Contactor assembly integrated with circuit board and battery system

Abstract

The utility model relates to a contactor assembly integrated with a circuit board. The contactor assembly comprises a housing; the first contactor comprises a first moving contact located in the shell, and a first positive static contact and a first negative static contact which are partially exposed from the shell; the second contactor comprises a second moving contact in the shell, and a second positive static contact and a second negative static contact which are partially exposed from the shell; and a circuit board mounted on the housing, on which a first adhesion detection unit associated with the first contactor and a second adhesion detection unit associated with the second contactor are integrated. The contactor assembly integrated with the circuit board can locally or self integrate a contact adhesion detection function, so that compact integration of a plurality of originally discrete contactors is realized, and compactness, reliability and high efficiency of contact adhesion detection of the plurality of contactors are guaranteed. In addition, the utility model also relates to a battery system.

Description

Technical Field

[0001] This utility model relates to the field of contactor technology, and in particular to a contactor assembly and battery system with an integrated circuit board. Background Technology

[0002] With the rapid development of electric and hybrid vehicles, the importance of power battery technology in improving cost-effectiveness and performance is becoming increasingly prominent. In these electric vehicles, high-voltage contactors (or high-voltage relays) are key components for maintaining the safety of high-voltage circuits, and their performance directly affects the safety and reliability of the electric vehicle. High-voltage contactors not only need to possess high voltage withstand capability, load withstand capability, and impact resistance, but also excellent arc extinguishing and breaking capabilities.

[0003] However, a major failure mode faced by high-voltage contactors is contact adhesion or contact sticking. In high-voltage environments, contact sticking can prevent the contactor from disconnecting properly. If this condition is not detected in time, it can lead to serious safety accidents. For example, under the operating conditions of a power battery, its output voltage can reach hundreds of volts, and the contactor is used to control the on / off state of the battery output. Under certain special operating or environmental conditions, contactor contacts are prone to sticking, which not only exposes downstream components to high-voltage, high-current surges but may also cause fuses to burn out, leading to even more serious safety hazards.

[0004] Currently, the detection of adhesion in high-voltage contactors mainly relies on hardware voltage sampling technology in the battery management system. This approach requires installing additional wiring harnesses in the battery distribution unit and fixing them to each stationary contact of the contactor. The battery management system determines the adhesion status by comparing the voltages at the front and rear ends of the contactor. Although existing technologies have proposed adhesion detection methods and systems for individual contactors, such as using voltage sampling units and logic judgment units to monitor a single contactor, in practical applications, these methods face problems such as complex circuit design, non-compact structure, and increased manufacturing costs when multiple contactors are present. Furthermore, the operating states of different contactors influence each other, making it difficult for existing detection schemes to accurately determine the true condition of each contactor. For example, from an installation process perspective, a large number of wiring harnesses need to be precisely installed and fixed to each contactor contactor, a process that is extremely cumbersome. The compact interior space of a car and limited wiring space mean that arranging a large number of wiring harnesses not only requires significant manpower and time but also demands extremely high wiring standards; even slight errors can lead to mutual interference between wiring harnesses, affecting the accuracy of signal transmission. From a system configuration perspective, a dedicated signal processing module must be included in the battery management system to handle these additional acquired signals. This module not only needs high-speed, high-precision data processing capabilities but also needs to work collaboratively with other functional modules of the battery management system. This undoubtedly increases the hardware cost and software programming complexity of the battery management system.

[0005] Furthermore, a scheme involving adding an auxiliary contact structure to the contactor is known. In this scheme, the auxiliary contact operates synchronously with the main contact, and the monitoring of the continuity of the auxiliary contact indirectly detects whether the main contact is stuck. However, this scheme has several drawbacks. It requires an additional mechanical motion mechanism on the contactor, which not only results in the use of more components but also necessitates insulation between the main and auxiliary contacts, making the overall structure of the contactor relatively complex. The main contacts typically use a thicker copper alloy to ensure good conductivity and durability, while the auxiliary contacts are often implemented with thinner springs. This makes the reliability of the auxiliary contacts lower than that of the main contacts, thus reducing the overall reliability of the contactor. In addition, the added mechanical structure and components significantly increase the cost.

[0006] In summary, existing contact adhesion detection solutions may have problems such as high cost, complex structure, large space occupation, and / or poor reliability, especially for contact adhesion detection solutions for multiple contactors.

[0007] Therefore, those skilled in the art urgently need a more reliable, compact, efficient, and / or cost-effective solution for detecting contact adhesion in contactors. Utility Model Content

[0008] Therefore, the purpose of this invention is to provide a contactor assembly with an integrated circuit board that overcomes at least one defect in the prior art. This achieves the beneficial technical effect that the contactor assembly with an integrated circuit board of this invention can locally integrate or integrate a contact adhesion detection function, thereby achieving compact integration of multiple previously separate contactors while ensuring the compactness, reliability, and efficiency of contact adhesion detection for multiple contactors. Furthermore, this invention also relates to a battery system.

[0009] To achieve the above objectives, the first aspect of this utility model provides a contactor assembly with an integrated circuit board, the contactor assembly comprising: a housing; a first contactor including a first moving contact located within the housing and a first positive stationary contact and a first negative stationary contact partially exposed from the housing; a second contactor including a second moving contact located within the housing and a second positive stationary contact and a second negative stationary contact partially exposed from the housing; and a circuit board mounted on the housing, wherein a first adhesion detection unit disposed on the first contactor and a second adhesion detection unit disposed on the second contactor are integrated on the circuit board.

[0010] In some embodiments, the contactor assembly includes: a first electrical connection element configured to snap onto a snap-fit ​​slot of a first positive stationary contact to achieve electrical connection between the first electrical connection element and the first positive stationary contact; a second electrical connection element configured to snap onto a snap-fit ​​slot of a first negative stationary contact to achieve electrical connection between the second electrical connection element and the first negative stationary contact; a third electrical connection element configured to snap onto a snap-fit ​​slot of a second positive stationary contact to achieve electrical connection between the third electrical connection element and the second positive stationary contact; and a fourth electrical connection element configured to snap onto a snap-fit ​​slot of a second negative stationary contact to achieve electrical connection between the fourth electrical connection element and the second negative stationary contact.

[0011] In some embodiments, the circuit board includes a flexible circuit board, which includes a first circuit region and a second circuit region.

[0012] In some embodiments, the first circuit area of ​​the flexible circuit board is at least partially mounted on the first surface of the housing, and the first positive stationary contact and the first negative stationary contact of the first contactor, as well as the second positive stationary contact and the second negative stationary contact of the second contactor, are exposed from the first surface of the housing.

[0013] In some embodiments, a second circuit region of the flexible circuit board is at least partially mounted on a second surface of the housing, the second surface being adjacent to the first surface.

[0014] In some embodiments, the circuit board includes a substrate that is mounted to the back of a second circuit region of the flexible circuit board.

[0015] In some embodiments, the circuit board is configured to be mounted to the second surface of the housing from top to bottom or from the side, wherein the second circuit region of the flexible circuit board, together with the substrate on the back, is fixed to the second surface of the housing, while the first circuit region of the flexible circuit board is bent relative to the second circuit region to the first surface of the housing and fixed to the second surface of the housing.

[0016] In some embodiments, a first line electrically connected to a first electrical connection element, a second line electrically connected to a second electrical connection element, a third line electrically connected to a third electrical connection element, and a fourth line electrically connected to a fourth electrical connection element are provided in the first circuit region of the flexible circuit board.

[0017] In some embodiments, the first adhesion detection unit and the second adhesion detection unit are provided in the second circuit region of the flexible circuit board.

[0018] In some embodiments, a limiting structure for a circuit board is formed on the second surface of the housing, and the second circuit area of ​​the flexible circuit board, together with the substrate on the back, is limited to the limiting structure.

[0019] In some embodiments, the first circuit area of ​​the flexible circuit board is attached to the first surface of the housing by bonding, welding, threading, and / or snapping.

[0020] In some embodiments, the second circuit area of ​​the flexible circuit board is attached to the second surface of the housing by bonding, welding, threading, and / or snapping.

[0021] In some embodiments, the second surface is perpendicular to the first surface.

[0022] In some embodiments, the first contactor further includes a first control module for controlling the on / off state between the first moving contact and the first positive stationary contact and the first negative stationary contact; the second contactor further includes a second control module for controlling the on / off state between the second moving contact and the second positive stationary contact and the second negative stationary contact.

[0023] In some embodiments, a first control pin of the first control module and a second control pin of the second control module extend from a second surface of the housing, and the first control pin and the second control pin are configured to extend and be electrically connected to a second circuit area of ​​the flexible circuit board.

[0024] In some embodiments, a connector is integrated on a second circuit region of the flexible circuit board, wherein the connector integrates: a first electrical connection terminal for a first control pin, wherein a control voltage can be applied to the first control pin via the first electrical connection terminal; a second electrical connection terminal for a second control pin, wherein a control voltage can be applied to the second control pin via the second electrical connection terminal; a third electrical connection terminal for a first adhesion detection unit, wherein a first signal output characterizing the contact adhesion state of the first contactor can be obtained via the third electrical connection terminal; and a fourth electrical connection terminal for a second adhesion detection unit, wherein a second signal output characterizing the contact adhesion state of the second contactor can be obtained via the fourth electrical connection terminal.

[0025] In some embodiments, the first electrical connection element includes a first arcuate contact portion and a first protruding pin extending upward from the first arcuate contact portion. The first arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of a first negative stationary contact, and the first protruding pin is configured to pass through a first through-hole in a first circuit region and be soldered to a first line. The second electrical connection element includes a second arcuate contact portion and a second protruding pin extending upward from the second arcuate contact portion. The second arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of a second negative stationary contact, and the second protruding pin is configured to pass through a second through-hole in a second circuit region and be soldered to a second line. The third electrical connection element includes a third arc-shaped contact portion and a third protruding pin extending upward from the third arc-shaped contact portion. The third arc-shaped contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the first positive stationary contact, and the third protruding pin is configured to pass through a third through hole in the third circuit region and be soldered to the third line. The fourth electrical connection element includes a fourth arc-shaped contact portion and a fourth protruding pin extending upward from the fourth arc-shaped contact portion. The fourth arc-shaped contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the second positive stationary contact, and the fourth protruding pin is configured to pass through a fourth through hole in the fourth circuit region and be soldered to the fourth line.

[0026] In some embodiments, the first adhesion detection unit includes a first input, a second input, and a first output. The first input is configured to be electrically connected to a first negative stationary contact via a second line and a second electrical connection element. The second input is configured to be electrically connected to a second negative stationary contact via a fourth line and a fourth electrical connection element. The first output is configured to output a first signal characterizing the contact adhesion state of the first contactor. The second adhesion detection unit includes a third input, a fourth input, and a second output. The third input is configured to be electrically connected to a first positive stationary contact via a first line and a first electrical connection element. The fourth input is configured to be electrically connected to a second positive stationary contact via a third line and a third electrical connection element. The second output is configured to output a second signal characterizing the contact adhesion state of the second contactor.

[0027] In some embodiments, the first adhesion detection unit includes a first input-side circuit, a first electrical isolation module, and a first output-side circuit. The first input-side circuit is configured to adjust a first input voltage falling on a first input and a second input, and to provide the adjusted first input voltage to the first electrical isolation module. The first electrical isolation module is configured to provide a first output voltage to the first output-side circuit based on the adjusted first input voltage. The first output-side circuit is configured to adjust the first output voltage and output the adjusted first output voltage as a first signal characterizing the contact adhesion state of the first contactor. The second adhesion detection unit includes a second input-side circuit, a second electrical isolation module, and a second output-side circuit. The second input-side circuit is configured to adjust a second input voltage falling on a third input and a fourth input, and to provide the adjusted second input voltage to the second electrical isolation module. The second electrical isolation module is configured to provide a second output voltage to the second output-side circuit based on the adjusted second input voltage. The second output-side circuit is configured to adjust the second output voltage and output the adjusted second output voltage as a second signal characterizing the contact adhesion state of the second contactor.

[0028] In some embodiments, the contactor assembly includes multiple pairs of contactors, each pair consisting of a first contactor and a second contactor, wherein the contactor assembly includes: a first pair of contactors, the first pair of contactors including a positive contactor serving as a first contactor in a DC charging circuit and a negative contactor serving as a second contactor in a DC charging circuit; and / or a second pair of contactors, the second pair of contactors including a positive contactor serving as a first contactor in a battery feeding circuit and a negative contactor serving as a second contactor in a battery feeding circuit; and / or a third pair of contactors, the third pair of contactors including a positive contactor serving as a first contactor in an AC charging circuit and a negative contactor serving as a second contactor in an AC charging circuit.

[0029] To achieve the above objectives, a second aspect of the present invention provides a battery system comprising a battery, a battery power distribution unit, and a battery management system, wherein the battery power distribution unit includes a contactor assembly with an integrated circuit board as described in some embodiments of the present invention. Attached Figure Description

[0030] The accompanying drawings, which form part of this specification, illustrate embodiments of the present invention and, together with the specification, serve to explain the principles of the present invention.

[0031] Figure 1 A simplified schematic block diagram of the battery system is shown.

[0032] Figure 2 A schematic block diagram of a battery system according to some embodiments of the present invention is shown;

[0033] Figure 3 An exemplary perspective view of a contactor assembly according to some embodiments of the present invention is shown;

[0034] Figure 4 and Figure 5 Some example diagrams of a circuit board for a contactor assembly according to some embodiments of the present invention are shown;

[0035] Figure 6 and Figure 7 Some exemplary mounting views of a circuit board for a contactor assembly according to some embodiments of the present invention are shown;

[0036] Figure 8 An exemplary perspective view of the electrical connection elements of a contactor assembly according to some embodiments of the present invention is shown;

[0037] Figure 9 An exemplary perspective view of the stationary contact of a contactor assembly according to some embodiments of the present invention is shown;

[0038] Figure 10 A schematic block diagram of an adhesion detection unit for a contactor assembly according to some embodiments of the present invention is shown.

[0039] Note that in the embodiments described below, the same reference numerals are sometimes used across different figures to denote the same parts or parts having the same function, and repeated descriptions are omitted. In some cases, similar reference numerals and letters are used to denote similar items, so once an item is defined in one figure, it does not need to be discussed further in subsequent figures.

[0040] For ease of understanding, the positions, dimensions, and ranges of the structures shown in the accompanying drawings and other materials may not represent actual positions, dimensions, and ranges. Therefore, this utility model is not limited to the positions, dimensions, and ranges disclosed in the accompanying drawings and other materials. Detailed Implementation

[0041] The present invention will now be described with reference to the accompanying drawings, which illustrate several embodiments of the present invention. However, it should be understood that the present invention can be presented in many 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 invention more complete and to fully illustrate the scope of protection of the present invention to those skilled in the art. It should also be understood that the embodiments disclosed herein can be combined in various ways to provide more additional embodiments.

[0042] In the various embodiments described, the same reference numerals or element names are used for the same elements, and the disclosure contained throughout the specification can be applied semantically to elements with the same reference numerals or element names. Furthermore, in the various embodiments, the number, implementation, and / or arrangement of elements are not limited to the examples shown, but other numbers, implementations, and / or arrangements can be selected according to actual needs.

[0043] In this document, spatial relation terms such as "up," "down," "left," "right," "front," "back," "high," and "low" are used to describe the relationship between one feature and another in the accompanying drawings. It should be understood that spatial relation terms include not only the orientation shown in the drawings but also different orientations of the device during use or operation. For example, when the device in the drawings is inverted, a feature previously described as "below" other features can now be described as "above" other features. The device can also be oriented in other ways (rotated 90 degrees or in other orientations), in which case the relative spatial relationships will be interpreted accordingly.

[0044] In this document, the term “A or B” includes both “A and B” and “A or B”, rather than exclusively including only “A” or only “B”, unless otherwise specified.

[0045] In this document, the terms "illustrative" or "exemplary" mean "used as an example, instance, or illustration," and not as a "model" to be precisely copied. Any implementation described herein by example is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, this invention is not limited to any theory expressed or implied in the foregoing technical field, background art, or specific embodiments.

[0046] In this document, the term “substantially” means any minor variation caused by defects in design or manufacturing, tolerances of devices or components, environmental influences and / or other factors.

[0047] Additionally, terms such as “first,” “second,” etc., may be used in this document for reference purposes only and are not intended to be limiting. For example, unless the context clearly indicates otherwise, the words “first,” “second,” and other such numerical terms relating to structures or elements do not imply order or sequence.

[0048] Some embodiments of the present invention will now be described in more detail with reference to the accompanying drawings.

[0049] like Figure 1 As shown, a simplified schematic block diagram of the battery system 100 is illustrated. Figure 1As shown, the battery system 100 may include a battery 1, a battery power distribution unit 2, and a battery management system 3. In some embodiments, the battery power distribution unit 2 and the battery management system 3 may be configured as independent modules. In some embodiments, the battery power distribution unit 2 and the battery management system 3 may be configured as an integrated module.

[0050] In electric vehicles, battery 1 (also known as power battery) may have an operating voltage of, for example, 100V to 1000V, especially 400V to 800V, and is configured to power the electric drive system.

[0051] The battery power distribution unit 2 (also known as the battery circuit breaker unit) can be configured to control the on / off state of the battery charging circuit and the battery power supply circuit. For this purpose, the battery power distribution unit 2 may include contactors or relays applied in the respective battery charging circuit and battery power supply circuit. It should be understood that the contactor of this invention can also be referred to as a relay, and this distinction is not required herein.

[0052] In some embodiments, the battery power distribution unit 2 may include a first pair of contactors, which includes a positive contactor and a negative contactor used in a DC charging circuit or a fast charging circuit.

[0053] Alternatively or additionally, the battery power distribution unit 2 may include a second pair of contactors, the second pair of contactors including a positive contactor and a negative contactor used in the battery power supply circuit.

[0054] Alternatively or additionally, the battery power distribution unit 2 may include a third pair of contactors, which includes a positive contactor and a negative contactor used in an AC charging circuit or a slow charging circuit.

[0055] A major failure mode faced by these contactors is contact adhesion or contact sticking. In high-voltage environments, contact sticking can prevent the contactor from disconnecting properly. If this condition is not detected in time, it can lead to serious safety accidents. For example, under the operating conditions of a power battery, its output voltage can reach hundreds of volts, and the contactor is used to control the on / off state of the battery output. Under certain special operating or environmental conditions, contactor contacts are prone to sticking, which not only exposes downstream components to high-voltage, high-current surges but may also cause fuses to burn out, leading to even more serious safety hazards.

[0056] This invention proposes a contactor assembly with an integrated circuit board that integrates a contact adhesion detection function locally or within itself. This achieves compact integration of multiple previously separate contactors while ensuring the compactness, reliability, and efficiency of contact adhesion detection. In some embodiments, this contactor assembly can integrate the first pair of contactors described above for use in a DC charging circuit, and / or the second pair of contactors for use in a battery feeding circuit, and / or the third pair of contactors for use in an AC charging circuit. That is, the contactor assembly can be configured as twin contactors, triplets, quadruplets, quintuplets, sextuplets, septuplets, etc.

[0057] Reference Figure 2 and 3 The present invention will further describe in detail the battery system and contactor assembly according to some embodiments of the present invention. Figure 2 A schematic block diagram of a battery system according to some embodiments of the present invention is shown; Figure 3 An exemplary perspective view of a contactor assembly according to some embodiments of the present invention is shown.

[0058] like Figure 2 and 3 As shown, the contactor assembly 50 may include a housing 10, a first contactor 21, a second contactor 22, and a circuit board 30 mounted on the housing 10. A first adhesion detection unit 31 disposed for the first contactor 21 and a second adhesion detection unit 32 disposed for the second contactor 22 may be integrated on the circuit board 30. In the illustrated embodiment, the contactor assembly 50 includes only one pair of contactors; therefore, the contactor assembly 50 may also be referred to as a twin contactor. It should be understood that in other embodiments, the contactor assembly 50 may include a greater number of contactors, and is not limited to the illustrated embodiment.

[0059] The first contactor 21 may include a first moving contact located within the housing 10 and a first positive stationary contact 211 and a first negative stationary contact 212 partially exposed from the housing 10. The switching function of the first contactor 21 can be achieved by controlling the movement of the first moving contact to cause the connection and disconnection between the first positive stationary contact 211 and the first negative stationary contact 212. The second contactor 22 may include a second moving contact located within the housing 10 and a second positive stationary contact 221 and a second negative stationary contact 222 partially exposed from the housing 10. The switching function of the second contactor 22 can be achieved by controlling the movement of the second moving contact to cause the connection and disconnection between the second positive stationary contact 221 and the second negative stationary contact 222. In some embodiments, this pair of contactors may be configured as the first pair of contactors mentioned above for use in a DC charging circuit. In some embodiments, this pair of contactors may be configured as the second pair of contactors mentioned above for use in a battery feeding circuit. In some embodiments, this pair of contactors may be configured as the third pair of contactors mentioned above for use in an AC charging circuit.

[0060] The circuit board 30 of the contactor assembly 50 may include a first adhesion detection unit 31 disposed on the first contactor 21 and a second adhesion detection unit 32 disposed on the second contactor 22. The first adhesion detection unit 31 may include a first input 311, a second input 312 and a first output 313. The first input 311 is configured to be electrically connected to a first negative stationary contact 212, the second input 312 is configured to be electrically connected to a second negative stationary contact 222 (the second negative stationary contact 222 may be electrically connected to the negative terminal of a battery), and the first output 313 is configured to output a first signal characterizing the contact adhesion state of the first contactor 21. The second adhesion detection unit 32 may include a third input 321, a fourth input 322, and a second output 3. The third input 321 is configured to be electrically connected to the first positive stationary contact 211 (the first positive stationary contact 211 may be electrically connected to the positive terminal of the battery), the fourth input 322 is configured to be electrically connected to the second positive stationary contact 221, and the second output 3 is configured to output a second signal characterizing the contact adhesion state of the second contactor 22.

[0061] Figure 4 and Figure 5 Views of the circuit board 30 of the contactor assembly 50 according to some embodiments of the present invention are shown. Figure 4 and 5 As shown, the circuit board 30 may include a flexible circuit board, which may include a first circuit region 301 and a second circuit region 302. The first circuit region 301 may have integrated or printed wiring for the electrical connection elements 36, which will be described in detail below. The second circuit region 302 may have a first adhesion detection unit 31 and a second adhesion detection unit 32.

[0062] The first circuit region 301 of the flexible circuit board can be at least partially mounted on a first surface of the housing 10, such as the upper surface, where the first positive stationary contact 211 and the first negative stationary contact 212 of the first contactor 21, and the second positive stationary contact 221 and the second negative stationary contact 222 of the second contactor 22, protrude from the first surface of the housing 10. The second circuit region 302 of the flexible circuit board can be at least partially mounted on a second surface of the housing 10 adjacent to the first surface. For example, the second surface can be perpendicular to the first surface.

[0063] To enhance the strength of the circuit board 30, the circuit board 30 may also include a substrate 33. For example... Figure 5 As shown, the substrate 33 can be mounted, for example, bonded to the back of the second circuit region 302 of the flexible circuit board. Therefore, the substrate 33 can also be referred to as a reinforcing rigid board, and its material can be, for example, FR4 or PI material.

[0064] Figure 6 and Figure 7 Mounting views of the circuit board 30 of the contactor assembly 50 according to some embodiments of the present invention are shown. In some embodiments, such as Figure 6 As shown, the circuit board 30 can be configured to be mounted from top to bottom onto the second surface of the housing 10. In some embodiments, such as Figure 7 As shown, the circuit board 30 can be configured to be mounted on the second surface of the housing 10 from the side.

[0065] In some embodiments, the second circuit region 302 of the flexible circuit board, together with the back substrate 33, can be fixed to the second surface of the housing 10, while the first circuit region 301 of the flexible circuit board can be bent relative to the second circuit region 302 to the first surface of the housing 10 and fixed to the second surface of the housing 10. For example, a limiting structure 17 for the circuit board 30 can be formed on the second surface of the housing 10, and the second circuit region 302 of the flexible circuit board, together with the back substrate 33, is limited to the limiting structure 17. Additionally or alternatively, the first circuit region 301 of the flexible circuit board can be attached to the first surface of the housing 10 by bonding, welding, threading, and / or snapping. Additionally or alternatively, the second circuit region 302 of the flexible circuit board can be attached to the second surface of the housing 10 by bonding, welding, threading, and / or snapping.

[0066] In order to achieve a reliable and simple electrical connection between the first adhesion detection unit 31 and the second adhesion detection unit 32 and the corresponding stationary contacts 211, 212, 221, 222, the contactor assembly 50 may further include an electrical connection element 36 mounted on the corresponding stationary contacts 211, 212, 221, 222. The contactor assembly 50 may include a first electrical connection element 36 configured to snap onto a slot 38 of a first positive stationary contact 211 to achieve an electrical connection between the first electrical connection element 36 and the first positive stationary contact 211; a second electrical connection element 36 configured to snap onto a slot 38 of a first negative stationary contact 212 to achieve an electrical connection between the second electrical connection element 36 and the first negative stationary contact 212; a third electrical connection element 36 configured to snap onto a slot 38 of a second positive stationary contact 221 to achieve an electrical connection between the third electrical connection element 36 and the second positive stationary contact 221; and a fourth electrical connection element 36 configured to snap onto a slot 38 of a second negative stationary contact 222 to achieve an electrical connection between the fourth electrical connection element 36 and the second negative stationary contact 222. Accordingly, the first circuit region 301 may be provided with a first line electrically connected to the first electrical connection element 36, a second line electrically connected to the second electrical connection element 36, a third line electrically connected to the third electrical connection element 36, and a fourth line electrically connected to the fourth electrical connection element 36.

[0067] Reference Figure 8 and 9 Further, exemplary perspective views of the corresponding electrical connection element 36 and stationary contacts 211, 212, 221, 222 are provided. (See reference) Figures 3 to 5 and appendix Figure 8 and 9 The corresponding electrical connection element 36 may include an arcuate contact portion 361 and an upwardly extending protruding pin 362 from the arcuate contact portion 361. The arcuate contact portion 361 is configured to snap, in particular, interfere with, the outer peripheral wall of the corresponding stationary contacts 211, 212, 221, 222, and the protruding pin 362 may be configured to pass through the corresponding through hole 366 on the first circuit region 301 and be soldered to the corresponding circuit. Advantageously, the corresponding electrical connection element 36 may surround 50%, 60%, 80%, or 90% or more of the outer peripheral wall of the corresponding stationary contacts 211, 212, 221, 222 to achieve a large area and good electrical contact. In some embodiments, the corresponding electrical connection element 36 may be configured as an annular contact element. Advantageously, the protruding pin 362 of the corresponding electrical connection element 36 may be configured to interfere with the corresponding through hole 366 to achieve reliable electrical connection and a robust assembly structure.

[0068] It should be understood that the arrangement and configuration of the circuit board 30 and the electrical connection element 36 can be flexibly designed and are not limited to the illustrated embodiment. For example, at least a portion of the circuit board 30 and / or the electrical connection element 36 may be arranged inside the housing 10 or on other surfaces or other locations. Furthermore, it should be understood that the at least one electrical connection element 36 may also be configured as other forms of electrical connectors, such as cables or electrical conductor structures, and this should not be interpreted as limiting.

[0069] like Figure 6 and 7 As shown, the first contactor 21 may further include a first control module for controlling its own on / off state. The second contactor 22 also includes a second control module for controlling its own on / off state. Control pins 388 of the respective control modules can extend from the second surface of the housing 10 and are configured to extend and electrically connect to the second circuit region 302 of the flexible circuit board. In some embodiments, the first and second control modules may, for example, each include a coil device, and the control pins 388 of the respective coil devices can extend and electrically connect to the second circuit region 302 of the flexible circuit board. For example, an opening 390, such as a U-shaped opening, may be provided on the underside of the second circuit portion of the circuit board 30 for the control pins 388 of the respective coil devices to extend into. The control pins 388 can pass through the opening 390 and be soldered to the second circuit region 302 of the flexible circuit board.

[0070] like Figures 3 to 7 As shown, a connector 39 can be integrated on the second circuit region 302 of the flexible circuit board. This connector 39 can integrate a first electrical connection terminal for the first control pin 388 and a third electrical connection terminal for the first adhesion detection unit 31. The battery management system 3 can be configured to apply a control voltage to the first control pin 388 via the first electrical connection terminal and to apply a control voltage to the second control pin 388 via the second electrical connection terminal. Furthermore, the connector 39 can integrate a third electrical connection terminal for the first adhesion detection unit 31 and a fourth electrical connection terminal for the second adhesion detection unit 32. The battery management system 3 can be configured to acquire a first signal output characterizing the contact adhesion state of the first contactor 21 via the third electrical connection terminal and a second signal output characterizing the contact adhesion state of the second contactor 22 via the fourth electrical connection terminal. It should be understood that the electrical connection between the battery management system 3 and the circuit board 30 can be achieved through wired and / or wireless connections, which will not be elaborated further here.

[0071] Therefore, the battery management system 3 can be configured to determine the contact adhesion state of the first contactor 21 based on a first signal and take corresponding measures accordingly; and to determine the contact adhesion state of the second contactor 22 based on a second signal and take corresponding measures accordingly. It should be understood that when performing contact adhesion detection, the first contactor 21 and the second contactor 22 should be in a theoretically open state. That is, the battery management system 3 can be configured to apply a disconnection signal to the first and second electrical connection terminals to cause the moving contact of the first contactor 21 to move, resulting in the disconnection between the first positive stationary contact 211 and the first negative stationary contact 212, and to cause the moving contact of the second contactor 22 to move, resulting in the disconnection between the second positive stationary contact 221 and the second negative stationary contact 222.

[0072] Advantageously, the contact adhesion detection function of the contactor assembly 50 fully utilizes the advantage of integrating multiple contactors together, simplifying the circuit complexity of contact adhesion detection. In detecting adhesion for the first contactor 21, the second negative stationary contact 222 of the second contactor 22 maintains an electrical connection with the negative terminal of the battery, thereby forming a closed loop when contact adhesion occurs. Similarly, in detecting adhesion for the second contactor 22, the first positive stationary contact 211 of the first contactor 21 maintains an electrical connection with the positive terminal of the battery, thereby forming a closed loop when contact adhesion occurs. Therefore, the contactor assembly 50 of this invention can efficiently and compactly integrate multiple contactors and perform contact adhesion detection for multiple contactors.

[0073] In some embodiments, the contactor assembly 50 may include a first pair of contactors, the first pair of contactors including a positive contactor as a first contactor 21 for use in a DC charging circuit and a negative contactor as a second contactor 22 for use in a DC charging circuit. Additionally or alternatively, the contactor assembly 50 may include a second pair of contactors, the second pair of contactors including a positive contactor as a first contactor 21 for use in a battery feeding circuit and a negative contactor as a second contactor 22 for use in a battery feeding circuit. Additionally or alternatively, the contactor assembly 50 may include a third pair of contactors, the third pair of contactors including a positive contactor as a first contactor 21 for use in an AC charging circuit and a negative contactor as a second contactor 22 for use in an AC charging circuit. It should be understood that the first contactor 21 and the second contactor 22 involved in each pair of contactors, and their first adhesion detection unit 31 and second adhesion detection unit 32, can be referenced according to... Figure 3 The content described in the examples will not be repeated here.

[0074] Reference Figure 10The diagram further illustrates a schematic block diagram of the adhesion detection units 31, 32 of the contactor assembly 50 according to some embodiments of the present invention.

[0075] like Figure 10 As shown, the first adhesion detection unit 31 may include a first input-side circuit 41, a first electrical isolation module 51, and a first output-side circuit 61. The first input-side circuit 41 may be configured to adjust a first input voltage falling on the first input 311 and the second input 312, and provide the adjusted first input voltage to the first electrical isolation module 51. The first electrical isolation module 51 may be configured to provide a first output voltage to the first output-side circuit 61 based on the adjusted first input voltage. The first output-side circuit 61 is configured to adjust the first output voltage and use the adjusted first output voltage as a first output 313 characterizing the contact adhesion state of the first contactor 21. As the first output 313 characterizing the contact adhesion state of the first contactor 21, the output value of the first output-side circuit 61 can be either an analog quantity, such as a voltage value, or a digital quantity, such as a digital signal from a communication bus like CAN or LIN.

[0076] Similarly, the second adhesion detection unit 32 may include a second input-side circuit 42, a second electrical isolation module 52, and a second output-side circuit 62. The second input-side circuit 42 may be configured to adjust a second input voltage falling on the third input 321 and the fourth input 322, and provide the adjusted second input voltage to the second electrical isolation module 52. The second electrical isolation module 52 may be configured to provide a second output voltage to the second output-side circuit 62 based on the adjusted second input voltage. The second output-side circuit 62 may be configured to adjust the second output voltage and use the adjusted second output voltage as a second output 3 characterizing the contact adhesion state of the second contactor 22. As the second output 3 characterizing the contact adhesion state of the second contactor 22, the output value of the second output-side circuit 62 may be either an analog quantity, such as a voltage value, or a digital quantity, such as a digital signal from a communication bus like CAN or LIN.

[0077] In some embodiments, the first input-side circuit 41 may include a first resistor network configured to adjust a first input voltage falling on the first input 311 and the second input 312, and the second input-side circuit 42 includes a second resistor network configured to adjust a second input voltage falling on the third input 321 and the fourth input 322. In some embodiments, the first electrical isolation module 51 and the second electrical isolation module 52 may be configured as an optocoupler isolation module, a capacitor isolation module, or an electromagnetic isolation module, respectively. In some embodiments, the first output-side circuit 61 includes a third resistor network configured to adjust a first output voltage, and the second output-side circuit 62 includes a fourth resistor network configured to adjust a second output voltage. It should be understood that the adhesion detection unit of this utility model can also be implemented based on existing solutions in the prior art, and is not limited to the embodiments described in this utility model.

[0078] The various embodiments of this utility model have now been described in detail. To avoid obscuring the concept of this utility model, some details known in the art have not been described. Those skilled in the art can fully understand how to implement the technical solutions disclosed herein based on the above description.

[0079] All features or combinations of features mentioned in the specification and drawings above, as long as they are meaningful within the scope of this utility model and do not contradict each other, can be used in any combination or individually.

[0080] The above description is only a preferred embodiment of the present utility model and does not limit the patent scope of the present utility model. All equivalent transformations made under the inventive concept of the present utility model using the contents of the present utility model specification and drawings, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present utility model.

Claims

1. A contactor assembly with an integrated circuit board, characterized in that, The contactor assembly includes: case; The first contactor includes a first moving contact located within a housing and a first positive stationary contact and a first negative stationary contact partially exposed from the housing; The second contactor includes a second moving contact located within a housing and a second positive stationary contact and a second negative stationary contact partially exposed from the housing; and A circuit board mounted on the housing integrates a first adhesion detection unit for the first contactor and a second adhesion detection unit for the second contactor.

2. The contactor assembly with integrated circuit board according to claim 1, characterized in that, The contactor assembly includes: A first electrical connection element is configured to snap onto a snap-fit ​​slot of a first positive stationary contact to achieve electrical connection between the first electrical connection element and the first positive stationary contact. A second electrical connection element is configured to snap onto a slot in the first negative stationary contact to achieve electrical connection between the second electrical connection element and the first negative stationary contact. A third electrical connection element is configured to snap onto a slot in the second positive stationary contact to achieve electrical connection between the third electrical connection element and the second positive stationary contact. A fourth electrical connection element is configured to snap onto the snap-fit ​​slot of the second negative stationary contact to achieve electrical connection between the fourth electrical connection element and the second negative stationary contact.

3. The contactor assembly with integrated circuit board according to claim 2, characterized in that, The circuit board includes a flexible circuit board, which includes a first circuit region and a second circuit region. The first circuit area of ​​the flexible circuit board is at least partially mounted on the first surface of the housing, and the first positive stationary contact and the first negative stationary contact of the first contactor, as well as the second positive stationary contact and the second negative stationary contact of the second contactor, are exposed from the first surface of the housing. The second circuit area of ​​the flexible circuit board is at least partially mounted on the second surface of the housing, which is adjacent to the first surface.

4. The contactor assembly with integrated circuit board according to claim 3, characterized in that, The circuit board includes a substrate, which is mounted to the back of a second circuit region of the flexible circuit board. The circuit board is configured to be mounted to the second surface of the housing from top to bottom or from the side, wherein the second circuit area of ​​the flexible circuit board, together with the substrate on the back, is fixed to the second surface of the housing, while the first circuit area of ​​the flexible circuit board is bent relative to the second circuit area to the first surface of the housing and fixed to the second surface of the housing.

5. The contactor assembly with integrated circuit board according to claim 3 or 4, characterized in that, The first circuit region of the flexible circuit board includes a first line electrically connected to a first electrical connection element, a second line electrically connected to a second electrical connection element, a third line electrically connected to a third electrical connection element, and a fourth line electrically connected to a fourth electrical connection element. The first adhesion detection unit and the second adhesion detection unit are provided in the second circuit area of ​​the flexible circuit board.

6. The contactor assembly with integrated circuit board according to claim 4, characterized in that, A limiting structure for the circuit board is formed on the second surface of the housing, and the second circuit area of ​​the flexible circuit board, together with the substrate on the back, is limited to the limiting structure; and / or The first circuit area of ​​the flexible circuit board is attached to the first surface of the housing by bonding, soldering, threading, and / or snapping; and / or The second circuit area of ​​the flexible circuit board is attached to the second surface of the housing by bonding, welding, threading, and / or snapping; and / or The second surface is perpendicular to the first surface.

7. The contactor assembly with integrated circuit board according to claim 3 or 4, characterized in that, The first contactor also includes a first control module for controlling the on / off state between the first moving contact and the first positive stationary contact and the first negative stationary contact; The second contactor also includes a second control module for controlling the on / off state between the second moving contact and the second positive stationary contact and the second negative stationary contact; The first control pin of the first control module and the second control pin of the second control module extend from the second surface of the housing, and the first control pin and the second control pin are configured to extend and be electrically connected to the second circuit area of ​​the flexible circuit board.

8. The contactor assembly with integrated circuit board according to claim 7, characterized in that, A connector is integrated on the second circuit region of the flexible circuit board, wherein the connector integrates: A first electrical connection terminal for a first control pin, wherein a control voltage can be applied to the first control pin via the first electrical connection terminal; The second electrical connection terminal of the second control pin allows a control voltage to be applied to the second control pin via the second electrical connection terminal; Regarding the third electrical connection terminal of the first adhesion detection unit, a first signal output characterizing the contact adhesion state of the first contactor can be obtained via the third electrical connection terminal; The fourth electrical connection terminal of the second adhesion detection unit can be used to obtain a second signal output that characterizes the contact adhesion state of the second contactor.

9. The contactor assembly with integrated circuit board according to claim 5, characterized in that, The first electrical connection element includes a first arcuate contact portion and a first protruding pin extending upward from the first arcuate contact portion. The first arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the first negative stationary contact, and the first protruding pin is configured to pass through a first through hole in the first circuit area and be soldered to the first line. The second electrical connection element includes a second arcuate contact portion and a second protruding pin extending upward from the second arcuate contact portion. The second arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the second negative stationary contact, and the second protruding pin is configured to pass through a second through hole in the second circuit area and be soldered to the second line. The third electrical connection element includes a third arcuate contact portion and a third protruding pin extending upward from the third arcuate contact portion. The third arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the first positive stationary contact, and the third protruding pin is configured to pass through a third through hole in the third circuit region and be soldered to the third line. The fourth electrical connection element includes a fourth arcuate contact portion and a fourth protruding pin extending upward from the fourth arcuate contact portion. The fourth arcuate contact portion is configured to snap onto a snap-fit ​​groove on the outer peripheral wall of the second positive stationary contact, and the fourth protruding pin is configured to pass through a fourth through hole in the fourth circuit region and be soldered to the fourth line.

10. The contactor assembly with integrated circuit board according to claim 9, characterized in that, The first adhesion detection unit includes a first input, a second input, and a first output. The first input is configured to be electrically connected to the first negative stationary contact via a second line and a second electrical connection element. The second input is configured to be electrically connected to the second negative stationary contact via a fourth line and a fourth electrical connection element. The first output is configured to output a first signal characterizing the contact adhesion state of the first contactor. The second adhesion detection unit includes a third input, a fourth input, and a second output. The third input is configured to be electrically connected to the first positive stationary contact via a first line and a first electrical connection element. The fourth input is configured to be electrically connected to the second positive stationary contact via the third line and the third electrical connection element. The second output is configured to output a second signal characterizing the contact adhesion state of the second contactor.

11. The contactor assembly with integrated circuit board according to claim 10, characterized in that, The first adhesion detection unit includes a first input-side circuit, a first electrical isolation module, and a first output-side circuit. The first input-side circuit is configured to adjust a first input voltage falling on a first input and a second input, and to provide the adjusted first input voltage to the first electrical isolation module. The first electrical isolation module is configured to provide a first output voltage to the first output-side circuit based on the adjusted first input voltage. The first output-side circuit is configured to adjust the first output voltage and output the adjusted first output voltage as a first signal characterizing the contact adhesion state of the first contactor. The second adhesion detection unit includes a second input-side circuit, a second electrical isolation module, and a second output-side circuit. The second input-side circuit is configured to adjust a second input voltage falling on a third input and a fourth input, and to provide the adjusted second input voltage to the second electrical isolation module. The second electrical isolation module is configured to provide a second output voltage to the second output-side circuit based on the adjusted second input voltage. The second output-side circuit is configured to adjust the second output voltage and output the adjusted second output voltage as a second signal characterizing the contact adhesion state of the second contactor.

12. The contactor assembly with integrated circuit board according to claim 1, characterized in that, The contactor assembly includes multiple pairs of contactors, each pair consisting of a first contactor and a second contactor, wherein the contactor assembly includes: A first pair of contactors, comprising a positive contactor used in a DC charging circuit as a first contactor and a negative contactor used in a DC charging circuit as a second contactor; and / or The second pair of contactors includes a positive contactor serving as a first contactor in the battery feeding circuit and a negative contactor serving as a second contactor in the battery feeding circuit; and / or The third pair of contactors includes a positive contactor used as a first contactor in the AC charging circuit and a negative contactor used as a second contactor in the AC charging circuit.

13. A battery system, characterized in that, The battery system includes a battery, a battery power distribution unit, and a battery management system, wherein the battery power distribution unit includes a contactor assembly with an integrated circuit board as described in any one of claims 1 to 12.

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