Electromagnetic Relay Insulation Structure for Compact High-Voltage Isolation
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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 such as a wall and canopy to extend insulation distances, and a base with integrated insulation walls to maintain compact size and component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the physical distance between components is increased to improve insulation performance, then the 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 closer proximity, thus preventing the relay size from increasing proportionally with the insulation distance requirement.
Solution Approach 2:
The insulating member extends insulation in multiple spatial dimensions rather than relying solely on increased linear distance. The insulating structure is designed to provide adequate insulation paths in critical directions while maintaining compact overall dimensions, effectively utilizing three-dimensional space optimization.
2Reliability
If an insulating material is placed between components to improve insulation performance, then the insulation performance is improved, but the number of parts increases
Solution Approach 1:
The insulating member is integrated with existing structural components of the relay. Rather than being a completely separate additional part, the insulating member is designed to combine insulation functionality with structural support and component mounting functions, thereby reducing the net increase in part count despite adding insulation capability.
Solution Approach 2:
The insulating member serves multiple functions simultaneously: providing electrical insulation between high-voltage and low-voltage components, serving as a mounting structure for the coil and terminals, and providing mechanical support for the electromagnet assembly. This multi-functionality reduces the need for separate dedicated insulation components.
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 enhanced insulation performance while minimizing size and component count, reducing assembly issues and malfunctions due to chip generation, and ensuring reliable operation.
Implementation Method 1
an electromagnet including a coil
Implementation Method 2
an insulating member positioned between the coil and the yoke
Data Source
Figure 1
Figure 2
Figure 3~4
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.