Mini High-Power Magnetic Latching Relay Compact Design
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Solution Overview
Problem
Conventional magnetic latching relays are large in structure, limiting their application on printed circuit boards due to size constraints.
Innovation Solution
A mini high-power magnetic latching relay with a compact magnetic circuit design, comprising a magnetic enclosure, iron core, yoke, and winding, along with a push rod and contact pair, optimized for small volume and balanced magnetic circuitry to ensure stable contact pressure and extended service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional magnetic latching relay structure is used, then the relay can achieve high power and stable operation, but the relay volume becomes large and cannot be mounted on printed circuit boards
Solution Approach 1:
The magnetic enclosure is formed by magnetic steel and armatures vertically located on both ends through injection, creating a nested compact structure. The armatures are collaterally inserted into the E-shaped gap formed by the iron core and yoke, maximizing space utilization and minimizing overall relay volume while maintaining structural integrity and contact stability
Solution Approach 2:
The push rod comprises a push seat and two push arms integrated with the push seat through integration. The magnetic enclosure is integrated with a push shaft, and the coupling shaft is installed inside the connecting hole of the coil former, merging multiple components into unified structures that reduce volume while ensuring reliable force transmission and contact pressure
2Volume of moving object
If the relay volume is minimized for PCB mounting, then the relay can be applied on printed circuit boards, but the contact pressure and service life may be compromised
Solution Approach 1:
One end of the yoke is designed as a U-shaped end, and the iron core penetrates through the coil to form an E shape with the yoke. This asymmetric design optimizes the magnetic circuit path and ensures balanced magnetic distribution, providing stable contact pressure and extended service life despite the minimized relay volume
Solution Approach 2:
The end of the yoke is located at the center of the U-shaped end to form an E shape, creating a localized optimal magnetic field distribution. The armatures are precisely positioned in the E-shaped gap for proper alignment, ensuring that critical contact areas maintain high pressure and stability while the overall volume is minimized
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
Enables the relay to be applied on printed circuit boards with a minimized volume, improved contact stability, and extended service life, expanding the application scope of magnetic latching relays.
Implementation Method 1
The winding comprises a coil former and a coil wrapped on the said coil former
Implementation Method 2
The magnetic circuit comprises a magnetic enclosure, an iron core, a yoke and a winding
Data Source
AI summary
A mini high-power magnetic latching relay comprising a base seat, an insulation sleeve, a push rod, a magnetic circuit, and a contact part. The magnetic circuit comprises a magnetic enclosure, an iron core, a yoke, and a winding; the winding comprising a coil former and a coil wrapped on the coil former. One end of the yoke is a U-shaped end; the iron core penetrates through the coil for forming a fixed connection with the other end of the yoke; and one end of the iron core is located at the center of the U-shaped end to form an E-shaped gap. The magnetic enclosure is formed by magnetic steel and armature vertically located on both ends of the magnetic steel.