Relay Framework with Arc-Extinguishing Windows
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Solution Overview
Problem
Existing relays face issues with arc extinguishing when handling higher loads, leading to damage of plastic frameworks and increased costs with ceramic frameworks, along with enlarged product size and prolonged acting time.
Innovation Solution
A hollow injection molding framework with aligned windows for arc gaps, incorporating magnetic steel and arc resistance pieces to effectively extinguish arcs without increasing product size or cost, using a combination of magnetic and ceramic materials for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the framework main body is made of plastic material, then the cost is reduced and manufacturing is simplified, but the insulation property decreases sharply when electric arc strikes the material
Solution Approach 1:
The framework is segmented into different material zones: the main body remains plastic for cost-effectiveness, while ceramic materials are strategically placed in arc-prone areas (contact gaps, around terminals) to provide localized insulation protection against electric arc damage
Solution Approach 2:
The framework uses a composite structure combining plastic and ceramic materials. The plastic provides overall structural support and cost benefits, while ceramic inserts provide high-temperature resistance and insulation where electric arcs occur, resolving the contradiction between manufacturing ease and reliability
2Reliability
If the whole framework is made of ceramic material to improve insulation property, then the relay can withstand higher loads, but the structure becomes complex, size increases, weight increases, and cost increases
Solution Approach 1:
Instead of making the entire framework from ceramic, the design segments the framework into plastic main body with localized ceramic components only where needed for arc extinction and insulation, simplifying overall structure while maintaining necessary reliability
Solution Approach 2:
Ceramic materials are applied locally in specific areas where high insulation and arc resistance are required (contact gaps, terminal regions), while the rest of the framework uses plastic, avoiding the complexity and cost of full ceramic construction
3Reliability
If the contact gap is increased to extinguish arc without permanent magnets, then the arc extinction capability is improved, but the product size increases and acting time is lengthened
Solution Approach 1:
The design converts the harmful electric arc into a beneficial tool for arc extinction by using ceramic materials that can withstand and control the arc, allowing effective arc management without increasing product size or acting time
Solution Approach 2:
The framework uses ceramic materials with high melting points and excellent arc resistance properties, changing the material parameters to enable effective arc extinction at optimized contact gap distances, avoiding the need for enlarged gaps
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 provides effective arc extinguishing with reduced material usage and costs, improved structural strength, and increased flexibility, while maintaining product efficiency and reliability.
Implementation Method 1
a magnetic steel 4 and at least one arc resistance piece 5 are mounted on the window 15
Implementation Method 2
a conductive gas mass, which is called electric arc, with extremely high temperature and brightness is created in the contact gap
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A framework part of a relay and a relay. An inner hollow portion and peripheral windows are formed by the framework. The windows are communicated with the exterior of the framework and the hollow portion. At least one group of contactors that can correspondingly contact are accommodated in the hollow portion. An arc gap is formed between the contactors that can correspondingly contact. The windows are aligned with the arc gap from an outer side. A main body of the framework is a hollowed injection molding framework, and has multiple windows that are aligned with the arc gap from the outer side, so that, under the precondition of ensuring the structural strength, materials can be reduced and the cost can be reduced. The windows can be used for installing functional components such as magnetic steel, a resistant act clip or an arcing and arc extinguishing piece. The framework is made be applicable to relays and breakers having more functions and requirements, so as to improve a scope of application of products to a great extent and facilitate reduction of molds and other manufacturing costs.