Electromagnetic Relay Insulation via Injection Molding

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Solution Overview

Problem

Existing electromagnetic relays face insufficient insulation between the yoke and coil, leading to increased risk of breakage and difficulty in assembling, which affects the insulation effect and winding space.

Innovation Solution

An electromagnetic relay design featuring a plastic layer formed by injection molding between the yoke and coil, with a plastic protrusion fixed to the movable contact piece, providing improved insulation without adding complexity to the assembly process and maintaining the winding space.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive tape is used to wrap the coil to increase insulation, then insulation between coil and yoke is improved, but manufacturing complexity increases and risk of wire breakage occurs

Engineering Contradiction:

Improveinsulation between coil and yokeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulating layer is integrated directly into the yoke structure through injection molding, merging the insulating function with the structural component. This eliminates the need for separate adhesive tape wrapping and reduces manufacturing steps while ensuring reliable insulation between the coil and yoke.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

An insulating layer made of plastic material serves as an intermediary between the coil and yoke. This layer is formed by injection molding on the yoke surface, providing electrical insulation while maintaining mechanical strength and avoiding the fragility issues of adhesive tape.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If insulating tape or plastic sheet is inserted between coil and yoke to improve insulation, then insulation effect is improved, but assembly difficulty increases and winding space is reduced

Engineering Contradiction:

Improveinsulation between coil and yokeVSAvoidassembly difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The insulating layer is combined with the yoke as an integrated component formed by injection molding. This eliminates the need for separate insertion steps and reduces assembly difficulty while maintaining adequate winding space since the layer is precisely formed on the yoke surface.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating layer is pre-formed on the yoke surface through injection molding before coil assembly. This preliminary formation ensures proper insulation is already in place, simplifying the subsequent assembly process and eliminating the need for complex insertion operations.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If plastic sheet is inserted to improve insulation, then insulation between coil and yoke is improved, but positional stability deteriorates due to shaking during use or transportation

Engineering Contradiction:

Improveinsulation between coil and yokeVSAvoidpositional stability of insulating component

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The insulating layer is merged with the yoke as an integrated component. This ensures the insulating layer maintains fixed positional relationship with the yoke during use and transportation, eliminating shaking or displacement issues that occur with separately inserted plastic sheets.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plastic insulating layer acts as a stable intermediary component that is firmly attached to the yoke. Its integrated formation ensures positional stability while maintaining the insulation function between the coil and yoke during dynamic conditions.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enhances insulation performance between the yoke and coil, ensures positional accuracy of insulating components, reduces assembly complexity, and maintains the winding space, while preventing stress-induced deformation of the movable contact piece.

Implementation Method 1

the plastic layer is provided between the yoke and the coil in an insulating manner

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

one side of the vertical edge of the yoke facing to the coil is provided with a plastic layer formed by means of injection molding

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS11075044B2Electromagnetic relay

Publication Date: 2021.07.27 XIAMEN HONGFA SIGNAL ELECTRONICS CO LTD

AI summary

An electromagnetic relay includes a movable contact piece, a yoke, and a coil, the coil being provided with an iron core, wherein the yoke is L-shaped, and has a horizontal edge and a vertical edge; the yoke is disposed outside the coil, and the horizontal edge of the yoke is fixedly connected to the bottom of the iron core, and the vertical edge of the yoke is parallel to an axis of the iron core, wherein one side of the vertical edge of the yoke facing to the coil is provided with a plastic layer formed by means of injection molding, the plastic layer is provided between the yoke and the coil in an insulating manner.