Magnetic Latching Relay with E-Shaped Core and Segmented Cavities
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Solution Overview
Problem
Magnetic latching relays in the existing art are large in size and fail to achieve miniaturization while maintaining high power capabilities, which limits their application in compact circuits requiring strong and weak electrical isolation.
Innovation Solution
A miniaturized high-power magnetic latching relay design featuring a base with a first blocking wall dividing it into upper and lower cavities, where the magnetic circuit portion with an E-shaped magnetic conductive structure and a seesaw armature is integrated, along with a pushing card connected to a movable spring, enabling strong and weak electrical isolation and compact size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional magnetic latching relay structures are used, then the relay can achieve high power capability, but the size becomes large and miniaturization cannot be achieved
Solution Approach 1:
The relay is divided into two separate cavities: an upper cavity for the magnetic circuit portion and a lower cavity for the contact portion. This segmentation allows independent optimization of each part, enabling miniaturization while maintaining high power capability through efficient spatial arrangement
Solution Approach 2:
The magnetic circuit portion uses an E-shaped magnetic conductive structure with 90-degree side turns, transforming the traditional linear arrangement into a three-dimensional configuration. This dimensional change increases magnetic flux density and efficiency within a smaller volume, achieving both miniaturization and high power capability
2Volume of moving object
If the relay size is reduced for miniaturization, then the product becomes compact, but the insulation distance between springs deteriorates
Solution Approach 1:
The base is divided into upper and lower cavities by a first blocking wall, providing inherent electrical isolation. Additionally, a second blocking wall is introduced to further separate the movable spring and stationary spring, ensuring adequate insulation distance even in the miniaturized design
Solution Approach 2:
Blocking walls are introduced as intermediary structures between the magnetic circuit portion and contact portion, and between the movable and stationary springs. These intermediaries provide electrical isolation and maintain insulation distance without increasing the overall product size
3Volume of moving object
If the relay size is reduced for miniaturization, then the product becomes compact, but the resistance to surge currents deteriorates
Solution Approach 1:
The movable spring is pre-loaded with appropriate tension to ensure reliable contact separation under surge current conditions. The blocking walls are positioned in advance to provide optimal electrical isolation, preventing surge-induced breakdown without requiring larger dimensions
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 achieves a small product size with large load capacity, enhanced insulation distance between springs, and improved resistance to surge currents, while maintaining simple manufacturing and low costs.
Implementation Method 1
coil structure comprising a bobbin, an enameled wire and coil terminals; the enameled wire is configured to start from the start terminal and connect to the bridge terminal after being wound by a single-coil method or a double-coil method
Implementation Method 2
the iron core, the two yokes and the magnetic steel are formed an E-shaped magnetic conductive structure with a 90 degrees side turn
Implementation Method 3
a movable spring and a stationary spring; the enameled wire is configured to start from the start terminal and connect to the bridge terminal after being wound by a single-coil method or a double-coil method
Data Source
AI summary
A magnetic latching relay includes a base, a magnetic circuit portion, a pushing card and a contact portion; the base is provided with a first blocking wall to divide the base into an upper cavity and a lower cavity, the magnetic circuit portion and the contact portion are installed in the upper cavity and the lower cavity respectively; an iron core, two yokes and a magnetic steel of the magnetic circuit portion are formed an E-shaped magnetic conductive structure with a 90 degrees side turn; the middle position of an armature is rotatably supported above the magnetic steel, two ends of the armature respectively correspond to the tops of the two yokes; an upper end of the pushing card is connected to one end of the armature, and a lower end of the pushing card is connected to a free end of a movable spring of the contact portion.