexity increases
Solution Approach 1:
The bent configuration of the fixed terminal creates localized regions with different thermal characteristics. The terminal portion that extends outward from the bent configuration is positioned to maximize exposure to air convection currents, while the portion near the contact piece maintains structural integrity and electrical connection. This local optimization of geometry allows natural convection to enhance heat dissipation without requiring active cooling systems or complex airflow management.
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 design effectively improves heat dissipation of the fixed terminals by increasing their surface area and utilizing air convection, thereby maintaining the relay's size without compromising performance.
Implementation Method 1
air convection tends to hit the first terminal portion outside the housing. Thereby, the heat dissipation of the first fixed terminal is improved.
Data Source
AI summary
An electromagnetic relay includes a housing, a movable contact piece, a first fixed terminal, and a drive device. The movable contact piece is disposed in the housing. The first fixed terminal includes a first contact portion and a first terminal portion. The first contact portion faces the movable contact piece in the housing. The first terminal portion protrudes out of the housing. The first terminal portion has a bent shape. The drive device moves the movable contact piece in a contact direction and an opening direction.