Integrated relay

Abstract

The utility model relates to an integrated relay, which comprises an upper shell assembly, a lower shell and a relay part, and is characterized in that the upper shell assembly comprises an upper shell and an electric connecting piece, and the upper shell and the lower shell are made of insulating materials and define a space for accommodating the relay part; the upper shell further comprises a fuse bearing portion used for bearing at least one fuse, the electric connecting piece is constructed to be used for being electrically connected with the at least one fuse, and the electric connecting piece and the upper shell are formed into a whole. The integrated relay is high in integration level, reduces the cost, and is convenient to install.

Description

Technical Field

[0001] The present disclosure relates to the field of relays, and more particularly to an integrated relay capable of integrating a fuse. Background Art

[0002] In the field of relay technology, such as high-voltage DC relays, it's common to design and install relays and fuses separately within a distribution box. Typically, the relay housing is bolted to the distribution box, while the fuse's ends are secured to the box with copper busbars and bolts. The relay and fuse are then connected via copper busbars or cables.

[0003] From a space perspective, separate relay and fuse installations require a larger installation space. This can create space constraints and layout difficulties for space-constrained equipment. Separate relay and fuse installations also require more wires and a more complex wiring structure. Furthermore, from a lightweighting perspective, separate relay and fuse installations require more parts. Summary of the Invention

[0004] In view of the problems existing in the prior art, the present disclosure provides an integrated relay, which has high integration and saves space.

[0005] According to one aspect of the present disclosure, an integrated relay is provided, comprising an upper housing assembly, a lower housing, and a relay component, wherein the upper housing assembly comprises an upper housing and an electrical connector, the upper housing and the lower housing being made of insulating material and defining a space for accommodating the relay component, the upper housing further comprising a fuse-carrying portion for carrying at least one fuse, the electrical connector being configured to be electrically connected to the at least one fuse and being formed integrally with the upper housing.

[0006] In one construction, the fuse-carrying portion includes a multi-layer fuse-carrying portion from top to bottom for carrying multiple fuses, and the electrical connector includes a common-end electrical connector and multiple non-common-end electrical connectors, the common-end electrical connector is configured to be connected to one end of each of the multiple fuses, and each of the multiple non-common-end electrical connectors is configured to be connected to the other end of a corresponding one of the multiple fuses, which is opposite to the one end.

[0007] In one configuration, the common-end electrical connector is integrally formed from a conductive plate, and each of the plurality of non-common-end electrical connectors is integrally formed from a conductive plate.

[0008] In one construction, the common-end electrical connector includes a first electrical connector located in the topmost fuse-carrying portion and at least one second electrical connector located in other layers, wherein the first electrical connector is arranged in a horizontal direction and the at least one second electrical connector is arranged in a vertical direction, and the multiple non-common-end electrical connectors include a first electrical connector located in the topmost fuse-carrying portion and at least one second electrical connector located in other layers, and the first electrical connector and the at least one second electrical connector both include a first part for connecting to the other end of the fuse and a second part for connecting to an external circuit, wherein the first part of the first electrical connector is arranged in a horizontal direction and the first part of the second electrical connector is arranged in a vertical direction.

[0009] In one configuration, the common-end electrical connector further includes a third electrical connection portion for electrically connecting to an output end of the integrated relay, and the third electrical connection portion is arranged in a horizontal direction.

[0010] In one configuration, the second portion of the first electrical connector and the second portion of the at least one second electrical connector are both arranged in a horizontal direction.

[0011] In one configuration, the first electrical connection portion, the second electrical connection portion, the first portion of the first electrical connector, and the first portion of the second electrical connector all have a stepped hole, a through-hole insert with an internal thread is fixed on a stepped surface in the stepped hole, and a boss is formed around the stepped hole on a side of the first electrical connection portion, the second electrical connection portion, the first portion of the first electrical connector, and the first portion of the second electrical connector opposite to a side on which the through-hole insert is fixed.

[0012] In one configuration, the third electrical connection portion has a stepped hole, a through-hole insert with an internal thread is fixed on a stepped surface in the stepped hole, and a boss is formed around the stepped hole on a side of the third electrical connection opposite to the side where the through-hole insert is fixed.

[0013] In one configuration, the bottom of the upper housing has at least one fixing hole for fixing the integrated relay, a gasket is integrally injection-molded in the fixing hole, and the lower portion of the fixing hole has a guide portion that tapers upward from the bottom.

[0014] In one configuration, the electrical connector is integrally injection-molded with the upper housing.

[0015] In one configuration, the integrated relay further includes the fuse.

[0016] The integrated relay according to the present disclosure has high integration, reduces cost, saves space, is lightweight, and is easy to assemble. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Various objects, features, and advantages of the present disclosure will become more apparent upon consideration of the following description of preferred embodiments of the present disclosure in conjunction with the accompanying drawings. The accompanying drawings are merely illustrative illustrations of the present disclosure and are not necessarily drawn to scale. In the drawings, like reference numerals designate identical or similar parts throughout.

[0018] Figure 1 is a schematic perspective view of an integrated relay with a fuse according to the present disclosure.

[0019] Figure 2 is a schematic front view of an integrated relay with an integrated fuse according to the present disclosure.

[0020] Figure 3 is a schematic perspective view of an upper housing assembly of an integrated relay according to the present disclosure.

[0021] Figure 4 is a schematic front view of an upper housing assembly of an integrated relay according to the present disclosure.

[0022] Figure 5 is a schematic bottom view of an upper housing assembly of an integrated relay according to the present disclosure.

[0023] Figure 6 is a schematic perspective view of a common-end electrical connector of an integrated relay according to the present disclosure.

[0024] Figure 7 is a schematic perspective view of a first electrical connector of an integrated relay according to the present disclosure.

[0025] Figure 8 is a schematic perspective view of a second electrical connector of an integrated relay according to the present disclosure.

[0026] Figure 9 is a schematic perspective view of a fuse of an integrated relay according to the present disclosure.

[0027] Figure 10 is a schematic perspective view of a through-hole insert of an integrated relay according to the present disclosure.

[0028] Figure 11 is a schematic perspective view of a common-end electrical connector of an integrated relay according to the present disclosure with a through-hole insert installed.

[0029] Figure 12 is a schematic perspective view of a first electrical connector and a second electrical connector with through-hole inserts installed in an integrated relay according to the present disclosure.

[0030] Figure 13Ais a schematic top view of a first electrical connector with a through-hole insert installed in an integrated relay according to the present disclosure.

[0031] Figure 13B yes Figure 13A AA cross-sectional view.

[0032] Figure 14 is a schematic circuit diagram of an integrated relay according to the present disclosure.

[0033] Figure 15 is a schematic cross-sectional view of a guide hole at the bottom of an upper housing of an integrated relay according to the present disclosure. DETAILED DESCRIPTION

[0034] The present disclosure will be described below with reference to the accompanying drawings, wherein the accompanying drawings illustrate preferred embodiments of the present disclosure. However, it should be understood that the present disclosure can be presented in a variety of different ways and is not limited to the embodiments described below; in fact, the embodiments described below are intended to make the disclosure of the present disclosure more complete and to fully illustrate the scope of protection of the present disclosure to those skilled in the art. It should also be understood that the technical features in the embodiments disclosed herein can be combined in various ways to provide more additional embodiments. Those skilled in the art may appropriately modify the detailed configuration without departing from the scope of the present disclosure.

[0035] It should be understood that like reference numerals refer to like elements throughout the drawings. In the drawings, the dimensions of some features may be distorted for clarity.

[0036] Unless otherwise specified, the terms used herein (including technical and scientific terms) shall have the meanings commonly understood by those skilled in the art in the art to which this disclosure relates. Unless otherwise specified, the terms "including," "having," or similar terms used in the specification and claims shall be interpreted as having an open-ended meaning. In other words, "including" and "having" shall be interpreted as synonymous with the terms "including at least" or "having at least."

[0037] Unless otherwise specified, the terms “upper”, “lower”, “top”, “bottom”, etc. used in this disclosure refer only to the relative orientations of the device and its related components in the state as shown in the drawings.

[0038] Unless otherwise specified, the terms "first," "second," and the like used in this disclosure are used to distinguish different elements in terms of title, but do not indicate the spatial arrangement or temporal order of these elements, and these elements should not be limited by these terms. The term "and / or" includes any and all combinations of one or more of the associated listed terms.

[0039] It should be understood that the terms used in the specification are only used to describe specific embodiments and are not intended to limit the present disclosure. For the sake of brevity and / or clarity, well-known functions or structures may not be described in detail.

[0040] In view of the above-mentioned defects in the prior art, the present disclosure provides an integrated relay. An embodiment for implementing the present disclosure will be described in detail below with reference to the accompanying drawings.

[0041] like Figures 1 to 15 As shown, according to an embodiment of the present disclosure, an integrated relay is provided. The integrated relay may be, for example, a high-voltage DC relay, a double relay, or any other known relay, which can be used in various occasions requiring relay control, such as in electric vehicles.

[0042] The integrated relay includes an upper housing assembly, a lower housing 2 and a relay component (not shown). The upper housing assembly includes an upper housing 1. The upper housing 1 and the lower housing 2 are made of insulating material. The insulating material can be plastic, resin material or any suitable insulating material. The upper housing 1 and the lower housing 2 define a space for accommodating the relay component. The relay component can be a component of any known relay, such as a component of a double relay, a component of a high-voltage DC relay, etc., which will not be described in detail here. The upper housing 1 also includes a fuse carrying portion 100 (see Figure 3 Since the relay components and the fuse are jointly carried by the upper housing 1 of the integrated relay, compared with separate arrangements of the relay and the fuse, the integration is higher, the space utilization is more convenient, the weight is lighter, and the cost is reduced.

[0043] The upper shell assembly also includes an electrical connector. The electrical connector can be a conductive plate such as a copper busbar or any other suitable electrical connector. The electrical connector is configured to be electrically connected to the at least one fuse. The electrical connector is formed as a whole with the upper shell. In one configuration, the electrical connector is integrally formed with the upper shell 1 by injection molding. In an alternative configuration, the electrical connector can also be formed as a whole with the upper shell by mechanical connection, welding, bonding, hot melting, crimping or other means. The electrical connector is formed as a whole with the upper shell to make the product more integrated, avoid complex wiring and wiring structure during fuse installation, thereby further reducing costs and simplifying installation.

[0044] The fuse carrier 100 may include multiple layers of fuse carriers from top to bottom for carrying multiple fuses. Figures 1 to 4The illustrated embodiment shows a three-layer fuse carrier for carrying three fuses M1, M2, and M3. However, the number of layers in the fuse carrier and the number of fuses are not limited thereto. The number of layers in the fuse carrier can be more or less than three. Accordingly, the number of fuses can also be more or less than three.

[0045] See also Figures 1 to 4 and Figure 6 The electrical connector includes a common terminal electrical connector 3. The common terminal electrical connector 3 is configured to connect to one end 16 (at the Figures 1 to 4 The common terminal electrical connector 3 can be formed integrally by a conductive plate such as a copper busbar. Figure 6 As shown in Figure 2, the integration of common terminal electrical connectors can save costs, increase reliability, and reduce the use of wiring harnesses.

[0046] The common terminal electrical connector 3 may include a fuse-bearing portion located on the uppermost layer (i.e. Figures 1 to 4 The first electrical connection portion 31 in the first layer fuse carrier portion located at the uppermost layer and at least one second electrical connection portion located in other layers. Figures 1 to 4 and Figure 6 In the example of the three-layer fuse carrier shown in FIG, two second electrical connection parts 32 and 33 are provided. The first electrical connection part 31 and the second electrical connection parts 32 and 33 are used to connect to one end 16 (in the case of the fuse) of a corresponding one of the plurality of fuses. Figures 1 to 4 The common-end electrical connector 3 may further include a third electrical connection portion 34 for electrically connecting to the output terminal 8 of the integrated relay.

[0047] The first electrical connection portion 31 can be arranged horizontally. The at least one second electrical connection portion 32 and 33 can be arranged vertically, perpendicular to the horizontal direction. With this arrangement, the topmost fuse M1 can be arranged upright and installed vertically, while the fuses M2 and M3 in the lower layers can be arranged horizontally and installed from the side. This ensures that the installation and maintenance space for the topmost fuse M1 is maximized, while also ensuring installation and maintenance space for fuses on each layer and achieving high space utilization.

[0048] The third electrical connection portion 34 can be positioned at the top of the common terminal electrical connector 3, so that it is close to the output terminal 8 of the integrated relay after assembly. The third electrical connection portion 34 can be arranged horizontally. This maximizes the installation and maintenance space for the third electrical connection portion and makes the integrated relay structure more compact.

[0049] In one configuration, the common terminal electrical connector 3 can be made of a conductive plate by bending and / or stamping. Figure 6 As shown, one end of the conductive plate in the vertical direction ( Figure 6 ), a first bend 351 is formed. At the first bend 351, the conductive plate is bent approximately 90 degrees relative to the vertical portion, thereby forming the third electrical connection portion 34 arranged in the horizontal direction. Below the third electrical connection portion 34, a second bend 352, a third bend 353, and a fourth bend 354 are formed. The conductive plate is bent approximately 90 degrees relative to the vertical portion at the second bend 352, then bent downward approximately 180 degrees at the third bend 353, and then bent downward approximately 90 degrees at the fourth bend 354, thereby forming the first electrical connection portion 31 arranged in the horizontal direction, consisting of two overlapping layers of plates. A fifth bend 355 and a sixth bend 356 may be formed below the first electrical connection portion 31. The conductive plate is bent upward and downward approximately 90 degrees at the fifth bend 355 and the sixth bend 356, respectively, to form second electrical connections 32 and 33 arranged in a vertical direction. The common-end electrical connector 3 thus formed is simple to manufacture, low in cost, and compact in structure, meeting the connection requirements of a multi-layer fuse.

[0050] See also Figures 1 to 4 and Figures 7 and 8 The electrical connector further comprises a plurality of non-common-end electrical connectors. Each of the plurality of non-common-end electrical connectors is configured to be connected to the other end 17 (at the end 16) of a corresponding one of the plurality of fuses. Figures 1 to 4 The non-common end electrical connector can be formed integrally with a conductive plate such as a copper busbar. Figures 7 to 8 The plurality of non-common end electrical connectors include a fuse-bearing portion located on the uppermost layer (i.e. Figures 1 to 4 The first electrical connection member 4 in the first layer fuse-bearing portion located at the uppermost layer and at least one second electrical connection member 5 located in other layers. Figures 1 to 4 and Figures 7 and 8 In the example of the three-layer fuse carrier shown, two second electrical connectors 5 are provided.

[0051] like Figure 7 As shown, the first electrical connector 4 includes a first portion 42 for connecting to the other end 17 of the fuse and a second portion 41 for connecting to an external circuit. The first portion 41 and the second portion 42 can be formed in a plane, that is, the first electrical connector 4 can be unbent. Figure 3As shown, the first portion 42 of the first electrical connector 4 is arranged in the horizontal direction. The second portion 41 of the first electrical connector 4 may also be arranged in the horizontal direction.

[0052] like Figure 8 As shown, the second electrical connector 5 includes a first portion 52 for connecting to the other end 17 of the fuse and a second portion 51 for connecting to an external circuit. The first portion 51 and the second portion 52 can be substantially perpendicular to each other. That is, the second electrical connector 5 is bent into an L shape. Figure 3 As shown, the first portion 52 of the second electrical connector 5 is arranged in a vertical direction. The second portion 51 of the second electrical connector 5 may be arranged in a horizontal direction.

[0053] With this arrangement, the topmost fuse M1 can be arranged in an upright position and installed vertically, while the fuses M2 and M3 in the lower layers can be arranged in a horizontal position and installed from the side. This ensures that the installation and maintenance space for the topmost fuse M1 is maximized, while also ensuring the installation and maintenance space for the fuses on each layer and achieving high space utilization. In addition, because the second portions of the first and second electrical connectors for connecting to the external circuit are arranged horizontally and parallel to each other, external wiring can be easily performed. In addition, the size and / or extension length of the second portion 41 and each second portion 51 can be designed to be the same, thereby being compatible with various types of external terminals.

[0054] Figure 14 The wiring diagram of the integrated relay according to the present disclosure is schematically illustrated, using three fuses M1, M2, and M3 as an example. As can be seen, one end of each of fuses M1, M2, and M3 is connected to the output terminal 8 of the integrated relay via a common electrical connector 3. The other end of each fuse M1, M2, and M3 is connected to external circuits C1, C2, and C3, respectively. As an example, external circuit C1 can be a heating circuit, such as a PTC heating circuit or a seat heating circuit in an automobile. External circuit C2 can be a low-voltage charging and control circuit. External circuit C3 can be an air conditioning control circuit, for example. In the present disclosure, due to the aforementioned structure, the installation and maintenance space for the topmost fuse M1 is large. Therefore, the fuses in the topmost fuse-carrying portion of the integrated relay can be connected to external circuits with relatively high failure rates, such as heating circuits, thereby facilitating rapid repair of faults.

[0055] In addition, if Figure 4 As shown schematically, a label indicating the name of the external circuit corresponding to the fuse in each layer may be provided in the fuse-bearing portion of each layer, thereby preventing incorrect connection.

[0056] like Figure 6As shown, the first electrical connection portion 31, the second electrical connection portions 32 and 33, and the third electrical connection portion 34 of the common terminal electrical connector 3 have stepped holes 312, 322, 332, and 342, respectively. Figure 7 As shown, the first portion 42 of the first electrical connector 4 has a stepped hole 422. Figure 8 As shown, the first portion 52 of the second electrical connector 5 has a stepped hole 522. The through hole insert 6 with internal thread (see Figure 10 ) is fixed on the step surface in the step hole. In one configuration, the through hole insert 6 with internal thread (see Figure 10 ) can be fixed on the step surface in the step hole by riveting. The through hole insert 6 can also be fixedly connected to the step hole by other means. A fuse can be connected on the other side of each step hole opposite to the side where the through hole insert is fixed. Specifically, one end 16 or the other end 17 of the fuse (see Figure 9 ) is aligned with the stepped hole, and bolts 13 are inserted through the fuse's through-hole, the stepped hole, and the through-hole of the through-hole insert 6, so that the external threads of bolts 13 mate with the internal threads of the through-hole insert 6, thereby securely connecting the fuse to the respective electrical connectors or components. This approach allows for the creation of standardized electrical connectors in a very simple manner, and fuse installation is accomplished in a simple and universal manner, simplifying fuse installation and reducing manufacturing costs.

[0057] Furthermore, on the side of the first electrical connection portion 31, the second electrical connection portions 32 and 33, the third electrical connection portion 34, the first portion 42 of the first electrical connector 4, and the first portion 52 of the second electrical connector 5 opposite to the side on which the through-hole insert 6 is secured, that is, on the side of these portions where the mounting bolts 13 are located, bosses 311, 321, 331, 341, 421, and 521 are formed around the stepped holes 312, 322, 332, 342, 422, and 522, respectively. The provision of these bosses prevents burrs from entering the connection surface with the fuse during processes such as injection molding, thereby improving product yield.

[0058] Figure 13A and Figure 13B Taking the first connector 4 as an example, the diagram illustrates the fixed connection method of the through-hole insert 6. As can be seen, the stepped hole has a stepped surface 423. The through-hole insert 6 is fixedly connected to the stepped surface within the stepped hole, for example, by riveting. A boss 421 is formed on the side of the first connector opposite the side where the through-hole insert 6 is fixed. Figure 11 and Figure 12 The common end electrical connector 3 with the through hole insert 6 fixed thereto and the first electrical connector 4 and the second electrical connector 5 with the through hole insert 6 fixed thereto are shown.

[0059] In addition, if Figure 3 As shown, at least one layer of the multi-layer fuse carrier can be provided with a support rib 7 for supporting the fuse. In one configuration, the support rib 7 is provided on the uppermost layer of the fuse carrier.

[0060] See also Figure 5 The bottom of the upper housing 1 may have at least one fixing hole 11 for fixing the integrated relay. The fixing hole can be used to cooperate with the mounting post on the mounting plane to fix the integrated relay. A gasket 10 is integrally injection-molded in the fixing hole 11 to protect the upper housing 1 from damage during installation. Figure 15 The lower portion of the fixing hole 11 has a guide portion 12 that tapers upward from the bottom. The guide portion is used to make it easier for the integrated relay to be installed on the installation column of the installation plane.

[0061] In the present disclosure, the common-end electrical connector 3, the first electrical connector 4, and the second electrical connector 5 can be integrally injection-molded into the upper housing 1 along with the gasket 10 after the through-hole insert 6 is secured, thereby forming an upper housing assembly. This approach achieves a high degree of integration, a simple manufacturing process, convenient assembly, and reduced manufacturing costs.

[0062] Although the present disclosure has been described with reference to exemplary embodiments, it should be understood that the present disclosure is not limited to the exemplary embodiments described above. Various variations and modifications may be made to the exemplary embodiments described above without departing from the scope of the present disclosure. The scope of the appended claims should be accorded the broadest interpretation so as to encompass all such variations and modifications and equivalent structures and functions.

Claims

1. An integrated relay comprising an upper housing assembly, a lower housing, and a relay component, characterized in that: The upper housing assembly includes an upper housing and an electrical connector. The upper housing and the lower housing are made of insulating material and define a space for accommodating the relay component. The upper housing also includes a fuse-carrying portion for carrying at least one fuse. The electrical connector is configured to be electrically connected to the at least one fuse and is formed as one piece with the upper housing.

2. The integrated relay according to claim 1, characterized in that: The fuse-carrying portion includes a multi-layer fuse-carrying portion from top to bottom for carrying multiple fuses, and the electrical connector includes a common-end electrical connector and multiple non-common-end electrical connectors. The common-end electrical connector is configured to be connected to one end of each fuse in the multiple fuses, and each non-common-end electrical connector in the multiple non-common-end electrical connectors is configured to be connected to the other end of a corresponding one of the multiple fuses, which is opposite to the one end.

3. The integrated relay according to claim 2, characterized in that: The common-end electrical connector is integrally formed from a conductive plate, and each of the plurality of non-common-end electrical connectors is integrally formed from a conductive plate.

4. The integrated relay according to claim 3, characterized in that: The common-end electrical connector includes a first electrical connector located in the topmost fuse-carrying portion and at least one second electrical connector located in other layers, wherein the first electrical connector is arranged in a horizontal direction and the at least one second electrical connector is arranged in a vertical direction. The multiple non-common-end electrical connectors include a first electrical connector located in the topmost fuse-carrying portion and at least one second electrical connector located in other layers, and the first electrical connector and the at least one second electrical connector both include a first part for connecting to the other end of the fuse and a second part for connecting to an external circuit, wherein the first part of the first electrical connector is arranged in a horizontal direction and the first part of the second electrical connector is arranged in a vertical direction.

5. The integrated relay according to claim 4, characterized in that: The common-end electrical connector further includes a third electrical connection portion for electrically connecting to the output end of the integrated relay, and the third electrical connection portion is arranged in a horizontal direction.

6. The integrated relay according to claim 4, characterized in that: The second portion of the first electrical connector and the second portion of the at least one second electrical connector are both arranged in a horizontal direction.

7. The integrated relay according to claim 4, characterized in that: The first electrical connection portion, the second electrical connection portion, the first portion of the first electrical connector, and the first portion of the second electrical connector all have a stepped hole, a through-hole insert with an internal thread is fixed on a stepped surface in the stepped hole, and a boss is formed around the stepped hole on a side of the first electrical connection portion, the second electrical connection portion, the first portion of the first electrical connector, and the first portion of the second electrical connector opposite to a side on which the through-hole insert is fixed.

8. The integrated relay according to claim 5, characterized in that: The third electrical connection portion has a stepped hole, a through-hole insert with an internal thread is fixed on a stepped surface in the stepped hole, and a boss is formed around the stepped hole on a side of the third electrical connection portion opposite to the side where the through-hole insert is fixed.

9. The integrated relay according to claim 1, characterized in that: The bottom of the upper housing has at least one fixing hole for fixing the integrated relay, a gasket is integrally injection-molded in the fixing hole, and the lower portion of the fixing hole has a guide portion that tapers upward from the bottom.

10. The integrated relay according to any one of claims 1 to 9, characterized in that: The electrical connector and the upper housing are integrally formed by injection molding.

11. The integrated relay according to any one of claims 1 to 9, characterized in that: The integrated relay further includes the fuse.

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