Moulded Electromagnetic Relay Casing for Compact High-Voltage Isolation
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Solution Overview
Problem
Existing electromagnetic relays face issues with insufficient clearance and creepage distance, affecting electrical insulation and safety, particularly in compact designs required for various applications.
Innovation Solution
The electromagnetic relay is designed with a monobloc structure enclosed in a moulded casing made of non-conductive materials, providing a clearance and creepage distance of 10-12 mm and ensuring electric isolation of over 8 KV VAC, with features like a floating pusher and sealing members to enhance insulation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electromagnetic relay is designed with compact structure, then the size is reduced, but the clearance and creepage distance between armature and connecting piece becomes insufficient
Solution Approach 1:
A molded casing made of non-conductive material is introduced as an intermediary component between the armature and connecting piece. This casing provides the necessary electrical insulation and maintains clearance distances while allowing the overall relay structure to remain compact. The casing acts as a mediator that enables both compactness and adequate insulation simultaneously.
Solution Approach 2:
The molded casing functions as a protective shell that encloses the internal components. This shell provides electrical insulation and maintains proper spacing between conductive parts without requiring large overall dimensions. The casing design allows the relay to achieve compact size while maintaining necessary clearance and creepage distances for electrical safety.
2Reliability
If the distance between armature and connecting piece is increased to improve insulation, then the electrical clearance is improved, but the device size increases
Solution Approach 1:
The insulation problem is solved by transitioning from a two-dimensional spacing approach to a three-dimensional enclosure approach. Instead of simply increasing the distance between armature and connecting piece in one dimension, the molded casing provides insulation in multiple dimensions, allowing compact overall size while maintaining adequate electrical clearance through the casing wall thickness and structural design.
3Ease of manufacture
If traditional assembly methods are used, then manufacturing is simpler, but the electrical insulation and stability during vibration are insufficient
Solution Approach 1:
Multiple functions are merged into the molded casing component: electrical insulation, mechanical support, vibration damping, and corrosion protection. This single integrated component provides all necessary functions that would otherwise require separate elements, achieving improved reliability while maintaining ease of manufacture through mold-based production. The casing combines insulation and structural support functions that traditional separate assemblies could not provide simultaneously.
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 improved electrical insulation and stability against vibration, preventing corrosion and ingress of foreign materials, suitable for compact and reliable operation in diverse environments.
Implementation Method 1
a bobbin assembly (10) comprising a bobbin (12) wound with an annular coil (14), a core (16) insertable into said bobbin (12) and plurality of yolks (18), wherein the coil (14) is configured to move an armature (22) upon activation by means of voltage application
Data Source
AI summary
The present invention is relating to an electromagnetic relay (100) comprising a bobbin assembly (10) a comprising a bobbin (12) wound with an annular coil (14), a core (16) insertable into said bobbin (12) and plurality of yolks (18). Further, the electromagnetic relay (100) comprises a plurality of contacts (20) that includes at least one fixed contact (20a) and at least one movable contact (20b) are configured to open and close the electromagnetic relay (100). In addition, a floating type pusher (30) configured to transfer armature (22) movement to the movable contact (20b) upon activation of said coil (14). Accordingly, the electromagnetic relay (100) is formed integrally enclosed in a moulded plastic casing (40) as a monobloc, and the casing (40) is configured to provide electric isolation in the electromagnetic relay (100).