Segmented Relay Contact Structure for Lower Heat and Short-Circuit Risk
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Relays face issues with temperature rise, accelerated aging of plastics and insulating materials, difficulty in arc extinguishing due to oxidation corrosion of contacts, and decay of electrical components, leading to reduced reliability and service life.
Innovation Solution
The relay design includes a base with spaced contact areas and a magnetic circuit that drives movable contact pieces to reduce thermal radiation influence between contact parts, enhancing the distance between movable and static contacts and improving the anti-short circuit function, thereby reducing temperature rise and increasing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If contact parts are arranged closer together to reduce device size, then miniaturization is achieved, but temperature rise increases due to thermal radiation between contact parts
Solution Approach 1:
The relay is divided into multiple contact parts (first contact part and second contact part) with distinct contact areas. Each contact part is spatially segmented and arranged in separate regions on the base, allowing thermal radiation from one contact part to be isolated from others. This segmentation enables miniaturization while controlling temperature rise by creating thermal zones.
Solution Approach 2:
The patent arranges contact parts not only in planar separation but also utilizes vertical dimension through the base structure. The first and second contact areas are positioned at different locations on the base, creating three-dimensional spatial distribution that increases thermal distance while maintaining compact overall device volume.
2Temperature
If distance between movable contact and static contact is increased to reduce thermal radiation influence, then temperature rise is reduced, but device complexity increases
Solution Approach 1:
The base structure serves multiple functions: it provides mechanical support for contact parts, establishes spatial separation to reduce thermal radiation, and positions magnetic circuit components. This multi-functionality allows increased contact distance for thermal management without proportionally increasing overall device complexity, as the base integrates multiple roles.
Solution Approach 2:
The magnetic circuit part is positioned in the middle area between contact parts, serving as both a functional component for relay operation and a thermal barrier. This merging of magnetic circuit placement with thermal management strategy reduces the need for additional structural elements, maintaining simplicity while achieving temperature control.
3Reliability
If contact parts are spaced apart to improve arc extinguishing by reducing oxidation corrosion, then reliability is improved, but device volume increases
Solution Approach 1:
The patent creates locally optimized contact environments by positioning contact parts in specific areas of the base with appropriate spacing. Each contact part has its own designated contact area with controlled dimensions and spacing from other contacts. This local quality optimization improves arc extinguishing capability through reduced oxidation corrosion while limiting the overall volume increase by confining spacing requirements to local contact zones rather than requiring uniform expansion throughout the device.
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 effectively reduces temperature rise and improves the reliability and service life of the relay by minimizing thermal radiation effects and maintaining the anti-short circuit function, while also simplifying manufacturing and reducing material costs.
Implementation Method 1
a magnetic circuit part arranged on the middle area of the base, and configured to drive four movable contact pieces of the pair of contact parts through a push rod assembly to move
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A relay includes a base (10) having a first contact area (120), a second contact area (130) and a middle area (110) between the first contact area (120) and the second contact area (130); a pair of contact parts (20) respectively arranged in the first contact area (120) and the second contact area (130); each contact part (20) including two sets of the movable contact part (20a), each set of the movable contact part (20a) including a movable contact piece (210) with a movable contact (221) and a static contact (231) on both ends, two movable contacts (221) corresponding to two static contacts (231) respectively in each contact part (20); and a magnetic circuit part (30) on the middle area (110) of the base (10) for drive four movable contact pieces (210) of the pair of contact parts (20) through a push rod assembly (40) to move, thereby realizing connection or disconnection of the movable contact (221) and the static contact (231).