A vehicle power distribution unit containing a double resilient protective cover

Abstract

This invention discloses a vehicle power distribution unit with a double-layer resilient protective cover, comprising a battery pack circuit breaker assembly and a double-layer resilient protective cover. The battery pack circuit breaker assembly includes a battery pack circuit breaker unit and an assembly cover. An opening is formed in the assembly cover, and the double-layer resilient protective cover closes onto the opening. The double-layer resilient protective cover includes a first protective cover and a second protective cover. One side of the first protective cover is rotatably connected to one side of the opening. The first and second protective covers are connected by an elastic reset structure, making the second protective cover a resilient protective cover. The double-layer resilient protective cover of this invention has a long service life, and the first protective cover meets IPXXB (anti-finger contact) requirements, providing good protection. Furthermore, the second protective cover can automatically retract and close, preventing maintenance personnel from contacting parts and preventing debris from falling into the opening, thus preventing serious safety accidents and achieving a high level of production line quality control.

Description

Technical Field

[0001] This invention relates to the field of vehicle power distribution unit technology, and specifically to a vehicle power distribution unit with a double-layer resilient protective cover. Background Technology

[0002] Safety is a critical issue for new energy vehicles, and the BDU (Battery Disconnect Unit), specifically designed for the internal components of the battery pack, is a type of distribution box. As a protective battery module within the electric vehicle battery box, the BDU is a safety solution for electric vehicle lithium batteries. It is a vital protection module for the high-voltage circuit system of electric vehicles and an important component of the overall vehicle control system. Its function is to coordinate the functional conversion and energy distribution of high-voltage accessories such as the drive motor control system, battery management system, charging management system, DC / DC converter, electric air conditioning, electric power steering, and braking system.

[0003] Therefore, protective covers are often installed on the copper busbars of the battery pack circuit breaker unit for safety protection. However, the protective covers in the existing technology are single-layer non-rebound protective covers, that is, they do not have an automatic rebound function, resulting in low safety protection performance. During the assembly process of new energy vehicles and subsequent maintenance, these protective covers need to be opened frequently, resulting in a short service life. Furthermore, they cannot meet the IPXXB (anti-finger touch) requirements. When maintenance personnel leave during maintenance (to retrieve tools, etc.), the single-layer protective cover cannot automatically rebound and close, which can easily lead to other maintenance personnel accidentally touching the copper busbars, thereby causing serious safety accidents. Summary of the Invention

[0004] The present invention aims to provide a vehicle power distribution unit with a double-layer resilient protective cover to solve the above-mentioned technical problems.

[0005] To achieve the above objectives, the technical solution of the present invention is as follows: a vehicle power distribution unit with a double-layer resilient protective cover, comprising a battery pack circuit breaker assembly and a double-layer resilient protective cover. The battery pack circuit breaker assembly includes a battery pack circuit breaker unit and an assembly cover disposed on the battery pack circuit breaker unit. An opening is provided on the assembly cover, and the double-layer resilient protective cover is closed on the opening. The double-layer resilient protective cover includes a first protective cover and a second protective cover. One side of the first protective cover is rotatably connected to one side of the opening. The first protective cover and the second protective cover are connected by an elastic reset structure, so that the second protective cover is a resilient protective cover.

[0006] Preferably, the first protective cover includes an integrally formed support portion, a first connecting portion, and a second connecting portion. The first connecting portion and the second connecting portion are respectively connected to the two ends on the same side of the support portion, and the second protective cover covers the opening space formed by the support portion, the first connecting portion, and the second connecting portion.

[0007] Preferably, the second protective cover is connected to the second connecting part through an elastic reset structure. The side of the second protective cover away from the elastic reset structure is provided with an upper buckle part, and the first connecting part is provided with an upper through hole that engages with the upper buckle part.

[0008] Preferably, when the second protective cover is normally closed such that the angle between it and the first protective cover is 0°, the rebound amount of the second protective cover is considered to be 100%. When an external force is applied to open the second protective cover such that the angle between it and the first protective cover is the maximum opening angle, the rebound amount of the second protective cover is considered to be 0%. Then, in the natural state without external force applied, the rebound amount of the second protective cover is greater than or equal to 60%.

[0009] Preferably, the upper snap-fit ​​portion of the second protective cover engages with the upper through hole of the first connecting portion in a snap-fit ​​state, and the second protective cover has a springback amount of 90% in its natural state, so that the second protective cover can basically spring back to the snap-fit ​​position.

[0010] Preferably, the first connecting part is further provided with a lower through hole, and the opening is provided with a lower latching part that engages with the lower through hole.

[0011] Preferably, the top wall of the second protective cover near the upper latching part is provided with a pushing part, and the pushing direction of the pushing part is toward the elastic reset structure.

[0012] Preferably, the second protective cover has two limiting parts on the side away from the elastic reset structure, and the top wall of the first connecting part has two grooves, with the limiting parts and the grooves engaging in a limiting fit.

[0013] Preferably, the second connecting portion extends outward to form two parallel extension portions, and the two extension portions are respectively provided with a rotating shaft on opposite sides. The opening is provided with a rotating shaft hole, and the rotating shaft is rotatably mounted on the rotating shaft hole.

[0014] Preferably, the position corresponding to the opening on the battery pack circuit breaker unit is a copper busbar, and an external copper busbar can also be detachably installed on the copper busbar. The second protective cover, the first connecting part, the second connecting part, and the opening form a clearance opening for making way for the external copper busbar.

[0015] The present invention has the following beneficial effects:

[0016] This invention includes a battery pack circuit breaker unit, an assembly cover, and a double-layer resilient protective cover. The assembly cover is disposed on the battery pack circuit breaker unit and has an opening. The double-layer resilient protective cover closes onto the opening. The double-layer resilient protective cover includes a first protective cover and a second protective cover. One side of the first protective cover is rotatably connected to one side of the opening. The first and second protective covers are connected by an elastic reset structure, making the second protective cover a resilient protective cover. The opening and closing of the second protective cover allows for the installation, disassembly, and maintenance of parts in the opening, while the opening and closing of the first protective cover allows for the insertion and removal of parts in the opening. This technical solution eliminates the need for frequent opening of the first protective cover. This design ensures the overall service life of the double-layered resilient protective cover. The first protective cover meets IPXXB (anti-finger contact) requirements, providing good protection and preventing maintenance personnel from easily touching parts inside the opening during installation and maintenance. This provides high safety performance. Furthermore, because the second protective cover is resilient, it automatically springs back to its original position when maintenance personnel leave during installation and maintenance (to retrieve tools, etc.). This prevents other maintenance personnel from contacting parts and also prevents debris from falling into the opening, thus preventing serious safety accidents and meeting high-level production line quality control requirements. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a battery pack circuit breaker unit according to an embodiment of the present invention in a state where no external copper busbar is installed and the double-layer resilient protective cover is not closed.

[0018] Figure 2 This is a schematic diagram of a battery pack circuit breaker unit according to an embodiment of the present invention with the external copper busbar installed and the double-layer resilient protective cover in an unclosed state;

[0019] Figure 3 This is a schematic diagram of a battery pack circuit breaker unit according to an embodiment of the present invention with the external copper busbar installed and the double-layer resilient protective cover in the closed state.

[0020] Figure 4 This is a front view of a double-layer resilient protective cover according to an embodiment of the present invention;

[0021] Figure 5 This is a top view of a double-layer resilient protective cover according to an embodiment of the present invention;

[0022] Figure 6 yes Figure 5 Sectional view at point AA;

[0023] Figure 7 This is a side view of a double-layer resilient protective cover according to an embodiment of the present invention;

[0024] Figure 8 This is a front view of a double-layer resilient protective cover according to an embodiment of the present invention.

[0025] Figure labels: 1 Battery pack circuit breaker unit, 2 Assembly top cover, 21 Opening, 3 Double-layer spring-loaded protective cover, 31 First protective cover, 311 First connecting part, 312 Second connecting part, 313 Support part, 32 Second protective cover, 4 Elastic spring-loaded structure, 5 Pushing part, 6 Limiting part, 7 Groove part, 8 Upper buckle part, 9 Upper through hole, 10 Lower buckle part, 11 Lower through hole, 12 Extension part, 13 Rotating shaft, 14 Rotating shaft hole, 15 Clearance opening, 16 Copper busbar, 17 External copper busbar, 18 Fastening bolt. Detailed Implementation

[0026] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention, primarily used to illustrate the embodiments and to explain the operating principles of the embodiments in conjunction with the relevant descriptions in the specification. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0027] See Figure 1-8 As shown in the figure, as an embodiment of the present invention, a vehicle power distribution unit with a double-layer resilient protective cover is provided, including a battery pack circuit breaker assembly and a double-layer resilient protective cover 3. The battery pack circuit breaker assembly includes a battery pack circuit breaker unit 1 and an assembly cover 2 disposed on the battery pack circuit breaker unit 1. An opening 21 is provided on the assembly cover 2, and the double-layer resilient protective cover 3 is closed on the opening 21. The double-layer resilient protective cover 3 includes a first protective cover 31 and a second protective cover 32. One side of the first protective cover 31 is rotatably connected to one side of the opening 21. The first protective cover 31 and the second protective cover 32 are connected by an elastic reset structure 4, so that the second protective cover 32 is a resilient protective cover.

[0028] In the above technical solution, when maintenance personnel need to install parts at the opening 21, they first rotate the first protective cover 31 upwards to open it, place the part into the corresponding installation position within the opening 21, then rotate the double-layer resilient protective cover 3 downwards to close it on the opening 21, and then open the second protective cover 32. Tools are then inserted through the opening space of the first protective cover 31 to enter the opening 21 and lock the part in place, thus completing the installation process. When maintenance personnel need to repair the part, they only need to open the second protective cover 32, leaving the first protective cover 31 closed on the opening 21, to disassemble the part within the opening 21. Then, the first protective cover 31 is opened again to remove the part. The first protective cover 31 of this invention does not need to be opened frequently, ensuring the overall service life of the double-layer resilient protective cover 3, and the first protective cover 31 meets IPXXB (anti-finger contact) standards. The second protective cover 32 provides good protection, making it difficult for maintenance personnel to touch the parts inside the opening 21 during installation and maintenance. It has a high level of safety protection. Furthermore, since the second protective cover 32 is a spring-loaded cover, it can automatically spring back and close under the action of the elastic reset structure 4 when maintenance personnel leave during installation and maintenance (to retrieve tools, etc.). This can prevent other maintenance personnel from touching the parts and prevent debris from falling into the opening 21, thus preventing serious safety accidents and meeting the requirements of a high level of production line quality control.

[0029] In this embodiment, the first protective cover 31 includes an integrally formed support portion 313, a first connecting portion 311, and a second connecting portion 312. The first connecting portion 311 and the second connecting portion 312 are respectively connected to the two ends on the same side of the support portion 313. The second protective cover 32 covers the opening space formed by the support portion 313, the first connecting portion 311, and the second connecting portion 312, so that the first protective cover 31 and the second protective cover 32 cooperate with each other to cover and protect the opening 21.

[0030] In this embodiment, the second protective cover 32 is connected to the second connecting part 312 through the elastic reset structure 4. The side of the second protective cover 32 away from the elastic reset structure 4 is provided with an upper latching part 8. The first connecting part 311 is provided with an upper through hole 9 that latches with the upper latching part 8. The upper latching part 8 latches with the upper through hole 9, so that the second protective cover 32 can be securely covered above the opening space of the first protective cover 31.

[0031] In this embodiment, when the second protective cover 32 is normally closed such that the angle between it and the first protective cover 31 is 0°, the rebound amount of the second protective cover 32 is considered to be 100%. When an external force is applied to open the second protective cover 32 such that the angle between it and the first protective cover 31 is the maximum opening angle, the rebound amount of the second protective cover 32 is considered to be 0%. Therefore, in the natural state without external force, the rebound amount of the second protective cover 32 is greater than or equal to 60%, so that when maintenance personnel leave during the maintenance process, the second protective cover 32 can automatically rebound to cover most of the area of ​​the opening 21, preventing external foreign objects or human bodies from contacting the components inside the opening 21, thereby reducing the probability of safety accidents.

[0032] Specifically, the maximum opening angle between the second protective cover 32 and the first protective cover 31 is 120°. In its natural state, the angle between the second protective cover 32 and the first protective cover 31 is 120° - 120° * 60% = 48°.

[0033] In this embodiment, the double-layer resilient protective cover 3 is made of a specific material, PP+GF10, and the elastic reset structure 4 is an elastic sheet with a certain length and a bending design. The elastic sheet is integrally formed with the second protective cover 32 and the first protective cover 31. The elastic sheet is set with a fixed bending length of 14.8mm and a bending angle of inner radius R3.5. The thickness of the deformed part is set to 1mm by calculation to ensure that the design life of the resilient part is ≥5 times, and the rebound amount is ≥60%, so as to ensure safety during any maintenance operation.

[0034] In this embodiment, the upper latching part 8 of the second protective cover 32 is engaged with the upper through hole 9 of the first connecting part 311 in a latching state. The second protective cover 32 has a springback amount of 90% in its natural state, so that the second protective cover 32 can basically spring back to the latching state position, further increasing the shielding and protection area of ​​the opening 21, thereby further reducing the probability of safety accidents.

[0035] In this embodiment, the first connecting part 311 is also provided with a lower through hole 11, and the opening part 21 is provided with a lower latching part 10 that engages with the lower through hole 11. By engaging with the lower through hole 11, the first protective cover 31 is fixed on the opening part 21.

[0036] In this embodiment, a pushing part 5 is provided on the top wall of the second protective cover 32 near the upper latching part 8. The pushing direction of the pushing part 5 is toward the elastic reset structure 4. When it is necessary to open the second protective cover 32 for installation and maintenance, it is only necessary to push the pushing part 5 toward the elastic reset structure 4 so that the upper latching part 8 disengages from the upper through hole 9, and then the second protective cover 32 can be opened manually.

[0037] In this embodiment, two limiting parts 6 are provided on the side of the second protective cover 32 away from the elastic reset structure 4, and two grooves 7 are provided on the top wall of the first connecting part 311. The limiting parts 6 and the grooves 7 are matched to limit and fit together, so that the second protective cover 32 can be stably covered and limited on the first protective cover 31.

[0038] In this embodiment, the second connecting part 312 extends outward to form two parallel extension parts 12. The two extension parts 12 are respectively provided with a rotating shaft 13 on opposite sides. The opening 21 is provided with a rotating shaft hole 14, and the rotating shaft 13 is rotatably disposed on the rotating shaft hole 14.

[0039] See Figure 1-3 As shown in this embodiment, the position corresponding to the opening 21 on the battery pack circuit breaker unit 1 is a copper busbar 16. An external copper busbar 17 can also be detachably installed on the copper busbar 16. The second protective cover 32, the first connecting part 311, the second connecting part 312, and the opening 21 form a clearance opening 15, which is used to make way for the external copper busbar 17.

[0040] The operation process of this embodiment is as follows:

[0041] When maintenance personnel need to install an external copper busbar 17 on the copper busbar 16 at the opening 21, they first disengage the lower latch 10 from the lower through hole 11, then rotate the double-layer resilient protective cover 3 upwards along the pivot 13 to open it. The external copper busbar 17 is then placed into the installation position corresponding to the copper busbar 16 in the opening 21. Next, the double-layer resilient protective cover 3 is rotated downwards along the pivot 13, causing the lower latch 10 to engage with the lower through hole 11, thus covering the opening 21. The second protective cover 32 is then opened, and the fastening bolt 18 is inserted through the opening of the first protective cover 31 into the opening 21 to lock the external copper busbar 17 and copper busbar 16 together, thereby completing the installation of the external copper busbar. The installation process of busbar 17: When maintenance personnel need to repair the external copper busbar 17, they only need to open the second protective cover 32 while the first protective cover 31 remains closed on the opening 21. The fastening bolts 18 inside the opening 21 can then be removed. The first protective cover 31 can then be opened to remove the external copper busbar 17. This method allows the second protective cover 32 to automatically spring back and close under the action of the elastic reset structure 4 when maintenance personnel leave during the maintenance process (to retrieve tools, etc.). This can prevent other maintenance personnel from contacting the copper busbar 16 and prevent debris from falling into the opening 21. It has a high level of safety protection performance, preventing serious safety accidents and meeting the requirements of a high level of production line quality control.

[0042] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail made to the invention without departing from the spirit and scope of the invention as defined in the appended claims fall within the protection scope of the invention.

Claims

1. A vehicle power distribution unit with a double-layer resilient protective cover, characterized in that: The device includes a battery pack circuit breaker assembly and a double-layer resilient protective cover. The battery pack circuit breaker assembly includes a battery pack circuit breaker unit and an assembly cover disposed on the battery pack circuit breaker unit. An opening is provided on the assembly cover, and the double-layer resilient protective cover is closed on the opening. The double-layer resilient protective cover includes a first protective cover and a second protective cover. One side of the first protective cover is rotatably connected to one side of the opening. The first protective cover and the second protective cover are connected by an elastic reset structure, making the second protective cover a resilient protective cover. The first protective cover includes an integrally formed support part, a first connecting part, and a second connecting part. The first connecting part and the second connecting part are respectively connected to the two ends on the same side of the support part. The second protective cover covers the opening space formed by the support part, the first connecting part, and the second connecting part. The second protective cover is connected to the second connecting part through an elastic reset structure.

2. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 1, characterized in that: The second protective cover has an upper latch on the side away from the elastic reset structure, and the first connecting part has an upper through hole that engages with the upper latch.

3. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 2, characterized in that: When the second protective cover is normally closed such that the angle between it and the first protective cover is 0°, the rebound of the second protective cover is considered to be 100%. When an external force is applied to open the second protective cover such that the angle between it and the first protective cover is the maximum opening angle, the rebound of the second protective cover is considered to be 0%. Therefore, in the natural state without external force, the rebound of the second protective cover is greater than or equal to 60%.

4. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 3, characterized in that: The second protective cover is in a latched state when its upper buckle part engages with the upper through hole of the first connecting part. The second protective cover has a springback amount of 90% in its natural state, so that the second protective cover can basically spring back to the latched state position.

5. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 1, characterized in that: The first connecting part is also provided with a lower through hole, and the opening is provided with a lower latching part that engages with the lower through hole.

6. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 2, characterized in that: The second protective cover has a pushing part on the top wall near the upper buckle part, and the pushing direction of the pushing part is towards the elastic reset structure.

7. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 1, characterized in that: The second protective cover has two limiting parts on the side away from the elastic reset structure, and the top wall of the first connecting part has two grooves, with the limiting parts and grooves engaging in a limiting fit.

8. The vehicle power distribution unit with a double-layer resilient protective cover as described in claim 1, characterized in that: The second connecting part extends outward to form two parallel extensions. The two extensions are respectively provided with a rotating shaft on one side away from each other. The opening is provided with a rotating shaft hole, and the rotating shaft is rotatably mounted on the rotating shaft hole.

9. The vehicle power distribution unit with a double-layer resilient protective cover according to any one of claims 2-8, characterized in that: The position corresponding to the opening on the battery pack circuit breaker unit is a copper busbar. An external copper busbar can also be detachably installed on the copper busbar. The second protective cover, the first connecting part, the second connecting part, and the opening form a clearance opening for making way for the external copper busbar.

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