Integrated Relay Housing Layout for Compact Multi-Core Packaging
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Solution Overview
Problem
Existing integrated relays occupy large spaces, leading to low space utilization rates in electrical devices, which hinders miniaturization.
Innovation Solution
An integrated relay design featuring a housing with a mounting cavity that encapsulates multiple relay cores, utilizing a potting compound for fixation and support, and incorporating features like arc extinguishing shields and drive assemblies to enhance stability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple relay cores are integrated together in a housing, then the quantity of relays is increased, but the volume of the integrated relay becomes large
Solution Approach 1:
Multiple relay cores are nested within a single housing structure, with each relay core positioned in a dedicated mounting cavity. The relay cores are arranged in a compact configuration where they share common structural elements such as the housing, potting compound, and arc extinguishing shields, thereby reducing the overall volume compared to separate relay assemblies.
Solution Approach 2:
The patent combines multiple relay cores into a single integrated unit by merging their mounting structures. The housing integrates multiple mounting cavities, the potting compound serves as a common fixing medium for all relay cores, and the arc extinguishing shields provide shared protection, thereby reducing redundant structural elements and overall volume.
2Area of stationary object
If relay cores are integrated in a housing with mounting cavity, then the space utilization rate is improved, but the complexity of the housing structure increases
Solution Approach 1:
The housing is segmented into multiple mounting cavities, each designed to accommodate a specific relay core. This segmentation allows for optimized space utilization while maintaining modular construction, where each cavity can be independently formed or assembled, thereby managing structural complexity through systematic division rather than monolithic design.
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 design reduces the volume of individual relay cores, improves space utilization, and enhances the reliability and efficiency of electrical devices by minimizing heat accumulation and arc impacts.
Implementation Method 1
The stator includes a stator core and a coil arranged on the stator core. The mover is at least partially sheathed in the stator. In addition, an end of the mover is connected to the contact member, to drive the contact member to move
Implementation Method 2
The relay core further includes an arc extinguishing shield. The arc extinguishing shield is arranged on an outer periphery of the fixing member. The arc extinguishing shield is in direct contact with the potting compound
Data Source
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AI summary
An integrated relay, an electrical device, and a vehicle are provided. The integrated relay includes a housing and a number of relay cores. The housing is an integrated piece and includes a mounting cavity. The number of relay cores are arranged spaced away from each other and encapsulated together in the mounting cavity. In the technical solutions of the present disclosure, unshelled relay cores are encapsulated in the mounting cavity of the housing, to reduce a volume of a single relay core, thereby reducing a volume of the integrated relay, and improving an aperture utilization rate of the integrated relay for the electrical device.