High-voltage direct-current relay with coil terminal module

Abstract

The invention relates to the technical field of electrical elements, and discloses a high-voltage direct-current relay with a coil terminal module, which comprises a shell, a contact system, an arc extinguishing system, the coil terminal module and a yoke assembly, the iron core is arranged in the framework, the winding is wound on the framework, the control panel assembly is connected with the framework, a terminal of the winding is electrically connected with the control panel assembly, and the iron core is used for being connected with a contact system; the yoke assembly is arranged in the shell and comprises a U-shaped yoke and a flat yoke, the flat yoke is connected with the upper end of the framework, one end of the U-shaped yoke is located on the outer side of the control panel assembly and matched with the control panel assembly in a positioning mode, and the two ends of the U-shaped yoke are fixedly connected with the flat yoke. And the production efficiency and the reliability of the high-voltage direct-current relay are improved.

Description

Technical Field

[0001] This invention relates to the field of electrical components technology, and in particular to a high-voltage DC relay with a coil terminal module. Background Technology

[0002] High-voltage DC relays, as key electrical components for reliable switching and isolation protection under high voltage and high current conditions, are widely used in core areas such as new energy vehicles, energy storage systems, rail transit traction converters, and ultra-high-voltage DC transmission projects. Their performance directly determines the operational safety, stability, and service life of downstream equipment. With the deepening of the global energy transition, the demand for new energy vehicle fast-charging piles and grid-based energy storage has exploded, driving the continuous growth of the high-voltage DC relay market. The domestic market size is projected to reach 68 billion yuan in 2026, with demand in the new energy vehicle sector growing by 25% year-on-year. The market is placing more stringent demands on product capacity, precision, reliability, and cost control, making traditional production models inadequate for the industry's development needs.

[0003] Currently, the traditional production of high-voltage DC relays mostly adopts a component-by-component manufacturing model. This means that each core component (including stationary contact assembly, moving contact assembly, relay coil, yoke, electrode support, etc.) is independently manufactured on different production lines or in different processes, and then centrally assembled, tested, and debugged. In the early stages of industry development, this production model could meet basic production needs due to small product demand and relatively simple structures. However, as the industry evolves towards higher reliability, miniaturization, and large-scale production, its inherent disadvantages have become increasingly prominent, becoming a bottleneck restricting the high-quality development of the industry. Component-by-component manufacturing requires independent processing equipment, operating positions, and process control for each component. The lack of coordination and linkage between processes results in significant gaps and waiting times, making continuous production impossible. This leads to low production efficiency and difficulty in adapting to large-scale demands. Summary of the Invention

[0004] The main objective of this invention is to provide a high-voltage DC relay with a coil terminal module, which aims to improve the production efficiency and reliability of high-voltage DC relays.

[0005] To achieve the above objectives, the present invention provides a high-voltage DC relay with a coil terminal module, comprising a housing, a contact system, and an arc-extinguishing system. The high-voltage DC relay with a coil terminal module further includes: A coil terminal module, disposed within the housing, includes a frame, an iron core disposed within the frame, a winding wound around the frame, and a control board assembly connected to the frame. The terminals of the winding are electrically connected to the control board assembly, and the iron core is used to connect to the contact system. A yoke assembly is disposed within the housing and includes a U-shaped yoke and a flat yoke. The flat yoke is connected to the upper end of the frame. One end of the U-shaped yoke is located outside the control panel assembly and is positioned and engaged with the control panel assembly. Both ends of the U-shaped yoke are connected and fixed to the flat yoke.

[0006] In one embodiment, the control board assembly includes a circuit board and a lead-out member, and a first positioning groove is formed at one end of the U-shaped yoke; The lead-out member is connected to the circuit board and is located on the side of the circuit board opposite to the winding; The first positioning groove is positioned and engaged with the side wall of the lead-out member.

[0007] In one embodiment, the control board assembly includes a circuit board and a lead-out member, wherein a second positioning groove is formed at the upper end of the circuit board and a first positioning protrusion is formed on the frame; The second positioning groove engages with the first positioning protrusion.

[0008] In one embodiment, the circuit board assembly has a positioning hole, and the lead-out member has a second positioning protrusion. The positioning hole is provided through the thickness direction of the circuit board assembly; The second positioning protrusion engages with the positioning hole.

[0009] In one embodiment, the circuit board assembly has at least two of the positioning holes, and the lead-out member has at least two of the second positioning protrusions; The second positioning protrusion is positioned and engaged with the positioning hole in a one-to-one correspondence.

[0010] In one embodiment, the lead-out member includes an insulating member and a current-conducting member connected together, the current-conducting member having a connecting end and a lead-out end; The insulating element has the second positioning protrusion and is connected to the circuit board; The connection end is located on the side of the insulating member facing the circuit board and is electrically connected to the circuit board; The lead-out end is located on the side of the guide member facing away from the circuit board and is used to connect to external circuitry.

[0011] In one embodiment, the circuit board assembly further includes electrical connection holes; The electrical connection hole is provided through the circuit board assembly along its thickness direction; The connection end passes through the electrical connection hole and is soldered to the circuit board assembly.

[0012] In one embodiment, the control panel assembly further includes an insulating protective plate having insulating side plates formed thereon; The insulating protective plate is located on the side of the circuit board opposite to the winding and cooperates with the lead-out component; The insulating side plate protrudes from the insulating protective plate toward the side of the circuit board and is located on both sides of the circuit board.

[0013] In one embodiment, the insulating protective plate is formed with a third positioning groove and a fourth positioning groove; The third positioning groove is positioned in conjunction with the first positioning protrusion. The fourth positioning groove is positioned and engaged with the side wall of the lead-out component.

[0014] In one embodiment, the skeleton is formed with insulating lead-out protrusions; The insulating lead-out protrusion extends from the edge of one end of the frame in a direction away from the other end and abuts against the side end of the flat yoke.

[0015] In the technical solution of this invention, the high-voltage DC relay with coil terminal module pre-assembles the frame, iron core, winding, and control board assembly as a whole module. When assembling with the yoke assembly, the U-shaped yoke is simply positioned and fitted with the outer side of the control board assembly from bottom to top to be installed in the designated position. Then, the two ends of the U-shaped yoke are connected and fixed to the flat yoke to complete the assembly between the coil terminal module and the yoke assembly. The coil terminal module is locked between the flat yoke and the U-shaped yoke through the connection between the flat yoke and the U-shaped yoke. Compared with the traditional installation method, after integrating the winding, frame, iron core, and control board assembly, there is only a simple positioning fit between the coil terminal module and the yoke assembly. This greatly simplifies the assembly process between the various structures in the coil terminal module and the yoke assembly, reduces the gap between processes and waiting time, and improves the production efficiency and reliability of the high-voltage DC relay. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of a structure of an embodiment of the high-voltage DC relay with coil terminal module provided by the present invention; Figure 2 for Figure 1 Schematic diagram of the structural breakdown of the embodiment; Figure 3 for Figure 1 A schematic diagram of the structure of the first part of the embodiment; Figure 4 for Figure 3 A magnified view of a section at point A in the middle; Figure 5 for Figure 1 A schematic diagram of the second part of the structure in the embodiment; Figure 6 for Figure 1 A schematic diagram of the third part of the embodiment.

[0018] Explanation of icon numbers: 100. High-voltage DC relay with coil terminal module; 1. Contact system; 2. Arc extinguishing system; 3. Coil terminal module; 31. Frame; 311. First positioning protrusion; 312. Insulating lead-out protrusion; 32. Winding; 33. Control board assembly; 331. Circuit board; 3311. Second positioning groove; 3312. Positioning hole; 3313. Electrical connection hole; 332. Lead-out component; 3321. Insulating component; 33211. Second positioning protrusion; 3322. Current guide; 33221. Connection end; 33222. Lead-out end; 333. Insulating protective plate; 3331. Insulating side plate; 3332. Third positioning groove; 3333. Fourth positioning groove; 4. Yoke assembly; 41. U-shaped yoke; 411. First positioning groove; 42. Flat yoke.

[0019] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0022] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0023] This invention proposes a high-voltage DC relay 100 with a coil terminal module. Figures 1 to 6 This is one embodiment of the present invention.

[0024] In embodiments of the present invention, such as Figure 1 and Figure 2 As shown, the high-voltage DC contactor includes a housing, a contact system 1, an arc-extinguishing system 2, a coil terminal module 3, and a yoke assembly 4. The coil terminal module 3 is located inside the housing and includes a frame 31, an iron core located inside the frame 31, a winding 32 wound around the frame 31, and a control board assembly 33 connected to the frame 31. The terminals of the winding 32 are electrically connected to the control board assembly 33, and the iron core is used to connect to the contact system 1. The yoke assembly 4 is located inside the housing and includes a U-shaped yoke 41 and a flat yoke 42. The flat yoke 42 is connected to the upper end of the frame 31, one end of the U-shaped yoke 41 is located outside the control board assembly 33 and is positioned and engaged with the control board assembly 33, and both ends of the U-shaped yoke 41 are connected and fixed to the flat yoke 42.

[0025] In the technical solution of this invention, the high-voltage DC relay 100 with coil terminal module pre-assembles the frame 31, iron core, winding 32, and control board assembly 33 as an integral module. When assembling with the yoke assembly 4, the U-shaped yoke 41 is simply positioned and fitted with the outer side of the control board assembly 33 from bottom to top to be installed in the designated position. Then, the two ends of the U-shaped yoke 41 are connected and fixed with the flat yoke 42 to complete the assembly between the coil terminal module 3 and the yoke assembly 4. The coil terminal module 3 is locked between the flat yoke 42 and the U-shaped yoke 41 through the connection between the flat yoke 42 and the U-shaped yoke 41. Compared with the traditional installation method, after integrating the winding 32, frame 31, iron core, and control board assembly 33, there is only a simple positioning fit between the coil terminal module 3 and the yoke assembly 4. This greatly simplifies the assembly process between the various structures in the coil terminal module 3 and the yoke assembly 4, reduces the gap between processes and waiting time, and improves the production efficiency and reliability of the high-voltage DC relay.

[0026] This embodiment provides a high-voltage DC relay 100 with a coil terminal module. The high-voltage DC relay is used in new energy vehicles, energy storage systems, rail transit and ultra-high voltage DC transmission, etc. It is a core electrical component used to realize circuit switching, electrical isolation and protection functions under high voltage and high current conditions. It realizes the contact opening and closing through an electromagnetic drive mechanism. The housing provides external encapsulation and internal structural support for the relay. The contact system 1 is used to realize the switching of the main circuit current. The arc extinguishing system 2 is used to extinguish the arc when breaking to improve safety and service life. The coil terminal module 3 is the core component of the electromagnetic drive and control circuit. The yoke assembly 4 is a magnetic conductive component used to form a closed magnetic circuit to improve electromagnetic attraction and magnetic circuit efficiency.

[0027] In one embodiment, such as Figure 5 As shown, the control board assembly 33 includes a circuit board 331 and a lead-out member 332. One end of the U-shaped yoke 41 has a first positioning groove 411. The lead-out member 332 is connected to the circuit board 331 and is located on the side of the circuit board 331 facing away from the winding 32. The first positioning groove 411 is positioned and engaged with the side wall of the lead-out member 332. The control board assembly 33 is a component that integrates electrical connection, signal lead-out, and positioning functions. It includes the circuit board 331 and the lead-out member 332 and is used to realize the electrical connection and structural positioning of the winding 32 with the external control circuit. The U-shaped yoke 41 is a magnetically conductive structural component. The first positioning groove 411 at its end is a positioning and engaging structure. By directly positioning and engaging the first positioning groove 411 of the U-shaped yoke 41 with the side wall of the lead-out member 332, the U-shaped yoke 41 and the control board assembly 33 can be quickly and accurately aligned, improving assembly consistency, avoiding assembly misalignment, and ensuring the relative positional accuracy of the magnetic circuit and electrical structure.

[0028] In one embodiment, such as Figure 4 and Figure 5 As shown, the control board assembly 33 includes a circuit board 331 and a lead-out member 332. A second positioning groove 3311 is formed at the upper end of the circuit board 331, and a first positioning protrusion 311 is formed on the frame 31. The second positioning groove 3311 and the first positioning protrusion 311 are positioned and engaged. The circuit board 331 is the electrical mounting and connection carrier of the control board assembly 33, the frame 31 is the supporting and insulating structure for the winding 32 and the iron core, and the first positioning protrusion 311 and the positioning groove are mechanical positioning structures used to limit the relative displacement between the two and ensure assembly accuracy. Through the mutual cooperation between the second positioning groove 3311 of the circuit board 331 and the first positioning protrusion 311 of the frame 31, the circuit board 331 and the frame 31 are precisely positioned, preventing the circuit board 331 from shifting or shaking during assembly or use, and improving the structural stability and electrical connection reliability of the coil terminal module 3.

[0029] In one embodiment, such as Figure 5As shown, the circuit board 331 assembly has a positioning hole 3312, and the lead-out member 332 has a second positioning protrusion 33211. The positioning hole 3312 is through-hole arranged along the thickness direction of the circuit board 331 assembly. The second positioning protrusion 33211 is positioned and engaged with the positioning hole 3312. The positioning hole 3312 is a through structure on the circuit board 331 for alignment and soldering, and the second positioning protrusion 33211 is a protrusion structure on the lead-out member 332 for positioning. The two work together to achieve the positioning function. The second positioning protrusion 33211 and the positioning hole 3312 ensure accurate assembly position between the lead-out member 332 and the circuit board 331.

[0030] In one embodiment, such as Figure 5 As shown, the circuit board 331 assembly has at least two positioning holes 3312, and the lead-out member 332 has at least two second positioning protrusions 33211; the second positioning protrusions 33211 are positioned and engaged with the positioning holes 3312 in a one-to-one correspondence. By providing at least two positioning holes 3312 and at least two second positioning protrusions 33211, the second positioning protrusions 33211 are positioned and engaged with the positioning holes 3312 in a one-to-one correspondence; multi-point positioning engagement can further improve the positioning accuracy between the lead-out member 332 and the circuit board 331, improve the reliability and load-bearing capacity of the electrical connection, and enhance the product's vibration and impact resistance.

[0031] In one embodiment, such as Figure 5 As shown, the lead-out member 332 includes an insulating member 3321 and a guide member 3322 connected to each other. The guide member 3322 has a connecting end 33221 and a lead-out end 33222. The insulating member 3321 has a second positioning protrusion 33211 and is connected to the circuit board 331. The connecting end 33221 is located on the side of the insulating member 3321 facing the circuit board 331 and is electrically connected to the circuit board 331. The lead-out end 33222 is located on the side of the guide member 3322 facing away from the circuit board 331 and is used to connect to an external circuit. Lead-out component 332 is a conductive connection component used to lead internal circuits to the outside. It usually has both conductive and insulating protection functions. The current-conducting component 3322 is the conductive body used to transmit current, and the insulating component 3321 is the insulating support structure used to isolate live parts and prevent short circuits and electric shocks. By integrating the insulating component 3321 and the current-conducting component 3322 into one unit, reliable conductive lead-out is achieved while electrical isolation is provided through the insulating component 3321, simplifying the structure and assembly and improving the safety of use.

[0032] In one embodiment, such as Figure 5As shown, the circuit board 331 assembly also has an electrical connection hole 3313; the electrical connection hole 3313 is through-hole along the thickness direction of the circuit board 331 assembly; the connecting end 33221 passes through the electrical connection hole 3313 and is soldered to the circuit board 331 assembly. After the circuit board 331 assembly and the lead-out piece 332 are positioned by the positioning structure, the connection end 33221 and the electrical connection hole 3313 are engaged and soldered, which not only realizes the electrical connection between the two, but also realizes the connection fixation between the two, so as to ensure that the lead-out piece 332 can lead the electrical signal of the coil terminal to the outside of the U-shaped yoke 41, and reduce the risk of poor soldering and misalignment.

[0033] In one embodiment, such as Figure 6 As shown, the control board assembly 33 also includes an insulating protective plate 333, which has insulating side plates 3331. The insulating protective plate 333 is located on the side of the circuit board 331 facing away from the winding 32 and cooperates with the lead-out member 332. The insulating side plates 3331 protrude from the insulating protective plate 333 toward the side of the circuit board 331 and are located on both sides of the circuit board 331. The insulating protective plate 333 is a plate-shaped component used to provide overall insulation protection for the circuit board 331 and its internal live structures. The insulating side plates 3331 are side insulation structures protruding from the insulating protective plate 333, used for lateral isolation and protection. The insulating protective plate 333 and the insulating side plates 3331 provide encapsulated insulation protection for the circuit board 331, improving the overall insulation strength and structural protection capability, and reducing the risk of contact with foreign objects, dust, and high-voltage discharge.

[0034] In one embodiment, such as Figure 6 As shown, the insulating protective plate 333 has a third positioning groove 3332 and a fourth positioning groove 3333; the third positioning groove 3332 engages with the first positioning protrusion 311; and the fourth positioning groove 3333 engages with the side wall of the lead-out member 332. Through the engagement of the third positioning groove 3332 with the first positioning protrusion 311 and the fourth positioning groove 3333 with the side wall of the lead-out member 332, dual precise positioning is achieved between the insulating protective plate 333 and the frame 31 and the lead-out member 332, ensuring stable and reliable assembly of the insulating protective plate 333 and improving the overall structural consistency and insulation protection effect.

[0035] In one embodiment, such as Figure 2 and Figure 3As shown, the frame 31 has an insulating lead-out protrusion 312. The insulating lead-out protrusion 312 protrudes from the edge of one end of the frame 31 in a direction away from the other end and abuts against the side end of the flat yoke 42. The insulating lead-out protrusion 312 is an insulating structure protruding from the edge of the frame 31, used to enhance end insulation and structural positioning. By abutting against the side end of the flat yoke 42, the positioning and positioning between the frame 31 and the flat yoke 42 are achieved, while improving the insulation performance between the frame 31 and the flat yoke 42, preventing surface discharge under high voltage conditions, and improving product safety and structural stability.

[0036] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A high-voltage DC relay with a coil terminal module, comprising a housing, a contact system, and an arc-extinguishing system, characterized in that, The high-voltage DC relay with coil terminal module also includes: A coil terminal module, disposed within the housing, includes a frame, an iron core disposed within the frame, a winding wound around the frame, and a control board assembly connected to the frame. The terminals of the winding are electrically connected to the control board assembly, and the iron core is used to connect to the contact system. A yoke assembly is disposed within the housing and includes a U-shaped yoke and a flat yoke. The flat yoke is connected to the upper end of the frame. One end of the U-shaped yoke is located outside the control panel assembly and is positioned and engaged with the control panel assembly. Both ends of the U-shaped yoke are connected and fixed to the flat yoke.

2. The high-voltage DC relay with coil terminal module as described in claim 1, characterized in that, The control board assembly includes a circuit board and lead-out components, and a first positioning groove is formed at one end of the U-shaped yoke. The lead-out member is connected to the circuit board and is located on the side of the circuit board opposite to the winding; The first positioning groove is positioned and engaged with the side wall of the lead-out member.

3. The high-voltage DC relay with coil terminal module as described in claim 1 or 2, characterized in that, The control board assembly includes a circuit board and a lead-out component. A second positioning groove is formed at the upper end of the circuit board, and a first positioning protrusion is formed on the frame. The second positioning groove engages with the first positioning protrusion.

4. The high-voltage DC relay with coil terminal module as described in claim 3, characterized in that, The circuit board assembly has positioning holes, and the lead-out member has a second positioning protrusion. The positioning hole is provided through the thickness direction of the circuit board assembly; The second positioning protrusion engages with the positioning hole.

5. The high-voltage DC relay with coil terminal module as described in claim 4, characterized in that, The circuit board assembly has at least two of the positioning holes, and the lead-out member has at least two of the second positioning protrusions; The second positioning protrusion is positioned and engaged with the positioning hole in a one-to-one correspondence.

6. The high-voltage DC relay with coil terminal module as described in claim 4, characterized in that, The lead-out component includes an insulating component and a current-conducting component connected together, and the current-conducting component has a connecting end and a lead-out end; The insulating element has the second positioning protrusion and is connected to the circuit board; The connection end is located on the side of the insulating component facing the circuit board and is electrically connected to the circuit board; The lead-out end is located on the side of the guide member facing away from the circuit board and is used to connect to external circuitry.

7. The high-voltage DC relay with coil terminal module as described in claim 6, characterized in that, The circuit board assembly also has electrical connection holes; The electrical connection hole is provided through the circuit board assembly along its thickness direction; The connection end passes through the electrical connection hole and is soldered to the circuit board assembly.

8. The high-voltage DC relay with coil terminal module as described in claim 3, characterized in that, The control board assembly also includes an insulating protective plate, which has insulating side plates formed thereon. The insulating protective plate is located on the side of the circuit board opposite to the winding and cooperates with the lead-out component; The insulating side plate protrudes from the insulating protective plate toward the side of the circuit board and is located on both sides of the circuit board.

9. The high-voltage DC relay with coil terminal module as described in any one of claims 8, characterized in that, The insulating protective plate has a third positioning groove and a fourth positioning groove; The third positioning groove is positioned in conjunction with the first positioning protrusion. The fourth positioning groove is positioned and engaged with the side wall of the lead-out component.

10. The high-voltage DC relay with coil terminal module as described in claim 1 or 2, characterized in that, The skeleton is formed with insulating lead-out protrusions; The insulating lead-out protrusion extends from the edge of one end of the frame in a direction away from the other end and abuts against the side end of the flat yoke.

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