Power Relay Assembly Layout for HV-LV Isolation and Moisture Drainage
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Solution Overview
Problem
Existing power relay assemblies in electric vehicles and hybrid electric vehicles lack effective separation of high-voltage and low-voltage circuits, leading to potential signal interference and increased risk of damage from moisture accumulation.
Innovation Solution
A power relay assembly with physically separated high-voltage and low-voltage circuits, where a relay module controls current flow in a first accommodation unit, and a wire module connected to the relay module is housed in a second accommodation unit, allowing for independent management and reduced interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage and low-voltage circuits are housed together in a single accommodation unit, then the device structure is simpler and easier to manufacture, but signal interference occurs and reliability decreases
Solution Approach 1:
The patent divides the accommodation unit into two separate compartments: a first accommodation unit for the relay module (high-voltage circuit) and a second accommodation unit for the wire module (low-voltage circuit). This physical segmentation prevents signal interference between high-voltage and low-voltage circuits while maintaining overall structural integration through the single housing design.
2Reliability
If circuits are housed together in a single accommodation unit, then manufacturing is simpler, but moisture accumulation risk increases
Solution Approach 1:
The accommodation space is segmented into two separate units with independent moisture discharge paths. The first accommodation unit has a first moisture discharge path and the second accommodation unit has a second moisture discharge path, allowing moisture to be discharged from each compartment independently, reducing the risk of moisture accumulation and corrosion.
Solution Approach 2:
The housing structure acts as an intermediary element that provides both accommodation and moisture discharge functionality. The moisture discharge paths are integrated into the housing structure itself, serving as a mediator that protects electronic components from moisture while maintaining a compact design.
3Reliability
If wire module is loosely positioned in the accommodation rail, then assembly is easier, but connection reliability decreases
Solution Approach 1:
The fixing member is designed to automatically engage with the wire module upon insertion into the accommodation rail. The wire module's own structure (with protrusions or engagement features) works together with the fixing member to create a self-securing connection, eliminating the need for additional fastening operations or complex assembly steps.
Data Source
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AI summary
The present disclosure provides a power relay assembly (3) including a first case (100), a first accommodation unit (200) inside the first case (100), a relay module (300) in the first accommodation unit (200), and configured to control a flow of a current, a second case (400) on the first case (100), a second accommodation unit (500) inside the second case (400), and separated from the first accommodation unit (200), and a wire module (600) in the second accommodation unit (500), and connected to the relay module (300).