Relay Insulation Wall Structure for Compact Contact Isolation
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Solution Overview
Problem
Existing relays face a challenge in increasing the insulation distance between the movable contact piece and the armature without enlarging the relay's size.
Innovation Solution
The relay design incorporates a card with protrusions and a wall between the armature and the movable contact piece, along with specific configurations of the armature and wall protrusions, to enhance insulation distance while maintaining the relay's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance between the movable contact piece and the armature is increased to improve insulation, then the insulation distance is improved, but the relay size increases
Solution Approach 1:
The patent introduces a wall structure that extends in the vertical direction (up-down direction) between the armature and the card. This vertical dimension approach allows the insulation distance to be increased by adding height rather than expanding the horizontal footprint, thereby improving insulation performance without proportionally increasing the overall relay volume.
Solution Approach 2:
The wall structure is nested within the existing relay housing space, utilizing the vertical space between the armature and the card assembly. This nesting approach allows the insulation wall to be integrated into the existing structure without requiring additional external space, effectively increasing insulation distance while maintaining compact dimensions.
2Volume of moving object
If the relay size is reduced to maintain compact dimensions, then the relay size is reduced, but the insulation distance between movable contact piece and armature decreases
Solution Approach 1:
By transitioning from horizontal to vertical dimension for insulation spacing, the patent achieves adequate insulation distance within a compact horizontal footprint. The wall extends vertically to provide the necessary insulation clearance without increasing the relay's overall width, length, or height significantly.
Solution Approach 2:
The wall structure provides localized insulation enhancement only in the critical region between the armature and the card, rather than uniformly increasing all dimensions. This targeted approach maintains compact overall size while ensuring adequate insulation distance where it is most needed for 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 effectively increases the insulation distance between the movable contact piece and the armature without increasing the relay's size, while also stabilizing the armature's operation and reducing magnetic loss.
Implementation Method 1
The armature is operable by electromagnetic force that is generated by the coil
Data Source
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AI summary
A wall is disposed between the armature and a card. The card includes a card body, a contact part, and a protrusion. The card body is disposed between the wall and the movable contact piece. The contact part extends from the card body toward the armature. The protrusion protrudes from the card body toward the wall and is disposed on a side of the connection portion.