Tilted contactor mounting for electrical relay

Abstract

An electrical relay system with tilted contactor mounting. The system may include a housing including a first circuit and a second circuit; a relay may be disposed within the housing and configured to move the contactor between a closed position and an open position to connect and disconnect the first and second circuits, respectively. The contactor may be tilted relative to the vertical axis or any specified axis such that the contactor moves in a tilted manner relative to the vertical axis or any specified axis.

Description

Cross Reference to Related Applications

[0001] This application claims priority to U.S. Provisional Application No. 63 / 502,458, filed May 16, 2023, and U.S. Provisional Application No. 63 / 508,800, filed June 16, 2023, the entire contents of which are hereby incorporated by reference herein.

[0002] INTRODUCTION The present disclosure relates to electrical relays having tilted contactor mounting, such as but not necessarily limited to electrical relays having movable contactors configured to facilitate high power electrical connections between circuits within a junction box or other device.

[0003] The commonly used type of electrical relays in junction boxes, battery control modules, battery disconnect units, or other devices can include a contactor assembly configured to move between closed and open positions to connect and disconnect two or more circuits, respectively. Electrical relays can need to operate according to various requirements, which can vary depending on the use, application, environment, or other factors accompanying the devices, circuits, etc. associated therewith. For electrical relays used in electric or other vehicles that need to selectively connect and disconnect low and / or high power circuits, the relays must operate as designed and / or as specified. For example, the Society of Automotive Engineers (SAE) and the International Organization for Standardization (ISO) have established standards or compliance requirements for electronic equipment environmental performance testing, which can include vibration, shock, and / or load testing standards to ensure that electronic components can withstand forces expected to be encountered during vehicle operation, see, e.g., SAE J1378 and / or ISO 16750-3. While the present disclosure is not intended to be limited to particular standards, specifications, or the like, it contemplates that electrical relays need to meet crash, shock, or vibration requirements, and / or operate properly under different load conditions. The need for relays to comply with design, standard, or other requirements can require that the relays be constructed such that the relays can need stronger, larger, or more expensive materials, components, constructions, designs, etc. when faced with meeting higher or more stringent requirements that increase cost, size, weight, etc. SUMMARY

[0004] One aspect of the present disclosure relates to an electrical relay that can meet higher or more stringent crash, vibration, shock, load, or other operational requirements in a manner that minimizes or limits corresponding increases in materials, components, construction, design, etc. This can be achieved by configuring the relay within a tilted contactor, contactor assembly, or other element portion that enables a movable contact to move relative to an actuation axis (axis of the relay shaft) between engaged and disengaged positions, the actuation axis being tilted, canted, or otherwise angled relative to any axis, using for simplicity the vertical axis of the associated junction box, battery control module, battery disconnect unit, vehicle, or other device. This tilted movement or manner of movement relative to the vertical axis can be beneficial for compliance with higher or more stringent crash, shock, vibration, load, or other operational requirements, and / or to provide a more robust configuration in a manner that minimizes or limits corresponding increases in materials, components, construction, design, etc. The improved performance and / or compliance can result from the tilted movement diverting, deflecting, or minimizing forces applied along the vertical axis away from and / or limiting their impact on the contactor and / or other components of the electrical relay, which in turn can allow the electrical relay to meet higher crash, vibration, shock, load, or other operational requirements than the contactor or the like would if operated with an actuation axis parallel to the vertical axis.

[0005] One aspect of the present disclosure relates to an electrical relay system for a vehicle. The electrical relay system can include a housing including a first circuit and a second circuit; and a relay disposed within the housing and configured for movement between an open position and a closed position, optionally the closed position electrically connecting the first circuit with the second circuit and the open position electrically disconnecting the first circuit from the second circuit. The relay can include a contactor assembly having a first stationary contact and a second stationary contact and a movable contact; a shaft assembly having a contact spring, a linear shaft, a return spring, a moving armature, and a stationary armature; a coil assembly having a coil and a bobbin; and a shaft assembly having a yoke and a yoke ring. A centerline of the relay defined along an actuation axis of the linear shaft can be tilted at a tilt angle relative to a vertical axis of the vehicle, optionally the tilt angle being less than 90 degrees, such that the linear shaft moves in a tilted manner relative to the vertical axis.

[0006] The electrical relay system can include a mounting bracket connected between the housing and the relay, optionally the mounting bracket configured to tilt the relay according to the tilt angle.

[0007] The electrical relay system can include the mounting bracket being configured to orient the bottom surface of the relay perpendicular to the actuation axis.

[0008] The electrical relay system can include the mounting bracket being attached to the bottom surface of the relay.

[0009] The electrical relay system can include the mounting bracket being wedge-shaped, optionally having a vertical surface, a horizontal surface, and a sloped surface extending between the vertical surface and the horizontal surface, and the mounting bracket orienting the bottom surface parallel to the sloped surface.

[0010] The electrical relay system can include a bottom surface area of the bottom surface matching a sloped surface area of the sloped surface.

[0011] The electrical relay system can include the mounting bracket including fasteners and / or adhesive to secure the bottom surface to the sloped surface.

[0012] The electrical relay system can include the mounting bracket being attached between a side of the housing and a side of the relay, optionally the side of the housing being parallel to the vertical axis.

[0013] The electrical relay system can include a mounting bracket connected between the housing and a support structure and / or device of the vehicle external to the housing, optionally the mounting bracket being configured to tilt the housing according to the tilt angle.

[0014] The electrical relay system can include the mounting bracket being wedge-shaped, optionally having a vertical surface, a horizontal surface, and a sloped surface extending between the vertical surface and the horizontal surface.

[0015] The electrical relay system can include a mounting bracket connected between the housing and the relay or between the housing and a support structure and / or device of the vehicle, optionally the mounting bracket being configured to tilt the housing or relay according to the tilt angle such that the first stationary contact and the second stationary contact are oriented parallel or perpendicular to the actuation axis.

[0016] The electrical relay system can include the first stationary contact connected to the first electrical circuit, the second stationary contact connected to the second electrical circuit, and the movable contact movable along the actuation axis such that the movable contact engages the first stationary contact and the second stationary contact when in the closed position and disengages the first stationary contact and the second stationary contact when in the open position.

[0017] The electrical relay system can include a mounting bracket having a sloped surface attached to the relay, optionally the sloped surface tilting the relay within the housing according to the tilt angle.

[0018] The electrical relay system can include a mounting bracket attached to an outer surface of the housing, wherein the mounting bracket is wedge-shaped, optionally having a vertical surface, a horizontal surface, and a sloped surface extending between the vertical surface and the horizontal surface, and / or the sloped surface is attached to the outer surface in a parallel manner to tilt the housing according to the tilt angle.

[0019] One aspect of the present disclosure relates to an electrical relay system. The electrical relay system can include a housing including a first circuit and a second circuit, optionally the housing shaped to include a vertical axis, a longitudinal axis, and a transverse axis, wherein the vertical axis is perpendicular to the longitudinal axis and the transverse axis. The electrical relay system can include a relay disposed within the housing and configured for movement between an open position and a closed position, optionally the closed position electrically connecting the first circuit with the second circuit, the open position electrically disconnecting the first circuit from the second circuit. The relay can include a first stationary contact connected to the first circuit, a second stationary contact connected to the second circuit, and a movable contact operable between an engaged position and a disengaged position, optionally the engaged position resulting from the movable contact engaging the first stationary contact and the second stationary contact to establish an electrical connection therebetween when the relay is in the closed position, and the disengaged position resulting from the movable contact disengaging the first stationary contact and the second stationary contact to break the electrical connection when the relay is in the open position. The electrical relay system can include a mounting element connected between the housing and the relay, optionally the mounting element configured to tilt the relay relative to the vertical axis such that an actuation axis of the movable contact follows a tilt angle that is tilted from the vertical axis.

[0020] The electrical relay system can include the mounting element being wedge-shaped, optionally having a vertical surface, a horizontal surface, and a sloped surface extending between the vertical surface and the horizontal surface, and / or the mounting element attached to a bottom surface or a side surface of the relay.

[0021] The electrical relay system may include: the mounting element attached between the side of the housing and the side of the relay, optionally, the side of the housing being parallel to the vertical axis.

[0022] The electrical relay system may include: the tilt angle relative to the vertical axis is less than 90 degrees.

[0023] One aspect of this disclosure relates to an electrical relay system for a vehicle. The electrical relay system may include a housing having a first circuit and a second circuit; and a plurality of relays disposed within the housing and configured to move between an open position and a closed position. Each relay may include: a first fixed contactor; a second fixed contactor; and a movable contactor operable between an engaged position and a disengaged position, optionally generated by the movable contactor engaging with the first and second fixed contactors to establish an electrical connection therebetween when the relay is in the closed position, and by the movable contactor disengaging from the first and second fixed contactors to disconnect the electrical connection when the relay is in the open position. The electrical relay system may include a mounting element connected between the housing and the vehicle, optionally configured to tilt the housing relative to the vertical axis of the vehicle such that the actuation axis of each of the movable contacts follows an angle of inclination relative to the vertical axis.

[0024] The electrical relay system may include a mounting bracket attached to an outer surface of the housing and a support structure of the vehicle, wherein the mounting bracket is wedge-shaped and optionally has a vertical surface, a horizontal surface, and an inclined surface extending between the vertical surface and the horizontal surface, wherein the inclined surface is attached to the outer surface to tilt the housing according to the inclined angle. Attached Figure Description

[0025] The accompanying drawings, which may be incorporated into and form part of this specification, illustrate specific embodiments of the present disclosure and, together with the specification, serve to explain the principles of the present disclosure.

[0026] Figure 1 A schematic diagram of an electrical system according to one aspect of this disclosure is shown.

[0027] Figure 2 A schematic diagram of a power switch system having one or more relays with contactors mounted at an angle, according to one aspect of this disclosure, is shown.

[0028] Figure 3A cross-sectional schematic diagram of a relay in the off position according to one aspect of this disclosure is shown.

[0029] Figure 4 A cross-sectional schematic diagram of a relay in the closed position according to one aspect of this disclosure is shown.

[0030] Figure 5 The force on a tilt relay, one aspect of this disclosure, is illustrated in schematic form.

[0031] Figure 6 A schematic cross-sectional view of a junction box according to one aspect of this disclosure is shown.

[0032] Figure 7 A schematic diagram of a wedge-shaped mounting bracket according to one aspect of this disclosure is shown.

[0033] Figure 8 A schematic diagram of a wedge-shaped mounting bracket supporting multiple relays according to one aspect of this disclosure is shown.

[0034] Figure 9 A schematic diagram of a wedge-shaped mounting bracket supporting multiple relays according to one aspect of this disclosure is shown.

[0035] Figure 10 A schematic diagram showing a junction box that is tilted according to one aspect of this disclosure is shown. Detailed Implementation

[0036] As requested, detailed embodiments of this disclosure are disclosed herein; however, it should be understood that the disclosed embodiments are merely examples of this disclosure that may be embodied in various alternative forms. The drawings are not necessarily drawn to scale; some features may be enlarged or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for instructing those skilled in the art to apply this disclosure in different ways.

[0037] Figure 1A schematic diagram of an electrical system 10 according to one aspect of this disclosure is shown. System 10 is intended as an example of various electrical systems, networks, circuit connections, etc., in which one or more relays 12A, 12B, 12C can be used to selectively connect and disconnect two or more circuit connections 14A, 14B, 14C, 16A, 16B, 16C, collectively referred to as 12, 14, 16 for simplicity. For non-limiting purposes, circuit connections 14, 16 are shown as corresponding to high-power circuits for facilitating an electrical connection between an energy source 18 and a load 20. For example, if used in a vehicle, the energy source 18 may correspond to a battery, a rechargeable energy storage system (RESS), or other power source for providing power to a high-voltage (HV) bus, such as a bus connected to an electric motor for propulsion or other load 20. Relay 12 may include contactors 22A, 22B, 22C mounted in an angled orientation and configured to selectively connect and disconnect circuit connections 14, 16. Contactor 22 can be tilted to best meet operational requirements while minimizing or limiting the use of more robust, larger, or more expensive materials, components, structures, designs, etc. Relay 12 can be included as part of a junction box, battery control module, battery disconnect unit, or other device 24 that may include additional components, circuitry, etc., such as within its housing 26, to facilitate various operations and processes. While primarily described with respect to relay 12 contained within a vehicle, those skilled in the art will understand that relay 12, or more specifically, the tilting contactor described herein, is advantageous for applications mounted outside of a vehicle.

[0038] Figure 2A schematic diagram of a power switching system 30 with one or more relays 12 having tilted contactors mounted according to one aspect of this disclosure is shown. The power switching system 30 can be configured for use within a vehicle to facilitate selective establishment of electrical connections. A non-limiting aspect of this disclosure contemplates a system including a smart contactor system 32, which may include one or more relays 12 having tilted contactors 22 for facilitating electrical connection and disconnection. The smart contactor system 32 can be used to provide reliable high-voltage, high-power switching capable of meeting stringent requirements for size and weight. System 30 can be integrated to support a variety of features and perform a variety of functions, optionally without relying on external components, including but not limited to current and voltage measurement, temperature measurement, communication, fuse control, and the ability of other relevant features within the vehicle for selectively connecting high-voltage power sources (e.g., batteries) to consumption units (e.g., electric motors). System 30 can operate in conjunction with a battery management controller (BMC) 34 and / or a pyrotechnic fuse 36. For non-limiting purposes, the intelligent contactor system 32, BMC, and / or pyrotechnic fuses 34, 36 are shown as separate devices or components; however, it is entirely conceivable that the BMC 34 and / or pyrotechnic fuse 36 be included in the intelligent contactor system 32, i.e., integrated with the integrated components of the intelligent contactor system 32. The intelligent contactor system 32 may include a power supply unit (PSU) 38, an isolation monitoring module 40, a local safety central processing unit (CPU) 42 operable to measure, sense, or otherwise calculate temperature and / or status, a high voltage (HV) measurement module 44, a current sensing module 46, an overload and short-circuit protection module 48, one or more relays 12 with tilting contactors 22 capable of switching between open and closed states, and / or a pre-charge module 50, optionally, each integrated within a common housing 26.

[0039] The intelligent contactor system 32 can be configured as described in U.S. Provisional Application No. 63 / 502,458, filed May 16, 2023, entitled “Integrated Smart High Voltage Battery Disconnect Unit,” the entire contents of which are incorporated herein by reference. The intelligent contactor system 32 can be configured to operate as a junction box and / or other type of battery disconnect unit (BDU), optionally with an additional BMC and / or pyrotechnic fuse integrated therein. Due to the integrated component portion, the power switching system 30 can be configured to provide high performance (power density, packaging, reliability, etc.) at a relatively low cost. The power switching system may include multiple discrete devices, including contactors, pyrotechnic fuse drivers, current sensors, voltage sensors, temperature sensors, isolation detection, diagnostics, collision signal response circuitry, and / or pre-charge circuitry. Integration into a single device can provide numerous improvements and benefits, including space savings (more compact), weight reduction, simplified parts handling during manufacturing (more compact, more robust, fewer connections required), improved robustness and reliability (fewer faulty connections), improved measurement accuracy (sensors can be closer to the measurement point, shorter cables generate less noise), and / or faster response time (fewer connections, smaller capacity, shorter cables).

[0040] Figure 3 and Figure 4 A cross-sectional schematic diagram of a relay 12 with a tilted contactor mounting according to one aspect of this disclosure is shown. Figure 3 The diagram shows relay 12 in the open, closed, or disengaged positions, and Figure 4The relay 12 is shown in a closed, open, or engaged position. The relay 12 may be housed within the housing 26 of the junction box 24 and is configured to move between an open and closed position. The closed position may correspond to electrically connecting the first circuit 14 to the second circuit 16, while the open position may correspond to electrically disconnecting the first circuit 14 from the second circuit 16. The relay 12 may include: a contactor assembly having a first fixed contactor 60, a second fixed contactor 62, and a movable contactor 64; a shaft assembly having a contact spring 68, a linear shaft 70, a return spring 72, a moving iron core 74, and a fixed iron core 76; a coil assembly having a coil 78 and a winding frame 80; and a shaft assembly having a yoke 82 and a yoke ring 84. Although shown illustratively, the relay 12 may include more or fewer components and / or be configured differently, while providing tilting contactor mounting. A controller or other device (not shown) may operate in conjunction with relay 12 to selectively energize coil 78, thereby moving linear shaft 70 along actuation axis 86, such that movable contactor 6422 is in an engaged position. Figure 4 ) and disengagement position ( Figure 3 Actuation is performed between the movable contactor 6422 and the first and second fixed contacts 60, 62 when the relay 12 is in the closed position. The engaged position is generated when the movable contactor 6422 disengages from the first fixed contactor 60 and the second fixed contactor 62 when the relay 12 is in the open position, thereby disconnecting the electrical connection.

[0041] The centerline of the relay 12, defined by the actuation axis 86 along the linear axis 70, can be tilted at an angle θ relative to the vertical axis (Z direction) 88 of the vehicle or the junction box 24 having the relay 12. The vertical axis 88 can be perpendicular to the longitudinal axis (Y direction) 90 and the transverse axis (X direction) 92, which can in turn be perpendicular to each other, with the longitudinal axis 90 corresponding to the length of the vehicle and the transverse axis 92 corresponding to the width of the vehicle. The tilt angle θ can be less than 90 degrees, allowing the linear axis 70 to move in an inclined manner relative to the vertical axis 88. The relay 12 can be configured as illustrated to meet higher or more stringent requirements for impact, vibration, shock, load, or other operations in a manner that minimizes or limits corresponding increases in materials, components, construction, design, etc. This is possible because the tilt of the relay 12 causes the movable parts to move relative to the actuation axis 86, which is tilted, obliquely inclined, or otherwise tilted relative to the vertical axis 88 of the junction box; and / or because the junction box is also tilted relative to the vehicle or other device. This tilting movement or actuation relative to the vertical axis 88 can be beneficial for improving performance and / or compliance because the tilting movement transfers, deflects, or minimizes the force applied along the vertical axis 88 away from or limits its influence on other components of the movable contactor 6422 and / or the electrical relay 12. This, in turn, allows the electrical relay 12 to meet higher requirements for impact, vibration, shock, load, or other operational conditions than when the movable contactor 6422, etc., operates along another actuation axis parallel to the vertical axis 88. The tilt angle θ can be between the actuation axis 86 and the X-axis 92 or the Y-axis 90, respectively. The above description of the tilt angle θ between the actuation axis 86 and the Z-axis 86 applies to both cases, but it is not necessary to repeat it.

[0042] For example, Figure 5The relay 12, shown as a general block, is tilted in a schematic manner, resulting in a smaller force applied along the actuation axis 86 than when the actuation axis 86 is aligned with the vertical axis 88 (Z direction). The relay 12 can be mounted tilted in the XY plane, XZ plane, or YZ plane, such that the mechanical shocks (acceleration shocks) experienced by the relay 12 can be limited along the + / -X, + / -Y, and + / -Z directions, respectively. For example, in an electric vehicle (EV) battery pack of a vehicle or other device, the relay 12 may be subjected to shocks of 60g, 90g, 150g, or higher. To meet the operational requirements under these and other higher mechanical shocks, the return spring force can be increased; however, this increase also leads to increased coil power, resulting in higher energy consumption and larger components. These increases may increase cost, weight, and energy consumption, and may limit the short-circuit current and / or levitation capability of the movable contacts. Due to its tilted or angled installation, the relay 12 envisioned herein can meet operational requirements for higher mechanical shocks (such as 60g, 90g, 150g, etc.) without increasing the return spring force. In other words, when installed in the manner described above, i.e., the actuation axis of the linear shaft (e.g., a plunger) is tilted, shown as tilted approximately 45 degrees relative to the Z direction or other impact direction, the amount of force on the linear shaft and / or other components moving parallel to the actuation axis 86 can be reduced compared to those components aligned with or parallel to the vertical axis 88. By decomposing 150g along the Z or Y direction onto the actuation axis 86 or direction, approximately 106g can be applied in the direction of the linear shaft, instead of the full 150g. The relay 12 or its components can be tilted at angles other than 45 degrees, such as larger or smaller angles depending on the desired reduction in force. Therefore, the tilt of the relay 12 and / or the junction box having the relay 12, relative to the case where the movable contactor 6422 and / or the junction box is upright, flat or otherwise not tilted, can help to redirect or redistribute the mechanical shocks and / or forces applied thereto.

[0043] Figure 6A schematic cross-sectional view of a junction box 24 according to one aspect of this disclosure is shown. This view shows a portion of the junction box 24, wherein a relay 12 is available for connecting and disconnecting a first circuit connection 14 and a second circuit connection 16. For illustrative purposes, additional components that may be additionally included within the associated junction box 24 are shown and are not labeled to indicate additional circuit connections 14, 16, devices, elements, etc. The relay 12 may be disposed within the housing 26 such that an actuation axis 86 may be inclined at an angle θ relative to a vertical axis 88. The junction box 24 may be rectangular, or otherwise configured such that the vertical axis 88 corresponds to or is parallel to a side or sidewall of the housing 26, and / or, due to the generally vertical orientation of the additional components relative to the inclined relay 12, these components may be considered vertically aligned or parallel to the vertical axis 88. One aspect of this disclosure envisions the junction box 24 being disposed within a vehicle in the manner shown such that the bottom surface 96 of the junction box 24 may be parallel to or coplanar with the X-axis 90 and the Y-axis 92.

[0044] Mounting bracket 98 may be connected between housing 26 and relay 12 and configured to tilt relay 12 according to the indicated tilt angle θ. Mounting bracket 98 may be configured to orient the bottom surface 100 of relay 12 perpendicular to actuation axis 88. Mounting bracket 98 may include fasteners and / or adhesives 102 configured to attach to the side 104 of housing 26 and the side of relay 12. Mounting bracket 98 is shown as having a single connection to junction box 24; however, additional connections, flanges, etc., may also be used to maintain the tilt angle θ. The ends or contactor portions of busbars, lines, or other connections used to engage the first fixed contactor 60 and the second fixed contactor 62 may similarly be tilted and / or programmed to match the tilt orientation. The illustrated mounting bracket 98 is intended as an example of various supports, brackets, etc., that may be used to connect relay 12 to housing 26, or optionally to other components within housing 26, such that relay 12 is held in a tilt orientation. The relay 12 is shown resting against and / or near the side 104 of the housing 26; however, the size, shape, etc. of the mounting bracket 98 and / or its additional components may be designed to provide a freestanding or independent support device for tilting the relay 12.

[0045] Figure 7 A schematic diagram of a wedge-shaped mounting bracket 98 according to one aspect of this disclosure is shown. The wedge shape may be characterized in that the mounting bracket 98 includes a vertical surface 106, a horizontal surface 108, and an inclined surface 110 extending therebetween. The wedge-shaped mounting bracket 98 may be formed from a single solid material, formed by attaching or molding individual material parts together, or formed in other suitable ways. The wedge-shaped element in...Figure 7 The bottom surface of the inclined surface 110 is shown as configured for mounting or supporting the relay 12, optionally by means of fasteners, adhesives and / or other attachment elements (not shown). The surface area of ​​the inclined surface 110 is shown as larger than the surface area of ​​the bottom surface of the relay 12; however, the size and shape of the mounting bracket 98 may alternatively be designed such that the two surface areas match each other or are substantially equal in size and shape. Figure 8 A schematic diagram of a wedge-shaped mounting bracket 98 supporting a plurality of relays 12 according to one aspect of the present disclosure is shown, wherein one of the relays 12 extends away from the inclined surface 110 and the other is perpendicular to it. Figure 9 A schematic diagram of a wedge-shaped mounting bracket 98 supporting a plurality of relays 12 according to one aspect of the present disclosure is shown, wherein two of the relays 12 extend together away from the inclined surface 110. The ability to mount a plurality of relays 12 in different orientations along the same inclined surface 110 of the mounting bracket 98 may be advantageous in customizing or designing the junction box 24 to accommodate a plurality of inclined relays 12 with a minimal amount of additional brackets 98, fasteners, etc.

[0046] Figure 10 A schematic diagram showing a junction box 114 according to one aspect of this disclosure is shown, in which it is inclined. An external mounting bracket 116, similar to that described above (i.e., a wedge-shaped bracket having a vertical surface, a horizontal surface, and an inclined surface), can be configured to support or attach to the bottom surface of the junction box 114. The junction box 114 shown in Figure 11 may omit the internal mounting bracket 98, i.e., it does not include... Figure 6 The mounting bracket 98 shown, and the junction box 114, can be configured such that one or more relays therein are not tilted, for example, parallel or coplanar with one or more of the sides of the junction box 114 and / or the vertical, longitudinal, and transverse axes of the vehicle or other device. Using the external mounting bracket 116 can help eliminate... Figures 5 to 10 While the internal mounting bracket 98 shown above is required, this disclosure fully envisions the use of multiple mounting brackets 98, 116, such as one or more internal mounting brackets 98 mate with external mounting bracket 116. External mounting bracket 116 can be advantageous as an aftermarket accessory or component suitable for use with existing or previously designed junction boxes, allowing for efficient tilting of the relay 12 therein without redesigning or altering the junction box 24, and / or allowing components of the junction box 24 to be assembled without tilting within it.

[0047] The terms “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components. Where possible, the order of steps, processes, and operations may be changed, and additional or alternative steps may be employed. As used in this specification, the term “or” includes any one and all combinations of the associated listed items. The term “any of…” should be understood to include any possible combination of the referenced items, including “any one” of the referenced items. “A,” “an,” “the,” “at least one,” and “one or more” are used interchangeably to indicate at least one of at least the items. Multiple such items may exist unless the context clearly indicates otherwise. Unless the context (including the appended claims) clearly or explicitly indicates otherwise, all numerical values ​​of parameters (e.g., numerical values ​​of quantities or conditions) should be understood to be modified by the term “about” in all instances, regardless of whether “about” actually appears before the numerical value. Components “configured” to perform the specified function perform the specified function without modification, rather than only having the potential to perform the specified function after further modification. In other words, when explicitly configured to perform a specified function, the described hardware is selected, created, implemented, utilized, programmed, and / or designed specifically for performing that specified function.

[0048] Although various embodiments have been described, this description is intended to be exemplary and not restrictive, and it will be apparent to those skilled in the art that many embodiments and implementations may be within the scope of this disclosure. Unless specifically limited, any feature of any embodiment may be used in combination with or substituted by any other feature or element in any other embodiment. Therefore, this embodiment is not limited except as provided in the appended claims and their equivalents. Furthermore, various modifications and alterations may be made within the scope of the appended claims. While several modes for carrying out many aspects of this teaching have been described in detail, those skilled in the art will recognize that various alternative aspects for practicing this teaching are within the scope of the appended claims. All that is included in the foregoing description or shown in the accompanying drawings should be construed as the entire illustrative and exemplary scope of alternative embodiments, which will be recognized by those skilled in the art as implied in, structurally and / or functionally equivalent to, or otherwise apparent from the included content, and not limited to those embodiments explicitly depicted and / or described.

Claims

1. An electrical relay system for a vehicle, comprising: A housing, the housing including a first circuit and a second circuit; A relay, disposed within the housing and configured to move between an open position and a closed position, the closed position electrically connecting the first circuit to the second circuit, and the open position electrically disconnecting the first circuit from the second circuit, the relay comprising: A contactor assembly having a first fixed contactor, a second fixed contactor, and a movable contactor; A shaft assembly, the shaft assembly having a contact spring, a linear shaft, a return spring, a moving iron core and a fixed iron core; A coil assembly having a coil and a winding frame; and Shaft assembly, the shaft assembly having a yoke and a yoke ring; and The centerline of the relay, defined by the actuation axis along the linear axis, is inclined at a certain angle relative to the vertical axis of the vehicle or any designated axis, wherein the angle of inclination is less than 90 degrees, such that the linear axis moves in an inclined manner relative to the vertical axis or any designated axis.

2. The electrical relay system according to claim 1, further comprising: A mounting bracket is connected between the housing and the relay, wherein the mounting bracket is configured to tilt the relay according to the tilt angle.

3. The electrical relay system according to claim 2, wherein: The mounting bracket is configured such that the bottom surface of the relay is oriented perpendicular to the actuation axis.

4. The electrical relay system according to claim 3, wherein: The mounting bracket is attached to the bottom surface of the relay.

5. The electrical relay system according to claim 4, wherein: The mounting bracket is wedge-shaped, having a vertical surface, a horizontal surface, and an inclined surface extending between the vertical surface and the horizontal surface; and The mounting bracket aligns the bottom surface parallel to the inclined surface.

6. The electrical relay system according to claim 5, wherein: The bottom surface region of the bottom surface matches the inclined surface region of the inclined surface.

7. The electrical relay system according to claim 6, wherein: The mounting bracket includes fasteners and / or adhesives to secure the bottom surface to the inclined surface.

8. The electrical relay system according to claim 2, wherein: The mounting bracket is attached between the side of the housing and the side of the relay, wherein the side of the housing is parallel to the vertical axis.

9. The electrical relay system according to claim 1, further comprising: Mounting brackets are connected between the housing and a support structure and / or device of the vehicle outside the housing, wherein the mounting brackets are configured to tilt the housing according to the tilt angle.

10. The electrical relay system according to claim 9, wherein: The mounting bracket is wedge-shaped, having a vertical surface, a horizontal surface, and an inclined surface extending between the vertical surface and the horizontal surface.

11. The electrical relay system according to claim 1, further comprising: Mounting brackets are connected between the housing and the relay or between the housing and the vehicle's support structure and / or device, wherein the mounting brackets are configured to tilt the housing or the relay according to the tilt angle, such that the first fixed contactor and the second fixed contactor are oriented parallel to or perpendicular to the actuation axis.

12. The electrical relay system according to claim 11, wherein: The first fixed contactor is connected to the first circuit, the second fixed contactor is connected to the second circuit, and the movable contactor is movable along the actuation axis such that the movable contactor engages with the first and second fixed contactors when in the closed position, and disengages from the first and second fixed contactors when in the open position.

13. The electrical relay system according to claim 1, further comprising: Mounting bracket having an inclined surface attached to the relay, the inclined surface causing the relay to tilt within the housing according to the inclined angle.

14. The electrical relay system according to claim 1, further comprising: Mounting brackets are attached to the outer surface of the housing, wherein the mounting brackets are wedge-shaped and have a vertical surface, a horizontal surface, and an inclined surface extending between the vertical surface and the horizontal surface, wherein the inclined surface is attached to the outer surface in a parallel manner to tilt the housing according to the inclination angle.

15. An electrical relay system, comprising: A housing, the housing including a first circuit and a second circuit, the housing being shaped to include a vertical axis, a longitudinal axis and a transverse axis, wherein the vertical axis is perpendicular to the longitudinal axis and the transverse axis; A relay, disposed within the housing and configured to move between an open position and a closed position, the closed position electrically connecting the first circuit to the second circuit, and the open position electrically disconnecting the first circuit from the second circuit, the relay comprising: A first fixed contactor is connected to the first circuit; A second fixed contactor, the second fixed contactor being connected to the second circuit; and A movable contactor operable between an engaged position and a disengaged position, the engaged position being generated by the movable contactor engaging with a first fixed contactor and a second fixed contactor to establish an electrical connection therebetween when the relay is in the closed position, and the disengaged position being generated by the movable contactor disengaging from the first fixed contactor and the second fixed contactor to disconnect the electrical connection when the relay is in the open position; and Mounting elements are connected between the housing and the relay, wherein the mounting elements are configured to tilt the relay relative to the vertical axis such that the actuation axis of the movable contact follows an angle of inclination relative to the vertical axis.

16. The electrical relay system according to claim 15, wherein: The mounting element is wedge-shaped, having a vertical surface, a horizontal surface, and an inclined surface extending between the vertical surface and the horizontal surface; and The mounting element is attached to the bottom or side surface of the relay.

17. The electrical relay system according to claim 15, wherein: The mounting element is attached between the side of the housing and the side of the relay, wherein the side of the housing is parallel to the vertical axis.

18. The electrical relay system according to claim 15, wherein: The tilt angle is less than 90 degrees relative to the vertical axis or any designated axis.

19. An electrical relay system for a vehicle, comprising: A housing, the housing including a first circuit and a second circuit; A plurality of relays, disposed within the housing and configured to move between an open position and a closed position, each relay comprising: First fixed contactor; The second fixed contactor; and A movable contactor operable between an engaged position and a disengaged position, the engaged position being generated by the movable contactor engaging with a first fixed contactor and a second fixed contactor to establish an electrical connection therebetween when the relay is in the closed position, and the disengaged position being generated by the movable contactor disengaging from the first fixed contactor and the second fixed contactor to disconnect the electrical connection when the relay is in the open position; and Mounting elements, connected between the housing and the vehicle, wherein the mounting elements are configured to tilt the housing relative to the vertical axis or any designated axis of the vehicle, such that the actuation axis of each of the movable contacts follows a tilt angle tilted relative to the vertical axis or any designated axis.

20. The electrical relay system according to claim 19, further comprising: Mounting brackets are attached to the outer surface of the housing and the support structure of the vehicle, wherein the mounting brackets are wedge-shaped and have a vertical surface, a horizontal surface and an inclined surface extending between the vertical surface and the horizontal surface, wherein the inclined surface is attached to the outer surface to tilt the housing according to the inclined angle.

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