Distribution box and bus bar

Abstract

A power distribution box includes a housing having a bottom and a power distribution module installed inside the housing, the power distribution module includes an insulating base that divides the housing into an upper space and a lower space in a state where the power distribution module is installed inside the housing. The base has: a horizontal base surface on the upper side of which the upper-layer space is located and on the lower side of which the lower-layer space is located, and which includes a plurality of horizontal partition walls at different horizontal heights; and a plurality of vertical partition walls erected from the horizontal base plane, so that a plurality of accommodating chambers are respectively formed in the upper layer space and the lower layer space by the plurality of horizontal partition walls and the plurality of vertical partition walls, and the electronic components can be accommodated in the accommodating chambers. By using the distribution box, both electrical performance and miniaturization are considered.

Description

Technical Field

[0001] The invention relates to a distribution box and a bus bar used in the distribution box, belonging to the field of electrical control. Background Art

[0002] Power distribution is often necessary for various electrical devices. For example, electric vehicles and plug-in hybrid electric vehicles (PHEVs) are equipped with a high-voltage distribution box to handle the power distribution of high-voltage power. It also distributes the high-voltage charging current from the AC and DC charging ports to the power battery for charging.

[0003] At present, with the increase in functional components in vehicles, the installation space for high-voltage distribution boxes may become limited. It is necessary to consider miniaturization as much as possible while meeting complex power distribution requirements and maintaining insulation.

[0004] Conventional distribution boxes are typically suitable for relatively simple circuits and non-modular installations, or for low- to medium-current electrical systems with single circuits, small and lightweight components, and low heat generation. However, when complex circuits and high-current components become larger, the existing space often becomes insufficient. Summary of the Invention

[0005] In order to solve the above problems, the present invention provides a distribution box, especially a high-voltage distribution box for new energy vehicles, which has a stacked distribution structure of circuits and components, fully utilizes the height space, and can ensure insulation and compact structure.

[0006] Specifically, the distribution box of the first aspect of the present invention includes:

[0007] A housing with a bottom, the housing comprising a first side wall and a second side wall opposite to each other in a first direction, and a third side wall and a fourth side wall opposite to each other in a second direction intersecting the first direction,

[0008] A power distribution module installed inside the housing, the power distribution module comprising: an insulating base, wherein when the power distribution module is installed in the housing, the base divides the housing into two spaces, an upper space located on the upper side for the branch circuit electrical system and a lower space located on the lower side for the main circuit electrical system; and a plurality of electronic components arranged in the upper space and the lower space.

[0009] In which, the base has: a horizontal base surface, the upper space is located on the upper side of the horizontal base surface, the lower space is located on the lower side of the horizontal base surface, and the horizontal base surface includes a plurality of horizontal partition walls at different horizontal heights; and a plurality of vertical partition walls erected from the horizontal base surface, so that the plurality of horizontal partition walls and the plurality of vertical partition walls respectively form a plurality of accommodating chambers in the upper space and the lower space, and the electronic components can be accommodated in the accommodating chambers.

[0010] According to the distribution box with the above structure, the internal space of the distribution box is optimized by using the base, and the base is provided with multiple horizontal partition walls of different heights and corresponding multiple vertical partition walls. Thus, multiple accommodating chambers composed of the horizontal partition walls and the vertical partition walls supporting the horizontal partition walls and rising upward from the horizontal partition walls exist in the installation space of the upper and lower layers. The main circuit electrical system and the branch circuit electrical system are arranged in layers, and the electronic components can be stacked. The wiring is simple and the installation is easy. In addition, the wires and connecting conductors used to connect the electronic components can also be separated by the partition walls to reduce wear and ensure absoluteness, and separate the electronic components of large current from those of medium and small current, which not only reduces the heat effect, but also can meet the requirements of different current capacities. At the same time, it also makes full use of the space and realizes versatility and miniaturization.

[0011] Preferably, in the distribution box of the first aspect, the shell includes: at least one first through hole passing through the first side wall, in which a first connector is installed so as to protrude outward; a plurality of second through holes passing through the second side wall, in which a plurality of second connectors are respectively installed so as to protrude outward; and at least one third through hole passing through the third side wall, in which a third connector is installed so as to protrude outward; the first connector, the second connector and the third connector are respectively electrically connected to the distribution module via a conductive connector, so that: the path from the first connector to the third connector constitutes the main circuit electrical system, and the path from the third connector to the plurality of second connectors constitutes the branch circuit electrical system.

[0012] According to the distribution box having the above structure, by designing the layout of the connectors, the paths of the main circuit electrical system and the branch circuit electrical system can be optimized, and the charging and power supply circuits can be arranged reasonably.

[0013] Preferably, the distribution box of the first aspect further includes a conductive connector for electrically connecting electronic components and between electronic components and connectors, the conductive connector includes an electric wire, the multiple accommodating chambers in the upper space include a fuse accommodating chamber for accommodating a branch circuit fuse and a wire accommodating chamber arranged adjacent to the fuse accommodating chamber, and the fuse accommodating chamber is arranged higher than the wire accommodating chamber, the electric wire is accommodated in the wire accommodating chamber, and the second connector is electrically connected to the branch circuit fuse by connecting one end thereof to the second connector and the other end thereof to the branch circuit fuse accommodated in the fuse accommodating chamber.

[0014] According to the distribution box having the above structure, a stacked tunnel-type bridging structure can be formed by utilizing the wire accommodating chambers and fuse accommodating chambers that are arranged in layers above and below, thereby making full use of the space of the upper layer and realizing space saving by the stacked arrangement. Moreover, the wires are connected to the second connector and the fuse in a state of being accommodated in the wire accommodating chamber, and the layout is beautiful and orderly.

[0015] Preferably, in the distribution box of the first aspect, the relay as one of the electronic components is arranged in the corresponding accommodating chamber of the lower space, namely the relay accommodating chamber, and the part of the upper space located on the upper side of the relay accommodating chamber does not form the accommodating chamber for accommodating electronic components.

[0016] According to the distribution box with the above structure, the surrounding space can be designed and optimized in an upper and lower layered layout based on the main circuit relays that are generally the highest and non-stacked, so that the height of the distribution box can be matched with the height of the main circuit relays to the greatest extent, while making full use of the space around the main circuit relays to achieve miniaturization.

[0017] Preferably, in the distribution box described in the first aspect, the horizontal partition wall constituting the relay accommodating chamber is at a higher position than the horizontal partition wall constituting the accommodating chamber adjacent to the relay accommodating chamber, the relay accommodating chamber is arranged at a position closer to the first side wall than the wire accommodating chamber and the fuse accommodating chamber, and the part of the upper space located on the upper side of the relay accommodating chamber is used for laying signal lines.

[0018] In a distribution box having the above structure, the horizontal partition wall for the non-stacked main circuit relays is positioned higher, allowing the relays located in the lower space to be at their highest height. This eliminates wasted space around the relays, effectively dividing them into two levels of layout space, thus achieving efficient and economical use of space. Furthermore, despite the height of the lower relay chamber, the upper portion of the relay chamber can still be used to route signal lines such as the signal output harness. This allows for efficient use of the height dimension of the distribution box, eliminating the need to expand the dimensions in other directions to accommodate electronic components, thus achieving miniaturization.

[0019] According to the distribution box having the above structure, a redundant space is formed around the fuse accommodating cavity in the upper space, and a signal port integrated board with multiple signal sockets is installed in the redundant space, and the signal sockets can be inserted with signal connectors.

[0020] According to the distribution box having the above structure, the redundant space (also referred to as scrap space) around the fuse accommodating chamber can be fully utilized to arrange the signal port integrated board to realize the configuration of the signal circuit.

[0021] Preferably, in the distribution box described in the first aspect, the conductive connector includes a U-shaped connecting conductor, which is arranged in the redundant space and fixed between the horizontal partition wall and the bottom surface of the signal port integrated board, so that the two end pins of the U-shaped connecting conductor pass through the bottom surface of the signal port integrated board and enter each signal socket.

[0022] According to the distribution box with the above structure, the U-shaped connecting conductor is fixed between the insulating base and the signal port integrated board, and the pins at both ends of the U-shaped connecting conductor pass through the signal port integrated board and enter the connection port, thereby forming a two-layer signal connection port with concealed connection function, making full use of the space and realizing capacity expansion.

[0023] Preferably, in the distribution box described in the first aspect, a wire trough is further provided in the signal port integrated board, and the extension direction of the wire trough is parallel to the arrangement direction of the multiple signal sockets, so that it is arranged on one side of the multiple signal sockets.

[0024] According to the distribution box having the above structure, the signal port integrated board is further integrated with a wire trough, so the wire trough can be used to guide the wiring, making the wiring more neat and orderly.

[0025] The distribution box described above, in accordance with the first aspect of the present invention, features a compact, space-efficient, laminated design, simple wiring, and easy installation. Insulation isolates wires and connecting conductors to reduce wear and ensure insulation. High-current components are separated from low- and medium-current components, allowing them to be arranged in separate spaces, thereby reducing the effects of heat generation. Furthermore, the structural arrangement separating high- and medium-current components allows for adaptability to circuits with varying current capacity requirements, meeting the electrical functional requirements of various vehicle models. This versatile structure effectively addresses the challenges of power distribution within confined spaces.

[0026] The second aspect of the present invention will now be described. The second aspect of the present invention provides a busbar for use in the distribution box described in the first aspect, wherein the busbar connects the relay to the terminal in the first connector, thereby electrically connecting the relay to the first connector, wherein the busbar has a smoothly curved portion, the curved portion being more flexible than the remaining portion.

[0027] The busbar with the above configuration utilizes a soft, rounded curved portion. Therefore, the busbar can be adjusted vertically and horizontally, with this curved portion as the base point, as needed. This minimizes space waste and helps achieve a distribution box height close to the relay's own height. Furthermore, the rounded curved portion's flexibility allows for tolerances to be accommodated, ensuring installation in the left and right directions is not affected by these tolerances. Similarly, the shape of the busbar's flexible connectors can be adjusted based on the size of the electronic components, maximizing space in the distribution box.

[0028] Preferably, in the busbar according to the second aspect, the smooth curved portion is formed by a plurality of copper sheets welded together.

[0029] By utilizing a structure in which multiple copper strips are stacked to form a smooth curved portion, the curved structure of the curved portion has excellent flexibility and a stronger ability to absorb tolerances.

[0030] In summary, by utilizing the present invention, the circuits and components in the distribution box have a stacked distribution, effectively utilizing the surrounding space and having a compact structure. The distribution box arranges the main power circuit and related conductive connectors and components in the space located in the insulating base of the shell. A plurality of branch circuits and related conductive connectors, wiring harnesses, fuses, and signal connection devices for circuit on / off are arranged in the space between the other side of the insulating base and the upper cover. The insulating base is designed with grooves of various heights, and the wiring harnesses, fuses, and conductive connectors are installed in different grooves to form a bridge-type stacked distribution, so as to realize the power distribution arrangement in a limited space. In addition, the insulating base of the distribution box isolates the main power circuit and the branch circuit in different spaces. When the power is turned on and the heat is dissipated, they are not affected by each other, and the phenomenon of small current components overheating due to the heat of large current will not occur. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings are provided for a better understanding of the present invention and are not intended to limit the present invention.

[0032] Figure 1 is a schematic perspective view of a distribution box according to an embodiment of the present invention;

[0033] Figure 2 is a schematic perspective view of a housing of a distribution box according to an embodiment of the present invention;

[0034] Figure 3 is a schematic top plan view of a distribution box according to an embodiment of the present invention;

[0035] Figure 4 is a schematic longitudinally cutaway perspective view of a distribution box according to an embodiment of the present invention, depicting a base surface;

[0036] Figure 5 is a longitudinally cutaway perspective view of a portion of a distribution box according to an embodiment of the present invention;

[0037] Figure 6 is a longitudinally cutaway perspective view of a portion of a distribution box according to an embodiment of the present invention, showing a state where an upper cover is assembled;

[0038] Figure 7 is a longitudinally cutaway perspective view of a portion of a distribution box according to an embodiment of the present invention, showing a signal port integrated board;

[0039] Figure 8 is a top plan view of a portion of a distribution box according to an embodiment of the present invention;

[0040] Figure 9 is a transversely cutaway perspective view of a portion of a distribution box according to an embodiment of the present invention;

[0041] Figure 10 is a schematic perspective view of a signal integration board of a distribution box according to an embodiment of the present invention;

[0042] Figure 11 This is a schematic diagram of the installation of the power distribution module when viewing the power distribution module from the bottom;

[0043] Figure 12 This is a schematic perspective view showing a bus bar used in a distribution box.

[0044] Reference Signs List

[0045] 10 distribution box

[0046] 100 shell

[0047] 101 first side wall

[0048] 102 second side wall

[0049] 103 third side wall

[0050] 104 fourth side wall

[0051] 105 first through hole

[0052] 106 second through hole

[0053] 107 third through hole

[0054] 108 fixed column

[0055] 200 power distribution module

[0056] 201 Base

[0057] 202 horizontal partition wall

[0058] 203 vertical partition wall

[0059] 204 base surface

[0060] 205 Upper Space

[0061] 206 Lower Space

[0062] 208 cavity

[0063] 209 deep cavity plane

[0064] 210 higher cavity

[0065] 211 vertical wall

[0066] 212 relay signal control interface

[0067] 213 cover opening signal control switch

[0068] 214 connector

[0069] 301 First Connector

[0070] 302 second connector

[0071] 303 third connector

[0072] 304 fourth connector

[0073] 305 voltage detection interface

[0074] 306 low voltage signal output port

[0075] 401 main circuit relay

[0076] 402 main circuit fuse

[0077] 403 branch circuit fuse

[0078] 404 terminal

[0079] 500 signal port integrated board

[0080] 501 Wire Slot

[0081] 601 wire

[0082] 602 signal output harness

[0083] 603U-shaped connecting conductor

[0084] 604 busbar

[0085] 700 top cover DETAILED DESCRIPTION

[0086] Hereinafter, the technical solutions of the present invention will be more clearly explained by describing specific embodiments of the present invention with reference to the accompanying drawings.

[0087] It should be noted that the drawings in the present invention are merely schematic diagrams for the purpose of clearly illustrating the parts related to the solutions of the present invention, and do not show some non-essential parts that may exist. Therefore, these drawings should not be understood as limiting the present invention, and they may differ from the actual structure when used. In addition, it should be understood that the terms "upper", "lower", "left", "right", "front", "back", etc. that may appear in the following description to indicate direction or position are for the purpose of convenience of explanation and are not restrictive. Similarly, for the sake of clarity and conciseness, the description of well-known functions and structures is omitted in the following description.

[0088] The present invention provides a power distribution box, particularly suitable for use in new energy hybrid vehicles, pure electric vehicles, and other future vehicles. This box serves as a high-voltage distribution box for battery pack power distribution. However, the use of this distribution box is not restrictive; it can also be used in other devices requiring power distribution.

[0089] Figures 1 and 2 The basic structure of the distribution box according to the embodiment of the present invention is shown. Figure 1 is a schematic perspective view of a distribution box according to an embodiment of the present invention; Figure 2 4 is a schematic three-dimensional diagram of a shell of a distribution box according to an embodiment of the present invention.

[0090] like Figures 1 and 2 As shown, the distribution box 10 of the embodiment of the present invention includes a housing 100 with a bottom and a distribution module 200 disposed inside the housing 100. In this embodiment, the distribution box 10 is, for example, a rectangular parallelepiped, so that the housing 100 is correspondingly an open rectangular frame and the distribution module 200 is a rectangular block. The distribution box 10 may also include an upper cover 700 (see FIG. Figure 6), used to close the opening of the shell 100.

[0091] The housing 100 of the distribution box 10 is made of metal such as aluminum alloy. Figure 2 As shown, the housing 100 of the distribution box 10 includes a first side wall 101 and a second side wall 102 that are opposite to each other in a first direction (length direction, longitudinal direction), and a third side wall 103 and a fourth side wall 104 that are opposite to each other in a second direction (width direction, transverse direction) that intersects the first direction. The first side wall 101, the second side wall 102, the third side wall 103, and the fourth side wall 104 each stand upright from the bottom wall, and are surrounded by these side walls and the bottom wall to form an installation space that can accommodate components inside.

[0092] On the shell 100 of the distribution box 10, through holes are also provided on the corresponding side walls to facilitate the installation of connectors. Through the connectors, electrical connection with the external power system can be achieved, and power transmission inside the distribution box can also be achieved. Specifically, Figure 2 As shown, the housing 100 includes: a first through hole 105 extending through the first side wall 101, a first connector 301 (see Figure 1 、 Figure 3 ) can be installed in the first through hole 101 so as to protrude outward; a plurality of second through holes 106 passing through the second side wall 102, a plurality of second connectors 302 (see Figure 1 、 Figure 3 ) can be respectively installed in the second through hole 102 so as to protrude outward; and two third through holes 107 passing through the third side wall 103, the third connector 303 and the fourth connector 304 (see Figure 1 、 Figure 3 ) may be respectively installed in the third through holes 107 so as to protrude outward.

[0093] When the distribution box 10 is in use, the first connector 301, the second connector 302, the third connector 303, and the fourth connector 304 can be electrically connected to the distribution module 200 via conductive connectors (such as wires). In this embodiment, the path from the first connector 301 to the third connector 303 constitutes the first power main circuit in the main circuit electrical system, the path from the third connector 303 to the fourth connector 304 constitutes the second power main circuit in the main circuit electrical system, and the path from the third connector 303 to the four second connectors 302 constitutes a branch circuit electrical system.

[0094] In this embodiment, as described above, housing 100 is provided with through-holes on only three sidewalls 101, 102, and 103 for mounting corresponding connectors, corresponding to different circuits (the first power main circuit, the second power main circuit, and the branch circuit electrical system of the main circuit electrical system mentioned above). The advantage of this arrangement is that, because the entire internal structure must be compactly arranged, the outlet is consistent with the compact connection of the wiring harness. The cross-section of the high-voltage wiring harness is relatively large. If it is arbitrarily arranged on different sidewalls, the compact arrangement is limited.

[0095] The distribution box 10 for a vehicle in this embodiment can have two operating states: charging and power consumption. Therefore, as described above, the "main power circuit" has two routes: the first main power circuit and the second main power circuit. The first connector 301 can be used as a charging port, the second connector 302 can be used as a branch circuit, the third connector 303 can be used as an output port for connecting to the battery, and the fourth connector 304 can be used as a high-voltage power port. In the charging state, current is input from the first connector 301, which serves as the charging port, and output from the third connector 303, which serves as the battery output port. This is the first main power circuit. In the power consumption state, current flows back out from the third connector 303, which serves as the battery output port, to supply power to the fourth connector 304, which serves as the high-voltage power port, and the four second connectors 302, which serve as branch circuits. In this case, the circuit from the third connector 303, which serves as the battery output port, to the third connector 303, which serves as the battery output port, is the second main power circuit.

[0096] However, it should be understood by those skilled in the art that the number of the through holes and connectors provided on the third side wall is configured as two in this embodiment and is not restrictive. In actual use, the number of the through hole and connector can be one or more than two.

[0097] According to the distribution box having the above structure, by designing the layout of the connectors, the paths of the main circuit electrical system and the branch circuit electrical system can be optimized, and the charging and power supply circuits can be arranged reasonably.

[0098] In this embodiment, if Figure 1 and Figure 2 As shown in the figure, the number of second through-holes 106 and second connectors 302 is configured as four. However, this is not restrictive and can be set as needed. It can be set to less than four, or, if sufficient layout space is available, it can be set to more to obtain more branch circuits. The four in this embodiment are merely examples. Similarly, the number of first through-holes 105 and third through-holes 107 is not limited to the number shown in the figure, but can be set as needed, for example, at least one first through-hole 105 and multiple third through-holes 107.

[0099] On the bottom surface of the housing 100 of the distribution box 10, fixing columns 108 protruding from the bottom wall are provided near the first side wall 101 and the second side wall 102. The fixing columns 108 can cooperate with the matching fixing portions (not shown) of the distribution module 200 described later to fix the distribution module 200 to the housing 100. In this embodiment, a total of three fixing columns 108 are provided near the approximate center of the first side wall 101 and near both ends of the second side wall 102. However, it can be understood that the configuration position and number of the fixing columns are not restrictive and can be arbitrarily set according to the specific circumstances, as long as the distribution module 200 can be fixed to the housing 100.

[0100] In vehicles, miniaturizing accessories such as the aforementioned distribution box is a popular choice to increase interior space for passengers and storage. Therefore, while a distribution box must house a variety of components and connecting conductors to establish connections between various circuits to fulfill its functions, the space available within the housing 100 for these components and conductors is often limited in pursuit of miniaturization. Conventional distribution boxes struggle to achieve both miniaturization and electrical compliance.

[0101] In the embodiment of the present invention, the power distribution module 200 is designed to solve the above problems, taking into account both miniaturization and meeting electrical requirements, and maximizing the use of the installation space in the housing 100 of the distribution box 10 .

[0102] The power distribution module 200 installed in the housing 100 includes a base 201 made of an insulating material such as resin and a plurality of electronic components ( Figure 1 The main circuit relay 401 is briefly shown as an example, and other electronic components not shown may also be provided. The power distribution module 200 is provided with fixing portions on two longitudinally opposite side surfaces for cooperating with the fixing posts 108 of the housing 100 .

[0103] like Figure 4As shown by the bold black lines in the cross-section (shown in bold for illustration purposes only, and does not mean that this part is an actual bold structure), the base 201 has a base surface 204 (the surface represented by the bold black lines in the cross-section), which is a continuously formed reference panel portion for mounting required electronic components on the upper and lower sides of the base surface 204. When the power distribution module 200 is installed in the housing 100, the base 201 of the power distribution module 200 can divide the space in the housing 100 into two upper and lower spaces based on the base surface 204 as a reference or dividing interface, namely, an upper space 205 located above the base surface 204 and a lower space 206 located below the base surface 204. In an embodiment of the present invention, the upper space 205 can be used for a branch circuit electrical system with a relatively small current, and the lower space 206 can be used for a main circuit electrical system with a relatively large current. By dividing the upper space 205 and the lower space 206 based on the base surface 204, several electronic components can be arranged in the upper space 205 and the lower space 206 in a layered and stacked manner according to the current size, main circuit or branch circuit, etc.

[0104] Further, if Figure 4 as well as Figure 5 As shown, the base surface 204 of the base 201 may have: a horizontal base surface, which may be constructed by a plurality of horizontal partition walls 202 at different levels ( Figure 4 The numbered lines in the figure are examples only and do not represent all horizontal partition walls. Figure 4 The horizontally extending walls in the base surface 204 are all horizontal partition walls), the upper space 205 is located on the upper side of the horizontal base surface, and the lower space 206 is located on the lower side of the horizontal base surface; and a plurality of vertical partition walls 203 are erected from the horizontal base surface. According to this structure of the base 201, a plurality of accommodating chambers of different sizes and depths are formed in the upper space 205 and the lower space 206 by the plurality of horizontal partition walls 202 and the plurality of vertical partition walls 203, and various electronic components can be accommodated in the accommodating chambers. The conductor connecting parts of the wires, etc. can also be accommodated in the corresponding accommodating chambers. The accommodating chambers are, for example, the cavity of the main circuit relay, the cavity of the main circuit fuse, the cavity of the branch circuit fuse, the installation cavity of the U-shaped connecting conductor, and the wiring space of the joint (second connector) (see Figure 4 the right wiring space of the rightmost vertical partition wall) and so on.

[0105] The lower space 206 houses the main power circuit's conductors, electronic components, and fuses, while the upper space 205 houses the branch circuit's conductors, electronic components, fuses, and signaling devices. The main circuit's conductors, electronic components, and fuses installed in the lower space are connected to the branch circuit's conductors, electronic components, fuses, and signaling devices installed in the upper space via conductors such as wires and busbars, forming a high-voltage distribution box assembly.

[0106] A main circuit relay 401 is designed on each of the positive and negative circuits of the main circuit electrical system, and a main circuit fuse is set on one of the positive circuits of the power main circuit, and a main circuit fuse is drawn out at both ends of the main power circuit of the relay. Figure 3 The voltage detection interface 305 is drawn from the main power circuit of the main circuit relay and connected to the external BMS system. It has the function of real-time monitoring of the voltage change of the high-voltage relay on the main power circuit. The branch circuit electrical system is designed with a branch circuit fuse 403. In addition, the main circuit relay 401 in the entire distribution box is provided with a Figure 3 The relay signal control interface 212 is connected to the low voltage signal output port 306 of the housing 100 by wires.

[0107] For the connection of the power main circuit related conductors and electronic components and protection devices of the main circuit electrical system located in the lower space 206, in this embodiment, bus bars (copper bars, etc., see Figure 11 ) for connection, rather than wire connection, and by using flat and bendable busbars to achieve connection guidance, it is possible to reliably achieve a small space arrangement compared to using wires. For the connection of branch circuit-related conductors and electronic components, fuses and signal devices located in the upper space 205, both busbars such as copper bars and wires can be used for connection. The group of branch circuit fuses 403 in the upper space of the base 201 (described later, for example, see Figure 3 ) and the output of the main power circuit are connected through a bus bar such as a copper bus; the branch circuit and the branch circuit fuse 403 are connected through a wire 601 (see Figure 5 ) connection. The wires and busbars, as well as the signal output harness and U-shaped connecting conductors described later, are collectively referred to as conductive connectors.

[0108] As described above, the general structure of the distribution box 10 of this embodiment can be understood. The base 201 is used to optimize the internal space of the distribution box 10. The base 201 is provided with multiple horizontal partition walls 202 of different heights and corresponding multiple vertical partition walls 203. Thus, multiple accommodating chambers composed of each horizontal partition wall and each vertical partition wall supporting the horizontal partition wall and rising upward from the horizontal partition wall exist in the installation space of the upper and lower layers. The main circuit electrical system and the branch circuit electrical system are arranged in layers, and the electronic components can be stacked. The wiring is simple and the installation is easy. In addition, the connecting conductors such as wires and bus bars used to connect electronic components (wires and connecting conductors are both conductive connecting parts) can also be separated by partition walls to reduce wear and ensure absolute isolation, thereby isolating electronic components with large current from those with medium and small currents, which not only reduces the impact of heat, but also can meet different current capacity requirements. At the same time, it also makes full use of space and achieves versatility and miniaturization.

[0109] like Figure 3 、 Figure 4 、 Figure 5 As shown, the electronic components installed in the upper space 205 include branch circuit fuses 403. The number of branch circuit fuses 403 corresponds to the number of branch circuits formed by the second connector 302, which is also formed as four. The branch circuit fuses 403 are arranged in a row in the longitudinal direction, with the extension direction being the width direction, and each is accommodated in a corresponding cavity (fuse accommodating cavity, upper cavity 210). Adjacent to the fuse accommodating cavity is a wire accommodating cavity, which can be a cavity 208 formed relatively deeply and arranged on the lower side of the upper cavity 210, as shown in FIG. Figure 9 See Figure 4-5 as well as Figure 3 One end of the wire 601 extending from the second connector 302 (in the form of a connecting joint) is laid out into the wire accommodating chamber along the horizontal partition wall 202, and the end portion enters the cavity 208 located on the lower side of the branch circuit fuse 403 and is connected to the respective branch circuit fuse 403; the other end of the wire extending from the second connector 302 (in the form of a connecting joint) is connected to the terminal 404.

[0110] According to the above configuration of the distribution box, a stacked tunnel-type bridging structure can be formed by utilizing the upper and lower layered configurations of the wire accommodating chamber (higher cavity) and the fuse accommodating chamber (cavity), which makes full use of the space of the upper layer and realizes space saving by the stacked arrangement. Moreover, the wires are connected to the second connector and the fuse in a state of being accommodated in the wire accommodating chamber, and the layout is beautiful and orderly.

[0111] like Figure 1 、 3As shown in Figures 5 and 9, in the distribution box 10, a main circuit relay 401, one of the electronic components, is located in a corresponding housing chamber, namely, a relay housing chamber, in the lower space 206. The horizontal partition wall constituting the relay housing chamber is located higher than the horizontal partition walls constituting the housing chambers adjacent to the relay housing chamber. When the electronic components are installed in the distribution module, the height of the relay housing chamber is preferably no less than the stacked height of the electronic components contained in the adjacent housing chambers. In other words, the height of the multi-component stacking area within the installation space of the housing 10 preferably does not exceed the height of the horizontal partition wall above the adjacent, tallest component, the main circuit relay. In this embodiment, as shown, the relay housing chamber is located closer to the first side wall 101 than the wire and fuse housing chambers, and the portion of the upper space 205 located above the relay housing chamber is used to route the signal output wiring harness 602. Because the signal output harness 602 is relatively thin and requires a low routing height, the signal output harness 602 can be freely arranged in the narrow space between the upper cover 700 and the horizontal partition wall even when the upper cover 700 is mounted on the housing 100 .

[0112] With this configuration, the main circuit relay is not stacked with electronic components, creating a non-stacked area. This allows the space around the main circuit relay to be designed in layers, based on the height of the main circuit relay, which is generally the tallest. Consequently, even if the main circuit relay located in the lower layer is the tallest, the space around the relay is not wasted. Instead, it is divided into two layers, allowing the electronic components of the main circuit and branch circuits to be stacked in height, thus fully utilizing and conserving space. Furthermore, despite the height of the lower relay chamber, the upper portion of the relay chamber can still be used to route the signal output wiring harness. This area is effectively utilized, effectively utilizing the height dimension of the distribution box, eliminating the need to expand the dimensions in other directions to accommodate electronic components, thus achieving miniaturization.

[0113] In addition, as shown in 5 and the like, in the upper space 205 of the distribution box 10, redundant space, i.e., scrap space, was originally formed around the fuse accommodating cavity. The scrap space originally could not play a role and was wasted as scrap. However, in this embodiment, the scrap space is separately divided out and can be reused. In this embodiment, the scrap space is, for example, provided between a vertical partition wall of the fuse accommodating cavity and a vertical partition wall of the adjacent relay accommodating cavity, and between a vertical partition wall of the fuse accommodating cavity and the adjacent fourth side wall 104, that is, an L-shaped scrap space is formed. A signal port integrated board 500 (see FIG. 5 ) is provided with a plurality of signal sockets. Figure 10) is configured to be installed in the redundant space, and the signal socket can be inserted into the signal connector (see Figure 7 ).

[0114] According to the distribution box with the above structure, the redundant space or scrap space around the fuse accommodating chamber that was originally useless and became scrap can be fully utilized to be used to arrange the signal port integrated board to realize the configuration of the signal circuit. Figure 5 、 7 As shown, another deep cavity plane 209 is provided in the scrap area, and a U-shaped connecting conductor 603 for signal control is laid on it. Specifically, the U-shaped connecting conductor 603 can be provided in the redundant space and fixed between the horizontal partition wall and the bottom surface of the signal port integrated board 500, so that the pins at both ends of the U-shaped connecting conductor pass through the bottom surface of the signal port integrated board and enter the signal sockets. Accordingly, by using the U-shaped connecting conductor, a two-layer signal connection port with a concealed connection function can be formed, which makes full use of the space and realizes capacity expansion, and ensures the safe signal transmission function of high-voltage power up and down. When the high-voltage distribution box is opened for maintenance or the shell connector is not inserted, the signal circuit is in a disconnected state, the battery management system BMS cannot receive the power-on signal, and the high voltage power will not be connected.

[0115] In this embodiment, the signal port integrated board 500 is, for example, L-shaped as shown in the figure, and a plurality of signal sockets are arranged along the L-shape. In addition, a wire slot 501 is also provided in the signal port integrated board (see FIG. Figure 10 ), the wire trough is arranged on one side of the multiple signal sockets along the L-shape, that is, the arrangement direction of the multiple signal sockets. The signal lines are superimposed and arranged on the wire trough 501 and connected to the signal port integrated board 500 and the first connector 301, the third connector 303 and the fourth connector 304 on the side wall of the shell. By utilizing the L-shape, signal sockets can be configured on both sides of the signal port integrated board, and can be fully adapted to the redundant space, ensuring the capacity setting while making full use of the space. However, it can be understood by those skilled in the art that the redundant space is not necessarily L-shaped, and accordingly, the shape of the signal port integrated board is not necessarily L-shaped. According to the actual arrangement and setting, the redundant space may also be in the shape of a straight line, a U-shape, a mouth shape, etc.

[0116] In addition, the distribution box is also equipped with relay switch signals and Figure 7 The cover opening signal control switch 213 is connected to the Figure 4 The signal port integrated board 500 in the middle, and then through the lower side of the signal port integrated board 500 as shown in FIG. Figure 7 The U-shaped connecting conductor 603 in Figure 5 The signal output harness 602 of each high voltage connector 301, 303, 304 is connected end to end to form a series loop, and finally integrated into Figure 3 The relay switch signal can also be called a signal line. To ensure the safety of high-voltage operation, when the relay box is opened, the low-voltage signal circuit is disconnected, and the external battery management system BMS cannot receive the signal (the battery management system BMS is in the external battery pack), thereby cutting off the high-voltage circuit for protection.

[0117] The above describes the distribution box according to the first aspect of the present invention. Its structure is compact and fully utilizes space for a stacked design. The wiring is simple and easy to install. The wires and connecting conductors are isolated by insulating partitions to reduce wear and ensure insulation. The large current and small and medium current components are separated and arranged in different spaces, thereby reducing the impact of heat. Moreover, the large current and small and medium current components are separated by a structural arrangement. It can be applied to circuits with different current capacity requirements to meet the electrical function requirements of different vehicle models. It has a universal structural feature and effectively solves the problem of difficult power distribution in a confined space. The main circuit relay with the highest height is arranged in the non-stacked area in the cavity of the lower space where the distribution module is placed. The main circuit fuse and several connecting conductors are arranged in the lower space of the stacked structure. They are installed on the insulating base from bottom to top through the fixing part set on the insulating base, thereby forming a multi-layer stacked distribution box that isolates large current from small and medium current.

[0118] The embodiment of the present invention also provides a second aspect, namely, a bus bar 604 that can be used in the above distribution box. The bus bar connects the main circuit relay with the terminal in the first connector, thereby electrically conducting the main circuit relay with the first connector. As shown schematically, the relay and the bus bar are Figure 11 As shown, the busbar has a smooth curved portion 605, which is more flexible than the remaining portion. Figure 11 It is only a simplified view used to illustrate the parts related to the connection between the main circuit relay and the bus bar of the second aspect of the embodiment, and the structures of other parts are omitted or are only used for reference.

[0119] The busbar with the above configuration utilizes a soft, rounded curved portion. Therefore, the busbar can be adjusted vertically and horizontally, with this curved portion as the base point, as needed. This minimizes space waste and helps ensure the height of the distribution box is close to the height of the relay itself. Furthermore, the soft nature of the rounded curved portion can be utilized to absorb tolerances, ensuring that installation in the left and right directions (width and lateral directions) is not affected by these tolerances. Similarly, the shape of the busbar's flexible connectors can be adjusted based on the size of the electronic components, maximizing the space available in the distribution box.

[0120] The smooth bend of the busbar can be formed by welding together multiple layers of copper sheets. By forming the smooth bend using a structure in which multiple copper strips are stacked, the curved structure of the bend has excellent flexibility.

[0121] Instead of welding multiple layers of copper sheets to form the rounded bend, a single layer of copper sheet can be used. For example, the copper sheet of the rounded bend can be made thinner or more delicate, or other methods can be used to increase the flexibility of the rounded bend compared to other parts. However, because the structure achieved by welding multiple layers of copper sheets is more flexible, this structure is more preferred.

[0122] The above specific embodiments do not limit the scope of protection of the present invention. Those skilled in the art will appreciate that various modifications, combinations, sub-combinations, and substitutions may occur depending on design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention are intended to be included within the scope of protection of the present invention.

Claims

1. A distribution box, comprising: A shell with a bottom, the shell comprising a first side wall and a second side wall opposite to each other in a first direction, and a third side wall and a fourth side wall opposite to each other in a second direction intersecting the first direction, A power distribution module installed inside the housing, the power distribution module comprising: an insulating base, when the power distribution module is installed in the housing, the base divides the housing into two spaces, namely, an upper space located on the upper side for the branch circuit electrical system and a lower space located on the lower side for the main circuit electrical system; and a plurality of electronic components arranged in the upper space and the lower space, Wherein, the base has: a horizontal base surface, the upper space is located on the upper side of the horizontal base surface, the lower space is located on the lower side of the horizontal base surface, and the horizontal base surface includes a plurality of horizontal partition walls at different horizontal heights; and a plurality of vertical partition walls erected from the horizontal base surface, so that a plurality of accommodating chambers are respectively formed in the upper space and the lower space by the plurality of horizontal partition walls and the plurality of vertical partition walls, and the electronic components can be accommodated in the accommodating chambers.

2. The distribution box according to claim 1, wherein: The housing comprises: at least one first through hole extending through the first side wall, in which a first connector is installed so as to protrude outward; a plurality of second through holes extending through the second side wall, in which a plurality of second connectors are respectively installed so as to protrude outward; and at least one third through hole extending through the third side wall, in which a third connector is installed so as to protrude outward; The first connector, the second connector and the third connector are electrically connected to the distribution module via conductive connectors, respectively, so that: the path from the first connector to the third connector constitutes the main circuit electrical system, and the path from the third connector to the multiple second connectors constitutes the branch circuit electrical system.

3. The distribution box according to claim 2 further comprises a conductive connector for connecting the electronic components to each other and between the electronic components and the connector. The conductive connection body comprises a wire, The plurality of accommodating chambers in the upper space include a fuse accommodating chamber for accommodating a branch circuit fuse and a wire accommodating chamber disposed adjacent to the fuse accommodating chamber, and the fuse accommodating chamber is disposed above the wire accommodating chamber. The electric wires are accommodated in the electric wire accommodation chamber, and the second connectors are electrically connected to the branch circuit fuses by having one ends connected to the second connectors and the other ends connected to the branch circuit fuses accommodated in the fuse accommodation chamber.

4. The distribution box according to claim 3, wherein: A relay as one of the electronic components is arranged in a corresponding accommodation chamber, namely, a relay accommodation chamber, in the lower space, and The portion of the upper space located above the relay accommodating chamber does not form the accommodating chamber for accommodating electronic components.

5. The distribution box according to claim 4, wherein: The horizontal partition wall constituting the relay accommodating chamber is located at a higher position than the horizontal partition wall constituting the accommodating chamber adjacent to the relay accommodating chamber. The relay accommodating chamber is disposed closer to the first side wall than the wire accommodating chamber and the fuse accommodating chamber, and The portion of the upper space located on the upper side of the relay accommodating chamber is used for laying signal lines.

6. The distribution box according to claim 5, wherein: In the upper space, a redundant space is formed around the fuse accommodating cavity. A signal port integrated board with a plurality of signal sockets is installed in the redundant space, and a signal connector can be inserted into the signal sockets.

7. The distribution box according to claim 6, wherein: The conductive connector includes a U-shaped connecting conductor, which is arranged in the redundant space and fixed between the horizontal partition wall and the bottom surface of the signal port integrated board, so that the two end pins of the U-shaped connecting conductor pass through the bottom surface of the signal port integrated board and enter each signal socket.

8. The distribution box according to claim 7, wherein: The signal port integrated board is also provided with a wire slot, the extension direction of which is parallel to the arrangement direction of the plurality of signal sockets, so that the wire slot is arranged on one side of the plurality of signal sockets.

9. A bus bar used in the distribution box according to any one of claims 4 to 8, wherein the bus bar connects the relay to the terminal in the first connector, thereby electrically connecting the relay to the first connector. in, The bus bar has a smoothly bent portion, and the bent portion has higher flexibility than the remaining portion.

10. The bus bar according to claim 9, wherein: The smooth curved portion is formed by multiple layers of copper sheets welded together.

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