PCB Magnetic Relay Layout for Miniaturized Reliable Switching

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Solution Overview

Problem

Existing relays are limited by their size and reliability, often failing after a high number of switchovers due to mechanical complexities and oxidation issues at contact points.

Innovation Solution

A miniaturized relay design utilizing a linear magnetic or electromagnetic actuator to control the movement of overlapping conductive planes, eliminating the need for traditional windings and ferromagnetic materials, and using graphene connectors for reduced wear and size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If traditional windings and ferromagnetic materials are used, then the relay can generate magnetic field, but the size of the relay increases

Engineering Contradiction:

Improverelay sizeVSAvoidswitchover durability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent extracts and eliminates the traditional winding and ferromagnetic core from the relay structure. Instead of using a coil wound around a ferromagnetic core, the invention uses a planar magnetic field generator integrated into a printed circuit board, thereby removing the bulky components while maintaining the magnetic field generation function.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the traditional mechanical winding structure with a planar electromagnetic structure integrated into a PCB. The magnetic field is generated through current paths etched on the PCB layers, substituting the mechanical coil winding with a planar conductive pattern that achieves the same electromagnetic function with significantly reduced size.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional contact structures are used, then the relay can perform switching function, but oxidation at contact points occurs after high number of switchovers

Engineering Contradiction:

Improvecontact reliabilityVSAvoidoxidation at contact points

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs graphene connectors at the contact points between the movable and fixed planes. Graphene's exceptional chemical stability and oxidation resistance protect the contact surfaces from degradation even after numerous switchover cycles, maintaining reliable electrical contact without the oxidation problems that plague traditional metal contacts.

Inventive Principle:

Principle #40Composite materials

3Volume of moving object

If miniaturization is achieved by removing traditional components, then the relay size decreases, but magnetic field generation capability must be maintained

Engineering Contradiction:

Improverelay sizeVSAvoidmagnetic field generation

Core Design Contradiction:

Volume of moving objectVSPower

Solution Approach 1:

The patent transitions from a three-dimensional coil structure to a two-dimensional planar structure integrated into the PCB. The magnetic field is generated through current paths etched on the PCB layers, utilizing the planar geometry to produce the necessary magnetic flux density while maintaining a compact form factor suitable for miniaturized applications.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution achieves significant miniaturization, increased lifespan, and improved reliability by eliminating mechanical faults and oxidation issues, while allowing for immediate switching between on and off positions without the generation of electrical spikes.

Implementation Method 1

said actuator is configured to generate at least one first magnetic field and the movable element (6) is an element sensitive to said magnetic field

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

when said first magnetic field has been generated, a first magnetic force is generated which causes a motion along said guide of said movable element (6)

Methodology Applied

Scientific EffectMagnetic force: Lorentz Force

Implementation Method 3

two overlapping planes (1, 2) which are electrically conductive... when the relay is in a contact configuration ('ON'), the signal passes through the two planes by means of the interposed probe

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20250069835A1A relay with magnetic field generation through a PCB

Publication Date: 2025.02.27 MICROTEST SPA

AI summary

A relay system includes a magnetic field generator, and a first and a second plane, which overlap each other at a predetermined distance, and of which one is movable towards and away from the other plane along a guide. A seat is interposed between the two planes, which can receive a probe of an electrically conductive material and which has a first aperture facing one plane and a second aperture facing the other plane. The probe ends protrude at least partially through the aperture so that each end can come into contact with the plane facing the aperture. The magnetic field generator is configured to generate a first magnetic field that determines a first magnetic force, which causes a motion along the guide and the approach of ne plane towards the other, bringing the two planes into electrical contact through a contact of each plane with the interposed probe.