Electromagnetic Relay Insulation Structure for Compact High-Voltage Use
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Solution Overview
Problem
Existing relays face challenges in achieving high insulation performance without increasing size or the number of components, particularly in high-voltage and high-current applications like on-board chargers for electric vehicles.
Innovation Solution
A relay design incorporating an insulating member between the coil and yoke, with specific structural features like a wall and protrusions to enhance insulation distances, and a base with integrated insulation walls to maintain compact size and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the physical distance between components is increased to improve insulation performance, then insulation performance is improved, but the size of the relay increases
Solution Approach 1:
An insulating member is introduced as an intermediary component between the coil and yoke, and between the coil terminal and fixed terminal. This insulating member provides the necessary insulation performance while allowing the components to remain in close proximity, thus preventing relay size increase.
2Reliability
If an insulating material is placed between components to improve insulation performance, then insulation performance is improved, but the number of parts increases
Solution Approach 1:
The insulating member integrates multiple insulation functions into a single component. It simultaneously insulates between the coil and yoke, and between the coil terminal and fixed terminal, thereby improving insulation performance without proportionally increasing the number of parts.
Solution Approach 2:
The insulating member serves multiple insulation purposes within the relay structure. By designing this single component to provide insulation at multiple critical interfaces, the patent reduces the need for separate insulating materials at each location.
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 high insulation performance while minimizing relay size and component count, reducing assembly issues and malfunctions due to chip generation and interference.
Implementation Method 1
an electromagnet including a coil
Implementation Method 2
an insulating member positioned between the coil and the yoke
Data Source
AI summary
An electromagnetic relay with high insulation while minimizing increases in size and the number of parts is provided. The electromagnetic relay has a coil, a bobbin around which the coil is wound, an iron core inserted into the bobbin, an electromagnet having a yoke forming a magnetic circuit with the iron core, a movable terminal having a movable contact configured to move with the operation of the electromagnet, fixed terminals having fixed contacts positioned opposed to the movable contact, a coil terminal attached to the bobbin and connected to the coil, an insulating member positioned between the coil and the yoke, and a base having a wall part configured to insulate between the coil terminal and the fixed terminals.