EP4597535A1

EP4597535A1 - Integrated relay, electrical device, and vehicle

Info

Publication number: EP4597535A1
Application number: EP25153717.1A
Authority: EP
Inventors: Caifang GUO; Bin Li; Luhui XU; Xiaofeng Lin
Original assignee: BYD Co Ltd
Current assignee: BYD Co Ltd
Priority date: 2024-01-30
Filing date: 2025-01-24
Publication date: 2025-08-06
Also published as: CN222867552U; WO2025161780A1

Abstract

An integrated relay, an electrical device, and a vehicle are provided. The integrated relay includes a housing and a number of relay cores. The housing is an integrated piece and includes a mounting cavity. The number of relay cores are arranged spaced away from each other and encapsulated together in the mounting cavity. In the technical solutions of the present disclosure, unshelled relay cores are encapsulated in the mounting cavity of the housing, to reduce a volume of a single relay core, thereby reducing a volume of the integrated relay, and improving an aperture utilization rate of the integrated relay for the electrical device.

Description

FIELD

The present disclosure relates to the field of relay technologies, and specifically, to an integrated relay, an electrical device, and a vehicle.

BACKGROUND

As a common controllable electronic switch, a relay is widely used in various high and low-voltage circuits. For an electrical device, a number of relays are often required to work together to implement circuit control.
However, in the related art, an integration manner of the relay results in a low space utilization rate for the electrical device, which is not conducive to miniaturization of the electrical device.

SUMMARY

An objective of the present disclosure is to provide an integrated relay, an electrical device, and a vehicle, to resolve a problem that an existing integrated relay occupies large space.
To achieve the objective of the present disclosure, according to a first aspect, the present disclosure provides an integrated relay. The integrated relay includes a housing and a number of relay cores.
The housing is an integrated piece and includes a mounting cavity.
The number of relay cores are spaced away from each other and encapsulated together in the mounting cavity.
In a possible embodiment, the integrated relay further includes a potting compound. The potting compound is filled in the mounting cavity to fix the number of relay cores.
In a possible embodiment, the potting compound is arranged between adjacent two of the relay cores.
In a possible embodiment, each of the relay cores includes a first power terminal, a second power terminal, and a contact member. The contact member is configured to electrically connect or disconnect the first power terminal and the second power terminal.
In a possible embodiment, the first power terminal and the second power terminal are each partially covered by the potting compound, and/or the second power terminal is partially covered by the potting compound.
In a possible embodiment, the housing includes an opening. The opening is in communication with the mounting cavity. The first power terminal and the second power terminal are located at the opening. The opening is sealed by the potting compound.
In a possible embodiment, the first power terminal and the second power terminal protrude out of the housing from the opening.
In a possible embodiment, the relay core further includes a fixing member. The first power terminal and the second power terminal are fixed to the fixing member.
In a possible embodiment, the integrated relay further includes a potting compound. The potting compound is filled in the mounting cavity to fix the number of relay cores.
The relay core further includes an arc extinguishing shield. The arc extinguishing shield is arranged on an outer periphery of the fixing member. The arc extinguishing shield is in direct contact with the potting compound.
In a possible embodiment, the relay core further includes a drive assembly. The drive assembly is configured to drive the contact member to move. The drive assembly includes a stator and a mover.
The stator includes a stator core and a coil arranged on the stator core.
The mover is at least partially sheathed in the stator. In addition, an end of the mover is connected to the contact member, to drive the contact member to move, to electrically connect or disconnect the first power terminal and the second power terminal.
In a possible embodiment, the integrated relay further includes a potting compound. The potting compound is filled in the mounting cavity to fix the number of relay cores.
The stator is directly in contact with and connected to the potting compound.
In a possible embodiment, the relay core further includes a signal pin. One end of the signal pin is connected to the coil, and another end thereof is adapted to connect to a circuit board.
According to a second aspect, the present disclosure provides an electrical device. The electrical device includes an integrated relay. The integrated relay includes a housing and a number of relay cores.
The housing is an integrated piece and includes a mounting cavity.
The number of relay cores are arranged spaced away from each other and encapsulated together in the mounting cavity.
In a possible embodiment, the electrical device further includes a first copper busbar and a second copper busbar.
The first copper busbar includes a first end and a second end oppositely arranged. The first end is welded to the first power terminal, and the second end is configured to connect to a control circuit.
In addition/alternatively, the second copper busbar includes a third end and a fourth end oppositely arranged. The third end is welded to the second power terminal, and the fourth end is configured to connect to the control circuit.
In a possible embodiment, the integrated relay further includes a potting compound. The potting compound is filled in the mounting cavity to fix the number of relay cores. The electrical device further includes a first copper busbar and a second copper busbar.
The first copper busbar includes a first end. The first end is connected to the first power terminal. The first end and the first power terminal are each covered by the potting compound.
In addition/alternatively, the second copper busbar includes a third end. The third end is connected to the second power terminal. The third end and the second power terminal are each covered by the potting compound.
According to a third aspect, the present disclosure provides a vehicle. The vehicle includes an electrical device. The electrical device includes an integrated relay. The integrated relay includes a housing and a number of relay cores.
The housing is an integrated piece and includes a mounting cavity.
The number of relay cores are arranged spaced away from each other and encapsulated together in the mounting cavity.
In the technical solutions of the present disclosure, unshelled relay cores are encapsulated in the mounting cavity of the housing, to reduce a volume of a single relay core, thereby reducing a volume of the integrated relay, and improving a space utilization rate of the integrated relay for the electrical device.

BRIEF DESCRIPTION OF THE DRAWINGS

To describe the technical solutions of the embodiments of the present disclosure or the related art more clearly, the following briefly introduces the accompanying drawings required for describing the embodiments or the related art. Apparently, the accompanying drawings in the following description show only some embodiments of the present disclosure, and a person of ordinary skill in the art may still derive other drawings from these accompanying drawings without creative efforts.

FIG. 1 is a schematic topological diagram of an integrated relay according to the present disclosure used in a motor control system;
FIG. 2 is a schematic three-dimensional structural diagram of an embodiment of an integrated relay according to the present disclosure;
FIG. 3 is a cross-sectional view of a relay core in FIG. 2;
FIG. 4 is a schematic diagram of assembly between a relay core in FIG. 1 and a first copper busbar and a second copper busbar;
FIG. 5 is a schematic diagram of assembly between a relay core in FIG. 1 and a circuit board according to an embodiment; and
FIG. 6 is a schematic diagram of assembly between a relay core in FIG. 1 and a circuit board according to another embodiment.

In the drawings:

2000: electrical device;
1000: integrated relay;
1: housing, 11: mounting cavity;
2: potting compound;
3: relay core, 31: first power terminal, 32: second power terminal, 33: contact member, 331: main unit, 332: first contact piece, 333: second contact piece, 34: fixing member, 341: accommodating cavity, 35: first copper busbar, 36: second copper busbar, 37: sealing cover, 371: third through hole, 38: drive assembly, 381: mounting frame, 382: stator, 3821: coil, 3822: stator core, 383: mover, 3831: body, 3832: connecting shaft, 39: first spring, 310: second spring, 320: arc extinguishing shield;
4: signal pin;
5: circuit board;
K1: first relay core, K2: second relay core, K3: third relay core, K4: fourth relay core, K5: fifth relay core, K6: sixth relay core, K7: seventh relay core;
2100: battery, 2110: first battery, and 2120: second battery;
2200: motor controller, R1: first resistor, R2: second resistor, C1: first capacitor, C2: second capacitor;
2300: direct current connector;
3000: motor.

DETAILED DESCRIPTION

The following clearly and completely describes the technical solutions in the embodiments of the present disclosure with reference to the accompanying drawings in the embodiments of the present disclosure. Apparently, the described embodiments are merely some rather than all of the embodiments of the present disclosure. All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present disclosure without creative efforts shall fall within the protection scope of the present disclosure.
It should be noted that, when a component is referred to as "being fixed to" another component, the component may be directly on another component, or an intervening component may exist. When a component is considered to be "connected to" another component, the component may be directly connected to another component, or an intervening component may exist.
Unless otherwise defined, all technical and scientific terms used in the present disclosure have the same meanings as commonly understood by a person of ordinary skill in the art to which the present disclosure belongs. The terms used in the specification of the present disclosure are merely used for describing specific embodiments, and are not intended to limit the present disclosure. The term "and/or" used in the present disclosure includes any and all combinations of one or more related listed items.
Some embodiments of the present disclosure are described below in detail with reference to the accompanying drawings. The following embodiments and features in the embodiments may be mutually combined if no conflict occurs.
The present disclosure provides a vehicle. The vehicle may be an electric vehicle or a fuel vehicle. This is not limited in the present disclosure. The vehicle includes a vehicle body, wheels, and an electrical device. The vehicle body serves as a support skeleton of the vehicle and is configured to support and connect assemblies of the vehicle. The wheels are rotatably arranged on the vehicle body. The wheels are configured to rotate to drive the vehicle to move forward.
The electrical device is arranged on the vehicle body. The electrical device may be a motor control system, a battery pack, or a power distribution box, which is not limited in the present disclosure. Using a motor control system as an example, referring to FIG. 1, FIG. 1 is a schematic topological diagram of an integrated relay according to the present disclosure used in a motor control system. An electrical device 2000 includes a battery 2100, a motor controller 2200, and an integrated relay 1000. The battery 2100 is connected to the motor controller 2200. The battery 2100 is configured to store and discharge electrical energy to maintain normal use of the motor controller 2200. The motor controller 2200 is configured to connect to a motor 3000. The motor controller 2200 can adjust a movement parameter of the motor 3000, to control the motor 3000 to move, and drive the wheels to rotate through the motor 3000. The integrated relay 1000 is arranged between the battery 2100 and the motor controller 2200. The integrated relay 1000 is configured to control on and off of a current between the battery 2100 and the motor controller 2200. Specifically, the integrated relay 1000 includes a first relay core K1 and a second relay core K2. A first end of the first relay core K1 is connected to a positive pole of the battery 2100 and a second end of the first relay core K1 is connected to the motor controller 2200. When the first relay core K1 and the second relay core K2 are closed, a closed loop is formed between the battery 2100 and the motor controller 2200, and the motor controller 2200 is energized. When the first relay core K1 and the second relay core K2 are open, a loop between the battery 2100 and the motor controller 2200 is open, and the motor controller 2200 is de-energized.
The electrical device 2000 further includes a first resistor R1, and the integrated relay 1000 further includes a third relay core K3. A first end of the third relay core K3 is connected to the positive pole of the battery 2100 and the first end of the first relay core K1, and a second end of the third relay core K3 is connected to the first resistor R1. A second end of the first resistor R1 is connected to the second end of the first relay core K1 and an electrical load. When a current of the circuit is excessively large, the controller may control a circuit of the first relay core K1 to open and a circuit of the third relay core K3 to close. In this way, the current is transferred through the first resistor R1 instead of the first relay core K1, to increase resistance of the circuit and protect safety of the circuit.
The battery 2100 includes a first battery 2110 and a second battery 2120. The electrical device 2000 further includes a second resistor R2. The integrated relay 1000 further includes a fourth relay core K4. A first end of the fourth relay core K4 is connected to a negative pole of the first battery 2110 and a positive pole of the second battery 2120. A second end of the fourth relay core K4 is connected to a first end of the second resistor R2. A second end of the second resistor R2 is connected to a neutral wire of the motor controller 2200. When the fourth relay core K4 is closed, a current between the first battery 2110 and the second battery 2120 may be grounded through the second resistor R2. Moreover, when passing through the second resistor R2, the current generates heat due to resistance of the second resistor R2, to raise a temperature of the battery pack, and improve heating performance of the battery pack in a low-temperature environment.
The electrical device 2000 further includes a direct current connector 2300. The integrated relay 1000 includes a fifth relay core K5 and a sixth relay core K6. The direct current connector 2300 is configured to connect to an external power supply, to introduce electrical energy from the external power supply into the electrical device 2000. A first end of the fifth relay core K5 is connected to a negative pole of the direct current connector 2300, and a second end of the fifth relay core K5 is connected to a negative pole of the battery 2100. A first end of the sixth relay core K6 is connected to a positive pole of the direct current connector 2300, and a second end thereof is connected to the positive pole of the battery 2100. When the fifth relay core K5 and the sixth relay core K6 are closed, a closed loop is formed between the direct current connector 2300 and the battery 2100, and a current of the external power supply may flow to the battery through the direct current connector 2300, thereby achieving fast charging of the battery 2100.
The integrated relay 1000 further includes a seventh relay core K7. A first end of the seventh relay core K7 is connected to the positive pole of the direct current connector 2300, and a second end of the seventh relay core K7 is connected to the neutral wire of the motor controller 2200. The seventh relay core K7 can for a closed loop with the fifth relay core K5. When the seventh relay core K7 and the fifth relay core K5 are closed by the controller, a current of the direct current connector 2300 can reach the neutral wire of the motor controller 2200 through the seventh relay core K7, and reach the battery 2100 after having an additional charging voltage introduced at the neutral wire, thereby achieving boost charging of the battery 2100, and improving charging efficiency of a charging apparatus.
The electrical device 2000 further includes a first capacitor C 1. A first end of the first capacitor C1 is connected between the second end of the first relay core K1 and a first end of the motor controller 2200, and the first end of the first capacitor C1 is connected to the second end of the sixth relay core K6. A second end of the first capacitor C1 is connected to the second end of the fifth relay core K5. The first capacitor C1 is configured to smooth a voltage of the circuit, reduce fluctuations of the voltage of the circuit, and absorb harmonics of the circuit, thereby maintaining the circuit stable.
The electrical device 2000 further includes a second capacitor C2. A first end of the second capacitor C2 is connected to the positive pole of the direct current connector 2300, and a second end of the second capacitor C2 is connected to a second end of the motor controller 2200. The second capacitor C2 is configured to smooth a voltage of the circuit, reduce fluctuations of the voltage of the circuit, and absorb harmonics of the circuit, thereby maintaining a current between the direct current connector 2300 and the motor controller 2200 stable.
The electrical device 2000 may further include an OBC module and/or a DC module. The OBC module and the DC module are connected between an alternating current connector and the battery. The OBC module is configured to convert alternating current electricity from a power grid into direct current electricity required by the battery 2100 to meet a charging need of the battery 2100. The DC module is a device configured to convert high-voltage direct current electricity into low-voltage direct current electricity, and provides electric energy to low-voltage electric appliances (such as a power steering system and an instrument panel) in the vehicle and the battery 2100.
Referring to FIG. 2, the integrated relay 1000 includes: a housing 1 and a number of relay cores 3. The housing 1 is an integrated piece and includes a mounting cavity 11. The number of relay cores 3 are arranged spaced away from each other and are encapsulated together in the mounting cavity 11. In the technical solutions of the present disclosure, unshelled relay cores 3 are encapsulated in the mounting cavity 11 of the housing, to reduce a volume of a single relay core 3, thereby reducing a volume of the integrated relay 1000, and improving an aperture utilization rate of the integrated relay 1000 for the electrical device.
The integrated relay 1000 provided in the present disclosure is described below in detail with reference to the accompanying drawings.
The integrated relay 1000 includes a housing 1. The housing 1 serves as a support skeleton of the integrated relay 1000 and is configured to support and connect various components of the integrated relay 1000. A shape of the housing 1 may be a rectangle, a square, or another regular or irregular shape. This is not limited in the present disclosure. The housing 1 may be a part of a device frame, or may be a structure independent of the device frame. This is also not limited in the present disclosure.
The housing 1 includes an opening and a mounting cavity 11. The opening is in communication with the mounting cavity 11. A relay core 3 may be arranged in the mounting cavity 11 through the opening. A number of relay cores 3 are arranged spaced away from each other in the mounting cavity 11. The relay core 3 is configured to connect to a control circuit of the electrical device. The relay core 3 can control a current direction of the electrical device by controlling its own opening and closing, thereby implementing different electrical functions. The relay cores 3 may be vertically placed relative to each other into the mounting cavity 11, or may be horizontally placed relative to each other into the mounting cavity 11, or may be partially vertically and partially horizontally placed into the mounting cavity 11. This is not limited in the present disclosure.
The integrated relay 1000 further includes a potting compound 2. The potting compound 2 is filled in the mounting cavity 11 to fix the number of relay cores 3. Arrangement of the potting compound 2 has two functions. First, the potting compound 2 can provide fixing for mounting of the relay core 3 in the mounting cavity 11, and second, the potting compound 2 can provide support for arrangement of the relay core 3 in the mounting cavity 11, thereby improving stability of the arrangement of the relay core 3. A material of the potting compound 2 may be one or more of epoxy resin, phenolic resin, or natural fibers. This is not limited in the present disclosure. In an embodiment of the present disclosure, the potting compound 2 includes one or more of insulating resin, aluminum nitride, or boron nitride. Use of insulating resin, aluminum nitride, and boron nitride leads to not only good insulation, but also good thermal conductivity. The relay core 3 can rapidly conduct heat to the housing 1 through the potting compound 2, and rapidly dissipate heat outward through the housing 1, thereby reducing impact of accumulated heat on the integrated relay 1000 and improving working stability of the integrated relay 1000.
In an embodiment of the present disclosure, the potting compound 2 is arranged between adjacent two of the relay cores 3, and the potting compound 2 is filled between the relay cores 3, to reduce a gap between the relay cores 3, reduce a shaking amplitude of the relay cores 3 during vibration, and improve shock resistance of the relay cores 3.
Referring to FIG. 3, the relay core 3 includes a first power terminal 31, a second power terminal 32, and a contact member 33. The first power terminal 31 and the second power terminal 32 are configured to connect to a circuit of the electrical device. The relay core 3 can control opening and closing of the circuit of the electrical device at the relay core 3 by controlling opening and closing of a current between the first power terminal 31 and the second power terminal 32, thereby controlling the circuit of the electrical device.
The contact member 33 is movably arranged in the housing 1, moves toward or away from the first power terminal 31 and the second power terminal 32, and is configured to control on and off of a current between the first power terminal 31 and the second power terminal 32. Specifically, the contact member 33 includes a main body piece 331 and a first contact piece 332 and a second contact piece 333 arranged at two ends of the main body piece 331. When the contact member 33 moves toward the first power terminal 31 and the second power terminal 32, the first contact piece 332 of the contact member 33 comes into contact with the first power terminal 31, and the second contact piece 333 comes into contact with the second power terminal 32. In this way, the circuit between the first power terminal 31 and the second power terminal 32 is closed. When the contact member 33 moves away from the first power terminal 31 and the second power terminal 32, the first contact piece 332 of the contact member 33 is separated from the first power terminal 31, the second contact piece 333 is separated from the second power terminal 32, and the circuit between the first power terminal 31 and the second power terminal 32 is open.
The relay core 3 further includes a fixing member 34. The fixing member 34 is configured to provide support for arrangement of the first power terminal 31, the second power terminal 32, and the contact member 33. Specifically, the fixing member 34 includes an accommodating cavity 341 with one end open. A surface of the fixing member 34 is provided with a first through hole and a second through hole that are in communication with the accommodating cavity 341. The first power terminal 31 extends from the first through hole into the accommodating cavity 341. The second power terminal 32 extends from the second through hole into the accommodating cavity 341. The contact member 33 is movably arranged in the accommodating cavity 341, and comes into contact with and moves away from the first power terminal 31 and the second power terminal 32 in the accommodating cavity 341. The arrangement of the fixing member 34 can provide protection for movement of the contact member 33, to prevent another structure in the electrical device from affecting the movement of the contact member 33, and extend a service life of the relay core 3.
When the contact member 33 is separated from the first power terminal 31 and the second power terminal 32, an arc is prone to occur, and the arc causes burns to the contact member 33, the first power terminal 31, and the second power terminal 32. To reduce impact of the arc on the contact member 33, the first power terminal 31, and the second power terminal 32, in an embodiment of the present disclosure, the accommodating cavity 341 is filled with an arc extinguishing gas. The arc extinguishing gas may be hydrogen, nitrogen, or sulfur dioxide. This is not limited in the present disclosure. The arc extinguishing gas is configured to extinguish an arc when the contact member 33, the first power terminal 31, and the second power terminal 32 generate the arc, thereby protecting the safety of the contact member 33, the first power terminal 31, and the second power terminal 32, and extending the service life of the relay core 3.
A material of the fixing member 34 may be plastic or ceramic. This is not limited in the present disclosure. In an embodiment of the present disclosure, the ceramic is used as the material of the fixing member 34. In this way, the fixing member 34 can shorten occurrence time of the arc, to protect the safety of the contact member 33, the first power terminal 31, and the second power terminal 32 while providing stable support for the first power terminal 31 and the second power terminal 32.
The relay core further includes an arc extinguishing shield 320. The arc extinguishing shield 320 is arranged on an outer periphery of the fixing member 34. When an arc is generated between the contact member 33 and the first power terminal 31 and between the contact member 33 and the second power terminal 32, the arc extinguishing shield 320 can separate the arc from a contact point, and quickly extinguish the arc by using a diffusion effect of the arc in the arc extinguishing shield 320. A large amount of heat may be generated by the arc extinguishing shield 320 during arc extinction. To reduce impact of accumulation of heat on the arc extinguishing shield 320 on the arc extinguishing shield 320, in an embodiment of the present disclosure, the potting compound 2 is wrapped around the arc extinguishing shield 320, and is in direct contact with the arc extinguishing shield 320. In this way, a contact area between the potting compound 2 and the arc extinguishing shield 320 is increased, a heat conduction effect of the potting compound 2 on the arc extinguishing shield 320 is improved, a heat dissipation effect of the arc extinguishing shield 320 is improved, impact of the heat on the arc extinguishing shield 320 is reduced, and working stability of the arc extinguishing shield 320 is improved.
The relay core 3 further includes a drive assembly 38 and a sealing cover 37. The sealing cover 37 covers an opening of the accommodating cavity 341. In this way, the contact member 33 arranged in the accommodating cavity 341 is isolated from the outside air, thereby reducing impact of moisture and impurities in the outside air on contact between the contact member 33 and the first power terminal and between the contact member 33 and the second power terminal. A third through hole 371 is further provided on the sealing cover 37. The third through hole 371 is configured for the drive assembly 38 to pass through.
The drive assembly 38 is configured to drive the contact member 33 to move. The drive assembly 38 may be a motor or a cylinder. This is not limited in the present disclosure. The drive assembly 38 includes a mounting frame 381, a stator 382, and a mover 383. The mounting frame 381 serves as a support skeleton of the drive assembly 38, and is configured to support and connect various parts of a support assembly. The stator is arranged on the mounting frame 381. The stator is configured to generate a magnetic field, to drive the mover 383 to move upward. The mover 383 is at least partially sheathed in the stator 382. The mover 383 is configured to drive the contact member 33 to move toward or away from the first power terminal 31 and the second power terminal 32. Specifically, the stator 382 includes a stator core 3822 and a coil 3821. The stator core 3822 is configured to provide support for arrangement of the coil 3821. The coil 3821 is wound around the stator core 3822. The coil 3821 is connected to the external power supply, and can convert electrical energy from the external power supply into magnetic energy, to attract the mover 383 to move upward. The mover 383 is sheathed in the stator 382. The mover 383 includes a body 3831 and a connecting shaft 3832. The body 3831 is arranged on a side of the stator core 3822 facing away from the first power terminal 31 and the second power terminal 32. One end of the connecting shaft 3832 is connected to the body 3831, and another end passes through the stator core 3822 and the third through hole 371 in sequence to connect to the contact member 33. To avoid destroying sealing of the accommodating cavity 341, the connecting shaft 3832 and the third through hole 371 are connected hermetically. The body 3831 of the mover 383 is made of a magnetic material. When the coil 3821 is energized, the coil 3821 generates a magnetic field at the stator core 3822, to attract the body 3831 to move upward. The body 3831 moves upward, thereby driving the connecting shaft 3832 to move upward. The movement of the connecting shaft 3832 drives the contact member 33 to move upward, and finally causes the contact member 33 to come into contact with the first power terminal 31 and the second power terminal 32. The circuit between the first power terminal 31 and the second power terminal 32 is closed. When the coil 3821 is de-energized, the magnetic field generated by the coil 3821 disappears, and the mover 383 falls back downward under the action of gravity. The contact member 33 is separated from the first power terminal 31 and the second power terminal 32, and the circuit between the first power terminal 31 and the second power terminal 32 is open.
In an embodiment of the present disclosure, the stator 382 is directly in contact with and connected to the potting compound 2. In this way, a contact area between the potting compound 2 and the stator 382 is increased, and a heat conduction capability of the potting compound 2 for the coil 3821 is improved, thereby improving a heat dissipation capability of the drive assembly 38, and improving working stability of the drive assembly 38.
In an embodiment of the present disclosure, the drive assembly 38 further includes a first spring 39. The first spring 39 is sleeved outside the connecting shaft 3832. One end of the first spring 39 is connected to the stator core 3822, and another end is connected to the body 3831 of the mover 383. When the coil 3821 is energized, the body 3831 moves upward and compresses the first spring 39. When the coil 3821 is de-energized, the first spring 39 is released and pushes the body 3831 downward, thereby increasing a falling speed of the body 3831. Therefore, after the coil 3821 is de-energized, the contact member 33 can be quickly separated from the first power terminal 31 and the second power terminal 32, thereby increasing a response speed of the relay core 3.
In an embodiment of the present disclosure, the drive assembly 38 further includes a second spring 310. The second spring is sleeved on an outer periphery of the connecting shaft 3832. One end of the second spring 310 is connected to the stator core 3822, and another end is connected to the contact member 33. In this embodiment, regardless of whether the coil 3821 is energized or de-energized, and regardless of whether the contact member 33 rises or falls, the second spring 310 is always in a compressed state. In this way, when the contact member 33 comes into contact with the first power terminal 31 and the second power terminal 32, the second spring 310 can apply an upward thrust to the contact member 33. Therefore, the contact member 33 can tightly abut against the first power terminal 31 and the second power terminal 32, thereby improving stability of a connection between the contact member 33 and the first power terminal 31 and stability of a connection between the contact member 33 and the second power terminal 32.
Referring to FIG. 4 and FIG. 5, the integrated relay 1000 further includes a circuit board 5. The circuit board 5 is electrically connected to the coil 3821. A control program is integrated into the circuit board 5. The circuit board 5 can control on and off the current of the coil 3821 through setting of the control program, thereby controlling on and off of currents at two ends of the relay core 3. The circuit board 5 may be connected to the coil 3821 in various manners. In an embodiment of the present disclosure, a harness interface is arranged outside the relay core 3. The coil 3821 is electrically connected to the harness interface. The integrated relay 1000 further includes a harness. One end of the harness is connected to the circuit board 5, and another end extends into a wiring terminal. In this way, the coil 3821 is electrically connected to the circuit board 5.
In some other embodiments of the present disclosure, the relay core 3 further includes a signal pin 4. One end of the signal pin 4 is connected to the coil 3821, and another end thereof is configured to connect to the circuit board 5. The signal pin 4 may be welded to the circuit board 5, or may be bonded to the circuit board 5 by an electrical adhesive. This is not limited in the present disclosure. When the relay core 3 is connected to the circuit board 5, each relay core 3 may be equipped with a group of signal pins 4, as shown in FIG. 4, to connect to the circuit board 5, or a number of relay cores 3 may be jointly equipped with a group of signal pins 4, as shown in FIG. 5, to jointly connect to the circuit board 5. This is also not limited in the present disclosure. The signal pin 4 of the relay core 3 may be connected to the circuit board 5 along a direction perpendicular to the relay core 3, or may connect to the circuit board 5 along a direction parallel to the relay core 3. This is also not limited in the present disclosure. In this embodiment, the signal pin 4 is connected to the circuit board 5 instead of the harness interface, which omits use of the harness, and reduces wiring costs of the coil 3821 and the circuit board 5.
Referring to FIG. 6, to connect the first power terminal 31 and the second power terminal 32 to the control circuit of the electrical device, the electrical device further includes a first copper busbar 35 and a second copper busbar 36. The first copper busbar 35 includes a first end and a second end oppositely arranged. The first end is connected to the first power terminal 31. The second end is connected to the control circuit. The second copper busbar 36 includes a third end and a fourth end oppositely arranged. The third end is connected to the second power terminal 32. The fourth end is connected to the control circuit of the electrical device.
The first copper busbar 35 may be connected to the first power terminal 31 in various manners, and the second copper busbar 36 may be connected to the second power terminal 32 in various manners. The first copper busbar 35 and the first power terminal 31, and the second copper busbar 36 and the second power terminal 32 may be connected by threaded members or by bonding. This is not limited in the present disclosure. Considering that if the first copper busbar 35 is bonded to the first power terminal 31, and the second copper busbar 36 is bonded to the second power terminal 32, stability of a connection between the first copper busbar 35 and the first power terminal 31 and stability of a connection between the second copper busbar 36 and the second power terminal 32 cannot be ensured. If the first copper busbar 35 is connected to the first power terminal 31 by a threaded member, and the second copper busbar 36 is connected to the second power terminal 32 by a threaded member, the first power terminal 31 and the second power terminal 32 each need to be provided with a threaded hole with a sufficient depth, to ensure the stability of the connection between the first copper busbar 35 and the first power terminal 31 and the stability of the connection between the second copper busbar 36 and the second power terminal 32. The arrangement of the threaded holes undoubtedly increases lengths of the first power terminal 31 and the second power terminal 32, which increases a height of the relay core 3, and further affects the space utilization rate of the relay core 3 for the mounting cavity 11. To resolve the foregoing problem, in an embodiment of the present disclosure, the first end of the first copper busbar 35 is welded to the first power terminal 31, and the third end of the second copper busbar 36 is welded to the second power terminal 32. Since the connection is no longer made through a threaded member, the first power terminal 31 and the second power terminal 32 do not need to reserve thread lengths. In this way, the lengths of the first power terminal 31 and the second power terminal 32 are reduced, thereby reducing the height of the relay core 3, and improving the space utilization rate of the relay core 3 for the electrical device.
In an embodiment of the present disclosure, the first power terminal 31 and the second power terminal 32 are arranged at the opening of the housing 1. The opening is sealed by the potting compound 2. In this way, external water vapor or dust is prevented from entering the mounting cavity 11 from the opening and affecting normal use of the relay core 3.
The first power terminal 31 and the second power terminal 32 may be covered in the potting compound 2, or may be exposed from the potting compound 2. This is not limited in the present disclosure. Specifically, in an embodiment of the present disclosure, the first power terminal 31 and the second power terminal 32 protrude out of the housing 1 from the opening. In this way, the first power terminal 31 and the second power terminal 32 can be exposed from the potting compound 2, thereby facilitating the connection between the first power terminal 31 and the first copper busbar 35 or the connection between the second power terminal 32 and the second copper busbar 36.
In another embodiment of the present disclosure, first, the first power terminal 31 and the first copper busbar 35 may be connected to each other, and the second power terminal 32 and the second copper busbar 36 may be connected to each other, and then, they are potted in the mounting cavity 11 through the potting compound 2. Specifically, in this embodiment, the first end of the first copper busbar 35 is connected to the first power terminal 31, and the second copper busbar 36 is connected to the second power terminal 32 by welding. The first end and the first power terminal 31, as well as the third end and the second power terminal 32 are each covered by the potting compound 2. In this way, the stability of the connection between the first power terminal 31 and the first copper busbar 35 and stability of the connection between the second power terminal 32 and the second copper busbar 36 are improved.
It may be understood that, in another embodiment of the present disclosure, alternatively, the first end of the first copper busbar 35 and the first power terminal 31 are covered by the potting compound 2, and the second power terminal 32 and the second copper busbar 36 are exposed from the potting compound 2. Alternatively, the third end of the second copper busbar 36 and the second power terminal 32 are covered by the potting compound 2, and the first end of the first copper busbar 35 and the first power terminal 31 are exposed from the potting compound 2. This is not limited in the present disclosure.
In the descriptions of the embodiments of the present disclosure, it should be noted that, orientations or position relationships indicated by terms, such as "center", "up", "down", "left", "right", "vertical", "horizontal", "in", and "out", are orientations or position relationships shown based on the accompanying drawings, are merely for the convenience of describing the present disclosure and simplifying the description, and are not intended to indicate or imply that an apparatus or element referred to needs to have a particular direction and be constructed and operated in a particular orientation, and therefore, cannot be understood as a limitation on the present disclosure.
The content disclosed above is merely exemplary embodiments of the present disclosure, and is certainly not intended to limit the patent scope of the present disclosure. A person of ordinary skill in the art may understand all or some of the procedures for implementing the foregoing embodiments, and any equivalent variation made according to the claims of the present disclosure still falls within the scope of the present disclosure.

Claims

An integrated relay, comprising:
a housing, the housing being an integrated piece and comprising a mounting cavity; and

a plurality of relay cores, arranged spaced away from each other and encapsulated together in the mounting cavity.
The integrated relay according to claim 1, further comprising a potting compound, the potting compound being filled in the mounting cavity to fix the plurality of relay cores.
The integrated relay according to claim 2, wherein the potting compound is arranged between adjacent two of the relay cores.
The integrated relay according to claim 1, wherein each of the relay cores comprises a first power terminal, a second power terminal, and a contact member, the contact member is configured to electrically connect or disconnect the first power terminal and the second power terminal.
The integrated relay according to claim 4, further comprising a potting compound, the potting compound being filled in the mounting cavity to fix the plurality of relay cores; and
the first power terminal and the second power terminal being each partially covered by the potting compound, and/or the second power terminal being partially covered by the potting compound.
The integrated relay according to claim 5, wherein the housing comprises an opening, the opening is in communication with the mounting cavity, the first power terminal and the second power terminal are located at the opening, and the opening is sealed by the potting compound.
The integrated relay according to claim 6, wherein the first power terminal and the second power terminal protrude out of the housing from the opening.
The integrated relay according to claim 4, wherein the relay core further comprises a fixing member, the first power terminal and the second power terminal are fixed to the fixing member.
The integrated relay according to claim 8, further comprising a potting compound, the potting compound being filled in the mounting cavity to fix the plurality of relay cores; and
the relay core further comprising an arc extinguishing shield, the arc extinguishing shield being arranged on an outer periphery of the fixing member, and the arc extinguishing shield being in direct contact with the potting compound.
The integrated relay according to claim 4, wherein the relay core further comprises a drive assembly, the drive assembly is configured to drive the contact member to move, and the drive assembly comprises:
a stator, comprises a stator core and a coil arranged on the stator core; and

a mover, wherein the mover is at least partially sheathed in the stator and one end of the mover is connected to the contact member to drive the contact member to move, to electrically connect or disconnect the first power terminal and the second power terminal.
The integrated relay according to claim 10, further comprising a potting compound, the potting compound being filled in the mounting cavity to fix the plurality of relay cores; and
the stator being directly in contact with and connected to the potting compound.
The integrated relay according to claim 10, wherein the relay core further comprises a signal pin, one end of the signal pin is connected to the coil and another end of the signal pin is adapted to be connected to a circuit board.
An electrical device, comprising the integrated relay according to any one of claims 1 to 12.
The electrical device according to claim 13, further comprising a first copper busbar and a second copper busbar,
the first copper busbar comprising a first end and a second end oppositely arranged, the first end being welded to the first power terminal, and the second end being configured to connect to a control circuit; and/or

the second copper busbar comprising a third end and a fourth end oppositely arranged, the third end being welded to the second power terminal, and the fourth end being configured to connect to the control circuit;

or wherein the integrated relay further comprises a potting compound, the potting compound is filled in the mounting cavity to fix the plurality of relay cores; and the electrical device further comprises a first copper busbar and a second copper busbar,

the first copper busbar comprises a first end, the first end is connected to the first power terminal, and the first end and the first power terminal is each covered by the potting compound;

and/or

the second copper busbar comprises a third end, the third end is connected to the second power terminal, and the third end and the second power terminal are each covered by the potting compound.
A vehicle, comprising the electrical device according to any one of claims 13 to 14.