Electromagnetic Relay Insulating Wall Design
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Solution Overview
Problem
Existing electromagnetic relays face challenges in achieving compact size, strong attracting force against spring load, and sufficient insulating distance, especially when operating at high voltages, which affects their reliability and safety.
Innovation Solution
The design incorporates a base block with an electromagnet unit, a contact unit, and a first insulating wall that extends from the base block, featuring a wider iron core with reduced magnetic pole face area and increased creepage distance, enhancing the attracting force and insulating distance while maintaining compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the size of the electromagnetic relay is reduced for compactness, then the device becomes more compact, but the insulating distance between the electromagnet and the contacts becomes insufficient
Solution Approach 1:
The patent introduces a first insulating wall extending from the base block in a direction perpendicular to the main electromagnetic relay components. This adds a vertical dimension to the insulating structure, allowing the insulating distance to be increased without expanding the horizontal footprint of the device, thus maintaining compactness while achieving sufficient insulation for high-voltage operation.
2Force
If the iron core is made wider to increase attracting force, then the magnetic pole face area increases, but the insulating distance decreases
Solution Approach 1:
The first insulating wall extends vertically from the base block, providing additional insulating distance in the vertical direction. This allows the iron core to be made wider horizontally to increase the magnetic pole face area and attracting force, while the vertical insulating wall compensates for any reduction in insulating distance, thus resolving the contradiction between force and reliability.
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 configuration ensures a stronger attracting force to prevent contact bounce and maintain high-voltage reliability, while the increased creepage distance meets safety standards, such as UL61010-2-201, and reduces the risk of defective products by preventing tool insertion and foreign substance entry.
Implementation Method 1
Electric current flowing through the coil of the electromagnet generates a magnetic field
Implementation Method 2
the iron core attracts the armature to cause the fixed contact and the movable contact to come in contact with each other
Data Source
AI summary
An electromagnetic relay includes an electromagnet unit, a contact unit including a movable contact spring with a movable contact provided thereon and a fixed contact spring with a fixed contact provided thereon, and a base block configured to support the electromagnet unit and the contact unit, wherein the electromagnet unit is supported at a first face of the base block, and the contact unit is supported at a second face of the base block facing in an opposite direction from the first face, and wherein the base block includes a first insulating wall extending from the first face alongside the electromagnet unit and a second insulating wall extending from the second face alongside the contact unit, the second insulating wall being situated on an opposite side from the first insulating wall across the second face.