Clapper Relay Contact Layout for Lower Heat Generation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hinge-type electromagnetic relays have a long current-carrying path between load lead-out terminals, leading to increased heat generation and difficulty in applying them to PCBA with low Tg value requirements.
Innovation Solution
The design locates the first and second load lead-out terminals and the contact set at the same side of the bobbin, with parallel current paths, and distributes the coil lead-out terminals at opposite sides, forming a compact structure that reduces heat generation and allows application to PCBA with higher Tg values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the load lead-out terminals are located on different sides of the bobbin in conventional hinge-type relays, then the electrical connection between contacts is achieved, but the current-carrying path becomes long leading to increased heat generation
Solution Approach 1:
The patent merges the load lead-out terminals and contact set to the same side of the bobbin, consolidating current-carrying components in one location. This spatial merging shortens the current path from traversing across the bobbin to a localized path on one side, directly reducing heat generation while maintaining electrical functionality
Solution Approach 2:
The patent repositions components along the vertical dimension by mounting the contact set on the flange portion rather than distributing them horizontally across opposite sides. This dimensional reorganization allows the current path to be shortened while preserving the hinge-type structural integrity
2Device complexity
If the contact set and load lead-out terminals are distributed on different sides of the bobbin, then electrical clearance is maintained, but the structure becomes complex and costs increase
Solution Approach 1:
The patent combines the contact set and load lead-out terminals on the same side of the bobbin, simplifying the overall structure by reducing the number of distributed components. This merging eliminates the complexity of inter-side connections while maintaining necessary electrical clearances through proper spatial arrangement on the single side
Solution Approach 2:
The flange portion of the bobbin serves multiple functions: it provides mechanical support for the contact set, accommodates the load lead-out terminals, and maintains electrical clearance. This multi-functional design consolidates several components into one structural element, reducing overall device complexity without compromising reliability
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 simplifies the structure, reduces costs, and enhances heat dissipation, enabling the relay to operate in high-current environments while maintaining electrical clearance and voltage resistance.
Implementation Method 1
a magnetic circuit part, a movable contact part, a static contact part... the magnetic circuit part including a bobbin, a coil, an iron core, a yoke, and an armature
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A clapper-type electromagnetic relay, comprising a magnetic circuit part, a moving reed part, a static reed part. a first load lead-out end (4). and a second load lead-out end (5) electrically connected to the static reed part. The magnetic circuit part comprises a coil former (11). A static contact (32) of the static red part and a moving contact (22) of the moving reed part form a contact set. The first load lead-out end (4). the second load lead-out end (5), and the contact set are located on the same side of the coil former (11), and current carrying paths flowing through the first load lead-out end (4) and the second load lead-out end (5) are located on the same side of the coil former (11).