Power relay with plug-in terminals

Abstract

The present application provides a high-capacity relay with a tab terminal, which can achieve miniaturization, reliability improvement or improvement of solderability. In one embodiment, it comprises: (1) a contact opening and closing unit comprising at least one movable contact and at least one fixed contact; (2) an opening and closing drive unit that brings the movable contact into contact with or away from the corresponding fixed contact; (3) at least two pairs of input and output tab terminals electrically connected to at least one pair of input and output terminals of the contact opening and closing unit; and (4) a pair of control tab terminals electrically connected to the control terminals of the opening and closing drive unit, (5) two input and output tab terminals electrically connected to the respective input and output terminals, which are arranged in close proximity to each other in the thickness direction, (6) the thickness and width of the input and output tab terminals and the control tab terminals are the same or at the same level.

Description

Technical Field

[0001] This invention relates to a power relay with tab terminals as input and output terminals. It particularly relates to high-capacity (e.g., 100V and above and 10A and above) power relays for fast charging of electric vehicles, various energy storage systems, elevators, industrial robots, and other applications. Background Technology

[0002] Flat, quick-connect terminations (IEC 60760 Flat) achieve electrical connection by inserting into a cable or socket with a socket (connector) at the front end. High-capacity power relays with flat terminations are used, for example, in electric vehicles and non-electric vehicles, in which case the flat terminations are basically in accordance with the ISO TS 16949 standard.

[0003] Such high-capacity power relays typically have a four-pole (SPST; 1a) or five-pole (SPDT; 1c) terminal arrangement. Two of the terminals are for control circuitry (coil terminals), and the remaining terminals are for power input / output. For example, patent documents 1 and 2 show examples of four-pole power relays.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2019-117810

[0005] Patent Document 2: Japanese Patent Application Publication No. 2020-174006

[0006] For the plug-in terminals of power relays, in order to cope with further increases in capacity, it is necessary to increase the cross-sectional area of ​​the plug-in terminals by increasing their width and thickness. This is because: if the current increases, the heat generated increases exponentially. Therefore, in order to ensure the reliability of the plug-in terminal connection, it is necessary to reduce the resistance and heat generation of the terminal connection.

[0007] However, in this case, the product size may also increase due to the increase in terminal size. Summary of the Invention

[0008] In a preferred embodiment, the power relay with plug-in terminals includes: (1) a contact opening / closing portion having at least one movable contact and at least one fixed contact; (2) an opening / closing drive portion that causes the movable contact to contact or move away from the corresponding fixed contact; (3) at least two pairs of input / output plug-in terminals electrically connected to at least one pair of input / output terminals of the contact opening / closing portion; and (4) a pair of control plug-in terminals electrically connected to control terminals of the opening / closing drive portion; (5) two input / output plug-in terminals electrically connected to each input / output terminal, the two input / output plug-in terminals being arranged close to each other in a manner that they are arranged in their thickness direction; and (6) the thickness and width of the input / output plug-in terminals and the control plug-in terminals are the same or at the same level.

[0009] Here, the same level can be set as follows: even if there is a difference in the size of the two, the difference based on the smaller size is less than 20%, less than 15%, less than 10%, or less than 5%.

[0010] In a preferred embodiment, each input / output terminal and the two input / output plug terminals electrically connected thereto are formed from a "コ"-shaped terminal component, which can be obtained from a sheet of metal by bending. Preferably, a portion of the "コ"-shaped terminal component constitutes the fixed contact.

[0011] In a preferred embodiment, the rated current is greater than 30A, for example, 35 to 100A, and the thickness of each input / output plug-in terminal is less than 1mm, for example, 0.5 to 0.9mm, and the width is less than 7mm, for example, 5 to 7mm.

[0012] In a preferred embodiment, the opening / closing drive unit includes a plunger, and the working end of the plunger has a conductive movable terminal portion. The movable terminal portion has two movable contacts, and when the movable contacts are in contact with the corresponding fixed contacts, the two input / output plug terminals are electrically connected to each other.

[0013] According to the preferred embodiment, at least any one of the following effects (i) to (ii) can be obtained.

[0014] (i) It can save space by setting up insert terminals, thereby enabling product miniaturization.

[0015] (ii) It can provide stable power supply with a large capacity. Attached Figure Description

[0016] Figure 1This is a perspective view showing the power relay of the embodiment, its plug terminals, and the socketed cable connected to the plug terminals.

[0017] Figure 2 It is a perspective perspective view showing a pair of "コ"-shaped terminal parts and the main parts in their vicinity.

[0018] Figure 3 Is with Figure 1 The same perspective view shows a typical existing relay and its plug terminals.

[0019] Figure 4 This is done while the cable is connected. Figure 2 Existing power relays and Figure 1 A pair of perspective views of the power relays in the embodiment of the present invention are shown for comparison.

[0020] Symbol Explanation

[0021] 1-1~1-4…First to fourth input / output plug-in terminals; 10…Power relay according to the embodiment; 100…Conventional power relay; 11…First input / output terminal section; 12…Second input / output terminal section; 11'…First input / output plug-in terminal; 12'…Second input / output plug-in terminal; 13…Terminal forming surface; 14…Housing; 2-1~2-2…Control plug-in terminals; 3-1~3-4, 3-1', 3-2'…Input / output cables; 31…Socket; 32…Resin cover; 35-1~35-2…Control cables; 4-1~4-2…“ko” shaped terminal components; 41…Fixed contact; 5…Modible terminal section; 51…Modible contact; 6…Plug; Z1…Front-back direction. Detailed Implementation

[0022] use Figures 1-2 The power relay of the embodiments of this application will be described.

[0023] Figure 1 This is a perspective view showing the power relay of the embodiment, its plug terminals, and the socketed cable connected to the plug terminals. Figure 2 It is shown Figure 2 A perspective view of the main components of a power relay, particularly showing a pair of "コ"-shaped terminal parts and their vicinity. Figure 2 The shape of the terminals was changed. Figure 3 Is with Figure 1 The same perspective view shows a typical existing relay and its plug terminals. Figure 4 This is done while the cable is connected. Figure 3 Existing power relays and Figure 1A pair of perspective views of the power relays in the embodiment of the present invention are shown for comparison.

[0024] The terminal forming surface (upper surface in the figure) 13 of the power relay 10 has four input / output plug-in terminals 1-1 to 1-4 and two control plug-in terminals 2-1 to 2-2. For ease of explanation, with the upper left side designated as the left side and the lower right side designated as the right side in each figure, the input / output plug-in terminals 1-1 to 1-4 are arranged close to the left edge of the rectangular terminal connection surface, and the control plug-in terminals 2-1 to 2-2 are arranged close to the right edge. The terminal faces of the input / output plug-in terminals 1-1 to 1-4 all extend in the direction along the right edge, i.e., the front-back direction Z1. Furthermore, the terminal faces of the control plug-in terminals 2-1 to 2-2 extend in the direction along the front-back edge, i.e., the left-right direction. It should be noted that the front-back, left-right, and up-down directions here are irrelevant to the actual configuration in use.

[0025] The first input / output (I / O) connectors 1-1 to 1-4 are arranged in pairs, close to each other in the thickness direction. Specifically, the first I / O connectors 1-1 and 1-2 are arranged close to each other in their thickness direction, forming the first I / O terminal section 11. Furthermore, the third I / O connectors 1-3 and 1-4 are arranged close to each other in their thickness direction, forming the second I / O terminal section 12. The first I / O terminal section 11 and the second I / O terminal section 12 are arranged along the left side of the terminal forming surface 13 in the front-rear direction Z1.

[0026] The first input / output plug-in terminals 1-1 and 1-2, constituting the first input / output terminal section 11, are electrically connected to each other inside the housing 14 of the power relay 10. Similarly, the third input / output plug-in terminals 1-3 and 1-4, constituting the second input / output terminal section 12, are electrically connected to each other inside the housing 14 of the power relay 10. That is, two sets of input / output plug-in terminals 1-1 to 1-2 and 1-3 to 1-4, which are close to each other in the thickness direction of the plug-in terminals, are connected to each other. In other words, the four input / output plug-in terminals 1-1 to 1-2 and 1-3 to 1-4 are connected in pairs to form the first input / output terminal section 11 and the second input / output terminal section 12.

[0027] The four input / output cables 3-1 to 3-4 are connected to the four input / output terminals 1-1 to 1-4 through their respective front-end sockets 31. Furthermore, the sockets 31 are covered with insulating resin covers 32.

[0028] like Figure 1As shown, each pair of input / output plug terminals 1-1 to 1-2 and 1-3 to 1-4 constituting the first input / output terminal section 11 and the second input / output terminal section 12 are separated from each other by a spacing that allows for the placement of the socket 31 and the resin cover 32. This spacing can be the limit to which they can be configured, or it can be configured with some clearance.

[0029] like Figure 2 As shown, each pair of input / output plug terminals 1-1 to 1-2 and 1-3 to 1-4 is formed by a "コ"-shaped terminal component 4-1 to 4-2. The "コ"-shaped terminal components 4-1 to 4-2 are formed by bending a long strip of thick metal plate into a "コ" shape. Furthermore, Figure 2 In the design, the input / output plug-in terminal 1 is depicted as tapering at the front end, and in high-capacity power relays, this is preferably the case. Figure 1 The shape shown.

[0030] And, as Figure 2 As shown, in the two "コ"-shaped terminal components 4-1 to 4-2 arranged in a front-to-back pattern, a fixed contact 41 is formed on the lower end face (the face facing the inside of the power relay 10). Movable contacts 51 are respectively arranged opposite each other from below on the two fixed contacts 41 arranged in the front-to-back direction Z1. The two movable contacts 51 arranged in the front-to-back direction Z1 are formed on the upper surfaces of both ends of a movable terminal portion 5, which is made of a metal plate that is longer in the front-to-back direction Z1. This movable terminal portion 5 is driven up and down by a plunger 6 to perform contact opening and closing operations.

[0031] like Figure 2 As shown, the two "コ"-shaped terminal parts 4-1 to 4-2 are identical in shape and size. Furthermore, as... Figure 1 Specifically, the first input / output plug-in terminals 1-1 to the fourth input / output plug-in terminals 1-4 have the same shape and size, and the two control plug-in terminals 2-1 to 2-2 also have the same shape and size.

[0032] Therefore, as Figure 1 As shown, for the input / output cables 3-1 to 3-4 that are connected to the input / output plug terminals 1-1 to 1-4 respectively, the same type and size of the plug 31 used for the control cables 35-1 to 35-2 that are connected to the control plug terminals 2-1 to 2-2 respectively can be used. Therefore, for each plug terminal 1, 2, the crimping operation for terminal connection and the soldering operation when necessary can be performed efficiently through the same operation.

[0033] In a specific example, the width of the insert terminals 1 and 2 in the power relay 10 of the embodiment is 6.3 mm, the thickness is 0.8 mm, and the cross-sectional area is 5.04 mm². 2It can handle a rated current of 30A. Therefore, each input / output terminal section 11 to 12, consisting of two sets (two strings) of input / output plug-in terminals 1-1 to 1-2 and 1-3 to 1-4, can handle a rated current of 60A. Furthermore, the minimum spacing between the paired input / output plug-in terminals 1 (the distance between the two strings) can be reduced to 6.5mm.

[0034] Figure 3 The text shows that it has the same characteristics as... Figure 1 The power relay 100 is of the same capacity (rated control capacity = rated current × rated voltage) as the existing power relay 100 in the embodiment. Control terminals 2-1 to 2-2 are connected to... Figure 1 The implementation method is the same.

[0035] The existing power relay 100 has input / output terminals, each consisting of an input / output blade terminal 11' or 12'. The dimensions of these input / output blade terminals 11' and 12' are larger than the dimensions of the control blade terminals 2-1 to 2-2. In a specific example, the input / output blade terminals 11' and 12' in the existing power relay 100 are both 9.5 mm wide, 1.2 mm thick, and have a cross-sectional area of ​​11.4 mm². 2 It can handle a rated current of 60A.

[0036] Figure 4 The text lists existing examples and implementations of power relays with the same rated current and rated control capacity, side by side. For example... Figure 4 As shown, input / output plug terminals 1, 11', and 12' are arranged along the left edge of the terminal forming surface 13 such that the terminal surface is arranged in the front-rear direction Z1. Therefore, compared with the width of the input / output plug terminals 11' and 12' of the power relay 10 in the prior art, the width of the input / output plug terminal 1 of the power relay 10 in this embodiment is smaller. As a result, the size in the front-rear direction Z1 required for arranging the above-mentioned input / output plug terminals and connecting them to the cable socket 31 can be reduced. Furthermore, according to the embodiment of this application, as Figure 4 As schematically shown, the other structures are the same; if the dimensions in the longitudinal direction Z1 can be reduced, the dimensions of the power relay in the longitudinal direction Z1 can be reduced.

Claims

1. A power relay comprising insert terminals, characterized in that, have: The contact opening and closing part has two movable contacts and two fixed contacts. The two movable contacts are arranged in the front-back direction and formed on the upper surface of both ends of the movable terminal part, which is made of a metal plate that is longer in the front-back direction. The conductive movable terminal portion has two movable contacts at its working end; An opening / closing drive unit that causes the movable contact to contact or move away from the corresponding fixed contact; Two pairs of input / output plug-in terminals are electrically connected to a pair of input / output terminals of the contact opening and closing part. Each pair is formed by a "コ"-shaped terminal component. The "コ"-shaped terminal component can be obtained by bending a metal plate. It is formed by bending a long strip of thick metal plate into a "コ" shape. The two ends of the "コ"-shaped terminal component constitute two input / output plug-in terminals. The outer end face of the part of the "コ"-shaped terminal component that connects the two ends is formed with the fixed contact. There are two "コ"-shaped terminal components arranged in the front-back direction. Each of them has only one fixed contact formed on its lower end face. The two "コ"-shaped terminal components have the same shape and size. A pair of control plug terminals, electrically connected to the control terminals of the opening / closing drive unit; and case, The opening / closing drive unit includes a plunger, and the working end of the plunger has a conductive movable terminal portion. The movable terminal portion has two movable contacts. When the movable contacts contact the corresponding fixed contacts, the two pairs of input / output plug terminals are electrically connected to each other. The two input / output plug-in terminals are electrically connected to each of the input / output terminals, and the two input / output plug-in terminals are arranged close to each other in a thickness direction that intersects the arrangement direction of the two pairs of input / output plug-in terminals. The thickness and width of the input / output plug-in terminals and the control plug-in terminals are all the same or at the same level. Each pair of input / output plug terminals is electrically connected to each other inside the housing. Each of the aforementioned input / output plug terminals can be connected to the corresponding input / output cable.

2. The power relay according to claim 1, characterized in that, The rated current is greater than 30A, and the thickness of each input / output plug-in terminal is less than 1mm and the width is less than 7mm.

3. The power relay according to claim 1, characterized in that, The fixed contacts are arranged in two along the front-to-back direction, and the movable contacts are respectively arranged opposite each other from below.

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