Bdu module, assembling method of bdu module, battery pack and electric device

Abstract

The application discloses a BDU module, an assembling method of the BDU module, a battery pack and a power utilization equipment. The BDU module comprises a voltage division relay core body, the voltage division relay core body is provided with a first low-voltage terminal and a second low-voltage terminal; an N-line relay core body is connected with the voltage division relay core body, the N-line relay core body is provided with a third low-voltage terminal and a fourth low-voltage terminal; a PCB electric board is provided with a voltage division relay low-voltage power supply circuit and an N-line relay low-voltage power supply circuit, the first low-voltage terminal and the second low-voltage terminal are connected with the PCB electric board and are connected in the voltage division relay low-voltage power supply circuit, and the third low-voltage terminal and the fourth low-voltage terminal are connected with the PCB electric board and are connected in the N-line relay low-voltage power supply circuit. According to the BDU module, the risk of line error failure is reduced, the manufacturing cost is reduced, the assembling efficiency is improved, and the integration degree is high.

Description

Technical Field

[0001] This invention relates to the field of battery technology, and in particular to a BDU module, a method for assembling the BDU module, a battery pack, and an electrical device. Background Technology

[0002] In related technologies, the battery pack plays a core power source role in new energy vehicles. Its performance, especially its range (energy density), reliability, and manufacturing cost, directly determines the market potential and sustainable development of electric vehicle technology. The Battery Management Unit (BDU), as a core component of battery management, undertakes crucial tasks. It performs precise monitoring of voltage and current, continuous insulation status checks, ensures efficient power transmission and control, data exchange, and diagnostic functions. The stability and efficiency of the BDU are directly related to the efficiency and safety of the entire system, especially during the pre-charging process, which is a key guarantee for the safety of the high-voltage system. Newer BDUs can achieve voltage division and self-heating functions of the power battery pack through different internal relays and the Battery Management System (BMS).

[0003] In traditional solutions, electrical connections rely on dense wiring harness assemblies and connectors. The harness design comprises multiple independent components, such as plugs, connectors, terminals, wires, and auxiliary materials, which are combined to form the harness. This structure increases the probability of failure because the failure of a single part can directly affect the performance of the entire system, leading to reduced reliability, high manufacturing costs, low efficiency, and difficulty in integration. Summary of the Invention

[0004] This invention aims to address at least one of the technical problems existing in the prior art. To this end, this invention proposes a BDU module that reduces the risk of line errors and faults, lowers manufacturing costs, improves assembly efficiency, and has a high degree of integration.

[0005] The present invention also proposes an assembly method for a BDU module, applicable to the aforementioned BDU module.

[0006] The present invention also proposes a battery pack comprising the aforementioned BDU module.

[0007] The present invention also proposes an electrical device, which includes the battery pack described above.

[0008] According to an embodiment of the present invention, a BDU module includes: a voltage divider relay core having a first low-voltage terminal and a second low-voltage terminal; an neutral (N) relay core connected to the voltage divider relay core, having a third low-voltage terminal and a fourth low-voltage terminal; and a PCB electrical board having a low-voltage power supply circuit for the voltage divider relay and a low-voltage power supply circuit for the N-line relay, wherein the first low-voltage terminal and the second low-voltage terminal are connected to the PCB electrical board and within the low-voltage power supply circuit for the voltage divider relay, and the third low-voltage terminal and the fourth low-voltage terminal are connected to the PCB electrical board and within the low-voltage power supply circuit for the N-line relay.

[0009] According to the BDU module of the present invention, by providing a first low-voltage terminal and a second low-voltage terminal on the voltage divider relay core, and a third low-voltage terminal and a fourth low-voltage terminal on the neutral (N) relay core, and by providing a low-voltage power supply circuit for the voltage divider relay and a low-voltage power supply circuit for the N-line relay on the PCB electrical board, the first low-voltage terminal and the second low-voltage terminal are connected to the PCB electrical board and connected within the low-voltage power supply circuit for the voltage divider relay, and the third low-voltage terminal and the fourth low-voltage terminal are connected to the PCB electrical board and connected within the low-voltage power supply circuit for the N-line relay, the low-voltage wiring harness and connectors between the voltage divider relay core and the low-voltage power supply circuit for the voltage divider relay, and between the N-line relay core and the low-voltage power supply circuit for the N-line relay can be reduced, thereby reducing the risk of circuit errors and failures, reducing manufacturing costs, improving assembly efficiency, and achieving high integration.

[0010] According to some embodiments of the present invention, at least one of the first low-voltage terminal, the second low-voltage terminal, the third low-voltage terminal and the fourth low-voltage terminal is inserted into the PCB electrical board.

[0011] According to some embodiments of the present invention, it further includes: a first connecting copper busbar, the two ends of which are respectively connected to the N-line relay core and the voltage divider relay core via fasteners.

[0012] According to some embodiments of the present invention, it further includes: a fourth connecting copper busbar, the fourth connecting copper busbar being connected to the N-line relay core via fasteners.

[0013] According to some embodiments of the present invention, the N-line relay core has a first auxiliary contact terminal and a second auxiliary contact terminal, the PCB electrical board has an auxiliary contact circuit, and the first auxiliary contact terminal and the second auxiliary contact terminal are connected to the PCB electrical board and to the auxiliary contact circuit.

[0014] In some embodiments of the present invention, at least one of the first auxiliary contact terminal and the second auxiliary contact terminal is inserted into the PCB electrical board.

[0015] According to some embodiments of the present invention, the PCB electrical board has a high-voltage sampling circuit, and the BDU module further includes: a fuse device connected to the voltage divider relay core; and a high-voltage sampling copper busbar, wherein the high-voltage sampling component is connected to the fuse device and the PCB electrical board and is connected within the high-voltage sampling circuit.

[0016] In some embodiments of the present invention, the high-voltage sampling copper busbar has a plug-in portion, which is plugged into the PCB electrical board.

[0017] In some embodiments of the present invention, a second connecting copper busbar is further included, the two ends of which are respectively connected to the safety device and the voltage divider relay core via fasteners.

[0018] In some embodiments of the present invention, a third connecting copper busbar is further included, the third connecting copper busbar being connected to the high-voltage sampling copper busbar, and the third connecting copper busbar and the high-voltage sampling copper busbar being connected together to the safety device by fasteners.

[0019] In some embodiments of the present invention, the device further includes: a housing having a mounting cavity, one side of which is open to form an opening, a PCB electrical board disposed at the opening to seal the opening, and the voltage divider relay core, the neutral line relay core, the fuse device, and the high-voltage sampling copper busbar fixedly disposed within the mounting cavity.

[0020] In some embodiments of the present invention, the opening is located on one side of the housing thickness direction, and the N-line relay core, the voltage divider relay core, the fuse device and the high-voltage sampling copper busbar are arranged sequentially along the length direction of the mounting cavity.

[0021] In some embodiments of the present invention, the housing has a potting structure for fixing the N-line relay core and the voltage divider relay core; and / or, the fuse and the high-voltage sampling copper busbar are fixed in the mounting cavity by fasteners.

[0022] In some embodiments of the present invention, the housing has a clearance hole, which is disposed opposite to the fasteners connecting the voltage divider relay core, the N-line relay core, the fuse device and the high-voltage sampling copper busbar.

[0023] In some embodiments of the present invention, a sealing plug is further included, wherein each of the clearance holes is provided with a sealing plug for sealing the clearance hole.

[0024] According to an embodiment of the present invention, an assembly method for a BDU module is provided, wherein the BDU module is as described above, the BDU module further includes a housing, the housing having a mounting cavity, one side of the mounting cavity being open to form an opening, and the assembly method includes:

[0025] The voltage divider relay core and the N-line relay core are placed inside the mounting cavity;

[0026] Injecting fixing adhesive into the mounting cavity to fix the voltage divider relay core and the N-line relay core;

[0027] The PCB electrical board is placed at the opening, and the connection terminals on the voltage divider relay core and the N-line relay core are inserted into the sockets on the PCB electrical board.

[0028] The connecting terminals and the PCB electrical board are soldered together.

[0029] According to the assembly method of the BDU module of the present invention, the voltage divider relay core and the N-line relay core are first placed in the housing, and then glue is poured into the housing to fix the voltage divider relay core and the N-line relay core. The PCB electrical board is placed at the opening and connected to the connection terminals on the voltage divider relay core and the N-line relay core by snap-fit ​​welding. During the BDU assembly process, the voltage divider relay core and the N-line relay core can be fixed in advance, which facilitates the assembly of the BDU module and improves the assembly efficiency.

[0030] The battery pack according to an embodiment of the present invention includes the BDU module described above.

[0031] According to the battery pack of the present invention, a third low-voltage terminal and a fourth low-voltage terminal are provided on the N-line relay core, and a voltage divider relay low-voltage power supply circuit and an N-line relay low-voltage power supply circuit are provided on the PCB electrical board. The first low-voltage terminal and the second low-voltage terminal are connected to the PCB electrical board and connected to the voltage divider relay low-voltage power supply circuit. The third low-voltage terminal and the fourth low-voltage terminal are connected to the PCB electrical board and connected to the N-line relay low-voltage power supply circuit. This can reduce the low-voltage wiring harness and connectors between the voltage divider relay core and the voltage divider relay low-voltage power supply circuit and between the N-line relay core and the N-line relay low-voltage power supply circuit, reduce the risk of circuit errors and failures, reduce manufacturing costs, improve assembly efficiency, and achieve high integration.

[0032] The electrical device according to an embodiment of the present invention includes the battery pack described above.

[0033] According to an embodiment of the present invention, the electrical equipment, by providing the aforementioned battery pack, which includes the aforementioned BDU module, has a first low-voltage terminal and a second low-voltage terminal on the voltage divider relay core, a third low-voltage terminal and a fourth low-voltage terminal on the neutral (N) relay core, and a voltage divider relay low-voltage power supply circuit and an N-line relay low-voltage power supply circuit on the PCB electrical board. The first and second low-voltage terminals are connected to the PCB electrical board and are connected within the voltage divider relay low-voltage power supply circuit, and the third and fourth low-voltage terminals are connected to the PCB electrical board and are connected within the N-line relay low-voltage power supply circuit. This reduces the low-voltage wiring harnesses and connectors between the voltage divider relay core and the voltage divider relay low-voltage power supply circuit, and between the N-line relay core and the N-line relay low-voltage power supply circuit, thereby reducing the risk of circuit errors and failures, lowering manufacturing costs, improving assembly efficiency, and achieving high integration.

[0034] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0035] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0036] Figure 1 This is a perspective view of the BDU module according to an embodiment of the present invention;

[0037] Figure 2 This is an exploded view of the BDU module according to an embodiment of the present invention;

[0038] Figure 3 This is a schematic diagram of the BDU module according to an embodiment of the present invention;

[0039] Figure 4 yes Figure 2 Enlarged view of point A in the middle.

[0040] Figure label:

[0041] 100. BDU module;

[0042] 1. Housing; 11. Opening; 12. Clearance hole;

[0043] 2. Voltage divider relay core; 21. First low-voltage terminal; 22. Second low-voltage terminal;

[0044] 3. Neutral (N) relay core; 31. Third low-voltage terminal; 32. Fourth low-voltage terminal; 33. First auxiliary contact terminal; 34. Second auxiliary contact terminal;

[0045] 4. PCB electrical board; 41. Hole; 42. Recess;

[0046] 5. Safety devices;

[0047] 6. High-voltage sampling copper busbar; 61. Connector;

[0048] 71. First connecting copper busbar; 72. Second connecting copper busbar; 73. Third connecting copper busbar; 74. Fourth connecting copper busbar;

[0049] 8. Fasteners; 9. Sealing plugs. Detailed Implementation

[0050] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0051] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, features defined with "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0052] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0053] The following is for reference. Figures 1-3 A BDU module 100 according to an embodiment of the present invention is described.

[0054] like Figures 1-3 As shown, the BDU module 100 according to an embodiment of the present invention includes a voltage divider relay core 2, an N-line relay core 3, and a PCB electrical board 4.

[0055] Specifically, the voltage divider function of the battery pack uses a voltage divider relay to divide the input voltage into two or more levels, thereby generating a stable and measurable low voltage at the output. This facilitates instrument reading or precise control of electronic equipment, and can also be used for signal transmission to protect equipment and personnel safety. Furthermore, it can be used for fault detection. By comparing the voltages after voltage division, changes in the input voltage can be detected for fault diagnosis or circuit protection, such as automatically disconnecting when the high voltage exceeds a predetermined value.

[0056] The battery pack's self-heating function utilizes a neutral (N) relay to activate and deactivate the heating element upon receiving a specific pulse signal, achieving periodic pulsed heating. For example, when preheating an engine, this relay may periodically provide short-term power to avoid energy waste caused by sustained high temperatures, extend equipment lifespan, prevent overheating, and avoid unnecessary prolonged operation of the heating element that could lead to overheating and damage, thus ensuring equipment safety. Pulse heating automatically stops once the set temperature is reached, ensuring the heated object reaches the required precise temperature. In the event of a heating equipment malfunction, the N-line relay acts as a protective device, stopping heating to prevent further damage.

[0057] The voltage divider relay core 2 has a first low-voltage terminal 21 and a second low-voltage terminal 22. The voltage divider relay core 2 may have a first stationary contact and a first moving contact, as well as a first coil for driving the first moving contact to move. The first low-voltage terminal 21 and the second low-voltage terminal 22 may be connected to the two ends of the first coil respectively. When the first coil is energized, the first moving contact may contact or disconnect from the first stationary contact. The first stationary contact and the first moving contact may each be one or two corresponding first stationary contacts and first moving contacts.

[0058] The neutral (N) relay core 3 is connected to the voltage divider relay core 2. The N-line relay core 3 has a third low-voltage terminal 31 and a fourth low-voltage terminal 32. The N-line relay core 3 may contain a second stationary contact, a second moving contact, and a second coil for driving the movement of the second moving contact. The third low-voltage terminal 31 and the fourth low-voltage terminal 32 can be connected to the two ends of the second coil, respectively. When the second coil is energized, the second moving contact can make or break contact with the second stationary contact. Either the second stationary contact or the second moving contact can be a single, or both can be corresponding pairs.

[0059] The PCB electrical board 4 has a low-voltage power supply circuit for a voltage divider relay and a low-voltage power supply circuit for an neutral (N) relay. The first low-voltage terminal 21 and the second low-voltage terminal 22 are connected to the PCB electrical board 4 and within the low-voltage power supply circuit of the voltage divider relay. Similarly, the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are also connected to the PCB electrical board 4 and within the low-voltage power supply circuit of the N-line relay. This allows the voltage divider relay core 2 to be connected to the PCB electrical board 4 via the first low-voltage terminal 21 and the second low-voltage terminal 22, and the N-line relay core 3 to be connected to the PCB electrical board 4 via the third low-voltage terminal 31 and the fourth low-voltage terminal 32. Power is supplied to the N-line relay core 3 and the voltage divider relay core 2, and signals are read from them via the internal electrical circuit of the PCB electrical board 4. The voltage divider relay core 2 and the N-line relay core 3 do not require wiring harnesses or connectors to connect and conduct the low-voltage power supply circuits of the voltage divider relay and the N-line relay, reducing the risk of circuit errors, lowering manufacturing costs, improving assembly efficiency, and achieving high integration.

[0060] Among them, the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31 and the fourth low-voltage terminal 32 can be copper sheets. The first low-voltage terminal 21 and the second low-voltage terminal 22 can be integrated with the voltage divider relay core 2, and the third low-voltage terminal 31 and the fourth low-voltage terminal 32 can be integrated with the neutral line relay core 3.

[0061] In addition, the first low-voltage terminal 21 and the second low-voltage terminal 22 are soldered to the PCB electrical board 4, and the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are soldered to the PCB electrical board 4. For example, the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are fixed to the PCB electrical board 4 by wave soldering.

[0062] According to the BDU module 100 of the present invention, by providing a first low-voltage terminal 21 and a second low-voltage terminal 22 on the voltage divider relay core 2, providing a third low-voltage terminal 31 and a fourth low-voltage terminal 32 on the N-line relay core 3, and providing a low-voltage power supply circuit for the voltage divider relay and a low-voltage power supply circuit for the N-line relay on the PCB electrical board 4, the first low-voltage terminal 21 and the second low-voltage terminal 22 are connected to the PCB electrical board 4 and connected within the low-voltage power supply circuit for the voltage divider relay, and the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are connected to the PCB electrical board 4 and connected within the low-voltage power supply circuit for the N-line relay, the low-voltage wiring harness and connectors between the voltage divider relay core 2 and the low-voltage power supply circuit for the voltage divider relay, and between the N-line relay core 3 and the low-voltage power supply circuit for the N-line relay can be reduced, thereby reducing the risk of circuit errors and failures, reducing manufacturing costs, improving assembly efficiency, and achieving high integration.

[0063] In some embodiments of the present invention, such as Figure 1 As shown, combined with Figure 2 At least one of the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32 is inserted into the PCB electrical board 4. This facilitates the connection between the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32 and the PCB electrical board 4.

[0064] For example, in Figure 1 and Figure 2 In the example shown, the PCB electrical board 4 has sockets 41 corresponding to the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32, respectively. The first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32 are respectively inserted into the corresponding sockets 41. For example, Figure 4 As shown, combined with Figure 2 The first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32 are strip-shaped sheet structures, and the insertion hole 41 is a strip-shaped hole. The two inner walls opposite each other in the width direction of the insertion hole 41 are provided with recesses 42. There are multiple recesses 42 spaced apart along the length direction of the insertion hole 41, such as two. This facilitates the insertion of the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32 into the insertion hole 41, and facilitates the formation of more solder in the insertion hole 41, ensuring the reliability of the connection between the PCB electrical board 4 and the first low-voltage terminal 21, the second low-voltage terminal 22, the third low-voltage terminal 31, and the fourth low-voltage terminal 32.

[0065] In some embodiments of the present invention, such as Figure 2 As shown, combined with Figure 3 The BDU module 100 also includes a first connecting copper busbar 71, the two ends of which are connected to the N-line relay core 3 and the voltage divider relay core 2 respectively via fasteners 8. This allows the N-line relay core 3 and the voltage divider relay core 2 to be connected via the first connecting copper busbar 71, facilitating the connection between them. Furthermore, it eliminates the need for wiring harnesses and connectors between the N-line relay core 3 and the voltage divider relay core 2, further reducing the risk of circuit errors, lowering manufacturing costs, improving assembly efficiency, and further enhancing integration.

[0066] like Figure 2 As shown, the first connecting copper busbar 71 is T-shaped. The first connecting copper busbar 71 includes a first connecting part and a second connecting part. The two ends of the first connecting part in the length direction are respectively connected to the N-line relay core 3 and the voltage divider relay core 2. The second connecting part is perpendicular to the first connecting part to form a T-shape. One end of the second connecting part is connected to the first connecting part, and the other end is bent and used to connect to the positive terminal of the battery.

[0067] In some embodiments of the present invention, such as Figure 2 As shown, combined with Figure 3 The BDU module 100 also includes a fourth connecting copper busbar 74, which is connected to the N-line relay core 3 via fasteners 8. It can be understood that one end of the fourth connecting copper busbar 74 is connected to the N-line relay core 3 via fasteners 8, and the other end is used to connect to the N-line. This facilitates the connection between the N-line relay core 3 and the N-line, and eliminates the need for wiring harnesses and connectors between the N-line relay core 3 and the N-line, further reducing the risk of circuit errors, lowering manufacturing costs, improving assembly efficiency, and further enhancing integration. The fourth connecting copper busbar 74 is L-shaped.

[0068] In some embodiments of the present invention, such as Figures 1-3 As shown, the N-line relay core 3 has a first auxiliary contact terminal 33 and a second auxiliary contact terminal 34. The PCB electrical board 4 has an auxiliary contact circuit. The first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 are connected to the PCB electrical board 4 and to the auxiliary contact circuit. This allows the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 of the N-line relay core 3 to be connected to the PCB electrical board 4, and the N-line relay core 3 is powered and signals are read by the electrical circuit inside the PCB electrical board 4. The N-line relay core 3 does not need to be connected to the auxiliary contact circuit via wiring harnesses and connectors, reducing the risk of circuit errors, lowering manufacturing costs, improving assembly efficiency, and achieving high integration.

[0069] The first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 can be connected to a measuring device on the N-line relay core 3 for measuring the current, voltage or temperature of the N-line relay core 3 to supply power to the measuring device.

[0070] In some embodiments of the present invention, such as Figure 1 As shown, combined with Figure 2 At least one of the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 is inserted into the PCB electrical board 4. This facilitates the connection between the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 and the PCB electrical board 4. The first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 are soldered to the PCB electrical board 4, specifically by wave soldering.

[0071] For example, in Figure 1 and Figure 2 In the example shown, the PCB electrical board 4 is provided with sockets 41 corresponding to the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34, respectively. The first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 are respectively inserted into the corresponding sockets 41. For example, Figure 4 As shown, combined with Figure 2 The multiple sockets 41 have the same structure. The sockets 41 are strip-shaped holes. The two inner walls of the sockets 41 opposite each other in the width direction are provided with recesses 42. The recesses 42 are multiple, for example two, arranged at intervals along the length direction of the sockets 41. This facilitates the insertion of the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 into the sockets 41 and facilitates the formation of more solder in the sockets 41, ensuring the reliability of the connection between the PCB electrical board 4 and the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34.

[0072] In some embodiments of the present invention, such as Figure 2 and Figure 3 As shown, the PCB electrical board 4 has a high-voltage sampling circuit. The BDU module 100 also includes a fuse device 5 and a high-voltage sampling copper busbar 6. The fuse device 5 contains a fuse, and the fuse device 5 in this application can be a passive fuse device. The fuse device 5 is connected to the voltage divider relay core 2, and the high-voltage sampling component is connected to the fuse device 5 and the PCB electrical board 4 and is connected within the high-voltage sampling circuit. This application sets the existing high-voltage sampling harness in the form of a copper busbar and then connects it to the PCB electrical board 4. The battery management system (BMS) can directly collect the voltage signal on the circuit through the PCB electrical board 4 without the need to set up a high-voltage sampling harness, reducing the risk of circuit errors and failures, reducing manufacturing costs, improving assembly efficiency, and achieving high integration.

[0073] In some embodiments of the present invention, the high-voltage sampling copper busbar 6 has a plug-in portion 61, which is plugged into the PCB electrical board 4. This facilitates the connection between the high-voltage sampling copper busbar 6 and the PCB electrical board 4. Specifically, the high-voltage sampling copper busbar 6 and the PCB electrical board 4 are soldered together using wave soldering.

[0074] For example, in Figure 1 and Figure 2 In the example shown, the PCB electrical board 4 has a corresponding socket 41 for the high-voltage sampling copper busbar 6, and the insertion part 61 of the high-voltage sampling copper busbar 6 is inserted into the corresponding socket 41. For example, Figure 4 As shown, combined with Figure 2 The multiple sockets 41 have the same structure. The sockets 41 are strip-shaped holes. The two inner walls of the sockets 41 opposite each other in the width direction are provided with recesses 42. The recesses 42 are multiple, for example two, arranged at intervals along the length direction of the sockets 41. This facilitates the insertion of the plug part 61 of the high-voltage sampling copper busbar 6 into the sockets 41 and facilitates the formation of more solder in the sockets 41, ensuring the reliability of the connection between the PCB electrical board 4 and the high-voltage sampling copper busbar 6.

[0075] In some embodiments of this invention, such as Figure 2 As shown, combined with Figure 3The BDU module 100 also includes a second connecting copper busbar 72, the two ends of which are connected to the fuse device 5 and the voltage divider relay core 2 respectively via fasteners 8. This allows the fuse device 5 and the voltage divider relay core 2 to be connected via the second connecting copper busbar 72, facilitating the connection between them. Furthermore, it eliminates the need for wiring harnesses and connectors between the fuse device 5 and the voltage divider relay core 2, further reducing the risk of circuit errors, lowering manufacturing costs, improving assembly efficiency, and further enhancing integration.

[0076] In some embodiments of the present invention, the BDU module 100 further includes a third connecting copper busbar 73, which is connected to the high-voltage sampling copper busbar 6. The third connecting copper busbar 73 and the high-voltage sampling copper busbar 6 are jointly connected to the safety device 5 by fasteners 8. The third connecting copper busbar 73 can be used to connect to the negative terminal of the battery, thereby facilitating the connection between the safety device 5 and the negative terminal of the battery.

[0077] In addition, the high-voltage sampling copper busbar 6 and the third connecting copper busbar 73 are connected to the safety device 5 by a fastener 8. The fastener 8 passes through both the third connecting copper busbar 73 and the high-voltage sampling copper busbar 6 and is then connected to the safety device 5, thereby reducing the number of parts and facilitating assembly.

[0078] In related technologies, traditional solutions consist of low-voltage wiring harnesses (low-voltage ends of neutral relays and voltage divider relays), auxiliary contact wiring harnesses (auxiliary contact wiring harnesses for the low-voltage ends of neutral relays and voltage divider relays), high-voltage wiring harnesses (high-voltage connector wiring harnesses), high-voltage connectors, fuses, neutral relays, voltage divider relays, four different sizes of bolts, connecting copper busbars, and plastic parts. Current needs to be transmitted between components through wiring harnesses. This involves a large number of materials, cumbersome assembly, high labor costs, and complex assembly processes, making large-scale automated mass production impossible.

[0079] In this application, a PCB electrical board 4 is provided, which integrates a low-voltage power supply circuit for a voltage divider relay, a low-voltage power supply circuit for an neutral-mode relay, and a high-voltage sampling circuit. The voltage divider relay core 2 is connected to the PCB electrical board 4 through a first low-voltage terminal 21 and a second low-voltage terminal 22. The neutral-mode relay core 3 is connected to the PCB electrical board 4 through a third low-voltage terminal 31 and a fourth low-voltage terminal 32. The high-voltage sampling harness is designed with a high-voltage sampling copper busbar 6 connected to the PCB electrical board 4. A first connecting copper busbar 71, a second connecting copper busbar 72, a third connecting copper busbar 73, and a fourth connecting copper busbar 74 are provided for the connection between the components. This design results in a low risk of circuit errors and failures, low manufacturing costs, high assembly efficiency, and high integration.

[0080] In some embodiments of the present invention, such as Figure 1 and Figure 2As shown, the BDU module 100 also includes a housing 1, which has a mounting cavity. One side of the mounting cavity is open to form an opening 11. A PCB electrical board 4 is disposed at the opening 11 to seal it. The voltage divider relay core 2, the neutral relay core 3, the fuse device 5, and the high-voltage sampling copper busbar 6 are fixed inside the mounting cavity. The housing 1 can protect the internal voltage divider relay core 2, neutral relay core 3, fuse device 5, and high-voltage sampling copper busbar 6. The PCB electrical board 4, located at the opening 11, can serve as part of the outer shell to protect the internal components, reducing the material cost of the housing 1 and reducing the space occupied by the housing 1. In addition, this application directly houses the voltage divider relay core 2 and the neutral relay core 3 inside the housing 1, merging the outer shells of the neutral relay and the voltage divider relay with the housing 1 to form the housing 1 of the BDU module 100. This reduces the number of assembly parts, optimizes the structure, reduces costs, and improves the integration of the BDU module 100.

[0081] Optionally, the housing 1 is made of plastic, which has good insulation, low cost, and is easy to process.

[0082] In some embodiments of the present invention, such as Figure 2 As shown, opening 11 is located on one side of the housing 1 along its thickness direction. The N-line relay core 3, voltage divider relay core 2, fuse device 5, and high-voltage sampling copper busbar 6 are arranged sequentially along the length of the mounting cavity. This allows for a more reasonable and compact arrangement of the N-line relay core 3, voltage divider relay core 2, fuse device 5, and high-voltage sampling copper busbar 6 within the housing 1, and facilitates the connection between the components.

[0083] Of course, the present invention is not limited to this. Different N-line relay cores 3 and voltage divider relay cores 2 can be selected according to the specific BDU module 100 selection, and the above-mentioned structural arrangement can be changed to adjust the size and installation method of the BDU module 100.

[0084] In some embodiments of the present invention, the housing 1 has a potting structure for fixing the N-line relay core 3 and the voltage divider relay core 2. It is understood that during the assembly of the BDU module 100, the N-line relay core 3 and the voltage divider relay core 2 can be placed inside the housing 1, and then potting is performed inside the housing 1. After the potted adhesive cures, the N-line relay core 3 and the voltage divider relay core 2 are fixed inside the housing 1.

[0085] In some embodiments of the present invention, such as Figure 2 As shown, the safety device 5 and the high-voltage sampling copper busbar 6 are fixed in the mounting cavity by fasteners 8. This facilitates the fixing of the safety device 5 and the high-voltage sampling copper busbar 6 to the housing 1, and at the same time improves the reliability of the fixing of the safety device 5 and the high-voltage sampling copper busbar 6.

[0086] In some embodiments of the present invention, such as Figure 2 As shown, the housing 1 has clearance holes 12, which are positioned opposite to the fasteners 8 that connect the voltage divider relay core 2, the neutral relay core 3, the fuse device 5, and the high-voltage sampling copper busbar 6. During the assembly of the BDU module 100, the voltage divider relay core 2, the neutral relay core 3, the fuse device 5, the high-voltage sampling copper busbar 6, and the connecting copper busbars (first connecting copper busbar 71, second connecting copper busbar 72, third connecting copper busbar 73, and fourth connecting copper busbar 74) can be placed inside the housing 1 first. Then, the fasteners 8 are fixed and connected outside the housing 1 through the clearance holes 12, simultaneously achieving the connection between each component and the housing 1.

[0087] Furthermore, such as Figure 1 and Figure 2 As shown, the BDU module 100 also includes a sealing plug 9, with a sealing plug 9 provided at each clearance hole 12 to seal the clearance hole 12. This can prevent dust or water from entering the clearance hole 12, thus better protecting the internal components of the housing 1.

[0088] The following describes an assembly method for a BDU module 100 according to an embodiment of the present invention, wherein the BDU module 100 is the BDU module 100 described above, and the BDU module 100 further includes a housing 1, the housing 1 having a mounting cavity, one side of the mounting cavity being open to form an opening 11, and the assembly method including:

[0089] Place the voltage divider relay core 2 and the neutral line relay core 3 into the mounting cavity;

[0090] Inject fixing adhesive into the mounting cavity to fix the voltage divider relay core 2 and the neutral line relay core 3;

[0091] Place the PCB electrical board 4 at the opening 11, and insert the connection terminals on the voltage divider relay core 2 and the N-line relay core 3 into the socket 41 on the PCB electrical board 4.

[0092] Solder the connection terminals and PCB electrical board 4 together, for example, by wave soldering.

[0093] Therefore, during the BDU assembly process, the voltage divider relay core 2 and the neutral line relay core 3 can be fixed in advance, which facilitates the assembly of the BDU module 100.

[0094] According to the assembly method of the BDU module 100 of the present invention, the voltage divider relay core 2 and the N-line relay core 3 are first placed in the housing 1, and then glue is poured into the housing 1 to fix the voltage divider relay core 2 and the N-line relay core 3. The PCB electrical board 4 is set at the opening 11 and connected to the connection terminals on the voltage divider relay core 2 and the N-line relay core 3 by snap-fit ​​welding. During the BDU assembly process, the voltage divider relay core 2 and the N-line relay core 3 can be fixed in advance, which facilitates the assembly of the BDU module 100 and improves the assembly efficiency.

[0095] In some embodiments of the present invention, when the BDU module 100 includes a safety device 5, a high-voltage sampling copper busbar 6, and first to fourth connecting copper busbars, before placing the PCB board at the opening 11, the assembly method of the BDU module 100 further includes placing the safety device 5, the high-voltage sampling copper busbar 6, and the first to fourth connecting copper busbars inside the housing 1, connecting the third connecting copper busbar 73, the high-voltage sampling copper busbar 6, and the safety device 5 to the housing 1 with a fastener 8, connecting the second connecting copper busbar 72 and the safety device 5 to the housing 1 with a fastener 8, connecting the second connecting copper busbar 72 and the voltage divider relay core 2 with a fastener 8, connecting the first connecting copper busbar 71 and the voltage divider relay core 2 with a fastener 8, connecting the first connecting copper busbar 71 and the N-line relay core 3 with a fastener 8, and connecting the fourth connecting copper busbar 74 and the N-line relay core 3 with a fastener 8. A total of six fasteners 8 are used to connect the components.

[0096] The housing 1 has clearance holes 12 for six fasteners 8, and the six fasteners 8 are installed through the six clearance holes 12 respectively.

[0097] After all components are installed in the housing 1, the PCB is placed at the opening 11, and the first auxiliary contact terminal 33 and the second auxiliary contact terminal 34 of the N-line relay core 3 and the plug-in part 61 of the high-voltage sampling copper busbar 6 are inserted into the plug hole 41 of the PCB electrical board 4 and soldered together.

[0098] Finally, the sealing plug 9 is placed at the clearance hole 12 to seal the clearance hole 12.

[0099] The following describes a battery pack according to an embodiment of the present invention.

[0100] The battery pack according to an embodiment of the present invention includes the BDU module 100 described above.

[0101] According to the battery pack of the present invention, by setting the above-mentioned BDU module 100, a first low-voltage terminal 21 and a second low-voltage terminal 22 are provided on the voltage divider relay core 2, a third low-voltage terminal 31 and a fourth low-voltage terminal 32 are provided on the neutral relay core 3, and a low-voltage power supply circuit for the voltage divider relay and a low-voltage power supply circuit for the neutral relay are provided on the PCB electrical board 4. The first low-voltage terminal 21 and the second low-voltage terminal 22 are connected to the PCB electrical board 4 and connected within the low-voltage power supply circuit for the voltage divider relay, and the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are connected to the PCB electrical board 4 and connected within the low-voltage power supply circuit for the neutral relay. This reduces the low-voltage wiring harness and connectors between the voltage divider relay core 2 and the low-voltage power supply circuit for the voltage divider relay, and between the neutral relay core 3 and the low-voltage power supply circuit for the neutral relay, thereby reducing the risk of circuit errors and failures, reducing manufacturing costs, improving assembly efficiency, and achieving high integration.

[0102] The following describes an electrical appliance according to an embodiment of the present invention, wherein the electrical appliance may be a vehicle, an aircraft, an energy storage device, or a computer, etc.

[0103] The electrical device according to an embodiment of the present invention includes the battery pack described above.

[0104] According to an embodiment of the present invention, the electrical equipment, by setting the above-mentioned battery pack, including the above-mentioned BDU module 100, has a first low-voltage terminal 21 and a second low-voltage terminal 22 on the voltage divider relay core 2, a third low-voltage terminal 31 and a fourth low-voltage terminal 32 on the neutral relay core 3, and a voltage divider relay low-voltage power supply circuit and a neutral relay low-voltage power supply circuit on the PCB electrical board 4. The first low-voltage terminal 21 and the second low-voltage terminal 22 are connected to the PCB electrical board 4 and connected within the voltage divider relay low-voltage power supply circuit, and the third low-voltage terminal 31 and the fourth low-voltage terminal 32 are connected to the PCB electrical board 4 and connected within the neutral relay low-voltage power supply circuit. This reduces the low-voltage wiring harness and connectors between the voltage divider relay core 2 and the voltage divider relay low-voltage power supply circuit, and between the neutral relay core 3 and the neutral relay low-voltage power supply circuit, thereby reducing the risk of circuit errors and failures, reducing manufacturing costs, improving assembly efficiency, and achieving high integration.

[0105] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0106] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A BDU module, characterized in that, include: The voltage divider relay core (2) has a first low-voltage terminal (21) and a second low-voltage terminal (22); The N-line relay core (3) is connected to the voltage divider relay core (2), and the N-line relay core (3) has a third low-voltage terminal (31) and a fourth low-voltage terminal (32). PCB electrical board (4), the PCB electrical board (4) has a voltage divider relay low voltage power supply circuit and an N-line relay low voltage power supply circuit, the first low voltage terminal (21) and the second low voltage terminal (22) are connected to the PCB electrical board (4) and connected to the voltage divider relay low voltage power supply circuit, the third low voltage terminal (31) and the fourth low voltage terminal (32) are connected to the PCB electrical board (4) and connected to the N-line relay low voltage power supply circuit; The first connecting copper busbar (71) is connected at both ends to the N-line relay core (3) and the voltage divider relay core (2) respectively via fasteners (8).

2. The BDU module according to claim 1, characterized in that, At least one of the first low-voltage terminal (21), the second low-voltage terminal (22), the third low-voltage terminal (31), and the fourth low-voltage terminal (32) is inserted into the PCB electrical board (4).

3. The BDU module according to claim 1, characterized in that, Also includes: The fourth connecting copper busbar (74) is connected to the N-line relay core (3) by fasteners (8).

4. The BDU module according to claim 1, characterized in that, The N-line relay core (3) has a first auxiliary contact terminal (33) and a second auxiliary contact terminal (34). The PCB electrical board (4) has an auxiliary contact circuit. The first auxiliary contact terminal (33) and the second auxiliary contact terminal (34) are connected to the PCB electrical board (4) and connected to the auxiliary contact circuit.

5. The BDU module according to claim 4, characterized in that, At least one of the first auxiliary contact terminal (33) and the second auxiliary contact terminal (34) is inserted into the PCB electrical board (4).

6. The BDU module according to claim 1, characterized in that, The PCB electrical board (4) has a high-voltage sampling circuit, and the BDU module (100) further includes: A safety device (5) is connected to the voltage divider relay core (2); A high-voltage sampling copper busbar (6) is connected to the safety device (5) and the PCB electrical board (4) and is connected within the high-voltage sampling circuit.

7. The BDU module according to claim 6, characterized in that, The high-voltage sampling copper busbar (6) has a plug-in part (61), which is plugged into the PCB electrical board (4).

8. The BDU module according to claim 6, characterized in that, Also includes: The second connecting copper busbar (72) is connected at both ends to the safety device (5) and the voltage divider relay core (2) respectively via fasteners (8).

9. The BDU module according to claim 6, characterized in that, Also includes: The third connecting copper busbar (73) is connected to the high-voltage sampling copper busbar (6), and the third connecting copper busbar (73) and the high-voltage sampling copper busbar (6) are connected to the safety device (5) by fasteners (8).

10. The BDU module according to claim 6, characterized in that, Also includes: The housing (1) has a mounting cavity, one side of which is open to form an opening (11). The PCB electrical board (4) is disposed at the opening (11) to seal the opening (11). The voltage divider relay core (2), the N-line relay core (3), the fuse device (5), and the high-voltage sampling copper busbar (6) are fixed in the mounting cavity.

11. The BDU module according to claim 10, characterized in that, The opening (11) is located on one side of the thickness direction of the housing (1), and the N-line relay core (3), the voltage divider relay core (2), the fuse device (5) and the high-voltage sampling copper busbar (6) are arranged sequentially along the length direction of the mounting cavity.

12. The BDU module according to claim 10, characterized in that, The housing (1) has a potting structure inside, which is used to fix the N-line relay core (3) and the voltage divider relay core (2); And / or, the safety device (5) and the high-voltage sampling copper busbar (6) are fixed in the mounting cavity by fasteners (8).

13. The BDU module according to claim 10, characterized in that, The housing (1) has a clearance hole (12), which is positioned opposite to the fastener (8) connecting the voltage divider relay core (2), the N-line relay core (3), the safety device (5) and the high-voltage sampling copper busbar (6).

14. The BDU module according to claim 13, characterized in that, Also includes: A sealing plug (9) is provided at each of the clearance holes (12) for sealing the clearance holes (12).

15. A method for assembling a BDU module, characterized in that, The BDU module (100) is the BDU module (100) according to any one of claims 1-14, the BDU module (100) further includes a housing (1), the housing (1) having a mounting cavity, one side of the mounting cavity being open to form an opening (11), the assembly method comprising: Place the voltage divider relay core (2) and the N-line relay core (3) into the mounting cavity; Inject fixing adhesive into the mounting cavity to fix the voltage divider relay core (2) and the N-line relay core (3); The PCB electrical board (4) is placed at the opening (11), and the connecting terminals on the voltage divider relay core (2) and the N-line relay core (3) are inserted into the socket (41) on the PCB electrical board (4). The connecting terminals and the PCB electrical board (4) are soldered together.

16. A battery pack, characterized in that, Includes the BDU module (100) according to any one of claims 1-14.

17. An electrical appliance, characterized in that, Includes the battery pack according to claim 16.

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