Heat dissipation arrangement for battery distribution unit

Abstract

A battery distribution unit (100) for a battery module (102) has a housing (110) including a bottom (120) configured to mount to a battery housing (104) of the battery module and including a component cavity (114). A contactor (140) received in the component cavity has a contactor housing (150) having a top end (154) and a bottom end (156). Terminals (242) at the bottom end of the contactor are coupled to corresponding termination ends (170) of corresponding stationary contacts (160) and a heat exchanger cap (134) at the bottom end of the contactor. The heat exchanger cap is disposed in the component cavity at the bottom of the housing. The heat exchanger cap is in thermal communication with the stationary contacts of the contactor and is configured to be in thermal communication with the battery housing of the battery module to dissipate heat from the stationary contacts into the battery housing of the battery module.

Description

TECHNICAL FIELD

[0001] The subject matter herein relates generally to a battery distribution unit for a battery module. BACKGROUND

[0002] A battery module, such as for use in a vehicle, includes a battery distribution unit (BDU) mounted thereto. The BDU includes circuit components, such as contactors, relays, fuses, bus bars, terminals, etc. The BDU controls power distribution. The circuit components are held in an enclosure of the BDU and can be electrically connected to power inputs / outputs through wires, terminals, bus bars, etc. The circuit components experience temperature increases during use and can become very hot, such as during long periods of use, during high current situations, during short circuit situations, etc. Overheating can damage the circuit components. Due to the density of the BDU, because of the close spacing of the large number of circuit components and enclosure internals, it is difficult to provide heat dissipation, such as heat sinks or airflow over the circuit components.

[0003] The problem to be solved herein is to provide a battery distribution unit having an improved heat dissipation arrangement for circuit components of the battery distribution unit. SUMMARY

[0004] The problem is solved by a battery distribution unit for a battery module having an enclosure including a bottom configured to be mounted to a battery housing of the battery module. The enclosure includes a component cavity. A contactor is received in the component cavity. The contactor has a contactor enclosure having a top end and a bottom end. The contactor defines a chamber. The contactor has a coil assembly in the chamber at the top end of the contactor enclosure. The coil assembly includes a coil and a plunger movable based on an operating state of the coil. The contactor has a movable contact in the chamber coupled to the plunger and movable with the plunger. The contactor has stationary contacts held by the contactor enclosure. Each stationary contact has a mating end and a termination end. The mating end is disposed in the chamber and is configured to engage with the movable contact to close a contactor circuit of the contactor. The termination end extends from the bottom end of the contactor enclosure. The battery distribution unit includes a terminal at the bottom end of the contactor. The terminal is coupled to a corresponding termination end of a corresponding stationary contact. The battery distribution unit includes a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is disposed in the component cavity of the bottom of the enclosure. The heat exchanger cap is in thermal communication with the stationary contacts of the contactor and is configured to be in thermal communication with the battery housing of the battery module to dissipate heat from the stationary contacts into the battery housing of the battery module. BRIEF DESCRIPTION OF DRAWINGS

[0005] The application will now be described, by way of example, with reference to the accompanying drawings, in which:

[0006] Figure 1 is a top perspective view of a battery distribution unit (BDU) according to an example embodiment.

[0007] Figure 2 is a partial exploded perspective view of a BDU according to an example embodiment.

[0008] Figure 3 is a cross-sectional view of a circuit component of a BDU according to an example embodiment.

[0009] Figure 4 is a top perspective exploded view of a heat exchanger cap of a BDU according to an example embodiment.

[0010] Figure 5 is a cross-sectional view of a portion of a BDU according to an example embodiment.

[0011] Figure 6 is an enlarged cross-sectional view of a portion of a BDU according to an example embodiment.

[0012] Figure 7 is an enlarged cross-sectional view of a portion of a BDU according to an example embodiment.

[0013] Figure 8 is an enlarged cross-sectional view of a portion of a BDU according to an example embodiment.

[0014] Figure 9 is a side view of a portion of a BUD according to an example embodiment showing a contactor coupled to a busbar.

[0015] Figure 10 is a bottom perspective view of a portion of a BDU according to an example embodiment showing a contactor coupled to a busbar.

[0016] Figure 11 is a top view of a busbar according to an example embodiment.

[0017] Figure 12 is a side partial cutaway view of a portion of a BDU according to an example embodiment showing a fixed contact of a contactor coupled to a busbar.

[0018] Figure 13 is a side partial cutaway view of a portion of a BDU according to an example embodiment showing a fixed contact of a contactor coupled to a busbar.

[0019] Figure 14 is a top perspective view of a portion of a BDU according to an example embodiment.

[0020] Figure 15 is a side perspective view of a BDU according to an example embodiment.

[0021] Figure 16 is a cross-sectional view of a BDU according to an example embodiment. DETAILED DESCRIPTION

[0022] Figure 1 is a top perspective view of a battery distribution unit (BDU) 100 according to an example embodiment. Figure 2 is a bottom partially exploded perspective view of the BDU 100 according to an example embodiment. Figure 1 The BDU 100 is shown mounted to a battery module 102. The BDU 100 can be electrically connected to the battery module 102, for example to one or more battery terminals of the battery module 102.

[0023] In example embodiments, the BDU 100 is thermally coupled to the battery module 102 and uses the battery housing 104 of the battery module 102 as a heat sink to dissipate heat from the circuit components 106 of the BDU 100. The circuit components 106 are arranged in proximity to the battery housing 104 to efficiently and reliably shed heat generated by the circuit components 106 into the battery housing 104. For example, hot spots of the circuit components 106 are located in proximity to the battery housing 104. In example embodiments, the BDU 100 includes a heat sink or other thermal interface element to create a direct thermal path between the circuit components 106 and the battery housing 104 to efficiently transfer heat from the circuit components 106 into the battery housing 104. In example embodiments, the battery housing 104 is manufactured from a metal material having high thermal conductivity. The battery housing 104 has a large surface area to shed heat to the surrounding environment, for example directly to the air surrounding the battery module 102 or to a cooling system coupled to the battery module 102. The battery housing 104 can include heat shedding features, for example fins, posts, or other features extending therefrom, to further increase the surface area of the battery housing 104 to enhance the heat shedding efficiency of the battery housing 104.

[0024] The BDU 100 includes a housing 110 that holds the circuit components 106. In example embodiments, different types of circuit components 106 can be held by the housing 110. For example, the circuit components 106 can include contactors, relays, fuses, electrical connectors, bus bars, terminals, etc. Optionally, the various circuit components 106 can be electrically connected by terminals, bus bars, wires, circuit boards, etc.

[0025] In example embodiments, the housing 110 is configured to be mounted directly to the battery housing 104. In various embodiments, the housing 110 includes mounting lugs 112 for mounting the housing 110 to the battery housing 104, for example using fasteners. In example embodiments, the housing 110 includes a plurality of component cavities 114 that receive corresponding circuit components 106. The component cavities 114 can be open at the top and / or bottom of the housing 110 to receive the circuit components 106. The component cavities 114 can have various shapes or sizes to receive various different types of circuit components 106.

[0026] In example embodiments, the housing 110 is a multi-piece housing. For example, the housing 110 includes a base 116 and a cover 118 coupled to the base 116. The base 116 can hold various circuit components 106 and / or the cover 118 can hold various circuit components 106. For example, the base 116 includes corresponding component cavities 114 and the cover 118 includes corresponding component cavities 114. The base 116 is disposed at a bottom 120 of the housing 110 and the cover 118 is disposed at a top 122 of the housing 110. Optionally, the cover 118 can include a cavity 124 at a bottom of the cover 118 that receives the top of the base 116 such that at least a portion of the base 116 is received within the cover 118. The cover 118 includes a sidewall 126 that extends along a portion of the base 116. The sidewall 126 can be coupled to the base 116, for example, using latches or other types of fasteners. The base 116 is configured to be mounted to the battery housing 104, for example, to a top of the battery housing 104. In alternative embodiments, the housing 110 can be a single-piece housing rather than a multi-piece housing.

[0027] In example embodiments, the BDU 100 includes a thermal interface element 130 at the bottom 120 of the housing 110 that is associated with a corresponding circuit component 106. The thermal interface element 130 is configured to be coupled in direct thermal engagement with the corresponding circuit component 106. The thermal interface element 130 includes a thermal interface surface 132 for directly conducting heat away from the circuit component 106. Optionally, the thermal interface surface 132 can be a planar surface. In various embodiments, the thermal interface surface 132 can be coplanar with the bottom 120 of the housing 110, for example, for interfacing with the battery housing 104. In other various embodiments, the thermal interface surface 132 of the thermal interface element 130 can be located below (e.g., protruding from) the bottom 120 of the housing 110, for example, for interfacing with the battery housing 104. The thermal interface surface 132 can be in direct thermal contact with a heat sink when the BDU 100 is mounted to the battery housing 104. However, in other various embodiments, another component, such as a heat sink plate (not shown) or another type of heat spreader, can be used as an interposer between the thermal interface element 130 and the battery housing 104.

[0028] In the illustrated embodiment, the thermal interface element 130 includes a heat exchanger cap 134 configured to couple to the bottom 120 of the housing 110. The heat exchanger cap 134 is configured to directly engage a hot spot of the circuit component 106 to dissipate heat from the circuit component 106, for example, directly to the battery housing 104. In the illustrated embodiment, the heat exchanger cap 134 is configured to couple to a stationary contact of a contactor defining a corresponding circuit component 106. For example, the contactor is arranged in a vertical orientation with the stationary contact at a distal end of the contactor extending through the bottom 120 of the housing 110 to interface with the heat exchanger cap 134. The stationary contact is a heat generating component of the contactor and thus defines a hot spot of the contactor. The heat exchanger cap 134 is directly thermally coupled to the hot spot of the contactor of the bottom 120 of the housing 110 to efficiently draw heat from the contactor and transfer the heat to the battery housing 104 where the heat can be efficiently dissipated through the large surface area of the battery housing 104.

[0029] Figure 3 is a cross-sectional view of a circuit component 106 according to an example embodiment. In example embodiments, the circuit component 106 is a contactor 140, for example, an electrical switch or relay, that safely connects and disconnects one or more circuits to protect the flow of electrical power through the circuit.

[0030] The contactor 140 includes a contactor housing 150 having a cavity 152. In various embodiments, the contactor housing 150 can be a multi-piece housing. The contactor housing 150 extends between a top end 154 and a bottom end 156. The contactor housing 150 includes a cover 158 for closing the cavity 152. For example, the cover 158 can be disposed at the bottom end 156. Optionally, the cover 158 can be sealed to an outer wall of the contactor housing 150. In various embodiments, the outer wall of the contactor housing 150 can be cylindrical to define a cylindrical cavity 152.

[0031] The contactor 140 includes stationary contacts 160 received in the cavity 152 and a movable contact 162 movable within the cavity 152 between a mated position and an unmated position. In the mated position, the movable contact 162 engages the stationary contacts 160 to electrically connect the stationary contacts 160 to close a contactor circuit of the contactor 140. In the illustrated embodiment, the contactor 140 includes a first stationary contact 160a and a second stationary contact 160b. The stationary contacts 160 are fixed to the contactor housing 150. For example, the stationary contacts 160 can be coupled to the cover 158. In various embodiments, the stationary contacts 160 can be coupled to an insert 164 of the contactor housing 150 inserted into the cavity 152. Each stationary contact 160 extends along a stationary contact axis 166. The movable contact 162 is movable in a direction parallel to the stationary contact axis 166. In example embodiments, the stationary contact axis 166 has a vertical orientation.

[0032] Each fixed contact 160 includes a terminating end 170 and a mating end 172. The terminating end 170 is configured to terminate to another component, such as a terminal (e.g., a terminal or busbar located at the end of a wire, either inside or outside the wire). The terminating end 170 is exposed externally to the contactor 140 for termination to another component. In an exemplary embodiment, the terminating end 170 extends below the bottom end 156 of the contactor housing 150 to terminate to a terminal. The terminating end 170 may be threaded to receive a nut. In the illustrated embodiment, the terminating end 170 extends through and below a cover 158. The mating end 172 is located within a cavity 152 to engage a movable contact 162, for example, when the contactor 140 is energized. In the illustrated embodiment, the mating end 172 is substantially flat to engage the movable contact 162. However, in alternative embodiments, the mating end 172 may have other shapes, such as a circular shape, to form a mating protrusion at the mating end 172 for mating with the movable contact 162. When the movable contact 162 mates with the fixed contact 160, the contactor circuit is closed and power flows through the contactor circuit, generating heat in both the movable contact 162 and the fixed contact 160. The termination end 170 of the fixed contact 160 extends below the bottom end 156 of the contactor housing 150 to position the termination end 170 within the battery housing 104 (e.g., Figure 1 (As shown) Heat dissipation is achieved from the fixed contact 160 near the contact point.

[0033] Contactor 140 includes a coil assembly 180 in cavity 152, for example, at the top 154 ​​of contactor housing 150. Coil assembly 180 operates to move a movable contact 162 between a disengaged position and an engaged position. Coil assembly 180 includes a winding or coil 182 wound around a core 184 to form an electromagnet. Coil assembly 180 includes a plunger 186 coupled to the core 184. The movable contact 162 is coupled to the plunger 186 and is movable with the plunger 186 during operation of coil assembly 180. Coil assembly 180 includes a spring 188 for returning the movable contact 162 to the disengaged position when coil assembly 180 is de-energized.

[0034] Figure 4is a top perspective exploded view of a heat exchanger cap 134 according to an example embodiment. The heat exchanger cap 134 includes a cap body 200 and a heat spreader 202 received in the cap body 200. In example embodiments, the cap body 200 is fabricated from a thermally conductive, electrically insulating material. For example, the cap body 200 can be fabricated from a ceramic material. In other various embodiments, the cap body 200 can be fabricated from a silicone rubber material or a composite material, such as an epoxy resin with boron nitride or aluminum nitride fillers. The cap body 200 provides electrical isolation between the circuit components 106 and the battery housing 104 or other circuit components 106 while having a thermal conductivity greater than 3.0 Btu ft / hr F. The cap body 200 includes a top portion 204 and a bottom portion 206. The cap body 200 includes a latching feature 208 for securing the heat exchanger cap 134 in the enclosure 110 (as shown) of the BDU 100 (as shown). Figure 1 Figure 1

[0035] The cap body 200 includes a recess 210 that receives the heat spreader 202. In the illustrated embodiment, the recess 210 includes an opening in the top portion 204. Additionally or alternatively, the recess 210 includes an opening in the bottom portion 206. In example embodiments, the cap body 200 includes an enclosure member 214 that defines the recess 210, which retains the heat spreader 202 and a pad 212 at a bottom end of the recess 210. The pad 212 is disposed at the bottom portion 206 of the enclosure member 214 of the cap body 200. The heat spreader 202 is configured to be mounted to the pad 212 and can transfer heat into the pad 212. The pad 212 can define the thermal interface surface 132 at the bottom portion 206 for dissipating heat into a heat sink defined by the battery housing 104 (as shown). Figure 1

[0036] ​​​In various embodiments, the pad 212 and the housing member 214 are integrally formed to create the cap 200. The pad 212 and housing member 214 may be made of the same material, for example, molded together as part of a single molded part. In alternative embodiments, the pad 212 is a separate and independent component from and attached to the housing member 214 of the cap 200. For example, the housing member 214 may be a structural element that holds the pad 212 and the heat sink 202. The pad 212 may be made of a different material than the housing member 214. For example, since the pad 212 is primarily used for heat transfer, the housing member 214 may be made of a material that is less expensive than the pad 212. The pad 212 may be made of a material that is more thermally conductive than the material of the housing member 214. In various embodiments, the cap 200 is manufactured using a two-shot molding process with different resins for the housing member 214 and the pad 212. In various other embodiments, housing component 214 and pad 212 may be manufactured separately, for example, separately molded, and then assembled together, for example, by snap-fitting, latching, gluing, or laser welding.

[0037] In an exemplary embodiment, the heat sink 202 is made of a thermally conductive material, such as a metal. For example, the heat sink 202 may be stamped from a sheet of copper or other metal. The heat sink 202 includes a base 220, fins 222 extending from the base 220, and spring fingers 224 extending from the base 220. The base 220 is mounted to a pad 212. The base 220 directly engages with and is in thermal communication with the pad 212. Heat is transferred from the base 220 of the heat sink 202 to the pad 212. The fins 222 extend upward from the base 220 and are configured to engage the sidewalls defining the recess 210. The fins 222 directly engage the cap 200 to transfer heat from the heat sink 202 to the cap 200. The fins 222 may be deflectable, and spring-biased against the cap 200. In an exemplary embodiment, the heat sink 202 includes a mounting protrusion 226 extending from the base 220 for mounting the heat sink 202 to the cap 200. The mounting protrusion 226 can engage the cap 200 and can transfer heat from the heat sink 202 to the cap 200.

[0038] Spring finger 224 extends from base 220 and is configured to engage circuit component 106, such as contactor 140 (e.g. Figure 3 (As shown). For example, spring finger 224 can directly engage fixed contact 160 (as shown). Figure 3The spring fingers 224 are deflectable and configured to spring bias against the stationary contact 160. The spring fingers 224 have an interface, e.g., at their distal ends, for direct thermal contact between the heat spreader 202 and the stationary contact 160. In the illustrated embodiment, the spring fingers 224 are located near the center of the base 220, and the fins 222 are located near the outer periphery of the base 220; however, other locations are possible in alternative embodiments. In the illustrated embodiment, the spring fingers 224 are disposed around an opening 228 in the base 220 and extend generally radially inward toward the center of the base 220. Other locations are possible in alternative embodiments.

[0039] Figure 5 is a cross-sectional view of a portion of the BDU 100 according to an example embodiment. Figure 6 is an enlarged cross-sectional view of a portion of the BDU 100 according to an example embodiment. Figure 5 and Figure 6 A pair of contactors 140 are shown held in corresponding component cavities 114 in the housing 110. In example embodiments, the contactors 140 are held in corresponding component cavities 114 in the cover 118. The termination end 170 of the stationary contact 160 extends below the bottom end 156 into the corresponding component cavity 114 and the base 116. The termination end 170 extends into the heat exchanger cap 134. In example embodiments, the heat spreader 202 mechanically and thermally engages the termination end 170 of the stationary contact 160 to transfer heat into the cap body 200, where the heat can be transferred away from the heat exchanger cap 134 into the battery housing 104.

[0040] In example embodiments, a nut 240 is threadably coupled to the termination end 170 of the stationary contact 160 to mechanically and electrically connect the stationary contact 160 to a corresponding terminal 242. In the illustrated embodiment, the terminal 242 is a busbar 244 having an opening 246 that receives the termination end 170 of the stationary contact 160. The terminal 242 is held in the housing 110. One busbar 244 extends between the corresponding stationary contacts 160 of a pair of contactors 140 to electrically connect the contactors 140. Other busbars 244 extend to ports 248 to electrically connect to other components, such as wires, power terminals, power connectors, or other components.

[0041] Figure 7is an enlarged cross-sectional view of a portion of the BDU 100 according to an example embodiment. In example embodiments, the heat sink 202 mechanically and thermally engages the terminated end 170 of the fixed contact 160. The spring fingers 224 are compressed against the fixed contact 160 to directly thermally engage the fixed contact 160. The heat exchanger cap 134 is spring loaded against the fixed contact 160 and the housing 110 via the spring fingers 224 of the heat sink 202. The deflection of the spring fingers 224 accounts for tolerances or slack in the positioning of the heat sink cap 134 relative to the housing 110 and / or the positioning of the contactor 140 relative to the housing 110. When the spring fingers 224 are compressed by the fixed contact 160, the base 220 of the heat sink 202 is driven downward into physical and thermal contact with the pad 212 of the cap body 200. A thermal flow path is formed through the heat sink 202 from the fixed contact 160 to the cap body 200. In example embodiments, the thermal interface surface 132 at the bottom 206 of the cap body 200 is configured to directly engage the battery housing 104 such that the battery housing 104 draws heat away from the cap body 200 and the heat sink 202 to cool the fixed contact 160. In other various embodiments, a thermal interface element, such as a heat sink plate, can be disposed between the bottom 206 of the cap body 200 and the top surface of the battery housing 104.

[0042] Figure 8 is an enlarged cross-sectional view of a portion of the BDU 100 according to an example embodiment. Figure 8 The heat sink 202 is shown including outer spring fingers 230 around the outer perimeter of the base 220, which are configured to engage and thermally couple to the nut 240. The outer spring fingers 230 form an additional heat transfer path from the contactor 140 to the heat exchanger cap 134, for example through the base of the heat sink 202. The outer spring fingers 230 can have a large surface area configured to engage a flat surface of the nut 240 to achieve efficient heat transfer between the nut 240 and the heat sink 202. The outer spring fingers 230 can be provided in addition to or instead of the spring fingers 224.

[0043] Figure 9 is a side view of a portion of the BUD 100 according to an example embodiment showing the contactor 140 coupled to the busbar 244. Figure 10 is a bottom perspective view of a portion of the BUD 100 according to an example embodiment showing the contactor 140 coupled to the busbar 244. Figure 11 is a top view of the busbar 244 according to an example embodiment. The terminated end 170 of the fixed contact 160 of the contactor 140 is mechanically and electrically connected to the busbar 244 using the nut 240.

[0044] In an example embodiment, the busbar 244 includes a plate 250 having an opening 246 that receives the terminated end 170 of the fixed contact 160 or other component. The plate 250 is fabricated from a metallic material, such as aluminum or copper. In an example embodiment, the plate 250 is an aluminum plate and includes a copper knob portion 252 that is pressed into the plate 250 at the opening 246. The knob portion 252 includes an opening 254 that receives the terminated end 170 of the fixed contact 160. The knob portion 252 has a top surface and a bottom surface that can be flush with the top and bottom surfaces of the plate 250. In the illustrated embodiment, the knob portion 252 has a circular shape; however, in alternative embodiments, the knob portion 252 can have other shapes. Fabricating the plate 250 from aluminum rather than copper reduces the weight of the busbar 244 and the material cost of the busbar 244. The copper knob portion 252 at the interface with the fixed contact 160 provides a robust interface between the fixed contact 160 and the plate 250. Fabricating the knob portion 252 with copper can provide better mechanical retention between the fixed contact 160 and the busbar 244 compared to aluminum. Additionally, the copper knob portion 252 is less prone to corrosion at the interface with the fixed contact 160.

[0045] Figure 12 is a side view partial cross-sectional view of the BDU 100 according to an example embodiment showing a fixed contact 260 of the contactor 140 coupled to the busbar 244. Figure 13 is a side view partial cross-sectional view of the BDU 100 showing a fixed contact 260 of the contactor 140 coupled to the busbar 244. The fixed contact 260 is similar to the fixed contact 160 (shown in Figure 3 ); except that the fixed contact 260 is configured to be press fit to the busbar 244, such as riveted to the busbar 244, rather than threadably coupled to the busbar 244. According to an example embodiment, the heat exchanger cap 134 is shown in Figure 13 where the heat sink 202 is thermally coupled to the fixed contact 260.

[0046] The terminated end 262 of the fixed contact 260 includes a rivet portion 264 configured to be coupled to the busbar 244. The rivet portion 264 includes a head 270 and a rivet stem 272 that extends from the head 270 through the opening 246 in the busbar 244. The rivet stem 272 has a recess 274. The rivet stem 272 is configured to be deformed, such as using a tool, to form a locking collar 276 Figure 13 that secures the rivet portion 264 to the busbar 244. For example, the rivet stem 272 can be folded or pressed outward to form the locking collar 276. The busbar 244 is trapped between the head 270 and the locking collar 276 to mechanically and electrically connect the fixed contact 260 to the busbar 244.

[0047] The heat exchanger cap 134 is directly thermally coupled to the fixed contact 260 to efficiently absorb heat from the hot spot of the contactor 140 and transfer heat from the fixed contact 260 to the battery housing 104 (e.g., Figure 1 As shown, heat at the battery housing 104 can be efficiently dissipated through the large surface area of ​​the battery housing 104. The heat sink 202 mechanically and thermally engages the end 262 of the fixed contact 260 to transfer heat to the pad 212, where heat can be transferred away from the heat exchanger cap 134 into the battery housing 104. The heat sink 202 can be formed to engage with the end 262 of the fixed contact 260, for example, with the locking ring 276. The spring finger 224 can directly engage the locking ring 276, for example, engaging the outer side of the locking ring 276 and / or the interior of the rivet 272 in the recess 274. The spring finger 224 is deflectable and configured to spring-biased abut against the fixed contact 260, such as the locking ring 276. The spring finger 224 has an interface, for example at the distal end, for direct thermal contact between the heat sink 202 and the fixed contact 260.

[0048] Figure 14 This is a top perspective view of a portion of a BDU 100 according to an exemplary embodiment. The BDU 100 includes a contactor 140. In an exemplary embodiment, a circuit component 106 of the BDU 100 includes a fuse 142. The fuse 142 includes a fuse body 300 extending between a first end 302 and a second end 304. The fuse 142 has a fuse element 306 (shown in dashed lines) between the first end 302 and the second end 304. In the illustrated embodiment, the fuse body 142 is rectangular and has flat walls 308, for example, along the sides, top, and bottom. In alternative embodiments, the fuse body 142 may have other shapes. The fuse 142 has a first fuse contact 312 at the first end 302 and a second fuse contact 314 at the second end 304. The fuse contacts 312, 314 are coupled to terminals, busbars, or other components, for example, using a nut.

[0049] In an exemplary embodiment, the BDU 100 includes a thermal interface element 330 at the bottom 120 of the housing 110. In the illustrated embodiment, the thermal interface element 330 is a heat sink including a heat sink 332. The heat sink 332 is located below the housing 110, for example, between the circuit components 106 and the battery housing 104 of the battery module 102. In an exemplary embodiment, the heat sink 332 is located below the contactor 140 and the fuse 142. The heat sink 332 is used to dissipate heat from the circuit components 106, for example, into the battery housing 104.

[0050] Figure 15 This is a side perspective view of the BDU 100 according to an exemplary embodiment. Figure 15A heat sink plate 332 is shown below the housing 110. In an example embodiment, a thermal interface element 334 is disposed between the circuit component 106 and the heat sink plate 332. The heat sink plate can be a metal plate having an upper surface and a lower surface. The thermal interface element 334 directly engages the upper surface, and the lower surface is configured to directly engage the battery case 104. In various embodiments, the thermal interface element 334 can be a thermal foam, a thermal pad, or the like. In other various embodiments, the heat sink plate 332 can be directly coupled to the circuit component 106 without an intervening thermal interface element 334. Figure 16 is a cross-sectional view of a BDU 100 according to an example embodiment. Figure 16 The thermal interface element 334 directly engages the heat sink plate 332 and directly engages the corresponding circuit component 106 to thermally couple the circuit component 106 to the heat sink plate 332. Heat is dissipated through the heat sink plate 332 and through the thermal interface element 334 to the battery case 104.

[0051] In an example embodiment, at the thermal interface with the contactor 140, the thermal interface element 334 directly engages the terminating end 170 of the fixed contact 160 and / or directly engages the nut 240 and / or directly engages the terminal 242 to thermally couple to the contactor 140. The thermal interface element 334 can be compressed against a surface of the fixed contact 160, the nut 240, and / or the terminal 242. The thermal interface element 334 can be compressed against the heat sink plate 332. The thermal interface element 334 and the heat sink plate 332 function to dissipate heat from the fixed contact 160 into the battery case 104. In other various embodiments, the thermal interface element 334 can be held in a heat exchanger cap (not shown), such as the heat exchanger cap 134 (shown in Figure 2 ), rather than standing freely in the component cavity 114 of the housing 110.

[0052] In an example embodiment, at the thermal interface with the fuse 142, the thermal interface element 334 directly engages the bottom surface 310 of the bottom wall 308 of the fuse 142. The thermal interface element 334 can be compressed against the bottom surface 310 of the fuse 142. The thermal interface element 334 can be compressed against the heat sink plate 332. The thermal interface element 334 and the heat sink plate 332 function to dissipate heat from the fuse body 142 into the battery case 104.

Claims

1. A battery distribution unit (100) for a battery module (102), comprising: a housing (110) including a bottom portion (120) configured to mount to a battery case (104) of the battery module, the housing including a component cavity (114); a contactor (140) received in the component cavity, the contactor having a contactor housing (150) with a top end (154) and a bottom end (156), the contactor including a movable contact within the contactor housing movable relative to a stationary contact to create an electrical switch for making and breaking the stationary contact; a terminal (242) at the bottom end of the contactor housing coupled to a corresponding termination end (170) of a corresponding stationary contact (160); and a heat exchanger cap (134) at the bottom end of the contactor disposed in the component cavity at the bottom portion of the housing, the heat exchanger cap in thermal communication with the stationary contact of the contactor and configured to be in thermal communication with the battery case of the battery module to dissipate heat from the stationary contact into the battery case of the battery module.

2. The battery dispensing unit (100) of claim 1, wherein, The heat exchanger cap (134) includes spring fingers (224) compressed against the stationary contact (160) to directly thermally engage the stationary contact.

3. The battery dispensing unit (100) of claim 1, wherein, The heat exchanger cap (134) includes a cap body (200) including a recess (210) receiving a termination end (170) of the stationary contact (160), the heat exchanger cap including a heat sink (202) received in the recess defining a direct thermal interface between the stationary contact and the cap body.

4. The battery dispensing unit (100) of claim 3, wherein, Each heat sink (202) includes a base (220) directly engaging the cap body (200) and a spring finger (224) extending from the base directly engaging the stationary contact (160).

5. The battery dispensing unit (100) of claim 4, wherein, Each heat sink (202) includes a fin (222) extending from the base (220) engaging a nut (240) threadably coupled to the corresponding stationary contact (160).

6. The battery dispensing unit (100) of claim 3, wherein, The cap body (200) includes a housing member (214) defining the recess (210) and a pad (212) at a bottom of the recess, the pad being fabricated from a first material, the housing member being fabricated from a second material different from the first material, the first material being more thermally conductive than the second material.

7. The battery dispensing unit (100) of claim 1, wherein, The heat exchanger cap (134) is disposed axially colinearly between the contactor (140) and the battery case (104) of the battery module (102).

8. The battery dispensing unit (100) of claim 1, wherein, Each stationary contact (160) extends along a stationary contact axis (166) between a mating end (172) and a termination end (170), the stationary contact axis being in a vertical orientation and perpendicular to the battery case (104).

9. The battery dispensing unit (100) of claim 1, wherein, The terminating end (170) of the fixed contact (160) is the portion of the contactor (140) closest to a battery housing (104) of the battery module (102), between which the heat exchanger cap (134) is disposed.

10. The battery dispensing unit (100) of claim 1, wherein, The terminating end (170) of each fixed contact (160) includes a clinch portion (264) including a locking collar (276) clinched to the terminal (242).

Images