Monobloc Electromagnetic Relay Layout for High-Voltage Isolation
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Solution Overview
Problem
Existing electromagnetic relays face issues with insufficient clearance and creepage distance due to the proximity of conducting parts, affecting safety and insulation performance, particularly in compact designs.
Innovation Solution
The electromagnetic relay is designed with a monobloc structure enclosed in a moulded casing made of non-conductive materials, providing a clearance and creepage distance of 10-12 mm and ensuring isolation up to 8-12 kV VAC, with features like a floating pusher and sealing members to enhance insulation and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electromagnetic relay is designed with compact size, then the device dimensions are reduced, but the clearance and creepage distance between conducting parts becomes insufficient
Solution Approach 1:
The patent increases clearance distance by utilizing vertical spacing between the armature and connecting piece in the Z-direction, rather than only horizontal spacing. The armature is positioned above the yoke with a vertical gap of 3-5mm, and the connecting piece is positioned below the yoke, creating three-dimensional spatial separation that maintains insulation while reducing overall device footprint.
Solution Approach 2:
The yoke serves as an intermediary non-conductive barrier positioned between the armature and connecting piece. This intermediate component physically separates the two conducting parts, preventing direct electrical contact and providing the necessary creepage distance while allowing the device to maintain a compact form factor.
2Reliability
If the distance between armature and connecting piece is increased to improve insulation, then the clearance distance is improved, but the device volume increases
Solution Approach 1:
The patent resolves the volume contradiction by transitioning from two-dimensional horizontal spacing to three-dimensional vertical spacing. The armature is positioned above the yoke and the connecting piece below it, utilizing the vertical dimension to achieve necessary clearance distances without increasing the device's planar footprint, thus maintaining compact overall dimensions.
Solution Approach 2:
The casing acts as a flexible enclosing structure that accommodates the vertical arrangement of components. The casing walls provide additional insulation barriers and allow the internal components to be arranged in a compact vertical configuration, achieving both sufficient clearance distance and compact external dimensions.
3Ease of manufacture
If conventional assembly methods are used, then manufacturing simplicity is maintained, but sufficient insulation distance cannot be achieved
Solution Approach 1:
The patent combines multiple components (casing, armature, yoke, connecting piece, contacts) into a single integrated assembly that is molded as one piece. This merging of components into a monobloc structure ensures that the insulation distances are built-in during the molding process itself, eliminating the need for complex post-assembly adjustments while maintaining manufacturing simplicity through injection molding technology.
Solution Approach 2:
The required clearance and creepage distances are predetermined and built into the mold cavity dimensions during the design phase. The injection molding process automatically creates the correct spacing between conducting parts as the components are formed in place, eliminating the need for subsequent assembly adjustments and ensuring consistent insulation distances.
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 improved electrical isolation and stability, preventing corrosion and ingress of foreign materials, suitable for compact applications with enhanced insulation performance.
Implementation Method 1
a bobbin assembly (10) comprising a bobbin (12) wound with an annular coil (14), a core (16) insertable into said bobbin (12) and plurality of yolks (18), wherein the coil (14) is configured to move an armature (22) upon activation by means of voltage application
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention is relating to an electromagnetic relay (100) comprising a bobbin assembly (10) a comprising a bobbin (12) wound with an annular coil (14), a core (16) insertable into said bobbin (12) and plurality of yolks (18). Further, the electromagnetic relay (100) comprises a plurality of contacts (20) that includes at least one fixed contact (20a) and at least one movable contact (20b) are configured to open and close the electromagnetic relay (100). In addition, a floating type pusher (30) configured to transfer armature (22) movement to the movable contact (20b) upon activation of said coil (14). Accordingly, the electromagnetic relay (100) is formed integrally enclosed in a moulded plastic casing (40) as a monobloc, and the casing (40) is configured to provide electric isolation in the electromagnetic relay (100).