Electromagnetic Relay Spool Layout for Compact Terminal Insulation

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Solution Overview

Problem

Existing electromagnetic relays face challenges in compactly arranging coil terminals while maintaining adequate insulation between the coil terminal and the contact terminal.

Innovation Solution

The electromagnetic relay design includes a coil terminal with a body portion and a tie-down portion, where the tie-down portion extends forward along the coil, and the spool features a vertical and lateral wall portion to increase the insulation distance between the contact terminal and the coil terminal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the tie-down portion extends from the body portion toward the contact terminal to compactly arrange the coil terminal, then the compactness is improved, but the insulation distance between the coil terminal and the contact terminal is reduced

Engineering Contradiction:

Improvecompactness of coil terminal arrangementVSAvoidinsulation between coil terminal and contact terminal

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The spool acts as an intermediary structure between the coil terminal and the contact terminal. By incorporating insulating wall portions (vertical wall portion and lateral wall portion) into the spool, the design introduces an intermediate insulating barrier that maintains adequate insulation distance even when the tie-down portion extends forward along the coil for compact arrangement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spool's wall portions extend the insulation path in multiple spatial dimensions. The vertical wall portion provides insulation in the vertical direction, while the lateral wall portion extends the insulation path laterally, effectively increasing the total insulation distance without requiring additional linear space between components.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If the tie-down portion is disposed to extend from the body portion toward the contact terminal, then the coil terminal can be compactly arranged with the coil, but the distance between the coil terminal and the contact terminal is shortened

Engineering Contradiction:

Improvearrangement complexity of coil terminal and coilVSAvoidinsulation distance between coil terminal and contact terminal

Core Design Contradiction:

Device complexityVSLength of stationary object

Solution Approach 1:

The spool serves as a mediating structure that allows the tie-down portion to extend forward for compact arrangement while simultaneously providing insulating wall portions that maintain the required insulation distance. This mediator enables both compact arrangement and adequate insulation to coexist.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spool's wall portions function as thin film-like insulating barriers that effectively increase the insulation path length without significantly increasing the overall device volume. The lateral wall portion, in particular, extends the insulation path in a space-efficient manner.

Inventive Principle:

Principle #30Flexible shells and thin films

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 allows for compact arrangement of the coil terminal while significantly improving the insulation between the contact terminal and the coil terminal, enhancing the relay's operational reliability.

Implementation Method 1

an electromagnetic relay includes a coil, a first contact terminal, a second contact terminal, a coil terminal, and a spool

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250046555A1Electromagnetic relay

Publication Date: 2025.02.06 OMRON CORP

AI summary

An electromagnetic relay includes a coil, a first contact terminal, a second contact terminal, a coil terminal, and a spool. The first contact terminal is disposed in front of the coil. The second contact terminal is disposed behind the coil. The coil terminal includes a body portion and a tie-down portion. The body portion is disposed between the first contact terminal and the second contact terminal. The tie-down portion extends forward from the body portion along the coil. The spool is disposed between the first contact terminal and the second contact terminal. The spool includes a front flange and a rear flange. The front flange includes a vertical wall portion and a lateral wall portion. The vertical wall portion is located between the first contact terminal and the tie-down portion. The lateral wall portion is bent relative to the vertical wall portion and extends forward from the vertical wall portion.