HVDC Relay Ceramic Cover Structure for Arc Spatter Insulation
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Solution Overview
Problem
High-voltage direct current relays suffer from insulation degradation and short circuits due to arc ablation, leading to reduced insulation capability and increased risk of electrical failures in applications like vehicle energy storage and marine electronics.
Innovation Solution
A high-voltage direct current relay design featuring a ceramic cover with staggered step surfaces on the fixed contacts and through holes, which prevent arc spatter from entering the fitting clearance, enhancing insulation capability and creepage distance while maintaining a simple structure and low production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a movable contact spring direct action structure is used to realize closing and breaking between contacts, then the switching function is achieved, but arc ablation causes pollutant deposition on the inner wall, leading to insulation short circuit and insulation reduction
Solution Approach 1:
The patent extracts and removes the harmful arc spatter from the insulation cavity by designing a movable contact spring that extends beyond the ceramic cover, directing arcs away from the inner wall where they cannot deposit pollutants that would compromise insulation
Solution Approach 2:
The patent introduces an intermediary structure (the extended movable contact spring) that acts as a barrier and director, intercepting arc spatter before it can reach the ceramic cover inner wall, thereby protecting the insulation surface from contamination
2Reliability
If the creepage distance and insulation resistance are increased to meet arc extinction requirements for high voltage and large current, then insulation capability is improved, but the structure becomes more complex and production cost increases
Solution Approach 1:
The patent extends the movable contact spring in a dimensional direction beyond the ceramic cover boundary, creating a three-dimensional spatial arrangement that increases creepage distance and protects the inner wall from arc spatter without requiring additional components or complex internal structures
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
The staggered design effectively reduces insulation short circuits and increases insulation resistance, meeting high voltage and current arc extinction requirements while maintaining cost-effectiveness and assembly simplicity.
Implementation Method 1
prevent arc spatter from entering into a region of fitting clearance between a fixed contact and a through hole of the ceramic cover
Data Source
AI summary
A high-voltage direct current relay capable of improving insulation capability, including a ceramic cover, two fixed contacts for respectively providing inflow and outflow current and one movable contact spring; a through hole for assembling the fixed contact being provided at a top wall of the ceramic cover; one segment of a body of the fixed contact being in clearance fitted with the through hole of the ceramic cover, a first step surface downward being provided at an outer peripheral wall of one segment of the body of the fixed contact, at a corresponding position, a second step surface upward being provided at an inner peripheral wall of the through hole of the ceramic cover, and the projections of the first step surface and the second step surface on the horizontal plane having an overlapped region.