Relay coil terminal leading-out structure

Abstract

The invention relates to the technical field of electrical elements, and discloses a relay coil terminal leading-out structure which is used for a high-voltage direct-current relay, the high-voltage direct-current relay comprises a coil assembly and a yoke assembly, and the coil assembly is arranged in the yoke assembly. The relay coil terminal leading-out structure comprises a control panel and a leading-out assembly, and the control panel is arranged in the yoke assembly and used for being electrically connected with the coil assembly. The leading-out assembly is provided with a leading-out end, the leading-out end is electrically connected with the control panel assembly and used for being connected with an external circuit, the leading-out end is arranged on the outer side of the yoke assembly, a control panel does not need to be additionally arranged on the outer side of the yoke assembly, the overall size of the relay is controlled, and the development direction of miniaturization and integration of the relay is met. And convenience is provided for upgrading a single coil of the relay into double coils.

Description

Technical Field

[0001] This invention relates to the field of electrical components technology, and in particular to a relay coil terminal lead-out structure. Background Technology

[0002] High-voltage DC relays, as core actuators in power control systems, are widely used in new energy vehicles, energy storage systems, and industrial DC power grids. With the development of power electronics technology and the increasing demands for power density and response speed in application scenarios, dual-coil relays, due to their superior performance, have gradually become the mainstream direction for industry upgrades and iterations. Compared to traditional single-coil designs, the dual-coil structure achieves time-sharing drive of the coils through independent control logic, significantly improving engagement reliability while reducing overall power consumption, effectively solving the technical challenge of insufficient response speed in high-voltage DC scenarios with single-coil relays.

[0003] However, upgrading a single-coil relay to a dual-coil structure faces significant structural layout and engineering application bottlenecks in existing product design and engineering implementation. Currently, the coil leads of conventional high-voltage DC relays typically extend directly to the outside of the yoke and are connected to external circuits via soldering or plugging. This structural design is a classic solution for single-coil control logic, and its wiring method is simple and direct. To introduce dual-coil control logic into the existing architecture, a dedicated control board must be added to achieve precise control over the current path and on / off timing of the dual coils. However, limited by the existing coil terminal layout, current designs can only adopt the form of an external control board.

[0004] An external control board means that the relay body requires additional installation space and mounting brackets, resulting in a significant increase in the axial or lateral dimensions of the entire device. This runs counter to the current trend of miniaturization and high-density integration in power equipment, increases installation difficulty, and limits its application prospects in compact devices such as high-density energy storage cabinets and small vehicle inverters. Summary of the Invention

[0005] The main objective of this invention is to provide a relay coil terminal lead-out structure, which aims to control the overall size of the relay and facilitate the upgrade of a single-coil relay to a dual-coil relay.

[0006] To achieve the above objectives, the present invention proposes a relay coil terminal lead-out structure for a high-voltage DC relay. The high-voltage DC relay includes a coil assembly and a yoke assembly, the coil assembly being disposed within the yoke assembly. The relay coil terminal lead-out structure includes: A control board, disposed within the yoke assembly and used for electrical connection with the coil assembly; and The lead-out assembly has a lead-out end that is electrically connected to the control board assembly and is used to connect to an external circuit. The lead-out end is located on the outside of the yoke assembly.

[0007] In one embodiment, the control board has a first positioning portion, and the lead-out assembly has a second positioning portion; The first positioning part and the second positioning part are positioned and engaged.

[0008] In one embodiment, the first positioning part is a positioning hole, and the second positioning part is a positioning protrusion; The positioning protrusion is inserted into and positioned in conjunction with the positioning hole.

[0009] In one embodiment, the first positioning part includes at least two positioning holes, and the second positioning part includes at least two positioning protrusions; The positioning holes and the positioning protrusions are positioned and engaged in a one-to-one correspondence.

[0010] In one embodiment, the lead-out assembly includes an insulating connector and a conductive component; The insulating connector connects to the control board; The conductive element is disposed through the insulating connector along the relative arrangement direction of the lead-out assembly and the control board. One end of the conductive element is electrically connected to the control board, and the other end of the conductive element forms the lead-out terminal.

[0011] In one embodiment, the insulating connector has an insulating barrier portion; The insulating barrier portion protrudes from the side of the insulating connector facing away from the control board, and the insulating barrier portion is located on a portion of the periphery of the lead-out end.

[0012] In one embodiment, the insulating barrier is two spaced-apart insulating baffles; An outlet channel is formed between the two insulating baffles, and the outlet end is located within the outlet channel. The outlet channel is used to avoid external circuit connections to the outlet end.

[0013] In one embodiment, the lead-out end is arranged in a ring shape.

[0014] In one embodiment, the relay coil terminal lead-out structure further includes an insulating protective plate, the insulating protective plate having a positioning slot, and the lead-out assembly having a positioning section; The positioning slot engages with the positioning segment for positioning. The insulating protective plate is located on the side of the control plate facing the lead-out assembly and is disposed within the yoke assembly. The projection of the insulating protective plate in the thickness direction of the control plate covers the control plate.

[0015] In one embodiment, the insulating protective plate has insulating side plates that protrude from the side of the insulating protective plate toward the control plate and are located on both sides of the control plate.

[0016] In the technical solution of this invention, the relay coil terminal lead-out structure includes a control board and a lead-out assembly. The control board is disposed inside the yoke assembly of the relay and is used to connect the terminals of the coil assembly. It is led out to the outside of the yoke assembly through the lead-out assembly. When it is necessary to upgrade the single coil of the relay to a double coil, it is only necessary to replace the coil and change the wiring of the coil on the control board. Compared with the traditional single coil to double coil conversion, the relay coil terminal lead-out structure proposed in this invention does not require the addition of a control board to the outside of the yoke assembly, thus controlling the overall size of the relay. This conforms to the development direction of relay miniaturization and integration, and provides convenience for upgrading a single coil relay to a double coil relay. Attached Figure Description

[0017] 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.

[0018] Figure 1 A schematic diagram of the first part of an embodiment of the relay coil terminal lead-out structure provided by the present invention; Figure 2 for Figure 1 A schematic diagram of the first part of the structure of the embodiment; Figure 3 for Figure 2 A schematic diagram of the structure from another perspective; Figure 4 for Figure 1 A schematic diagram of the second part of the structure in the embodiment; Figure 5 This is a schematic diagram of the comparative embodiment.

[0019] Explanation of icon numbers: 100. Relay coil terminal lead-out structure; 1. Control board; 11. First positioning part; 11a. Positioning hole; 2. Lead-out assembly; 21. Second positioning part; 21a. Positioning protrusion; 22. Insulating connector; 221. Insulating barrier part; 23. Conductive component; 231. Lead-out end; 24. Positioning section; 3. Insulating protective plate; 31. Positioning slot; 32. Insulating side plate; 200. Control group; 201. Coil terminal; 202. Coil frame; 203. Yoke assembly.

[0020] 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

[0021] 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.

[0022] 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.

[0023] 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.

[0024] Figure 5 This is a schematic diagram of a part of the structure of a common single-coil high-voltage DC relay in the prior art. In this case, it serves as a control group, with its coil terminals directly led out from the coil frame to the outside of the yoke assembly.

[0025] A high-voltage DC relay is composed of core components such as a coil assembly, a yoke assembly, a contact actuation structure, and a terminal lead-out structure. These components work together to achieve the on / off control function of the high-voltage DC circuit. The coil assembly is the core of the relay's power drive; when energized, it generates electromagnetic attraction, driving the internal moving iron core to move, thereby controlling the closing and opening of the contacts. It is the fundamental actuation component for circuit switching. The yoke assembly is a magnetically conductive and protective structure, primarily serving to concentrate the magnetic circuit and improve electromagnetic conversion efficiency. It also provides a mounting carrier and external protection for the internal coil, iron core, and other precision components, preventing external impurities and electromagnetic interference from affecting internal operational stability. Traditional terminal lead-out structures are designed for a single coil, with the coil leads extending directly from the outside of the yoke. Figure 5 As shown, direct connection to external circuits via welding and plugging can only accommodate single-coil, single-drive control logic, failing to meet the requirements of dual-coil time-sharing drive and independent control. The overall operating principle is as follows: the external circuit supplies power to the coil assembly through a terminal lead-out structure. The energized coil assembly generates electromagnetic attraction, forming a stable magnetic circuit based on the magnetic conductivity of the yoke assembly, driving the relay contacts to perform actions and complete the on / off control of the high-voltage DC circuit. The proposed relay coil terminal lead-out structure 100 integrates the control board 1 internally within the yoke assembly, replacing the traditional external control board 1 layout. This opens up the electrical connection between the coil assembly and the external circuit, allowing for adaptation to both single-coil and dual-coil control logic without altering the relay's main structure. This fundamentally solves the problems of excessive size, low integration, and installation limitations when upgrading traditional structures to dual coils, aligning with the industry trend of miniaturization and high-density integration in power equipment. It also simplifies the dual-coil retrofit process and improves the relay's structural stability and adaptability.

[0026] This invention proposes a relay coil terminal lead-out structure 100. Figures 1 to 4 This is one embodiment of the present invention.

[0027] In this embodiment of the invention, the relay coil terminal lead-out structure 100 includes a control board 1 and a lead-out assembly 2. The control board 1 is disposed inside the yoke assembly and is used to electrically connect with the coil assembly. The lead-out assembly 2 has a lead-out end 231, which is electrically connected to the control board 1 assembly and is used to connect to an external circuit. The lead-out end 231 is disposed outside the yoke assembly.

[0028] In the technical solution of this invention, the relay coil terminal lead-out structure 100 includes a control board 1 and a lead-out component 2. The control board 1 is disposed inside the yoke assembly of the relay and is used to connect the terminals of the coil assembly. It is led out to the outside of the yoke assembly through the lead-out component 2. When it is necessary to upgrade the single coil of the relay to a double coil, it is only necessary to replace the coil and change the wiring of the coil on the control board 1. Compared with the traditional single coil to double coil conversion, the relay coil terminal lead-out structure 100 proposed in this invention does not require the addition of an external control board 1, nor does it require modification of the main structure of the yoke and the overall shape of the relay. It only requires the replacement of the coil assembly and adjustment of the wiring points of the coil and the control board 1 to complete the conversion. The entire conversion process is simplified and the conversion difficulty is reduced. At the same time, the overall axial and lateral dimensions of the relay are strictly controlled, and no additional installation space is occupied. It is perfectly adapted to compact power equipment such as small vehicle inverters and high-density energy storage cabinets, which conforms to the industry development trend of relay miniaturization and high-density integration, and provides convenience for upgrading a single coil relay to a double coil.

[0029] In one embodiment, reference Figure 1 and Figure 2 The control board 1 has a first positioning part 11, and the lead-out component 2 has a second positioning part 21; the first positioning part 11 and the second positioning part 21 are positioned and engaged. During assembly, the first positioning part 11 and the second positioning part 21 are engaged and positioned to achieve precise docking between the control board 1 and the lead-out component 2. The pre-installation positioning of the control board 1 and the lead-out component 2 is achieved through positioning and engagement, which greatly reduces the assembly difficulty of the two and avoids problems such as wiring misalignment and poor conductive contact caused by manual assembly. At the same time, it improves the tightness of the connection between the two, prevents the relay from vibrating for a long time, and prevents the components from shifting or falling off during operation. This ensures the stability of the coil circuit connection and improves the overall reliability of the relay.

[0030] In one embodiment, reference Figure 1 and Figure 2 The first positioning part 11 is a positioning hole 11a, and the second positioning part 21 is a positioning protrusion 21a; the positioning protrusion 21a is inserted into the positioning hole 11a for positioning. During assembly, the positioning protrusion 21a is directly inserted into the corresponding positioning hole 11a, and the two are positioned and engaged by the insertion method. This positioning method, which adopts a purely mechanical insertion method, has a simple structure, low processing cost, and convenient assembly. It can achieve precise positioning without the need for additional fasteners, which can ensure positioning accuracy without increasing the complexity of the overall structure. At the same time, the insertion method has a foolproof effect, further avoiding assembly misalignment, and is suitable for the needs of mass industrial production.

[0031] In one embodiment, the first positioning part 11 and the second positioning part 21 can also adopt a snap-fit ​​positioning method, which is an elastic mechanical positioning structure. The first positioning part 11 on the control plate 1 is set as an elastic snap-fit, and the snap-fit ​​has an elastic claw and is integrally formed on the side of the control plate 1. The second positioning part 21 on the lead-out component 2 is correspondingly set as a snap-fit ​​groove, and the inner wall of the groove is provided with a clamping groove adapted to the elastic claw. During assembly, the elastic snap-fit ​​is directly aligned with the snap-fit ​​groove and pressed. The elastic claw is deformed and inserted into the groove to realize the clamping and positioning cooperation between the first positioning part 11 and the second positioning part 21, and to complete the quick docking between the control plate 1 and the lead-out component 2.

[0032] In one embodiment, the first positioning part 11 includes at least two positioning holes 11a, and the second positioning part 21 includes at least two positioning protrusions 21a; the positioning holes 11a and the positioning protrusions 21a are positioned and engaged in a one-to-one correspondence. Each positioning protrusion 21a is inserted into the positioning hole 11a in a one-to-one correspondence, realizing multi-point synchronous positioning. The synchronous operation of multiple sets of positioning structures can restrict the radial and circumferential displacement between the control board 1 and the lead-out component 2 in all directions, eliminating the problem of component rotation and offset. Compared with a single set of positioning structures, the stability is greatly improved. Even if the relay is under long-term high-frequency vibration and complex working conditions, the connection between the two can be guaranteed to be stable, further ensuring the continuity of the conductive connection of the coil circuit.

[0033] In one embodiment, such as Figure 1 and Figure 2 As shown, the first positioning part 11 includes two positioning holes 11a, and the second positioning part 21 includes two positioning protrusions 21a. The two points are positioned synchronously, which can not only improve the positioning stability and make the connection more stable, but also avoid the adverse effects on the structural strength caused by too many repetitive designs of the same structure.

[0034] In one embodiment, such as Figure 2 and Figure 3As shown, the lead-out component 2 includes an insulating connector 22 and a conductive component 23. The insulating connector 22 connects to the control board 1. The conductive component 23 extends through the insulating connector 22 along the relative orientation of the lead-out component 2 and the control board 1. One end of the conductive component 23 is electrically connected to the control board 1, and the other end of the conductive component 23 forms a lead-out terminal 231. The insulating connector 22 is made of insulating plastic and is commonly used around conductive parts of electrical equipment to provide insulation, component fixation, and protective support, preventing leakage and short circuits in conductive parts. The conductive component 23 is made of conductive metal and is the core carrier for current transmission. It has excellent conductivity and low resistance, and is responsible for achieving stable current transmission. In this example, the insulating connector 22 achieves insulation isolation between the conductive component 23 and the yoke assembly and external mounting structure, eliminating problems such as leakage, short circuit, and electromagnetic interference, and ensuring the safety of high-voltage DC operation. At the same time, the through-type arrangement of the conductive component 23 can not only ensure low current transmission loss and strong stability, but also simplify the overall structure of the lead-out assembly 2, realizing the dual functions of insulation protection and conductive transmission, and improving the electrical safety of the terminal lead-out structure.

[0035] In order to ensure a more stable electrical connection between the conductive component 23 and the control board 1, the end of the conductive component 23 that is electrically connected to the control board 1 is also welded to avoid poor contact or power failure under vibration conditions.

[0036] In one embodiment, such as Figure 3 As shown, the insulating connector 22 has an insulating barrier portion 221; the insulating barrier portion 221 protrudes from the side of the insulating connector 22 facing away from the control board 1, and is located on a portion of the periphery of the lead-out terminal 231. The insulating barrier portion 221 can enhance local insulation protection and avoid creepage and short circuits between adjacent conductive terminals, especially suitable for high-safety-requirement working scenarios such as high-voltage DC. By having the insulating barrier portion 221 surround a portion of the periphery of the lead-out terminal 231, a local insulation barrier is formed. In response to the creepage and short circuit risks that are prone to occur in high-voltage DC working scenarios, the insulating barrier portion 221 achieves local insulation isolation around the lead-out terminal 231, reduces the range of leakage and discharge risks, and eliminates safety hazards caused by accidental contact between adjacent circuits, external metal parts and the lead-out terminal 231, further improving the safety of high-voltage DC relay operation. At the same time, the one-piece molded structure requires no additional assembly and does not increase processing and assembly costs.

[0037] In one embodiment, such as Figure 3As shown, the insulating barrier 221 consists of two spaced insulating baffles; a lead-out channel is formed between the two insulating baffles, and the lead-out end 231 is located within the lead-out channel. The lead-out channel is used to avoid external circuit connection to the lead-out end 231. The double-baffle insulating barrier design uses two spaced insulating baffles as an integrated insulating structure with controllable spacing and strong targeted protection. It also reserves dedicated wiring space, balancing insulation protection and wiring convenience. The double baffles provide comprehensive insulation protection on both sides and, through the reserved lead-out channel, provide sufficient space for the insertion and soldering operations of external circuits and the lead-out end 231, solving the problem of mutual interference between insulation protection and wiring operations. This ensures high-voltage insulation safety while improving the convenience of external wiring, adapting to various wiring methods.

[0038] In one embodiment, such as Figure 3 As shown, the lead-out terminal 231 is arranged in a ring shape. The ring-shaped lead-out terminal 231 has a ring-shaped conductive structure, which, compared to traditional pin-shaped or sheet-shaped lead-out terminals 231, offers a larger contact area and stronger wiring adaptability. It is a commonly used optimized structure for electrical terminals, adaptable to various wiring methods such as bolt tightening, welding, and plugging. The ring structure increases the contact area with external circuits, reduces contact resistance, decreases circuit losses, and improves current transmission stability. Simultaneously, it adapts to various external wiring methods; whether bolt tightening or wire welding, it achieves a stable connection, reduces the risk of loose wiring, and enhances the versatility of the terminal lead-out structure.

[0039] In one embodiment, such as Figure 3 and Figure 4 As shown, the relay coil terminal lead-out structure 100 also includes an insulating protective plate 3. The insulating protective plate 3 forms a positioning groove 31, and the lead-out assembly 2 has a positioning section 24. The positioning groove 31 and the positioning section 24 are positioned and engaged. The insulating protective plate 3 is located on the side of the control plate 1 facing the lead-out assembly 2 and is disposed within the yoke assembly. The projection of the insulating protective plate 3 in the thickness direction of the control plate 1 covers the control plate 1. The insulating protective plate 3 is a large-area insulating protective component, and its main function is to achieve comprehensive protection of the control plate 1 as a whole, isolate external dust, impurities, and moisture, and further enhance the overall insulation performance to avoid damage to the internal control plate 1 from external electromagnetic interference and mechanical impact. The protective plate is positioned and installed by engaging with the positioning slot 31 and the positioning section 24. The insulating protective plate 3 is installed on the side of the control board 1 facing the lead-out component 2, and the projection of the protective plate in the thickness direction of the control board 1 completely covers the control board 1, achieving all-round protection and preventing external impurities from intruding and mechanical damage from affecting the circuit stability of the control board 1. At the same time, it improves the overall insulation level and eliminates high-voltage leakage and electromagnetic interference problems. The positioning and engaging assembly method is simple and convenient, requiring no additional fasteners. It can ensure that the protective plate is installed firmly without increasing the overall structural volume, thus maintaining the miniaturization advantage of the relay.

[0040] In one embodiment, such as Figure 4 As shown, the insulating protective plate 3 has insulating side plates 32, which protrude from the side of the insulating protective plate 3 toward the control plate 1. The insulating side plates 32 are located on both sides of the control plate 1. The insulating side plates 32 are integral protruding extension structures on the side of the protective plate. Their main function is to achieve lateral protection and limiting on both sides of the control plate 1. The insulating side plates 32 are integrally protruding on the side of the insulating protective plate 3 toward the control plate 1. The insulating side plates 32 are arranged on the left and right sides of the control plate 1 to form a lateral wrapping structure, which strengthens lateral insulation protection, eliminates the risk of lateral leakage and short circuit, and works with the main protective plate to achieve all-round, no-dead-angle protection of the control plate 1, thus comprehensively improving the operational stability and service life of the internal circuit of the relay.

[0041] 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 relay coil terminal lead-out structure for a high-voltage DC relay, the high-voltage DC relay comprising a coil assembly and a yoke assembly, the coil assembly being disposed within the yoke assembly, characterized in that, The relay coil terminal lead-out structure includes: A control board, disposed within the yoke assembly and used for electrical connection with the coil assembly; and The lead-out assembly has a lead-out end that is electrically connected to the control board assembly and is used to connect to an external circuit. The lead-out end is located on the outside of the yoke assembly.

2. The relay coil terminal lead-out structure as described in claim 1, characterized in that, The control board has a first positioning part, and the lead-out component has a second positioning part; The first positioning part and the second positioning part are positioned and engaged.

3. The relay coil terminal lead-out structure as described in claim 2, characterized in that, The first positioning part is a positioning hole, and the second positioning part is a positioning protrusion; The positioning protrusion is inserted into and positioned in conjunction with the positioning hole.

4. The relay coil terminal lead-out structure as described in claim 3, characterized in that, The first positioning part includes at least two positioning holes, and the second positioning part includes at least two positioning protrusions; The positioning holes and the positioning protrusions are positioned and engaged in a one-to-one correspondence.

5. The relay coil terminal lead-out structure as described in any one of claims 1 to 4, characterized in that, The lead-out assembly includes insulating connectors and conductive components; The insulating connector connects to the control board; The conductive element is disposed through the insulating connector along the relative arrangement direction of the lead-out assembly and the control board. One end of the conductive element is electrically connected to the control board, and the other end of the conductive element forms the lead-out terminal.

6. The relay coil terminal lead-out structure as described in claim 5, characterized in that, The insulating connector has an insulating barrier portion; The insulating barrier portion protrudes from the side of the insulating connector facing away from the control board, and the insulating barrier portion is located on a portion of the periphery of the lead-out end.

7. The relay coil terminal lead-out structure as described in claim 6, characterized in that, The insulating barrier consists of two spaced insulating baffles. An outlet channel is formed between the two insulating baffles, and the outlet end is located within the outlet channel. The outlet channel is used to avoid external circuit connections to the outlet end.

8. The relay coil terminal lead-out structure as described in any one of claims 1 to 4, characterized in that, The lead-out end is arranged in a ring shape.

9. The relay coil terminal lead-out structure as described in any one of claims 1 to 4, characterized in that, The relay coil terminal lead-out structure also includes an insulating protective plate, the insulating protective plate having a positioning slot, and the lead-out component having a positioning section; The positioning slot engages with the positioning segment for positioning. The insulating protective plate is located on the side of the control plate facing the lead-out assembly and is disposed within the yoke assembly. The projection of the insulating protective plate in the thickness direction of the control plate covers the control plate.

10. The relay coil terminal lead-out structure as described in claim 9, characterized in that, The insulating protective plate has insulating side plates that protrude from the side of the insulating protective plate toward the control plate and are located on both sides of the control plate.

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