Integrated Relay Switch With Pre-Charge for Compact Battery Disconnect Units
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Solution Overview
Problem
Conventional battery disconnect units (BDUs) are large and costly due to the need for multiple components, which hinders the miniaturization of battery packs and reduces energy density.
Innovation Solution
A relay switch device that integrates the functions of a high potential main relay, a pre-charge relay, and a pre-charge resistor, using a circuit mode switch module and a driving module to control electrical connections between a battery pack and a load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (main relay, pre-charge relay, pre-charge resistor) are used in the BDU, then the reliability and functionality are improved, but the device size and cost increase
Solution Approach 1:
The patent combines the main relay, pre-charge relay, and pre-charge resistor into a single integrated relay switch device. The housing contains all three functional components arranged in a compact configuration, eliminating the need for separate discrete components while maintaining all required functions for safe battery pack connection and discharge protection.
Solution Approach 2:
The integrated relay switch device performs multiple functions simultaneously: it acts as a main relay for primary circuit connection, a pre-charge relay for controlled voltage application, and incorporates a pre-charge resistor for current limiting. This multi-functional design reduces the overall component count in the BDU.
2Adaptability or versatility
If multiple separate components are used in the BDU, then the functional requirements are met, but the battery pack size increases and energy density decreases
Solution Approach 1:
By integrating the pre-charge resistor and pre-charge relay into the same housing as the main relay, the patent significantly reduces the volume occupied by BDU components. This consolidation allows for a more compact battery pack design while maintaining all necessary functional capabilities for safe operation.
3Ease of operation
If multiple separate components are used in the BDU, then the circuit control functions are achieved, but the manufacturing cost increases
Solution Approach 1:
The patent describes an integrated relay switch device that combines multiple functional components into a single manufacturable unit. This integration reduces assembly steps, minimizes the number of separate parts to be sourced and assembled, and simplifies quality control processes, thereby reducing overall manufacturing costs despite maintaining full circuit control functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The relay switch device enables the miniaturization of BDUs by eliminating the need for separate pre-charge relays and resistors, thereby increasing energy density and reducing costs.
Implementation Method 1
a coil configured to generate an electromagnetic force capable of moving the moving shaft
Implementation Method 2
a pre-charge resistor 40 and a capacitor 50, and a pre-charge relay 30 connected to the high potential main relay 10 in parallel
Data Source
AI summary
Provided is a relay switch device including: a relay housing; a first upper fixing terminal and a second upper fixing terminal arranged side by side over an inside and an outside of the relay housing; a first lower fixing terminal electrically connected to the first upper fixing terminal and arranged under the first upper fixing terminal to be apart a predetermined distance from the first upper fixing terminal, and a second lower fixing terminal electrically connected to the second upper fixing terminal and arranged under the second upper fixing terminal to be apart a predetermined distance from the second upper fixing terminal; and a circuit mode switch module provided to selectively contact the first and second upper fixing terminals or the first and second lower fixing terminals by moving a predetermined distance.