Ultra-Small Relay Bobbin Retaining Walls for Insulation Accuracy

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Solution Overview

Problem

Ultra-small electromagnetic relays face issues with position consistency accuracy of contact portions, insufficient creepage distance leading to insulation performance deterioration, and functional failures due to laser welding imperfections.

Innovation Solution

The relay incorporates first and second retaining walls protruding from the bobbin flanges to limit the static spring contact position, increasing creepage distance and avoiding direct exposure to the enameled wire, while using interference fit for permanent magnet fixation to prevent welding slag accumulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the contact portion is positioned close to the flange to reduce relay size, then the relay volume is reduced, but the position consistency accuracy of the contact portion deteriorates

Engineering Contradiction:

Improverelay volumeVSAvoidcontact position consistency accuracy

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent introduces a retaining wall structure as an intermediary element between the contact portion and the flange. This retaining wall provides precise positioning and limiting functions, ensuring that the contact portion maintains accurate positional consistency while being located close to the flange. The retaining wall acts as a mediator that enables both compact positioning and high precision simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the creepage distance between contact portion and enameled wire is reduced to minimize relay size, then the relay volume is reduced, but the insulation performance deteriorates

Engineering Contradiction:

Improverelay volumeVSAvoidinsulation performance

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The patent utilizes the vertical dimension by making the retaining wall protrude upward from the flange. This vertical protrusion creates additional insulation distance in the height direction, effectively increasing the creepage distance between the contact portion and the enameled wire without increasing the relay's planar footprint, thus maintaining compact size while improving insulation performance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Device complexity

If laser welding is used to fix the permanent magnet to reduce assembly steps, then the manufacturing process is simplified, but welding slag accumulation causes functional failures

Engineering Contradiction:

Improveassembly process complexityVSAvoidrelay functional reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent extracts and removes the harmful element (welding slag) from the system by eliminating the laser welding process entirely. Instead of using laser welding to fix the permanent magnet, the patent employs an alternative fixation method that does not generate welding slag, thereby preventing functional failures while maintaining process simplicity.

Inventive Principle:

Principle #2Taking out (Extraction)

4Device complexity

If the contact portion is exposed above the enameled wire to simplify structure, then the structural complexity is reduced, but the environmental resistance deteriorates due to plastic material expansion

Engineering Contradiction:

Improvestructural complexityVSAvoidenvironmental resistance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent provides beforehand protection by having the retaining wall protrude upward to cover and protect the contact portion. This proactive design prevents the contact portion from being directly exposed to environmental factors that could cause plastic material expansion issues, thereby improving environmental resistance while maintaining structural simplicity.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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

This design enhances contact position consistency, increases creepage distance without enlarging the relay, and improves insulation and environmental resistance by reducing reliance on plastic material expansion, and eliminates welding slag issues.

Implementation Method 1

the permanent magnet 206 is welded between the two end portions 106 of the U-shaped iron core 103 of the coil portion

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

Ultra-small electromagnetic relays... consist of a movable spring armature portion, a base portion and a housing

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12500054B2Highly-reliable insulating ultra-small electromagnetic relay

Publication Date: 2025.12.16 XIAMEN HONGFA SIGNAL ELECTRONICS CO LTD

AI summary

The present disclosure provides a highly-reliable insulating ultra-small electromagnetic relay, comprising a coil portion and static spring portions. The coil portion comprises a bobbin; the bobbin comprises two flanges that are located at the two end portions of the bobbin; each static spring portion comprises a static spring provided at at least one end of the bobbin; the static spring comprises a contact portion comprising a static contact; the contact portion of the static spring is provided at the position close to the flange of the bobbin; and in each flange of the bobbin, a first retaining wall and a second retaining wall used for together limiting the position of the contact portion of the static spring in two horizontal directions are respectively and upwardly arranged in a protruding mode.