Electromagnetic Relay Thermal Conductive Polymer Base
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Solution Overview
Problem
Conventional electromagnetic relays suffer from poor heat dissipation, leading to reduced service life and safety issues due to excessive heat generation and electric arc formation during operation, which complicates electrical connections and affects circuit efficiency.
Innovation Solution
The electromagnetic relay incorporates a polymer thermal conductive base with integrated heat conduction parts and thermally conductive fins, along with an arc blow component, to effectively dissipate heat and extinguish electric arcs, featuring a modular design for improved thermal management and arc cutting within a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If conventional relay structure is used, then the device complexity is low, but the heat dissipation performance is poor leading to reduced service life
Solution Approach 1:
The base is made of polymer thermal conductive material instead of conventional insulating materials, enabling the base itself to function as a heat dissipation component. This composite material approach allows the structural base to simultaneously provide mechanical support and thermal management, resolving the contradiction between simple structure and effective heat dissipation.
Solution Approach 2:
The heat dissipation function is segmented into multiple independent paths: the first heat conduction part embedded in the base, the second heat conduction part extending outward, and multiple thermal conduction components with fins. This segmentation creates redundant heat dissipation pathways, ensuring reliable heat dissipation while maintaining overall structural simplicity.
2Reliability
If conventional relay structure is used, then the manufacturing cost is low, but the safety is reduced due to electric arc generation
Solution Approach 1:
The patent utilizes the thermal conductivity of the polymer base and thermal conduction components to convert the harmful electric arc energy into beneficial heat dissipation. The arc blow component directs arcs toward thermally conductive surfaces that efficiently dissipate the arc energy, transforming a harmful effect into a controlled thermal management opportunity.
Solution Approach 2:
The arc blow component acts as an intermediary that controls and directs the electric arc toward designated thermal conduction paths. This intermediary component safely manages the arc phenomenon by channeling it toward heat dissipation structures, preventing uncontrolled arcing that would compromise safety.
3Temperature
If heat dissipation structures are added to improve thermal management, then the temperature control is improved, but the device complexity increases
Solution Approach 1:
The patent merges the heat dissipation function with the existing base structure by embedding the first heat conduction part within the base and making the base itself thermally conductive. This merging approach integrates thermal management into the structural foundation rather than adding separate, complex cooling systems, thus improving heat dissipation while minimizing structural complexity.
Solution Approach 2:
The base structure serves multiple functions: mechanical support, electrical insulation (through the polymer material), and heat dissipation (through its thermal conductivity). This multi-functionality eliminates the need for separate dedicated heat dissipation structures, maintaining device simplicity while achieving effective thermal management.
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 design enhances the service life and safety of the relay by efficiently dissipating heat and eliminating electric arcs, improving operational reliability and reducing the risk of damage from high temperatures and electrical malfunctions.
Implementation Method 1
the base is made of a polymer thermal conductive material, and the fixed connecting plate has a first heat conduction part and a second heat conduction part for dissipating the heat generated by the electrical connection or disconnection of the movable contact and the fixed contact
Implementation Method 2
the electromagnet is installed on a side of the movable conductive sheet assembly for driving the movable plate, so that the movable contact and the fixed contact form an electrical connection or disconnection due to the electromagnetic effect
Implementation Method 3
capable of cutting the electric arc generated during the operation of the relay and dissipating the heat generated during the operation effectively
Data Source
AI summary
An electromagnetic relay includes a base, at least one fixed conductive sheet assembly, at least one movable conductive sheet assembly, at least one arc blow component, an electromagnet and an outer cap. The fixed conductive sheet assembly includes a fixed connecting plate and a fixed contact, and the movable conductive sheet assembly includes a movable connecting plate and a movable contact. The base is made of a thermal conductive polymer, and the fixed connecting plate has a first heat conduction part installed in the base and a second heat conduction part connected to the first heat conduction part and extended to an outer side of the base. The electromagnetic relay further includes at least two thermal conduction components installed in the base and symmetrically configured on both opposite sides of the fixed and movable contacts respectively for dissipating the heat generated by the electromagnetic relay.