Relay Armature Assembly With Integrated Insulator and Arc Control
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Solution Overview
Problem
Existing electromagnetic relays face issues with ineffective arc extinguishing due to limited electric arc length, component complexity leading to high costs and reduced production efficiency, and mechanical weakness of plastic insulation bases causing wear and performance degradation.
Innovation Solution
Integration of the armature, movable leaf spring, and insulator through embedded injection molding, increased creepage distance via grooves and ribs, and magnetic field-enhanced arc extinguishing with recesses and magnets to extend arc length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connection pieces are provided to connect armature and movable leaf spring, then electrical isolation is achieved, but the number of components increases and production efficiency decreases
Solution Approach 1:
The patent combines the connection piece function with the insulator by integrating the insulating structure directly into the connection mechanism. The insulator serves dual purposes: providing electrical isolation between the armature and movable leaf spring, and facilitating their mechanical connection, thereby reducing component count and improving production efficiency.
Solution Approach 2:
The insulator is designed to perform multiple functions simultaneously: it provides electrical isolation, mechanical support, and connection between components. This multi-functional design eliminates the need for separate connection pieces while maintaining reliability.
2Ease of operation
If the reset leaf spring is fixed to the partition wall of the insulation base, then resetting function is achieved, but the plastic partition wall is prone to rupture or wear due to frequent movement
Solution Approach 1:
The patent extracts the reset leaf spring mounting function from the partition wall by providing a dedicated mounting structure on the yoke. This separates the high-stress reset mechanism from the weak plastic partition wall, preventing rupture and wear while maintaining the reset function.
3Strength
If riveting is used to connect movable leaf spring and connecting piece, then strong mechanical connection is achieved, but production efficiency is reduced
Solution Approach 1:
The patent replaces the mechanical riveting process with an embedded injection molding process. The insulator is molded directly onto the armature and movable leaf spring, creating a strong mechanical bond without requiring separate riveting operations, thereby maintaining connection strength while improving production efficiency.
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
Enhances arc extinguishing effectiveness, reduces component count and costs, and improves reliability by minimizing wear on the insulation base.
Implementation Method 1
The armature and the movable leaf spring are fixed to the insulator and electrically isolated from each other by the insulator
Implementation Method 2
When extinguishing the electric arc with magnetic force, the length of the electric arc pulled down between the movable contact and the static contact is limited
Implementation Method 3
the electric arc pulled down between the movable contact and the static contact
Data Source
AI summary
The present invention discloses a relay armature assembly, a relay module, and a relay. The relay armature assembly comprises: an armature which is suitable for being movably installed on a yoke of a relay, and can swing relative to the yoke between an initial position and a suction position; a movable leaf spring adapted to be connected to a movable contact assembly of the relay, for applying elastic contact force to the movable contact assembly; and an insulator. The armature and the movable leaf spring are fixed to the insulator and electrically isolated from each other by the insulator. In the present invention, the movable leaf spring is directly connected to the insulator, reducing the number of components of the relay, simplifying the structure of the relay, reducing the cost of the relay, and improving the manufacturing efficiency of the relay. In addition, in some embodiments of the present invention, the reset leaf spring is fixed to the yoke. Therefore, when the reset leaf spring is frequently moved, the insulation base is not affected and will not break or wear, thereby improving the service life and reliability of the relay.