Battery pack disconnecting unit and battery pack

Abstract

The present invention proposes a battery pack disconnecting unit and a battery pack, which relates to the technical field of BDU, and includes: a support seat; a plurality of relay elements, which are fixed in a horizontal position in the support seat, and the top surface of the relay elements is provided with coil contacts; a main control circuit board, which is fixedly provided on the top of the support seat; a plurality of connecting components, each connecting component is provided between the main control circuit board and a relay element, and the connecting component includes a plastic body, a conductive sheet and an electrical connector, the conductive sheet is integrally formed on the plastic body, one end of the conductive sheet is welded to the coil contact, and the other end of the conductive sheet is welded to the main control circuit board through the electrical connector. The battery pack disconnecting unit disclosed in the present invention places the relay element in a horizontal position, and is connected to the main control circuit board with a connecting component of a special structure, so as to avoid large mechanical stress at the connection point, ensure the reliability of the main control circuit board, and realize a significant reduction in the height of the battery pack disconnecting unit, so as to make the battery pack thinner.

Description

Technical Field

[0001] The present invention relates to the technical field of automobile BDU, and in particular to a battery pack disconnecting unit and a battery pack. Background Art

[0002] BDU (battery disconnect unit) refers to the battery pack disconnect unit, which is an important part of new energy vehicles. It provides charge and discharge control, circuit overload protection and other functions for the high-voltage system of new energy vehicles. Various types of relays are important components in the battery pack disconnect unit, providing support for the normal operation of the battery pack disconnect unit.

[0003] The existing BDU main control circuit board and various relays mainly use multiple male and female terminals for plug-in connection. However, the various relays and the BDU main control circuit board use multiple male and female terminals for plug-in connection, which will generate unpredictable large mechanical stress during the assembly process. During the driving process of the vehicle, the mechanical stress cannot be effectively released, which will affect the reliability of the BDU main control circuit board. In addition, the relays and the BDU main control circuit board use multiple male and female terminals for plug-in connection, which will cause the relays, terminals and circuit boards to be installed in the battery pack disconnect unit, occupying a large space, making the entire battery pack disconnect unit larger and unable to achieve lightness and thinness. Summary of the invention

[0004] In view of this, the present invention proposes a battery pack circuit breaker unit and a battery pack, which are used to solve the problem that the BDU main control circuit board of the battery pack circuit breaker unit is connected to various relays through multiple male and female terminals, which may generate unpredictable large mechanical stress and thus affect the reliability of the BDU main control circuit board, and the battery pack circuit breaker unit is large in size and cannot be made thin and light.

[0005] The technical solution of the present invention is achieved in this way:

[0006] In a first aspect, the present invention provides a battery pack disconnecting unit, comprising:

[0007] Support seat;

[0008] A plurality of relay elements are fixed in the support seat in a horizontal position, and coil contacts are arranged on the top surfaces of the relay elements;

[0009] A main control circuit board is fixedly arranged on the top of the support base;

[0010] A plurality of connection components, each connection component is arranged between the main control circuit board and one of the relay elements, the connection components include a plastic body, a conductive sheet and an electrical connector, the conductive sheet is integrally formed on the plastic body, one end of the conductive sheet is welded to the coil contact sheet, and the other end of the conductive sheet is welded to the main control circuit board through the electrical connector.

[0011] On the basis of the above technical solution, preferably, the conductive sheet includes a first sheet body, a second sheet body and a third sheet body connected in sequence;

[0012] The second sheet is formed inside the plastic body, the first sheet and the third sheet are respectively located at two ends of the plastic body, and at least a portion of the first sheet and the third sheet extends out of the plastic body;

[0013] The first sheet is arranged horizontally, and the top surface of the first sheet is used for welding with the electrical connector;

[0014] The plastic body has plug-in slots symmetrically arranged on both sides of one end away from the first sheet in the vertical direction, and a welding notch is opened on the side of the plug-in slot away from the second sheet. The third sheet is vertically located in the welding notch, and the third sheet is used to connect with the coil contact piece vertically inserted in the plug-in slot.

[0015] Further, preferably, the electrical connector includes a connecting piece body and an extension portion extending vertically upward along the side of the connecting piece body, the connecting piece body is used to be welded to the surface of the first piece, the extension portion extends upward to form a first welding head, the two sides of the extension portion are bent to form a bending portion, each of the bending portions extends upward to form a second welding head, the first welding head and the two second welding heads cooperate with the welding holes on the main control circuit board, and each of the bending portions is also provided with a limit head.

[0016] Furthermore, preferably, a positioning installation hole is provided on the connecting piece body, and a positioning column matching with the positioning installation hole is provided on the top surface of the plastic body.

[0017] On the basis of the above technical solution, preferably, two electrode contacts are further provided on the side of the relay element;

[0018] The connection assembly also includes two electrode connection pieces integrally formed on the plastic body, one end of the electrode connection piece is horizontally embedded in the plastic body, and the other end is vertically attached downward to the side of the relay element;

[0019] The electrode connecting sheet is provided with conductive mounting holes corresponding to the electrode contacts, and the plurality of relay elements are electrically connected to each other through a conductive copper busbar, and the conductive copper busbar is electrically connected to the electrode contacts through the conductive mounting holes;

[0020] One end of the two electrode connecting pieces located on the plastic body is welded to the main control circuit board through an electrical connector according to the high voltage sampling requirement.

[0021] Further, preferably, a plurality of mounting grooves are provided in the support base, each of the mounting grooves accommodates one of the relay elements, the conductive copper busbar is integrally injection molded on the outer bottom surface of the support base, the conductive copper busbar has input and output ends and at least one connecting end, the connecting end is vertically embedded in the side wall of the mounting groove, and is used to connect to the electrode contacts on the relay element through the electrode connecting sheet, and the input and output ends extend to the outside of the support base, and are used to connect to the electrical elements.

[0022] On the basis of the above technical solution, preferably, it also includes a main fuse and a current sensor arranged in the support seat, the relay element includes a main positive relay, a main negative relay, a fast charging positive relay and a fast charging negative relay, and the main positive relay and the main negative relay are arranged in reverse;

[0023] The main fuse is directly connected to the positive electrode of the battery pack, and the current sensor is directly connected to the negative electrode of the battery pack;

[0024] The main fuse and the main positive relay are electrically connected in series via a conductive copper busbar to form an output positive circuit;

[0025] The current sensor and the main negative relay are electrically connected in series via a conductive copper busbar to form an output negative electrode loop;

[0026] The main fuse, main positive relay and fast charging positive relay are connected in series in sequence through a conductive copper busbar to form a fast charging positive circuit;

[0027] The current sensor, the main negative relay and the fast charging negative relay are electrically connected in series via a conductive copper busbar to form a fast charging negative electrode circuit.

[0028] Further, preferably, it also includes a heating relay, a pre-charging relay, a pre-charging resistor and a heating fuse;

[0029] The heating relay, pre-charging relay and pre-charging resistor are arranged in the support seat, and the heating fuse is connected to the main control circuit board;

[0030] The pre-charging resistor is electrically connected in series with the pre-charging relay, and the pre-charging resistor and the pre-charging relay are electrically connected in parallel with the main positive relay through a main control circuit board to form a pre-charging circuit;

[0031] The heating fuse is welded to the main control circuit board, and the main fuse, main positive relay, fast charging positive relay, heating fuse and heating relay are electrically connected in sequence to form a heating circuit.

[0032] Preferably, it also includes a high-power fuse installed in the support base, the high-power fuse is connected in series with the main positive relay and the main fuse through the conductive copper busbar, the conductive copper busbar connected to the main negative relay is installed with a conductive column, the conductive column is provided with a high-current copper busbar, the high-current copper busbar is installed with a first mounting part at one end away from the conductive column, and the high-power fuse is installed with a second mounting part, and the first mounting part and the second mounting part are used to connect a high-current load.

[0033] In a second aspect, the present invention discloses a battery pack, comprising the battery pack disconnecting unit described in the first aspect.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] (1) A connecting component is respectively arranged between the main control circuit board and each relay element. Since the main control circuit board is pre-welded to one end of the electrical connector, and the coil contact on the relay element is pre-welded to one end of the conductive sheet on the plastic body, when the relay element is installed in the support seat and the main control circuit board is horizontally installed on the top surface of the support seat, the end of the electrical connector away from the main control circuit board can correspond to the end of the conductive sheet away from the coil contact. The electrical connector and the conductive sheet are in welding surface contact, and there can be a certain assembly error, which will not affect the welding of the two. Therefore, after the welding of the electrical connector and the conductive sheet, the mechanical stress can be greatly reduced. Compared with the male and female terminal plug-in connection method which requires a higher assembly positioning accuracy, the battery pack disconnecting unit disclosed in the present invention does not require the electrical connector and the conductive sheet to maintain an absolutely high assembly positioning accuracy during the assembly process, so that the connection between the main control circuit board and the relay element can be completed quickly, avoiding the generation of large mechanical stress at the connection point, and ensuring the reliability of the main control circuit board. At the same time, the relay components are placed horizontally and connected to the main control circuit board with specially structured connection components, which greatly reduces the height of the battery pack's circuit breaker unit and allows the battery pack to be made thinner.

[0036] (2) By providing a plug-in slot and a welding notch on the plastic body, and vertically positioning the third sheet above the welding notch, a mechanical connection between the coil contact and the third sheet can be quickly established by plugging, and an electrical connection between the third sheet and the coil contact can be quickly established by welding at the welding notch, thereby improving the assembly efficiency of the electrical connection components and the relay elements, and also improving the assembly operability.

[0037] (3) The connection component adopts an integrated injection molding process to integrate the electrode connecting piece with the plastic body, thereby realizing the electrical connection between the conductive piece and the relay element. The electrode connecting piece is perpendicular to the front side of the relay element and corresponds to the electrode contact. After installation, the connection end of the conductive copper busbar is installed on the outside of the electrode connecting piece. The conductive copper busbar, the conductive mounting holes and the electrode contacts are locked by bolts to realize the conduction of multiple relay elements in the electrical circuit. According to the requirements of high-voltage sampling, electrical connectors can be selectively connected between the conductive connecting piece and the main control circuit board. There is no need to set connection terminals or wiring harnesses. The entire assembly process is simple, fast and efficient.

[0038] (4) The conductive copper busbar is integrally formed and arranged on the outer bottom surface of the support seat, so that most of the conductive copper busbar is embedded in the inner wall of the bottom of the support seat. In this way, it can avoid the conductive copper busbar being directly installed inside the support seat to cause occupation in the height direction, thereby reducing the height of the battery pack circuit breaker unit and achieving lightness and thinness. In addition, the conductive copper busbar is integrated into the support seat through an integral injection molding process, and the secondary installation of the conductive copper busbar is required to improve the assembly efficiency. At the same time, since the conductive copper busbar is embedded in the support seat, the overall structural strength of the support seat can be improved, ensuring the safety and reliability of the entire battery pack circuit breaker unit.

[0039] (5) The connection end is vertically embedded in the side wall of the mounting groove. On the one hand, the connection end of the conductive copper busbar is vertically arranged and does not occupy space in the height direction of the inner side of the support base. On the other hand, the connection end is embedded in the side wall of the mounting groove, which can improve the structural strength of the mounting groove. At the same time, the connection end and the mounting groove are embedded, which ensures that after the relay element is installed in the mounting groove, the conductive mounting hole of the conductive connecting piece on the relay element can just correspond to the mounting hole on the conductive copper busbar connection end, so that the conductive copper busbar can be quickly connected to the electrode contact of the relay element through the conductive connecting piece. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0041] Figure 1 It is a schematic diagram of the three-dimensional structure of the battery pack disconnecting unit disclosed in the present invention;

[0042] Figure 2 A schematic diagram of the internal structure of the battery pack disconnecting unit disclosed in the present invention;

[0043] Figure 3It is a three-dimensional schematic diagram of the assembly structure of the relay element and the connection assembly disclosed in the present invention;

[0044] Figure 4 It is a first-view exploded schematic diagram of the relay element and the connection assembly disclosed in the present invention;

[0045] Figure 5 It is a schematic diagram of the relay element and the connection assembly disclosed in the present invention from a second perspective;

[0046] Figure 6 It is a plan view schematic diagram of the assembly structure of the relay element and the connection assembly disclosed in the present invention;

[0047] Figure 7 for Figure 6 Plane section view at AA in the middle;

[0048] Figure 8 It is a schematic diagram of the three-dimensional structure of the electrical connector disclosed in the present invention;

[0049] Fig. 9 It is a front structural schematic diagram of the support base disclosed in the present invention;

[0050] Fig.10 It is a schematic diagram of the bottom surface structure of the support base disclosed in the present invention;

[0051] Fig.11 It is a schematic diagram of the assembly structure of the conductive copper busbar and the support seat disclosed in the present invention;

[0052] Fig.12 It is a front view of the battery pack disconnecting unit disclosed in the present invention;

[0053] Fig.13 It is a schematic diagram of the three-dimensional structure from a first perspective of the battery pack circuit breaker unit disclosed in the present invention after removing the support base and the main control circuit board;

[0054] Fig.14 It is a schematic diagram of the three-dimensional structure from a second perspective of the battery pack circuit breaker unit disclosed in the present invention after removing the support base and the main control circuit board;

[0055] Fig.15 The electrical schematic diagram of the battery pack disconnect unit disclosed in the present invention;

[0056] Reference numerals:

[0057] 1. Support seat; 11. Mounting slot; 12. Embedded slot;

[0058] 2. Relay element; 21. Coil contact; 22. Electrode contact;

[0059] 3. Main control circuit board;

[0060] 4. Connecting assembly; 41. Plastic body; 411. Insertion slot; 412. Welding notch; 413. Positioning column;

[0061] 42, conductive sheet; 421, first sheet; 422, second sheet; 423, third sheet;

[0062] 44. electrode connecting piece; 441. conductive mounting hole;

[0063] 43, electrical connector; 431, connecting piece body; 4311, positioning and mounting hole; 432, extension portion; 4321, first welding head; 433, bending portion; 4331, second welding head; 4332, limiting head;

[0064] 5. Conductive copper busbar; 51. Input and output terminals; 52. Connection terminals;

[0065] 6. Main fuse; 7. Current sensor;

[0066] 2a, main positive relay; 2b, main negative relay; 2c, fast charge positive relay; 2d, fast charge negative relay;

[0067] 8. Heating relay; 9. Pre-charging relay; 10. Pre-charging resistor; 12. Heating fuse; 13. High-power fuse; 14. Conductive column; 15. High-current copper busbar; 151. First installation part; 131. Second installation part. DETAILED DESCRIPTION

[0068] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0069] The embodiment of the present invention provides a battery pack disconnecting unit, which can solve the problem that the BDU main control circuit board of the battery pack disconnecting unit is connected to various relays through multi-way male and female terminals, which may generate unpredictable large mechanical stress, thereby affecting the reliability of the BDU main control circuit board, and the battery pack disconnecting unit is too large and cannot be made thin and light.

[0070] like Figure 1 As shown, combined Figure 2-7 An embodiment of the present invention provides a battery pack circuit breaker unit, including a support base 1, a plurality of relay elements 2, a main control circuit board 3 and a plurality of connection components 4.

[0071] The support base 1 is a mounting box for the entire battery pack circuit breaker unit, which is made of plastic and is used to mount electrical components.

[0072] A plurality of relay elements 2 are fixed horizontally in the support base 1. Such an arrangement can reduce the installation space of the relay elements 2 in the support base 1, making the entire battery pack circuit breaker unit thinner and lighter, thereby reducing the space occupancy of the battery pack circuit breaker unit in the battery pack.

[0073] In this embodiment, the relay element 2 is placed horizontally, and a coil contact 21 is provided on the top surface of the relay in the horizontal direction. The coil contact 21 is used to be electrically connected to the main control circuit board 3. The coil contact 21 is used to connect to the coil in the relay and has a positive contact and a negative contact.

[0074] The main control circuit board 3 is fixedly arranged on the top of the support base 1 and is used to establish an electrical connection with the relay element 2 .

[0075] In some prior arts, the main control circuit board 3 and various relay components 2 are connected by multi-way male and female terminals, which will generate unpredictable large mechanical stress during the assembly process. During the driving of the vehicle, the mechanical stress cannot be effectively released, which will affect the reliability of the main control circuit board 3. At the same time, the relay components 2 and the main control circuit board 3 are connected by multi-way male and female terminals, which will cause the relays, terminals and circuit boards to be installed in the battery pack disconnecting unit, occupying a large space, making the entire battery pack disconnecting unit larger in size and unable to achieve lightness and thinness.

[0076] To this end, the solution adopted in the embodiment of the present invention is to respectively set a connecting component 4 between the main control circuit board 3 and each relay element 2 to solve the above problem.

[0077] Specifically, the connection component 4 disclosed in this embodiment includes a plastic body 41, a conductive sheet 42 and an electrical connector 43. The conductive sheet 42 is integrally formed on the plastic body 41, one end of the conductive sheet 42 is welded to the coil contact 21, and the other end of the conductive sheet 42 is welded to the main control circuit board 3 through the electrical connector 43.

[0078] With such a technical solution, the conductive sheet 42 is a bridge for establishing electrical connection between the coil contact 21 of the relay element 2 and the main control circuit board 3. In this embodiment, the conductive sheet 42 is integrally formed in the plastic body 41 to ensure that the conductive sheet 42 can achieve insulation protection in the plastic body 41, and at the same time, the conductive sheet 42 and the plastic body 41 are integrally formed to have a higher structural strength. In the specific implementation process, the conductive sheet 42 and the plastic body 41 are implemented by an insert injection molding process, and the two are an organic whole. In this embodiment, two conductive sheets 42 are provided to respectively establish electrical connection with the two coil contact sheets 21 on the relay element 2.

[0079] When installing in the battery pack circuit breaker unit, first place the connecting component 4 on the top surface of the horizontally set relay element 2, connect one end of the conductive sheet 42 to the coil contact 21 on the relay element 2 by welding, and then install the connecting component 4 and the relay element 2 as a whole in the support seat 1, ensuring that the connecting component 4 is located on the top surface of the relay element 2. When each relay element 2 is installed in place in the support seat 1, install multiple electrical connectors 43 at corresponding positions of the main control circuit board 3 and weld them, then install the main control circuit board 3 horizontally on the top surface of the support seat 1. At this time, the end of the electrical connector 43 away from the main control circuit board 3 can be connected to a point of the conductive sheet 42 away from the coil contact 21 by welding.

[0080] Since the main control circuit board 3 is pre-welded to one end of the electrical connector 43, and the coil contact 21 on the relay element 2 is pre-welded to one end of the conductive sheet 42 on the plastic body 41, when the relay element 2 is installed in the support seat 1 and the main control circuit board 3 is horizontally installed on the top surface of the support seat 1, the end of the electrical connector 43 away from the main control circuit board 3 can correspond to the end of the conductive sheet 42 away from the coil contact 21. The electrical connector 43 and the conductive sheet 42 are in welding surface contact, and there can be a certain assembly error, which will not affect the welding of the two. Therefore, after the welding of the electrical connector 43 and the conductive sheet 42 is completed, the mechanical stress can be greatly reduced. Compared with the male and female terminal plug-in connection method which requires a higher assembly positioning accuracy, this embodiment does not require the electrical connector 43 and the conductive sheet 42 to maintain an absolutely high assembly positioning accuracy during the assembly process, so that the connection between the main control circuit board 3 and the relay element 2 can be completed quickly, avoiding the generation of large mechanical stress at the connection point, and ensuring the reliability of the main control circuit board 3. At the same time, the relay element 2 is placed horizontally and connected to the main control circuit board 3 with a special structure connection component 4, which greatly reduces the height of the battery pack circuit breaker unit and allows the battery pack to be made thinner.

[0081] In addition, online welding technology is used between the connection component 4, the relay element 2 and the main control battery board, which realizes the de-wiring of the BDU, enables fully automated production, and improves assembly efficiency.

[0082] In order to realize welding of the conductive sheet 42, the coil contact sheet 21 and the electrical connector 43, this embodiment shows a preferred structural mode of the conductive sheet 42. Figure 4 and 7 As shown, the conductive sheet 42 includes a first sheet 421 , a second sheet 422 and a third sheet 423 connected in sequence. In this embodiment, the first sheet 421 , the second sheet 422 and the third sheet 423 are integrally formed, and the entire conductive sheet 42 is made of conductive metal.

[0083] The second sheet 422 is formed inside the plastic body 41, and the second sheet 422 is wrapped inside the plastic body 41, so that the second sheet 422 is electrically isolated from the relay element 2 and the main control circuit board 3 through the plastic body 41. The first sheet 421 and the third sheet 423 are respectively located at two ends of the plastic body 41, and at least a portion of the first sheet 421 and the third sheet 423 extend out of the plastic body 41. Specifically, the first sheet 421 and the third sheet 423 are embedded in the plastic body 41 under the injection molding process. Since it is necessary to establish an electrical connection with other components, at least a portion of the first sheet 421 and the third sheet 423 are exposed outside the plastic body 41 to facilitate welding with other components.

[0084] The first sheet 421 is arranged horizontally, and the top surface of the first sheet 421 is used for welding with the electrical connector 43. The top surface of the first sheet 421 is a horizontal plane, so that a certain welding area can be provided between the first sheet 421 and the electrical connector 43, ensuring that the electrical connector 43 can be effectively welded at any position on the top surface of the first sheet 421. Different from the male and female terminal plug-in connection method in the prior art, this welding operation does not require high assembly positioning accuracy, and can greatly reduce the mechanical stress generated at the connection.

[0085] In order to realize the welding between the third sheet 423 and the coil contact 21, the present embodiment makes a structural arrangement for the plastic body 41. Specifically, plug-in slots 411 are symmetrically arranged along the vertical direction on both sides of one end of the plastic body 41 away from the first sheet 421, and a welding notch 412 is provided on the side of the plug-in slot 411 away from the second sheet 422. The third sheet 423 is vertically located in the welding notch 412, and the third sheet 423 is used to connect with the coil contact 21 vertically inserted in the plug-in slot 411.

[0086] Preferably, a positioning groove is provided at one end of the bottom of the plastic body 41 close to the first sheet 421, and a positioning plate is provided on the front side of the relay element 2. During the specific installation operation, the plastic body 41 is placed horizontally on the top surface of the relay element 2, so that the positioning groove on the bottom surface of the plastic body 41 and the positioning plate on the front side of the relay element 2 are inserted into each other, so as to realize the position positioning of the plastic body 41 on the top surface of the relay element 2. During the placement of the plastic body 41, the coil contact 21 on the top surface of the relay element 2 is vertically inserted into the plug-in slot 411. When the coil contact 21 enters the plug-in slot 411, it can be fitted with the third sheet 423 at the welding notch 412. Through the welding notch 412, the third sheet 423 and the coil contact 21 can be laser welded, thereby completing the electrical connection between the conductive sheet 42 and the coil contact 21.

[0087] Under the above-mentioned structural setting, since the plug-in groove 411 and the welding notch 412 are set on the plastic body 41, and the third sheet 423 is vertically located above the welding notch 412, the coil contact 21 can be quickly mechanically connected to the third sheet 423 by plugging, and the electrical connection between the third sheet 423 and the coil contact 21 can be quickly achieved at the welding notch 412 by welding.

[0088] In order to realize the electrical connection between the electrical connector 43 and the conductive sheet 42 and the main control circuit board 3, this embodiment shows a preferred structural mode of the electrical connector 43.

[0089] For details, please refer to the attached Figure 8 As shown, the electrical connector 43 includes a connecting piece body 431 and an extension portion 432 extending vertically upward along the side of the connecting piece body 431. The connecting piece body 431 is used to weld with the surface of the first piece 421. The extension portion 432 extends upward to form a first welding head 4321. The two sides of the extension portion 432 are bent to form a bending portion 433. Each bending portion 433 extends upward to form a second welding head 4331. The first welding head 4321 and the two second welding heads 4331 cooperate with the welding holes on the main control circuit board 3. Each bending portion 433 is also provided with a limit head 4332. The first welding head 4321 and the two second welding heads 4331 cooperate with the welding holes on the main control circuit board 3. The first welding head 4321 and the two second welding heads 4331 form a triangular welding structure with better stability and convenient welding. The two limit heads 4332 fit the lower side of the main control circuit board 3, which can ensure the assembly position of the electrical connector on the main control circuit board 3 and facilitate welding processing.

[0090] Preferably, a positioning installation hole 4311 is provided on the connecting piece body 431, and a positioning column 413 matching with the positioning installation hole 4311 is provided on the top surface of the plastic body 41. With this arrangement, when the electrical connector 43 is welded on the main control circuit board 3, the main control circuit board 3 is horizontally placed on the top surface of the support seat 1, the positioning installation hole 4311 on the connecting piece body 431 and the positioning column 413 on the plastic body 41 can be matched to achieve the corresponding position of the connecting piece body 431 and the first piece 421. In this embodiment, the positioning installation hole 4311 and the positioning column 413 can be roughly positioned.

[0091] In order to realize the electrical conduction of multiple relay elements 2 in the entire battery pack disconnection unit, the present embodiment further provides two electrode contacts 22 on the side of the relay element 2, and the two electrode contacts 22 are respectively connected in the electrical circuit through the conductive copper bus 5. By closing the two electrode contacts 22, the conduction of the electrical circuit can be realized, and by disconnecting the two electrode contacts 22, the electrical circuit can be cut off. Specifically, the conduction and closing of the two electrode contacts 22 are controlled by the internal coil of the relay. The coil contact 21, the electrode contact 22 and the control principle are all in the prior art. As a preferred embodiment, the structural form of the electrode contact 22 implemented in the present embodiment is a bolt hole.

[0092] Normally, the conductive copper busbar 5 can be electrically connected directly to the electrode contact 22 by bolt connection. However, since the conductive copper busbar 5 is connected to an external load, it is necessary to collect high-voltage signals at the electrode contact 22 of the relay element 2, so that when high voltage or high current is overloaded, the battery pack circuit breaker unit can be disconnected in time by collecting high-voltage signals to ensure the safety of the battery pack. In some prior arts, connection terminals 52 are usually set at the electrode contact 22 of the relay element 2 and on the main control circuit board 3, and then the connection between the two terminals is established through a wiring harness. This method is complicated to operate and will cause more wiring harnesses to be arranged in the battery pack circuit breaker unit.

[0093] To this end, the solution set in this embodiment is to further configure the structure of the connecting component 4. For details, refer to the attached Figure 3-5 As shown, the connection assembly 4 further includes two electrode connection pieces 44 integrally formed on the plastic body 41 , one end of the electrode connection piece 44 is horizontally embedded in the plastic body 41 , and the other end is vertically attached downward to the side of the relay element 2 .

[0094] The electrode connecting sheet 44 is provided with a conductive mounting hole 441 corresponding to the electrode contact 22, and the plurality of relay elements 2 are electrically connected through the conductive copper bus 5, and the conductive copper bus 5 is electrically connected to the electrode contact 22 through the conductive mounting hole 441;

[0095] One end of the two electrode connecting pieces 44 located on the plastic body 41 is welded to the main control circuit board 3 through the electrical connector 43 according to the high voltage sampling requirement.

[0096] By adopting such a technical solution, the electrode connecting piece 44 is integrated into the plastic body 41 through an integral injection molding process. After the entire connecting component 4 is assembled on the relay element 2, firstly, the conductive piece 42 and the coil contact piece 21 on the relay element 2 are electrically connected through a welding process. Secondly, the electrode connecting piece 44 is vertically located on the front side of the relay element 2. At this time, the conductive mounting hole 441 on the electrode connecting piece 44 just corresponds to the electrode contact 22. In this way, when the connecting component 4 and the relay element 2 are installed as a whole in the support seat 1, the connecting end 52 of the conductive copper bus 5 can be directly installed on the outside of the electrode connecting piece 44, and the bolts are passed through the conductive copper bus 5, the conductive mounting hole 441 and the electrode contact 22 for locking, so that multiple relay elements 2 can be connected to the electrode contact 22 through the conductive copper bus 5 to achieve conduction in the electrical circuit.

[0097] In actual operation, according to the high-voltage sampling requirements, the electrical connector 43 can be selectively connected between the upper end of the conductive connecting piece and the main control circuit board 3. Specifically, when high-voltage signal acquisition is required at the electrode contact 22 of a certain relay element 2, the electrical connector 43 is pre-welded to the main control circuit board 3, and then the end of the electrical connector 43 away from the main control circuit board 3 is welded to the end of the conductive connecting piece away from the electrode contact 22. This operation method is consistent with the welding method of the main control circuit board 3 and the conductive sheet 42 through the electrical connector 43. There is no need to set the connection terminal 52 or the wiring harness. The entire assembly process is simple, fast and efficient.

[0098] Specifically, after the entire connection component 4 is assembled on the relay element 2, each relay element 2 is fixedly installed in the support base 1, and the corresponding electrical connector 43 is welded at a predetermined position of the main control circuit board 3, and then the main control circuit board 3 is placed horizontally on the top surface of the support base 1. The corresponding electrical connectors 43 correspond to the first sheet 421 and the conductive connecting sheet respectively, so that the welding between the electrical connector 43 and the conductive sheet 42 and the conductive connecting sheet can be completed quickly online. In this process, the electrical connecting sheet and the conductive sheet 42 and the conductive connecting sheet do not require high assembly positioning accuracy. After welding is completed, no mechanical stress will be generated at the connection, which greatly improves the reliability of the main control circuit board 3.

[0099] As some preferred implementations, refer to the attached Figure 9-12 As shown, a plurality of mounting grooves 11 are provided in the support base 1, and each mounting groove 11 accommodates a relay element 2 respectively. Usually, the relay element 2 is square in shape, so a card slot can be provided on the two opposite inner side walls of the mounting groove 11, and a buckle can be provided on the two opposite outer side walls of the relay element 2, so that the relay element 2 is fixed in the mounting groove 11 by the cooperation of the buckle and the card slot.

[0100] Since the conductive copper busbar 5 needs to establish connections between the various relay elements 2 in the support base 1, the conductive copper busbar 5 needs to occupy a certain space inside the support base 1, resulting in the battery pack circuit breaker unit volume being unable to achieve optimal lightness and thinness.

[0101] To this end, the solution adopted in this embodiment is: the conductive copper bar 5 is integrally injection molded on the outer bottom surface of the support seat 1, and the conductive copper bar 5 has an input and output terminal 51 and at least one connection terminal 52. The connection terminal 52 is vertically embedded in the side wall of the installation groove 11, and is used to connect with the electrode contact 22 on the relay element 2 through the electrode connecting piece 44. The input and output terminal 51 extends to the outside of the support seat 1 for connecting with the electrical component. With such a structural setting, the conductive copper bar 5 is integrally molded and set on the outer bottom surface of the support seat 1, so that most of the conductive copper bar 5 is embedded in the inner wall of the bottom of the support seat 1. In this way, it can be avoided that the conductive copper bar 5 is directly installed inside the support seat 1 to cause occupation in the height direction, thereby reducing the height of the battery pack circuit breaker unit and achieving lightness and thinness. At the same time, the conductive copper busbar 5 is embedded in the inner wall of the bottom of the support base 1 by an integrated injection molding process, which can avoid affecting the installation slot 11 of the relay element 2 when it is directly installed inside the support base 1. This is because a plurality of installation slots 11 are arranged inside the support base 1. If the conductive copper busbar 5 is arranged inside the support base 1, it is necessary to open an avoidance space for the installation slot 11, which will undoubtedly cause the internal structure of the support base 1 to be complicated and the production cost of the support base 1 to be relatively high. At the same time, when the conductive copper busbar 5 is installed inside the support base 1, it is also necessary to consider the fixed connection mode between it and the support base 1. The overall installation process is complicated and is not conducive to efficient assembly production. In this embodiment, the conductive copper busbar 5 is integrated into the support base 1 by an integrated injection molding process, and a secondary installation of the conductive copper busbar 5 is required to improve the assembly efficiency. At the same time, since the conductive copper busbar 5 is embedded in the support base 1, the overall structural strength of the support base 1 can be improved to ensure the safety and reliability of the entire battery pack circuit breaker unit.

[0102] In addition, it is worth noting that the connection end 52 is vertically embedded in the side wall of the installation groove 11. On the one hand, the connection end 52 of the conductive copper busbar 5 is vertically arranged and will not occupy space in the height direction inside the support base 1. On the other hand, the connection end 52 is embedded in the side wall of the installation groove 11, which can improve the structural strength of the installation groove 11. At the same time, the connection end 52 and the installation groove 11 are embedded, ensuring that after the relay element 2 is installed in the installation groove 11, the conductive mounting hole 441 of the conductive connecting piece on the relay element 2 can just correspond to the mounting hole on the connection end 52 of the conductive copper busbar 5, so as to facilitate and quickly establish a connection between the conductive copper busbar 5 and the electrode contact 22 of the relay element 2 through the conductive connecting piece.

[0103] In some specific embodiments, an operating hole corresponding to the position of the connection end 52 of the conductive copper busbar 5 can be opened on the side wall of the support base 1, and the bolt can be quickly passed through the conductive copper busbar 5 and the conductive connecting piece through the operating hole to achieve locking with the electrode contact 22 on the relay element 2.

[0104] In order to realize the multi-mode operation of the entire battery pack disconnect unit, refer to the attached Figure 13-15 As shown, this embodiment also includes a main fuse 6 and a current sensor 7 in the support seat 1, wherein the relay element 2 includes a main positive relay 2a, a main negative relay 2b, a fast charging positive relay 2c and a fast charging negative relay 2d, and the main positive relay 2a and the main negative relay 2b are arranged in reverse. By placing the main positive relay 2a and the main negative relay 2b in reverse, the risk of adhesion caused by the relays being disconnected and then connected again when the vehicle collides can be effectively resisted, thereby improving the reliability of the vehicle.

[0105] In this embodiment, the main fuse 6 is directly connected to the positive electrode of the battery pack, and the current sensor 7 is directly connected to the negative electrode of the battery pack; thereby, the positive and negative electrodes of the battery pack are connected to the entire battery pack circuit breaker unit.

[0106] The main fuse 6 and the main positive relay 2a are electrically connected in series through the conductive copper bar 5 to form an output positive circuit; the input and output ends 51 of the conductive copper bar 5 connected to the main positive relay 2a are connected to the positive end of the electrical equipment.

[0107] The current sensor 7 and the main negative relay 2b are electrically connected in series through the conductive copper bus 5 to form an output negative pole loop; the input and output end 51 of the conductive copper bus 5 connected to the negative positive relay is connected to the positive terminal of the electrical equipment.

[0108] By providing the main positive relay 2a and the main negative relay 2b, when a certain relay is disconnected and then connected again, the other relay can play a disconnecting role, thereby improving the reliability of the circuit breaking.

[0109] The main fuse 6, the main positive relay 2a and the fast charging positive relay 2c are electrically connected in series in sequence through the conductive copper bus 5 to form a fast charging positive pole circuit; in this embodiment, the input and output ends 51 of the conductive copper bus 5 connected to the fast charging positive relay 2c are connected to the positive pole of the charging gun.

[0110] The current sensor 7, the main negative relay 2b and the fast charge negative relay 2d are electrically connected in series through the conductive copper bus 5 to form a fast charge negative electrode circuit. In this embodiment, the input and output ends 51 of the conductive copper bus 5 connected to the fast charge negative relay 2d are connected to the negative electrode of the charging gun.

[0111] Through such a design, not only the management of the positive and negative poles and fast charging circuit of the battery pack circuit breaker unit is achieved, but also the layout and connection method of the circuit are optimized, thereby improving the stability and reliability of the system.

[0112] As a preferred embodiment, it also includes a heating relay 8, a pre-charging relay 9, a pre-charging resistor 10 and a heating fuse 12;

[0113] The heating relay 8, the pre-charging relay 9 and the pre-charging resistor 10 are arranged in the support seat 1, and the heating fuse 12 is connected to the main control circuit board 3;

[0114] The pre-charging resistor 10 is electrically connected in series with the pre-charging relay 9, and the pre-charging resistor 10 and the pre-charging relay 9 are electrically connected in parallel with the main positive relay 2a through the main control circuit board 3 to form a pre-charging circuit; the pre-charging relay 9 and the pre-charging resistor 10 are combined to pre-charge the battery pack at startup to reduce the current shock at startup.

[0115] The heating fuse 12 is welded to the main control circuit board 3, and the main fuse 6, the main positive relay 2a, the fast charge positive relay 2c, the heating fuse 12 and the heating relay 8 are electrically connected in sequence to form a heating circuit. The heating fuse 12 is used to protect the circuit from dangers such as overload or short circuit. By setting the heating circuit, the battery pack can be heated during the charging process.

[0116] As some optional embodiments, it also includes a high-power fuse 13 installed in the support base 1, the high-power fuse 13 is connected in series with the main positive relay 2a and the main fuse 6 through the conductive copper busbar 5, the conductive copper busbar 5 connected to the main negative relay 2b is installed with a conductive column 14, and a high-current copper busbar 15 is arranged on the conductive column 14, and a first mounting part 151 is installed at one end of the high-current copper busbar 15 away from the conductive column 14, and a second mounting part is installed on the high-power fuse 13, and the first mounting part 151 and the second mounting part are used to connect a high-current load.

[0117] By setting the high-current copper busbar 15, the high current can be prevented from passing through the main control circuit board 3, because the main control circuit board 3 is usually designed to process low-power signals and control currents, rather than to transmit high-power currents. Therefore, setting the high-current copper busbar 15 is an effective way to prevent the high current from passing through the main control circuit board 3.

[0118] By installing the high-current copper busbar 15 on the conductive copper busbar 5 on the main negative relay 2b and connecting them through the conductive column 14, the high-power current can be guided to the appropriate location, thereby avoiding the situation where the high current passes through the main control circuit board 3. In this way, the main control circuit board 3 can be protected from the influence of high-power current, ensuring its normal operation and extending its service life.

[0119] The present invention also provides a battery pack, including the battery pack circuit breaker unit disclosed in the above embodiment. Since the relay element 2 in the battery pack circuit breaker unit is placed horizontally and connected with the main control circuit board 3 by a connection component 4 with a special structure, the height of the battery pack circuit breaker unit is greatly reduced, which can make the battery pack thinner. At the same time, the connection component 4 is used to establish an electrical connection between the relay element 2 and the main control circuit board 3. During the assembly process, it is not necessary to maintain an absolutely high assembly positioning accuracy between the electrical connector 43 and the conductive sheet 42, so that the connection between the main control circuit board 3 and the relay element 2 can be quickly completed, avoiding large mechanical stress at the connection, ensuring the reliability of the main control circuit board 3, and thus ensuring the safe operation of the battery pack.

[0120] In general, by properly setting the high-current copper busbar 15, high-power current can be effectively shunted and processed, thereby protecting the main control circuit board 3 and other electronic components and ensuring the stability and reliability of the system.

[0121] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A battery pack disconnect unit, characterized in that: include: Support seat (1); A plurality of relay elements (2) are fixed in a horizontal position in the support seat (1), and a coil contact piece (21) is provided on the top surface of the relay element (2); A main control circuit board (3) is fixedly arranged on the top of the support base (1); A plurality of connection components (4), each connection component (4) being arranged between the main control circuit board (3) and one of the relay elements (2), the connection component (4) comprising a plastic body (41), a conductive sheet (42) and an electrical connector (43), the conductive sheet (42) being integrally formed on the plastic body (41), one end of the conductive sheet (42) being welded to the coil contact sheet (21), and the other end of the conductive sheet (42) being welded to the main control circuit board (3) via the electrical connector (43); The conductive sheet (42) comprises a first sheet (421), a second sheet (422) and a third sheet (423) connected in sequence; The second sheet (422) is formed inside the plastic body (41), the first sheet (421) and the third sheet (423) are respectively located at two ends of the plastic body (41), and at least a portion of the first sheet (421) and the third sheet (423) extend out of the plastic body (41); The first sheet (421) is arranged horizontally, and the top surface of the first sheet (421) is used for welding with the electrical connector (43); Insertion slots (411) are symmetrically arranged on both sides of one end of the plastic body (41) away from the first sheet (421) in the vertical direction, a welding notch (412) is provided on one side of the insertion slot (411) away from the second sheet (422), the third sheet (423) is vertically located in the welding notch (412), and the third sheet (423) is used to connect with the coil contact piece (21) vertically inserted in the insertion slot (411); The electrical connector (43) comprises a connecting piece body (431) and an extension portion (432) extending vertically upward along the side of the connecting piece body (431); the connecting piece body (431) is used for welding with the surface of the first piece (421); the extension portion (432) extends upward to form a first welding head (4321); both sides of the extension portion (432) are bent to form a bending portion (433); each of the bending portions (433) extends upward to form a second welding head (4331); the first welding head (4321) and the two second welding heads (4331) cooperate with welding holes on the main control circuit board (3); and each of the bending portions (433) is also provided with a limit head (4332).

2. The battery pack disconnect unit according to claim 1, wherein: The connecting piece body (431) is provided with a positioning installation hole (4311), and the top surface of the plastic body (41) is provided with a positioning column (413) matched with the positioning installation hole (4311).

3. The battery pack disconnect unit according to claim 1, wherein: Two electrode contacts (22) are also provided on the side of the relay element (2); The connecting assembly (4) further comprises two electrode connecting pieces (44) integrally formed and arranged on the plastic body (41), one end of the electrode connecting piece (44) being horizontally embedded in the plastic body (41) and the other end being vertically attached downward to the side surface of the relay element (2); The electrode connecting sheet (44) is provided with a conductive mounting hole (441) corresponding to the electrode contact (22); the plurality of relay elements (2) are electrically connected via a conductive copper bus (5); and the conductive copper bus (5) is electrically connected to the electrode contact (22) via the conductive mounting hole (441); One end of the two electrode connecting pieces (44) located on the plastic body (41) is welded to the main control circuit board (3) via an electrical connector (43).

4. The battery pack disconnect unit according to claim 3, wherein: The support base (1) is provided with a plurality of mounting grooves (11), each of the mounting grooves (11) accommodating one of the relay elements (2); the conductive copper busbar (5) is integrally injection-molded on the outer bottom surface of the support base (1); the conductive copper busbar (5) has input and output terminals (51) and at least one connecting terminal (52); the connecting terminal (52) is vertically embedded in the side wall of the mounting groove (11) and is used to connect to the electrode contact (22) on the relay element (2) via the electrode connecting sheet (44); the input and output terminals (51) extend to the outside of the support base (1) and are used to connect to the electrical element.

5. The battery pack disconnect unit according to claim 4, characterized in that: It also includes a main fuse (6) and a current sensor (7) arranged in the support seat (1); the relay element (2) includes a main positive relay (2a), a main negative relay (2b), a fast charging positive relay (2c) and a fast charging negative relay (2d); the main positive relay (2a) and the main negative relay (2b) are arranged in reverse. The main fuse (6) is directly connected to the positive electrode of the battery pack, and the current sensor (7) is directly connected to the negative electrode of the battery pack; The main fuse (6) and the main positive relay (2a) are electrically connected in series via a conductive copper busbar (5) to form an output positive electrode circuit; The current sensor (7) and the main negative relay (2b) are electrically connected in series via a conductive copper bus (5) to form an output negative electrode loop; The main fuse (6), the main positive relay (2a) and the fast charging positive relay (2c) are electrically connected in series in sequence through the conductive copper busbar (5) to form a fast charging positive circuit; The current sensor (7), the main negative relay (2b) and the fast charging negative relay (2d) are electrically connected in series via a conductive copper bus (5) to form a fast charging negative electrode circuit.

6. The battery pack disconnect unit according to claim 5, characterized in that: It also includes a heating relay (8), a pre-charging relay (9), a pre-charging resistor (10) and a heating fuse (12); The heating relay (8), the pre-charging relay (9) and the pre-charging resistor (10) are arranged in the support seat (1), and the heating fuse (12) is connected to the main control circuit board (3); The pre-charging resistor (10) is electrically connected in series with the pre-charging relay (9), and the pre-charging resistor (10) and the pre-charging relay (9) are electrically connected in parallel with the main positive relay (2a) via a main control circuit board (3) to form a pre-charging circuit; The heating fuse (12) is welded to the main control circuit board (3), and the main fuse (6), the main positive relay (2a), the fast charging positive relay (2c), the heating fuse (12) and the heating relay (8) are electrically connected in sequence to form a heating circuit.

7. The battery pack disconnect unit according to claim 5, characterized in that: The invention also comprises a high-power fuse (13) installed in the support seat (1), wherein the high-power fuse (13) is connected in series with a main positive relay (2a) and a main fuse (6) via a conductive copper bar (5), a conductive column (14) is installed on the conductive copper bar (5) connected to the main negative relay (2b), a high-current copper bar (15) is arranged on the conductive column (14), a first installation part (151) is installed on one end of the high-current copper bar (15) away from the conductive column (14), and a second installation part (131) is installed on the high-power fuse (13), wherein the first installation part (151) and the second installation part are used to connect a high-power load.

8. A battery pack, characterized in that: A battery pack disconnect unit comprising the battery pack disconnect unit as claimed in any one of claims 1 to 7.

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