Relay Structure with Segmented Heat Dissipation and Tracking Resistance
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Solution Overview
Problem
Conventional relays used in automobile circuits suffer from poor heat dissipation, leading to reduced performance and potential damage due to excessive thermal energy generation during operation, making them difficult to install and maintain.
Innovation Solution
A relay structure with a heat dissipation function is designed, featuring fixed metal plates connected to polymeric heat conductors, including a front heat convection portion, middle heat conduction portion, and terminal heat radiation portion, along with tracking resistant plates and magnetic members to enhance thermal management and reduce electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional relay structure is used, then the relay can control the circuit system, but the heat dissipation effect is poor leading to damage and reduced performance
Solution Approach 1:
The fixed connector is divided into multiple fixed metal plates with distinct functional regions: a front heat convection portion, a middle heat conduction portion, and a terminal heat radiation portion. This segmentation allows each region to specialize in a specific heat dissipation mechanism, improving overall thermal management effectiveness.
Solution Approach 2:
The patent extends the heat dissipation function into multiple spatial dimensions by creating a three-dimensional heat dissipation structure. The front heat convection portion interfaces with air for convective cooling, the middle portion conducts heat internally, and the terminal portion radiates heat outward, utilizing different spatial orientations for optimal thermal performance.
2Ease of operation
If conventional relay installation method is used, then the relay can be installed, but it requires screwing which increases operational burden
Solution Approach 1:
The patent replaces the traditional mechanical screw connection system with a direct insertion system. The terminal heat radiation portion of the fixed metal plates serves as both a thermal management component and an electrical connection interface, eliminating the need for separate screw fastening operations.
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 relay structure effectively dissipates thermal energy through convective and radiative means, improving operational efficiency, reducing the risk of damage, and simplifying installation by eliminating the need for screw connections, thereby extending the service life and usability of the relay.
Implementation Method 1
the thermal energy is further conducted to the polymeric thermal conductor through the middle heat conduction portion to be dissipated in a heat conduction manner
Implementation Method 2
thermal energy of the electric arc high-temperature forming region is dissipated through the convective heat dissipation region and the heat convection space in a convective manner
Implementation Method 3
the thermal energy is further radiated through the terminal radiation portion
Implementation Method 4
an electromagnetic effect formed by the electromagnetic unit after electrified drives the movable metal assembly to move
Data Source
AI summary
A relay structure with a heat dissipation function includes fixed metal plates, at least one movable metal assembly, and at least one electromagnetic unit. Each fixed metal plate is connected to a polymeric heat conductor. A tracking resistant plate is provided between the fixed metal plates. The tracking resistant plate is connected to the polymeric heat conductor for blocking a tracking occurred between the polymeric heat conductor and the fixed metal plates. The movable metal assembly is disposed at one side of the metal fixed plats. The movable metal assembly has movable contacts. The electromagnetic unit is disposed at one side of the movable metal assembly.