Relay Device Inner Space Segmentation for Heat Management
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Solution Overview
Problem
The miniaturization of relay devices leads to increased heat generation within the internal components, causing temperature rises that can result in carbonization or fusion of contact points and weakening the electromagnetic force, which in turn increases contact resistance and generates more arcs, posing challenges for effective heat elimination while maintaining economic efficiency and product competitiveness.
Innovation Solution
The relay device is designed with an optimized volume ratio of inner space, dividing it into two regions to effectively eliminate heat generated by the coil and contact points, with a preferred ratio of 19% to 27% for the second space's volume in the entire inner volume and 21% to 42% for the volume occupied by components in this space, allowing for efficient heat radiation and convection while maintaining miniaturization and economic efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the relay device is miniaturized to improve product size and economic efficiency, then the product size decreases and manufacturing cost reduces, but the heat generated from internal components increases causing temperature rise that can carbonize or fuse contact points and weaken electromagnetic force
Solution Approach 1:
The inner space of the cover is divided into two distinct regions: a first space accommodating the electronic block and a second space accommodating the contact points. This spatial segmentation isolates the heat-generating coil from the contact points, preventing direct thermal interference while maintaining a compact overall structure.
Solution Approach 2:
Different regions within the cover are assigned different functional qualities: the first space is optimized for electromagnetic force generation with adequate ventilation for the coil, while the second space is optimized for contact point operation with controlled thermal exposure. This local differentiation allows each component to operate in its optimal thermal environment.
2Temperature
If empty space is increased inside the relay device to improve heat elimination, then heat radiation and convection efficiency increases, but the product size increases and economic efficiency deteriorates
Solution Approach 1:
The relay device incorporates a movable contact point that dynamically changes position between closed and open states. This dynamic movement creates variable spacing between contact points during operation, facilitating heat convection pathways without requiring permanently increased empty space in the static structure.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement within the cover, positioning components at different heights and depths. The first space and second space are arranged in vertical layers, allowing efficient heat elimination through convection currents that move vertically and horizontally without increasing the device's external footprint.
3Reliability
If the temperature in the inner space increases, then the surface of the contact point may be carbonized or fused not to ensure the connection of electric current, but increasing the temperature also increases the resistance value of the magnetic circuit weakening the electromagnetic force
Solution Approach 1:
The cover's inner space is segmented into thermally zoned regions that maintain different temperature characteristics. The first space housing the coil allows higher temperatures for electromagnetic force generation, while the second space protecting the contact points maintains lower temperatures to prevent carbonization and fusion, ensuring both reliability and force.
Solution Approach 2:
The spatial arrangement of the first and second spaces acts as a thermal intermediary, with the cover structure and air gaps serving as thermal barriers that mediate between the heat-generating coil and the temperature-sensitive contact points, protecting the latter from excessive thermal exposure.
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 effectively eliminates heat from the coil and contact points, preventing damage and maintaining the relay device's performance, while balancing miniaturization and economic efficiency by optimizing the volume ratios within the device's inner space.
Implementation Method 1
an electronic block configured to selectively generate an electromagnetic force by means of a coil
Implementation Method 2
the heat generated from internal components of the relay device must be effectively eliminated by radiation and convection
Implementation Method 3
the heat generated from internal components of the relay device must be effectively eliminated by radiation and convection
Implementation Method 4
the relay device generates an arc when the fixed contact point and the movable contact point are opened
Data Source
AI summary
A relay device includes an electronic block configured to selectively generate an electromagnetic force by means of a coil; two fixed contact point terminals at which fixed contact points are respectively installed; a movable contact point assembly having a movable contact point installed at a front end thereof, the movable contact point being fluctuated by the electromagnetic force to be contacted with or separated from the fixed contact points; and a base block configured to hold the electronic block, the fixed contact point terminals and the movable contact point assembly, which are accommodated in a cover. An entire space inside the cover is divided into two regions based on a contact surface between the fixed contact point and the fixed contact point terminal.