High-voltage direct-current relay
By introducing stop elements and elastic elements into the high-voltage DC relay, the problem of the moving and stationary contacts being forced apart by electric repulsion is solved, thus achieving the miniaturization and low cost of the high-voltage DC relay.
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- XIAMEN HONGFA ELECTRIC POWER CONTROLS CO LTD
- Filing Date
- 2025-12-30
- Publication Date
- 2026-07-30
AI Technical Summary
Existing high-voltage DC relays suffer from arcing and damage when the moving and stationary contacts are blown apart by excessive electric repulsion during short circuits or overloads. Furthermore, increasing the number of coil turns to improve holding force using traditional methods increases size and cost.
A high-voltage DC relay was designed, comprising a stationary contact, a moving component, an elastic element, and a stop element. The stop element provides support when the moving spring mechanism springs open, buffering the electric repulsive force, reducing the springing distance, and lowering the holding force requirement of the electromagnetic component.
It effectively reduces the spring-off distance between moving and stationary contacts, avoids arcing, reduces the cost and size of electromagnetic components, and achieves miniaturization and low-cost design.
Smart Images
Figure CN2025147078_30072026_PF_FP_ABST
Abstract
Description
High voltage DC relay
[0001] Related applications
[0002] This application claims priority to Chinese patent application No. 2025101038254, filed on January 22, 2025, entitled "High Voltage DC Relay", the entire contents of which are incorporated herein by reference. Technical Field
[0003] This application relates to the field of relay technology, and in particular to a high-voltage DC relay. Background Technology
[0004] High-voltage DC relays, as a new type of automatic electrical switch, can achieve normally open or normally closed states through electromagnetic holding force. Current high-voltage DC relays typically consist of an electromagnetic component, a moving component, and a stationary contact. The moving contact on the moving spring of the moving component and the stationary contact on the stationary contact together form the contact part of the high-voltage DC relay. The electromagnetic component includes a coil, an upper iron core, and a lower iron core. When the coil is energized, it magnetizes the lower iron core, causing the lower iron core to attract the upper iron core, thereby driving the moving component closer to the stationary contact until the moving contact on the moving component and the stationary contact on the stationary contact make contact, thus completing the circuit.
[0005] However, current high-voltage DC relays, when a short circuit or overload occurs, will have their moving and stationary contacts spring apart due to excessive electrodynamic repulsion, causing arcing between them and leading to relay damage. Industries using high-voltage circuits, such as the new energy sector, are increasingly demanding miniaturization and short-circuit protection for high-voltage DC relays. Summary of the Invention
[0006] According to various embodiments of this application, a high-voltage DC relay is provided.
[0007] A high-voltage DC relay includes a stationary contact and a moving assembly. The stationary contact has a stationary contact point; the moving assembly includes a moving spring mechanism, a pushing mechanism, an elastic element, and a stop element. The moving spring mechanism has a moving contact point opposite to the stationary contact point. The elastic element is disposed on the pushing mechanism, and the moving spring mechanism elastically engages with the pushing mechanism through the elastic element. The stop element is connected to the elastic element and is fixed relative to the pushing mechanism. When the moving contact point and the stationary contact point spring apart under the action of a short-circuit current, the stop element abuts against the moving spring mechanism on the path in which the moving spring mechanism moves closer to the pushing mechanism.
[0008] In one embodiment, the elastic element is located between the moving spring mechanism and the pushing mechanism, with its two ends abutting against the moving spring mechanism and the pushing mechanism, respectively.
[0009] In one embodiment, the elastic element includes a leaf spring, the elastic element includes a base and two spring arms, the two spring arms are respectively connected to both ends of the base, the base is disposed on the push mechanism, and the end of the spring arm away from the base abuts against the moving spring mechanism.
[0010] In one embodiment, the stop element is connected to the base and located between the two spring arms.
[0011] In one embodiment, the stop element includes a connecting portion connected to the base and a stop portion protruding from the connecting portion on the side away from the push mechanism, the side of the stop portion away from the connecting portion being used to abut against the moving spring mechanism on the path of the moving spring mechanism moving toward the push mechanism.
[0012] In one embodiment, the stop element has two stop portions, which are spaced apart in the direction of the vertical line connecting the two spring arms.
[0013] In one embodiment, the moving spring mechanism includes a moving spring and a lower armature. The moving contact is located on the side of the moving spring facing the stationary contact. The lower armature is fixed relative to the moving spring. Both ends of the moving spring protrude from the lower armature. The two spring arms respectively abut against the two ends of the moving spring protruding from the lower armature. The stop element is opposite to the lower armature.
[0014] In one embodiment, the stop element is fixedly connected to the side of the base facing away from the pushing mechanism; or,
[0015] The stop element is made of plastic, and the elastic element is integrally formed with the stop element by an insert injection molding process, with the base at least partially located within the stop element.
[0016] In one embodiment, the stop element is located between the moving spring mechanism and the pushing mechanism.
[0017] In one embodiment, the moving spring mechanism includes a moving spring and a lower armature, the moving contact is located on the side of the moving spring facing the stationary contact, the lower armature is fixed relative to the moving spring, and the stop element is opposite to either the lower armature or the moving spring.
[0018] In one embodiment, the moving component further includes two first arms, which are located on opposite sides of the moving spring mechanism in the direction of movement relative to the pushing mechanism. The first arms are fixed relative to the pushing mechanism and slidably engaged with the moving spring mechanism. The high-voltage DC relay further includes an upper armature opposite to the lower armature.
[0019] Wherein, the upper armature is disposed outside the moving assembly and fixed relative to the stationary contact; or...
[0020] The moving assembly also includes a second arm connected to the two first arms. The second arm is located on the side of the moving spring mechanism opposite to the pushing mechanism, and the upper armature is fixed to the second arm.
[0021] In one embodiment, the pushing mechanism can drive the moving spring mechanism to move towards the stationary contact, so that the high-voltage DC relay has a first state and a second state. In the first state, the moving contact is in contact with the stationary contact. In the second state, the moving contact is pressed against the stationary contact by the elastic element. During the switching from the first state to the second state, the pushing mechanism moves relative to the moving spring mechanism towards the stationary contact. The distance between the stop element and the moving spring mechanism is smaller in the second state than in the first state.
[0022] In one embodiment, in the second state, the difference between the dimension of the elastic element in the direction of motion of the moving spring mechanism relative to the pushing mechanism and the ultimate compression length of the elastic element is greater than the distance between the stop element and the moving spring mechanism.
[0023] In one embodiment, the moving spring mechanism is able to spring away from the stationary contact under the electric repulsive force generated by the short-circuit current, so that the high-voltage DC relay switches from the second state to the third state. In the third state, the stop element abuts against the moving spring mechanism to prevent the moving spring mechanism from getting close to the push mechanism. The dimension of the elastic element in the direction of movement of the moving spring mechanism relative to the push mechanism is greater than the ultimate compression length of the elastic element.
[0024] In one embodiment, the high-voltage DC relay further includes an electromagnetic component, the actuating mechanism includes a actuating seat and a actuating rod connected to the actuating seat on the side opposite to the moving spring mechanism, the elastic element is disposed on the actuating seat, the moving spring mechanism is elastically engaged with the actuating seat through the elastic element, and the electromagnetic component can drive the actuating seat to move toward or away from the stationary contact through the actuating rod.
[0025] Details of one or more embodiments of the present invention are set forth in the following drawings and description. Other features, objects, and advantages of the invention will become apparent from the specification, drawings, and claims. Attached Figure Description
[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the conventional technology, the drawings used in the description of the embodiments or the conventional technology will be briefly introduced below. Obviously, the drawings described below are only embodiments of this application. For those skilled in the art, other drawings can be obtained based on the disclosed drawings without creative effort.
[0027] Figure 1 is a schematic diagram of the structure of a high-voltage DC relay in some embodiments.
[0028] Figure 2 is a cross-sectional view of the high-voltage DC relay shown in Figure 1 along the AA direction.
[0029] Figure 3 is a schematic diagram of the moving component in the high-voltage DC relay shown in Figure 2.
[0030] Figure 4 is an explosion diagram of the moving component shown in Figure 3.
[0031] Figure 5 is a schematic diagram of the structure of the stop element, elastic element and pushing mechanism in some embodiments.
[0032] Figure 6 is a schematic diagram of the structure in some embodiments where the stop element and the elastic element are integrally formed.
[0033] Figure 7 is a schematic diagram of the structure of the high voltage DC relay in the first state in some embodiments.
[0034] Figure 8 is a schematic diagram of the structure of the high voltage DC relay in the second state in some embodiments.
[0035] Figure 9 is a schematic diagram of the structure of the high-voltage DC relay in the third state in some embodiments. Detailed Implementation
[0036] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.
[0037] In the description of this application, it should be understood that if terms such as "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" appear, these terms indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.
[0038] Furthermore, where the terms "first" and "second" appear, these terms are for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, where the term "multiple" appears, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.
[0039] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise expressly limited. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.
[0040] In this application, unless otherwise expressly specified and limited, the use of descriptions such as "above" or "below" the second feature indicates that the first and second features are in direct contact or indirect contact via an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. Similarly, "below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.
[0041] It should be noted that if an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. If an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. If so, the terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used in this application are for illustrative purposes only and do not represent the only possible implementation.
[0042] As high-voltage DC relays are increasingly used in various fields, the industry's requirements for their heat loss resistance, short-circuit protection, and voltage are also becoming more stringent. Specifically, the current and voltage of the circuits in which high-voltage DC relays are used are increasing. For example, in new energy vehicles, as the required driving range increases, the capacity of battery packs in these vehicles is also increasing, leading to higher current and voltage requirements for the high-voltage DC relays used in the battery pack circuits. Therefore, when the circuit is short-circuited or overloaded, the electro-repulsive force generated between the moving and stationary contacts of the high-voltage DC relay is relatively large, which can easily cause the moving and stationary contacts to spring apart by a large distance. For example, the moving and stationary contacts may spring apart to the point where the moving spring mechanism compresses the elastic element to its limit, and then the impact force is transmitted to the push mechanism and the electromagnetic component. At this point, the impact force is too large, which can easily cause the electromagnetic component and the moving component to detach from the stationary contact, resulting in damage to the high-voltage DC relay. Alternatively, the distance between the moving and stationary contacts may be too far, leading to arcing between the moving and stationary contacts, generating excessive heat and burning out the high-voltage DC relay, or even causing the high-voltage DC relay to explode. However, in traditional high-voltage DC relays, to increase the holding force of the electromagnetic component on the moving component to prevent insufficient holding force from detaching from the stationary contact or to reduce the spring distance between the moving and stationary contacts, it is usually necessary to increase the number of turns of the coil winding. This increases the cost and size of the electromagnetic component, thus increasing the size and cost of the high-voltage DC relay.
[0043] To address the aforementioned problems, this application provides a high-voltage DC relay.
[0044] Please refer to Figures 1-4. Figure 1 is a structural schematic diagram of the high-voltage DC relay 10 in some embodiments. Figure 2 is a cross-sectional schematic diagram of the high-voltage DC relay 10 shown in Figure 1 along the AA direction. Figures 3 and 4 are structural schematic diagram and exploded schematic diagram of the moving component 13 in the high-voltage DC relay 10 shown in Figure 2, respectively. The high-voltage DC relay 10 shown in Figure 2 is in its initial state. In some embodiments, the high-voltage DC relay 10 includes a yoke plate 11, an electromagnetic component 12, a moving component 13, stationary contacts 14, and an insulating cover 142. The insulating cover 142 is disposed on the yoke plate 11, and the stationary contacts 14 are disposed on the insulating cover 142. Two stationary contacts 14 may be arranged at intervals, and each of the two stationary contacts 14 is provided with a stationary contact point 141. The insulating cover 142 includes, but is not limited to, an insulating shell such as a ceramic cover. The moving component 13 includes a moving spring mechanism 131, an elastic element 132, and a pushing mechanism 133. The moving spring mechanism 131 is provided with two moving contacts 1313 that are one-to-one opposite to the two stationary contacts 141. The moving spring mechanism 131 elastically engages with the pushing mechanism 133 via the elastic element 132. This means that the moving spring mechanism 131 can move towards the pushing mechanism 133 to jointly compress the elastic element 132 with the pushing mechanism 133, or it can move away from the pushing mechanism 133 to release the elastic element 132. The electromagnetic component 12 is located on the side of the yoke plate 11 facing away from the moving spring mechanism 131. It can drive the pushing mechanism 133 to move the moving component 13 as a whole towards or away from the stationary contact 141, thereby making the moving contact 1313 contact the stationary contact 141 to achieve circuit connection, or making the moving contact 1313 disengage from the stationary contact 141 to achieve circuit disconnection.
[0045] It is understood that the high-voltage DC relay 10 can be used as a switching element in a circuit. The stationary contact 14 may have a lead-out terminal electrically connected to the two stationary contacts 141, and the lead-out terminal is electrically connected to the circuit. When the moving contact 1313 and the stationary contact 141 are in contact one by one, the moving contact 1313 conducts the two stationary contacts 141 to make the circuit conduct, and the high-voltage DC relay 10 is turned on. When the moving contact 1313 is disengaged from the stationary contact 141, the two stationary contacts 141 are electrically isolated, the circuit is broken, and the high-voltage DC relay 10 is turned off. In some embodiments, the high-voltage DC relay 10 may also include a housing (not shown) covering the insulating cover 142 and the stationary contact 14. The stationary contact 14 can be led out to the outside of the housing through conductive structures such as electrodes and leads to be electrically connected to the circuit. The material of the housing includes, but is not limited to, insulating materials such as plastic. The housing can isolate the stationary contact 14, the insulating cover 142 and the moving component 13 from the outside world to achieve insulation protection.
[0046] In some embodiments, the pushing mechanism 133 includes a pushing seat 1331 and a pushing rod 1332 connected to the side of the pushing seat 1331 facing away from the moving spring mechanism 131. The electromagnetic assembly 12 may include an upper iron core 121, a lower iron core 122, and a coil arranged around the upper iron core 121 and the lower iron core 122. The upper iron core 121 is fixedly disposed on the yoke plate 11, and the coil is fixed relative to the yoke plate 11. The lower iron core 122 is opposite to the upper iron core 121 and located on the side of the upper iron core 121 facing away from the yoke plate 11. The lower iron core 122 is movable relative to the yoke plate 11 in a direction closer to or away from the upper iron core 121. The pushing rod 1332 passes through the upper iron core 121 and is inserted into the lower iron core 122. The pushing rod 1332 is slidably engaged with the upper iron core 121 and is fixed relative to the lower iron core 122. When the coil is energized, it can magnetize the upper iron core 121 and the lower iron core 122, causing the upper iron core 121 and the lower iron core 122 to attract each other and drive the lower iron core 122 to move closer to the upper iron core 121, thereby driving the push rod 1332 to drive the entire moving assembly 13 to move closer to the stationary contact 141.
[0047] In some embodiments, the moving assembly 13 further includes two first arms 1351, which are located on opposite sides of the moving spring mechanism 131 in the direction of movement relative to the pushing mechanism 133, and are directly or indirectly connected to the pushing seat 1331. The two first arms 1351 slide in cooperation with the moving spring mechanism 131 on opposite sides of the moving spring mechanism 131 to limit the movement of the moving spring mechanism 131 relative to the pushing seat 1331 in the direction of approaching or moving away from the stationary contact 141. When the moving spring mechanism 131 and the pushing seat 1331 are relatively close, the moving spring mechanism 131 and the pushing seat 1331 can compress the elastic element 132, causing the elastic element 132 to undergo elastic deformation. The sliding limitation of the moving spring mechanism 131 by the two first arms 1351 can guide the movement of the moving spring mechanism 131 relative to the pushing seat 1331, improving the performance stability of the high-voltage DC relay 10.
[0048] In some embodiments, the moving assembly 13 may further include a second arm 1352 connected to the two first arms 1351. The second arm 1352 may be disposed on the side of the moving spring mechanism 131 facing away from the push mechanism 133 and located between the moving spring mechanism 131 and the insulating cover 142. The second arm 1352 can limit the extreme position of the moving spring mechanism 131 away from the push seat 1331 on the side of the moving spring mechanism 131 facing the stationary contact 141, preventing the moving spring mechanism 131 from disengaging from the elastic element 132 and the push seat 1331, thereby improving the performance stability of the high-voltage DC relay 10.
[0049] In some embodiments, the moving spring mechanism 131 includes a moving spring 1311 and a lower armature 1314 fixedly connected to the moving spring 1311. The high voltage DC relay 10 also includes an upper armature 143 opposite to the lower armature 1314. The moving contact 1313 is located on the side of the moving spring 1311 facing the stationary contact 14, and the upper armature 143 is located on the side of the lower armature 1314 facing away from the push seat 1331. The upper armature 143 and the lower armature 1314 together form an anti-short-circuit ring structure. When the moving contact 1313 and the stationary contact 141 come into contact, the magnetic field generated by the moving spring 1311 and the stationary contact 14 can magnetize the upper armature 143 and the lower armature 1314, so that the upper armature 143 and the lower armature 1314 attract each other, which can provide a holding force for the contact between the moving contact 1313 and the stationary contact 141. This is beneficial to reducing the holding force required for the electromagnetic component 12, and also beneficial to reducing the cost and volume of the electromagnetic component 12.
[0050] In the embodiment shown in Figure 2, the upper armature 143 is disposed outside the moving assembly 13 and fixed relative to the stationary contact 14. For example, the upper armature 143 can be disposed on the insulating cover 142, and the upper armature 143 is disposed corresponding to the stationary contact 141 and located between the insulating cover 142 and the second arm 1352. The moving assembly 13 may also not be provided with the second arm 1352, in which case the upper armature 143 is located between the insulating cover 142 and the moving spring 1311. When the moving assembly 13 is not provided with the second arm 1352, the upper armature 143 can limit the moving spring mechanism 131 on the side of the moving spring mechanism 131 away from the push seat 1331, limiting the moving spring mechanism 131 to the extreme position away from the push seat 1331. In some embodiments, an insulating cover 142 is disposed over the moving assembly 13 and on the yoke plate 11. The stationary contact 14 and the upper armature 143 are both fixedly disposed on the insulating cover 142. The stationary contact 14 extends out of the insulating cover 142, facing away from the moving spring mechanism 131. In other embodiments, when the moving assembly 13 is provided with a second arm 1352, the upper armature 143 can also be fixed to the second arm 1352 and located between the second arm 1352 and the moving spring mechanism 131.
[0051] Further, referring to Figures 2, 4, 5, and 6, in some embodiments, the elastic element 132 is disposed on the push seat 1331, and the moving assembly 13 further includes a stop element 136, which is connected to the elastic element 132 and fixed relative to the push seat 1331. When the moving contact 1313 and the stationary contact 141 spring open under the action of a short-circuit current, the stop element 136 is used to abut against the moving spring mechanism 131 on the path of its movement toward the push seat 1331. It is understood that when the stop element 136 abuts against the moving spring mechanism 131, the stop element 136 can prevent the moving spring mechanism 131 and the push seat 1331 from continuing to move closer to each other. In some embodiments, the direction of movement of the moving spring mechanism 131 away from the stationary contact 14 is the same as the direction of movement toward the push seat 1331. It should be noted that the stop element 136 can be opposite to one of the moving spring 1311 and the lower armature 1314 of the moving spring mechanism 131, so as to abut against one of the moving spring 1311 and the lower armature 1314 on the path of the moving spring mechanism 131 moving toward the push seat 1331. Alternatively, it can be opposite to both the moving spring 1311 and the lower armature 1314, so as to abut against both the moving spring 1311 and the lower armature 1314 at the same time, as long as it can achieve the supporting function of the moving spring mechanism 131.
[0052] Referring to Figure 2, in this application, the state in which the moving contact 1313 and the stationary contact 141 are spaced apart, and the electromagnetic component 12 does not apply force to the push rod 1332, i.e., the high-voltage DC relay 10 is disconnected, is called the initial state of the high-voltage DC relay 10. In the initial state, the stop element 136 is spaced apart from the moving spring mechanism 131. When it is necessary to bring the moving contact 1313 and the stationary contact 141 into contact to conduct the circuit, the coil in the electromagnetic component 12 is energized, and the lower iron core 122 moves towards the upper iron core 121, which can drive the push rod 1332 to drive the push seat 1331, and then drive the moving spring mechanism 131 to move towards the stationary contact 141, so that the moving component 13 has a first state and a second state. Referring to Figure 7, when the moving component 13 moves to the first state, the moving contact 1313 is just in contact with the stationary contact 141, and the high-voltage DC relay 10 conducts the circuit. In the first state, the length of the elastic element 132 is the same as the length in the initial state. In other words, during the process of the pushing mechanism 133 driving the moving spring mechanism 131 to move towards the stationary contact 141 to switch from the initial state to the first state, the moving spring mechanism 131, the first support arm 1351, the elastic element 132 and the pushing mechanism 133 move synchronously.
[0053] Please refer to Figure 8. After the electromagnetic component 12 drives the moving spring mechanism 131 to move to the first state via the pushing mechanism 133, the electromagnetic component 12 can continue to drive the pushing mechanism 133 to move towards the stationary contact 141 to the second state. During the transition from the first state to the second state, since the moving contact 1313 is in contact with the stationary contact 141, the moving spring mechanism 131 and the stationary contact 141 are relatively fixed. As the pushing mechanism 133 continues to move towards the stationary contact 141, the distance between the pushing seat 1331 and the moving spring mechanism 131 decreases. That is, during the transition from the first state to the second state, the moving spring mechanism 131 and the pushing seat 1331 are relatively close. This relative closeness between the moving spring mechanism 131 and the pushing seat 1331 will compress the elastic element 132, causing the length of the elastic element 132 to decrease and the elastic element 132 to undergo elastic deformation. Understandably, in both the first and second states, the moving contact 1313 is in contact with the stationary contact 141. In the second state, the elastic element 132 applies an elastic force to the moving spring mechanism 131 to press the moving contact 1313 against the stationary contact 14, improving the stability and reliability of the contact between the moving contact 1313 and the stationary contact 141. Simultaneously, the elastic element 132, in conjunction with the electromagnetic assembly 12, can counteract at least part of the electrodynamic repulsion between the moving contact 1313 and the stationary contact 141, which helps reduce the holding force required by the high-voltage DC relay 10 for the electromagnetic assembly 12, and consequently reduces the cost and size of the electromagnetic assembly 12.
[0054] It is understandable that during the transition from the initial state to the first state, and during the transition from the first state to the second state, the lower iron core 122 gradually approaches the upper iron core 121. In the first state, the lower iron core 122 and the upper iron core 121 are spaced apart. In the second state, the lower iron core 122 can just make contact with the upper iron core 121, which is beneficial to enhance the magnetic attraction between the upper iron core 121 and the lower iron core 122 in the second state, thereby enhancing the holding force of the electromagnetic component 12 on the moving component 13.
[0055] In some embodiments, the structure and position of the stop element 136 are designed such that, in the second state, the stop element 136 remains spaced apart from the moving spring mechanism 131, and the distance between the stop element 136 and the moving spring mechanism 131 is smaller in the second state than in the first state. Furthermore, in the second state, the difference between the dimension of the elastic element 132 in the direction of movement of the moving spring mechanism 131 relative to the push seat 1331 and the ultimate compression length of the elastic element 132 is greater than the distance between the stop element 136 and the moving spring mechanism 131. This ensures that when the stop element 136 abuts against the moving spring mechanism 131, the dimension of the elastic element 132 in the direction of movement of the moving spring mechanism 131 relative to the push seat 1331 is greater than the ultimate compression length; in other words, the elastic element 132 will not be compressed to its ultimate compression length. In some embodiments, the length of the elastic element 132 may be equal to the vertical distance between the moving spring mechanism 131 and the push seat 1331.
[0056] Referring to Figure 9, it can be understood that when the circuit is short-circuited or overloaded (taking a current exceeding 8kA as an example in this application), the electrodynamic repulsion between the moving contact 1313 and the stationary contact 141 is greater than the elastic force exerted by the elastic element 132 on the moving spring mechanism 131. This causes the moving contact 1313 to spring apart from the stationary contact 141, causing the moving spring mechanism 131 to move towards the push seat 1331 and further compress the elastic element 132 until the stop element 136 abuts against the moving spring mechanism 131. At this time, the stop element 136 provides support for the moving spring mechanism 131, preventing the moving spring mechanism 131 from moving towards the push seat 1331 relative to the stationary contact 14. In this application, the state in which the stop element 136 abuts against the moving spring mechanism 131 to provide support for the moving spring mechanism 131 is referred to as the third state of the high voltage DC relay 10. In the third state, the moving spring mechanism 131, the first support arm 1351 and the push mechanism 133 are relatively fixed, and the electromagnetic component 12 bears the impact force of the moving spring mechanism 131.
[0057] When the circuit connected to the high-voltage DC relay 10 is short-circuited or overloaded, causing the moving contact 1313 of the moving spring mechanism 131 and the stationary contact 141 of the stationary contact 14 to spring open due to electric repulsion, the moving spring mechanism 131 can first compress the elastic element 132 until the stop element 136 abuts against the moving spring mechanism 131 to prevent the moving spring mechanism 131 and the pushing mechanism 133 from continuing to approach each other. Since the electric repulsion between the moving contact 1313 and the stationary contact 141 disappears after the moving contact 1313 and the stationary contact 141 spring open, the elastic element 132 can effectively buffer the kinetic energy of the moving spring mechanism 131 during the process of the moving spring mechanism 131 moving away from the stationary contact 141 until the stop element 136 abuts against the moving spring mechanism 131. Furthermore, due to the supporting effect of the stop element 136 on the moving spring mechanism 131, the maximum spring-opening distance between the moving spring mechanism 131 and the stationary contact 141 can be shortened. This ensures that when the stop element 136 abuts against the moving spring mechanism 131, the elastic element 132 will not be compressed to its limit compression length, and the impact of the moving spring mechanism 131 on the pushing mechanism 133 will not be too great. This avoids damage to the high-voltage DC relay 10 caused by the moving assembly 13 completely separating from the stationary contact 14 due to excessive impact.
[0058] Furthermore, the stop element 136's contact with the moving spring mechanism 131 prevents the moving spring mechanism 131 from moving further away from the stationary contact 141, which helps reduce the relative spring-back distance between the moving contact 1313 and the stationary contact 141. Combined with the buffering effect of the elastic element 132 to prevent the moving assembly 13 from detaching from the stationary contact 14, the distance between the moving contact 1313 and the stationary contact 141 is not too great. This helps prevent excessive heat generated by arcing between the moving contact 1313 and the stationary contact 141, which could damage or even cause an explosion of the high-voltage DC relay 10. Additionally, the buffering effect of the elastic element 132 on the moving spring mechanism 131 also reduces the holding force required by the moving assembly 13 on the electromagnetic assembly 12, allowing the electromagnetic assembly 12 to support the entire moving assembly 13 with a smaller holding force. This helps reduce the number of coil turns and / or the volume of the core of the electromagnetic assembly 12, contributing to the low-cost and miniaturized design of the high-voltage DC relay 10. Furthermore, the stop element 136 connected to the elastic element 132 abuts against the moving spring mechanism 131 on the movement path of the moving spring mechanism 131. The stop element 136 has a simple structure and assembly, and low installation cost, which helps to simplify the structure and manufacturing process of the moving component 13. It also helps to achieve miniaturization and low cost of the high voltage DC relay 10.
[0059] Therefore, during the transition from the second state to the third state, the aforementioned high-voltage DC relay 10 first buffers the impact of the moving spring mechanism 131 through the elastic element 132, and then the electromagnetic component 12 bears the impact of the moving spring mechanism 131. This helps reduce the holding force required by the electromagnetic component 12, reduces its cost and size, and also reduces the spring-off distance between the moving contact 1313 and the stationary contact 141, thereby reducing the heat generated by the arcing phenomenon. The aforementioned high-voltage DC relay 10 achieves a balance between small size, low cost, and high resistance to short-circuit current and voltage. Based on this, the high-voltage DC relay 10 provided in this application can be used in circuits with high current, such as circuits with operating currents below 8kA. The high-voltage DC relay 10 includes, but is not limited to, applications in battery pack circuits of new energy vehicles. The high-voltage DC relay 10 can also be used as a switching element in circuits of any other applicable equipment, which will not be elaborated upon in this application.
[0060] It is understood that in this application, the stop element 136 only contacts the moving spring mechanism 131 in the third state to provide support for the moving spring mechanism 131. In other states, the stop element 136 will not interfere with the relative movement between the moving spring mechanism 131 and the push seat 1331. This helps to avoid the stop element 136 causing other types of interference to the movement of the moving spring mechanism 131, such as sliding fit or limiting fit, which would increase the risk of the moving spring mechanism 131 getting stuck, uneven force, or wear and scraping. While providing support, it also helps to maintain the structural reliability of the moving assembly 13 and reduce the impact of the stop element 136 on the contact reliability of the moving assembly 13.
[0061] In some embodiments, the elastic element 132 is disposed between the push seat 1331 and the moving spring mechanism 131, and its two ends abut against the moving spring mechanism 131 and the push seat 1331 respectively, for example, against the lower armature 1314 and the push seat 1331, or against the moving spring 1311 and the push seat 1331. The two ends of the elastic element 132 can be connected to the moving spring mechanism 131 and the push seat 1331 respectively. This arrangement can rationally plan the spatial layout between the moving spring mechanism 131, the elastic element 132 and the push mechanism 133, making the structure of the moving assembly 13 more compact, which is beneficial to improving the space utilization efficiency of the moving assembly 13. At the same time, it is also beneficial to keep the elastic element 132 relatively far away from the contact position of the moving contact 1313 and the stationary contact 141, reducing the impact of high temperature and ablation spatter on the elastic element 132, and reducing the assembly difficulty of the elastic element 132 with other components.
[0062] Referring to Figures 4, 5, and 6, in some embodiments, the elastic element 132 is a leaf spring. The elastic element 132 includes a base 1321 and two spring arms 1322. The base 1321 is located on the side of the push seat 1331 facing the moving spring mechanism 131. The two spring arms 1322 are respectively connected to both ends of the base 1321, and the end of the spring arm 1322 away from the base 1321 abuts against the moving spring mechanism 131. When the distance between the moving spring mechanism 131 and the push seat 1331 changes, the spring arm 1322 can be driven to undergo elastic deformation. In some embodiments, the stop element 136 is connected to the base 1321 and located between the two spring arms 1322. This facilitates the rational planning of the spatial layout of each element, improves the structural compactness of the moving assembly 13, and avoids interference between the stop element 136 and the elastic element 132.
[0063] In some embodiments, the stop element 136 is located between the moving spring mechanism 131 and the push seat 1331, and in the initial state, the stop element 136 is spaced apart from both the moving spring mechanism 131 and the push seat 1331. Therefore, the stop element 136 is far from the contact positions of the moving contact 1313 and the stationary contact 141, which helps to reduce the impact of high temperature and ablation spatter on the stop element 136. For example, it prevents the distance between the stop element 136 and the moving spring mechanism 131 from decreasing due to spatter, thus avoiding interference with the transition from the second state to the third state.
[0064] In some embodiments, the stop element 136 includes a connecting portion 1361 connected to the base 1321 and a stop portion 1362 protruding from the connecting portion 1361 on the side facing away from the push mechanism 133. The side of the stop portion 1362 away from the connecting portion 1361 is used to abut against the moving spring mechanism 131 on the path in which the moving spring mechanism 131 moves toward the push mechanism 133. Providing the connecting portion 1361 can increase the connection area between the stop element 136 and the elastic element 132, thereby improving the reliability of the connection. In some embodiments, the stop element 136 is provided with two stop portions 1362, which are spaced apart in the direction of the vertical connection between the two spring arms 1322. The arrangement of the two spring arms 1322 can improve the stability of the moving spring mechanism 131 during its movement relative to the push seat 1331. The two stop parts 1362 cooperate with the two spring arms 1322 to improve the support stability of the moving spring mechanism 131 in the third state and prevent the moving spring mechanism 131 from swaying relative to the push seat 1331.
[0065] Furthermore, in some embodiments, the two ends of the movable spring 1311 protrude beyond the lower armature 1314. The extending direction of the movable spring 1311 can be approximately parallel to the vertical line connecting the two spring arms 1322. The two spring arms 1322 respectively abut against the two ends of the movable spring 1311 protruding beyond the lower armature 1314. The stop element 136 is opposite to the lower armature 1314 to abut against the lower armature 1314. In this way, the layout between the movable spring 1311, the lower armature 1314, the elastic element 132, and the stop element 136 can be rationally planned, improving the structural compactness of the moving assembly 13 and avoiding mutual interference between the components. This improves the space utilization efficiency of the moving assembly 13 while enhancing its structural stability and performance reliability.
[0066] The connection relationship between the stop element 136 and the elastic element 132 is not limited, as long as it meets the requirements for structural reliability and support for the moving spring mechanism 131. Referring to Figure 4, in some embodiments, the stop element 136 is fixedly connected to the side of the base 1321 facing away from the pushing mechanism 133, for example, the connecting part 1361 is fixed to the side of the base 1321 facing away from the pushing seat 1331. In this embodiment, both the stop element 136 and the elastic element 132 can be made of metal. The stop element 136 and the elastic element 132 are separate components, and the connecting part 1361, the base 1321, and the pushing seat 1331 are connected to each other by any applicable fixed connection method such as riveting. Referring to Figure 6, in some embodiments, the material of the stop element 136 includes plastic, and the elastic element 132 is integrally formed with the stop element 136 through an insert injection molding process, with the base 1321 at least partially located within the stop element 136. For example, a metal elastic element 132 can be prepared first and placed in an injection mold. Then, a plastic stop element 136 can be obtained by injection molding based on the elastic element 132. This can improve the bonding strength between the base 1321 and the connecting part 1361, which is beneficial to improving the structural reliability of the moving assembly 13.
[0067] In this application, the sliding engagement between the first arm 1351 and the moving spring mechanism 131 can be described as follows: the opposing sides of the lower armature 1314 can be in sliding engagement with the surfaces opposite to the two first arms 1351; the opposing sides of the moving spring 1311 can be in sliding engagement with the two first arms 1351; or a portion of the moving spring 1311 or the lower armature 1314 can be inserted into and slidably disposed on the first arm 1351, as long as the first arm 1351 can provide guidance and limiting function for the movement of the moving spring mechanism 131 relative to the push seat 1331. In some embodiments, the first arm 1351 can be directly connected to the push seat 1331, for example, integrally formed with the push seat 1331 by insert injection molding; or the first arm 1351 and the push seat 1331 can have an insertion relationship. The moving component 13 can also include a fixing piece connected to the first arm 1351 and the push seat 1331, indirectly connecting the first arm 1351 to the push seat 1331 through the fixing piece.
[0068] In the accompanying drawings of this application, the moving spring 1311 may include two sub-springs arranged side by side and spaced apart from each other. The lower armature 1314 may be connected to both sub-springs simultaneously. The lower armature 1314 may also include two spaced-apart sub-armatures, with each sub-armature corresponding to one of the two sub-springs. Thus, each moving contact 1313 of the moving spring 1311 can be formed by the corresponding positions of the two sub-springs. With this arrangement, the two sub-springs can provide more stable electrical contact, reduce poor contact caused by wear or damage to a single spring, share the mechanical load of the moving contact 1313, reduce the stress on a single spring, improve the durability of the high-voltage DC relay 10, and provide a more uniform current distribution, reducing arcing and contact resistance, and improving electrical contact performance. Furthermore, when one sub-spring fails, the other sub-spring can still achieve on / off control of the circuit with the stationary contact 141, improving the performance reliability of the high-voltage DC relay 10. In other embodiments, each sub-reed can also be provided with two moving contacts 1313, and each sub-reed can be used to conduct different circuits, so that the high-voltage DC relay 10 can be used as a switch for multiple circuits simultaneously. Of course, the moving reed 1311 can also be an integral reed structure. When the moving reed 1311 includes sub-reeds, the number of sub-reeds is not limited, and can be designed according to connection reliability and functional requirements.
[0069] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0070] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.
Claims
1. A high-voltage DC relay, comprising: The stationary contact is equipped with a stationary contact point; The moving component includes a moving spring mechanism, a pushing mechanism, an elastic element, and a stop element. The moving spring mechanism has a moving contact opposite to the stationary contact. The elastic element is disposed on the pushing mechanism, and the moving spring mechanism is elastically engaged with the pushing mechanism through the elastic element. The stop element is connected to the elastic element and is fixed relative to the pushing mechanism. When the moving contact and the stationary contact spring apart under the action of a short-circuit current, the stop element is used to abut against the moving spring mechanism on the path in which the moving spring mechanism moves toward the pushing mechanism.
2. The high-voltage DC relay according to claim 1, wherein, The elastic element is located between the moving spring mechanism and the pushing mechanism, and its two ends abut against the moving spring mechanism and the pushing mechanism, respectively.
3. The high-voltage DC relay according to claim 2, wherein, The elastic element includes a leaf spring, and the elastic element includes a base and two spring arms. The two spring arms are respectively connected to the two ends of the base. The base is disposed on the pushing mechanism, and the end of the spring arm away from the base abuts against the moving spring mechanism.
4. The high-voltage DC relay according to claim 3, wherein, The stop element is connected to the base and located between the two spring arms.
5. The high-voltage DC relay according to claim 4, wherein, The stop element includes a connecting portion connected to the base and a stop portion protruding from the connecting portion on the side away from the push mechanism. The side of the stop portion away from the connecting portion is used to abut against the moving spring mechanism on the path in which the moving spring mechanism moves toward the push mechanism.
6. The high-voltage DC relay according to claim 5, wherein, The stop element has two stop portions, which are spaced apart in the direction of the vertical connection between the two spring arms.
7. The high-voltage DC relay according to claim 4, wherein, The moving spring mechanism includes a moving spring and a lower armature. The moving contact is located on the side of the moving spring facing the stationary contact. The lower armature is fixed relative to the moving spring. Both ends of the moving spring protrude from the lower armature. The two spring arms respectively abut against the two ends of the moving spring protruding from the lower armature. The stop element is opposite to the lower armature.
8. The high-voltage DC relay according to claim 3, wherein, The stop element is fixedly connected to the base on the side facing away from the pushing mechanism.
9. The high-voltage DC relay according to claim 3, wherein, The stop element is made of plastic, and the elastic element is integrally formed with the stop element by an insert injection molding process, with the base at least partially located within the stop element.
10. The high-voltage DC relay according to claim 1, wherein, The stop element is located between the moving spring mechanism and the pushing mechanism.
11. The high-voltage DC relay according to claim 1, wherein, The moving spring mechanism includes a moving spring and a lower armature. The moving contact is located on the side of the moving spring facing the stationary contact. The lower armature is fixed relative to the moving spring. The stop element is opposite to either the lower armature or the moving spring.
12. The high-voltage DC relay according to claim 11, wherein, The moving assembly further includes two first arms, which are located on opposite sides of the moving spring mechanism in the direction of movement relative to the pushing mechanism. The first arms are fixed relative to the pushing mechanism and slidably engaged with the moving spring mechanism. The high-voltage DC relay also includes an upper armature opposite to the lower armature. The upper armature is located outside the moving assembly and is fixed relative to the stationary contact.
13. The high-voltage DC relay according to claim 11, wherein, The actuator also includes two first arms, which are located on opposite sides of the moving spring mechanism relative to the pushing mechanism in the direction of motion. The first arms are fixed relative to the pushing mechanism and slidably engaged with the moving spring mechanism. The high-voltage DC relay also includes an upper armature opposite to the lower armature. The actuator also includes a second arm connected to the two first arms, which is located on the side of the moving spring mechanism opposite to the pushing mechanism. The upper armature is fixed to the second arm.
14. The high-voltage DC relay according to any one of claims 1-13, wherein, The pushing mechanism can drive the moving spring mechanism to move towards the stationary contact, so that the high-voltage DC relay has a first state and a second state. In the first state, the moving contact is exactly in contact with the stationary contact. In the second state, the moving contact is pressed against the stationary contact by the elastic element. During the switching process from the first state to the second state, the pushing mechanism moves towards the stationary contact relative to the moving spring mechanism. The distance between the stop element and the moving spring mechanism is smaller in the second state than in the first state.
15. The high-voltage DC relay according to claim 14, wherein, In the second state, the difference between the dimension of the elastic element in the direction of motion of the moving spring mechanism relative to the pushing mechanism and the ultimate compression length of the elastic element is greater than the distance between the stop element and the moving spring mechanism.
16. The high-voltage DC relay according to claim 14, wherein, The moving spring mechanism can spring away from the stationary contact under the electric repulsive force generated by the short-circuit current, so that the high-voltage DC relay switches from the second state to the third state. In the third state, the stop element abuts against the moving spring mechanism to prevent the moving spring mechanism and the push mechanism from getting close to each other. The dimension of the elastic element in the direction of movement of the moving spring mechanism relative to the push mechanism is greater than the limit compression length of the elastic element.
17. The high-voltage DC relay according to any one of claims 1-13, wherein, The high-voltage DC relay also includes an electromagnetic component. The pushing mechanism includes a pushing seat and a pushing rod connected to the side of the pushing seat facing away from the moving spring mechanism. The elastic element is disposed on the pushing seat. The moving spring mechanism is elastically engaged with the pushing seat through the elastic element. The electromagnetic component can drive the pushing seat to move towards or away from the stationary contact through the pushing rod.