Eccentric Bobbin Design for Relay Insulation and Coil Density
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Solution Overview
Problem
Small-sized hinged electromagnetic relays face challenges with poor insulation performance due to structural limitations, inadequate insulation distance, difficulty in adjusting mechanical parameters, space constraints affecting coil winding, and potential for foreign matter contamination leading to insulation degradation.
Innovation Solution
The design includes a bobbin with an eccentrically arranged cylindrical portion and iron core, increasing the creepage distance between the coil and fixed contact terminal, and a movable spring armature block with L-shaped yoke to enhance insulation, while the fixed contact terminals are assembled from the top down through annularly closed through holes to improve positioning and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the relay is made small-sized, then the size is reduced, but the insulation performance deteriorates
Solution Approach 1:
The patent applies asymmetry by deviating the axis of the cylindrical portion from the central line of the bobbin width direction. This asymmetric arrangement increases the creepage distance between the coil and fixed contact terminal while maintaining a compact overall size, directly resolving the contradiction between small size and insulation performance.
2Device complexity
If the axis of cylindrical portion is on the central line, then the structure is symmetric and simple, but the creepage distance is insufficient
Solution Approach 1:
The patent deliberately breaks structural symmetry by positioning the cylindrical portion's axis off-center. This asymmetric design increases the creepage distance from the coil to the fixed contact terminal, prioritizing insulation performance over symmetric simplicity while maintaining reasonable structural complexity.
3Area of stationary object
If the fixed contact terminal is positioned close to the coil, then the relay width is reduced, but the insulation distance is insufficient
Solution Approach 1:
The patent resolves the spatial conflict by utilizing the length dimension (axial direction) to create insulation distance. The eccentric positioning of the cylindrical portion extends the creepage path along the axial direction rather than relying solely on lateral separation, thereby maintaining compact width while ensuring adequate insulation distance.
4Power
If more ampere turns are added to the coil, then the electromagnetic force is improved, but the relay height increases
Solution Approach 1:
The patent segments the coil winding space by utilizing the eccentric cylindrical portion structure, allowing more turns to be packed into the available winding window area without increasing height. The asymmetric positioning creates additional winding space efficiency, enabling increased ampere turns within the same height constraint.
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 increases insulation capability, reduces manufacturing complexity, enhances contact stability, and allows for more ampere turns without increasing the relay's height, thereby improving the overall performance and reliability of the small-sized hinged electromagnetic relay.
Implementation Method 1
a bobbin, coil terminals, an iron core and a fixed contact block; the bobbin has an upper flange, a lower flange, and a cylindrical portion connected between the upper flange and the lower flange and used for winding a coil
Data Source
AI summary
A high-insulation small-sized hinged electromagnetic relay, includes a bobbin, coil terminals, an iron core and a fixed contact block. The bobbin has a cylindrical portion for winding a coil, and the iron core includes a mandrel and a magnetic pole portion arranged on the upper end of the mandrel; the mandrel of the iron core is fitted into the central hole of the cylindrical portion of the bobbin, the coil terminals is assembled on the lower flange of the bobbin and positioned on one side in the width direction of the bobbin, and the fixed contact block is interposed in the upper flange and the lower flange of the bobbin and positioned on the other side in the width direction of the bobbin; the cylindrical portion is offset.