Onboard BDU, battery pack and new energy vehicles

Abstract

This invention relates to the field of new energy vehicle power system technology, and discloses an on-board battery distribution unit (BDU), a battery pack, and a new energy vehicle. The on-board BDU includes an upper housing, a lower housing, and multiple electrical modules. The upper housing has multiple installation areas formed by partitions, with access electrodes located in each installation area. The outer surface of the upper housing has an insertion port connecting to the installation areas. The electrical modules are installed within a housing, and each module has conductive terminals on its outer side. The housing can be laterally inserted into the upper housing so that the conductive terminals contact the access electrodes. The lower housing is connected to the lower part of the upper housing. Connection terminals extending from the access electrodes into the lower housing, along with wires, form a wiring network according to a preset wiring layout, enabling electrical connections between the electrical modules. The electrical modules and the wiring network are located in different spaces. This invention results in a neat electrical module layout, reduces electromagnetic interference, significantly improves assembly and maintenance efficiency, and is suitable for high-voltage power distribution systems in new energy vehicle battery packs.

Description

Technical Field

[0001] This invention relates to the technical field of power systems for new energy vehicles, and particularly to on-board BDUs, battery packs, and new energy vehicles. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the battery distribution unit (BDU), as the core hub between the battery system and the vehicle's high-voltage circuit, directly affects the vehicle's safety performance and user experience through its structural rationality and operational stability. In existing technologies, the internal structural design of the vehicle BDU often has many limitations, with the installation and wiring methods of electrical modules being particularly prominent. Traditional BDUs typically employ a layout scheme with low integration, where various electrical modules such as relays, fuses, and pre-charge resistors are directly fixed to predetermined points on the lower housing using studs. This dispersed installation method not only results in a lack of unified planning for the arrangement of components within the housing but also makes subsequent wiring work cumbersome and complex.

[0003] Because each electrical module is installed independently without clear wiring constraints, the actual assembly process requires connecting the terminals of different electrical modules one by one with a large number of wires to form a complete high-voltage power distribution circuit. This results in an extremely chaotic wiring layout within the housing, occupying excessive internal space and easily causing severe electromagnetic interference due to tangled and crossed wires. This affects the signal transmission accuracy and operational stability of each electrical module and makes automated wiring impossible. Furthermore, the chaotic wiring and dispersed installation structure greatly inconvenience subsequent maintenance work. When an electrical module malfunctions, maintenance personnel must first untangle the corresponding circuit from the complex wiring before disassembling related components for repair. This not only slows down the repair process but also risks accidentally touching other normal components during operation, introducing new fault risks. In addition, in the traditional structure, electrical modules and wires are in the same space. If an electrical module leaks current or the wire insulation is damaged, it can easily lead to short circuits and other safety hazards, further reducing the safety of the BDU. Summary of the Invention

[0004] The present invention aims to solve the technical problems existing in the above-mentioned related technologies, and proposes a vehicle-mounted BDU that can realize the rapid installation and removal of electrical modules, and also realize the regional management of electrical modules and wires.

[0005] According to a first aspect of the present invention, an on-board BDU includes:

[0006] The upper housing has multiple installation areas formed by partitions inside. Each partition is equipped with an access electrode at the location of each installation area. The outer surface of the upper housing has an embedding port that connects to each installation area.

[0007] The lower housing is connected to the lower part of the upper housing. Each of the access electrodes is provided with a connection terminal in the lower housing. The lower housing is provided with multiple wires. The multiple connection terminals and multiple wires are arranged in a preset wiring layout to form a wire network.

[0008] The electrical modules are provided in multiple quantities and are installed in a package box. Each electrical module has a conductive terminal on the outer side of the package box. The electrical module is laterally embedded into the corresponding insertion port of the upper housing through the package box until the conductive terminal of the package box contacts the access electrode of the corresponding installation area. The multiple electrical modules are electrically connected through the wire mesh, thereby isolating the electrical modules and the wire mesh in different spaces.

[0009] According to embodiments of the present invention, the vehicle-mounted BDU has at least the following beneficial effects: the partition design of the upper housing provides independent installation space for each electrical module, and the side-embedding method of the encapsulation box replaces the traditional stud-based scattered fixing, making the layout of each module neat and orderly, and greatly improving assembly efficiency; the wire network inside the lower housing forms a unified connection method through a preset wiring layout, avoiding the problem of messy wire arrangement and structurally reducing the generation of electromagnetic interference; the electrical modules and the wire network are isolated in different spaces, which not only reduces the risk of mutual interference, but also allows the maintenance of electrical modules to be completed by direct side disassembly through the encapsulation box without touching the wire network area. At the same time, the maintenance of the wire network only requires operation on the lower housing, which greatly improves the convenience of maintenance.

[0010] According to some embodiments of the present invention, the encapsulation box is provided with a mounting plate externally placed in the embedding port, and the encapsulation box is fixedly connected to the upper housing through the mounting plate.

[0011] According to some embodiments of the present invention, the encapsulation box and the corresponding embedding port have a unique embedding orientation.

[0012] According to some embodiments of the present invention, the inner side of the partition is provided with a plurality of slots communicating downward with the lower housing, the slots being used to install the access electrode, such that the position of the access electrode in the installation area is adjustable.

[0013] According to some embodiments of the present invention, each of the installation areas is provided with a detector for detecting the connection status between the electrical module and the access electrode.

[0014] According to some embodiments of the present invention, the top surface of the upper housing is provided with a plurality of indicator lights, each of which is controlled by a detector in one of the installation areas.

[0015] According to some embodiments of the present invention, the plurality of electrical modules include at least a precharge module and a relay module.

[0016] According to some embodiments of the present invention, the outer surface of the lower housing is provided with an interface for external connection, and the interface is electrically connected to the wire mesh.

[0017] According to a second aspect of the present invention, a battery pack includes a battery assembly and the aforementioned vehicle-mounted BDU, wherein the vehicle-mounted BDU is electrically connected to the battery assembly.

[0018] A new energy vehicle according to a third aspect embodiment of the present invention includes the battery pack described above.

[0019] 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

[0020] Figure 1 This is a three-dimensional structural diagram of the vehicle-mounted BDU provided in an embodiment of the present invention;

[0021] Figure 2 yes Figure 1 The exploded 3D view of the vehicle-mounted BDU shown;

[0022] Figure 3 This is a front view of the vehicle-mounted BDU provided in an embodiment of the present invention after the hidden encapsulation box is installed;

[0023] Figure 4 This is a cross-sectional view of the vehicle-mounted BDU provided in an embodiment of the present invention after the hidden encapsulation box is installed;

[0024] Figure 5 This is a cross-sectional view of the mounting plate provided in an embodiment of the present invention.

[0025] In the attached diagram: 100-Upper housing, 200-Lower housing, 110-Partition, 120-Mounting area, 300-Encapsulation box, 400-Connection electrode, 410-Upper vertical section, 420-Horizontal section, 430-Lower vertical section, 411-Contact, 111-Slot, 500-Connecting board, 510-Connecting sleeve, 520-Conductor, 130-Embedding port, 310-Mounting plate, 320-Conductive terminal, 140-Indicator light, 210-Connecting ear, 220-Interface, 610-Outer wall, 620-Inner wall, 630-Liquid suction core, 640-Sealing strip, 311-Mounting hole, 611-Boss, 650-Heat pipe inner cavity, 660-Liquid working fluid, 631-First liquid suction section, 632-Second liquid suction section. Detailed Implementation

[0026] 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.

[0027] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this 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. Therefore, they should not be construed as limiting this invention.

[0028] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0029] In the description of this invention, unless otherwise explicitly defined, terms such as "set up," "install," and "connect" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this invention in conjunction with the specific content of the technical solution.

[0030] like Figure 1 and Figure 2 As shown, this invention discloses a vehicle-mounted BDU, aiming to solve the problems of scattered electrical component installation, messy wiring, severe electromagnetic interference, inconvenient maintenance, and low safety in existing vehicle-mounted BDUs. This vehicle-mounted BDU, through a modular design of the upper housing 100, lower housing 200, and encapsulation box 300, achieves rapid assembly and disassembly of electrical modules and regional management, significantly improving assembly efficiency, operational stability, and safety. The following detailed description of each component, based on specific embodiments, ensures that those skilled in the art can fully reproduce the technical solution of this invention based on this description.

[0031] The upper housing 100 is made of high-strength flame-retardant engineering plastic material, specifically glass fiber reinforced PA66 (polyhexamethylene adipamide). This material not only has excellent mechanical strength, with tensile strength ≥80MPa and flexural strength ≥120MPa, but also has good high temperature resistance and flame retardant rating, which can effectively adapt to complex working conditions such as vibration, high temperature and electromagnetic radiation in the vehicle environment.

[0032] The upper housing 100 has multiple independent installation areas 120 formed inside by partitions 110. The partitions 110 and the upper housing 100 are integrally injection molded structures. To ensure smooth demolding of the plastic parts, the upper housing 100 is formed by bonding upper and lower injection molded parts during processing, creating a box structure with upper and lower covers. In this embodiment, the partitions 110 form four installation areas 120. The dimensions of each installation area 120 are designed according to the specifications of the corresponding encapsulation box 300. Each encapsulation box 300 can install one or more electrical modules. The electrical modules are the core components for the vehicle-mounted BDU to achieve high-voltage power distribution functions. There are multiple electrical modules, including but not limited to relay modules, pre-charge modules, fuse modules, and voltage detection modules, with at least pre-charge modules and relay modules required. Each electrical module is encapsulated by an encapsulation box 300, which serves as both a protective shell and a mounting carrier for the electrical module.

[0033] Partition 110 is equipped with an access electrode 400 at each installation area 120. The access electrode 400 serves as an electrical connection relay component for the electrical module, and its material and structural design directly affect the reliability of the electrical connection. The access electrode 400 is made of high-purity copper with a silver-plated surface. The silver plating effectively reduces contact resistance, decreases Joule heating during current flow, and improves the electrode's corrosion resistance, preventing poor contact due to oxidation during long-term use. Figure 4 As shown, the structure of the access electrode 400 is stepped, which is divided into an upper vertical section 410, a horizontal section 420 and a lower vertical section 430. The horizontal section 420 is connected between the two vertical sections. The upper vertical section 410 is located in the mounting area 120 of the upper housing 100 and is provided with a contact 411 for electrical connection with the electrical module. The lower vertical section 430 extends below the upper housing 100. The horizontal section 420 is used to offset the positions of the two vertical sections to facilitate spatial layout and fixation.

[0034] like Figure 3 As shown, in this embodiment, the inner surface of the partition 110 is provided with a plurality of downwardly communicating slots 111. The slots 111 are used to install the access electrode 400 from bottom to top, so that the position of the access electrode 400 within the installation area 120 is adjustable. Since the upper vertical section 410 of the access electrode 400 is provided with a contact 411, in order to enable the access electrode 400 to be installed in the slot 111 from bottom to top, either the opening of the slot 111 needs to be enlarged, or the installation step of the contact 411 needs to be postponed.

[0035] Specifically, on the inner side of the partition 110 corresponding to each installation area 120, three to five slots 111 are evenly arranged horizontally. When all five slots 111 are equipped with access electrodes 400, the installation area 120 has a total of five contacts 411 for electrical connection of electrical modules. When three slots 111 are equipped with access electrodes 400, the installation area 120 has a total of three contacts 411 for electrical connection of electrical modules. The relative positions of the three access electrodes 400 can be adjusted within a certain range to adapt to the wiring requirements of different electrical modules. The advantage of this design is that when it is necessary to replace electrical modules of different specifications, there is no need to redesign the structure of the partition 110. Only by adjusting the position of the access electrodes 400 in the slots 111, precise docking with the conductive terminals 320 of the new module can be achieved, which greatly improves the versatility and compatibility of the upper housing 100 and reduces the cost of subsequent product upgrades.

[0036] like Figure 4 As shown, furthermore, to define the position of the access electrode 400 in the slot 111 and to facilitate subsequent wiring, the bottom of each set of access electrodes 400 is reinforced by a terminal block 500. The terminal block 500 has an even number of terminal sleeves 510, and every two terminal sleeves 510 are paired by a conductor 520. The lower vertical segment 430 of each access electrode 400 is inserted into the corresponding terminal sleeve 510 of the terminal block 500, while the other terminal sleeve 510 paired with it is used for electrical connection with other electrical components. After each set of access electrodes 400 is assembled with the terminal block 500, the terminal block 500 is fixed to the bottom surface of the upper housing 100 with screws, so that the horizontal segment 420 of the access electrode 400 abuts against the bottom surface of the upper housing 100, thereby defining the position of the access electrode 400. Since the terminal sleeve 510 of the terminal block 500 is made of non-conductive material 520, the two adjacent access electrodes 400 will not short-circuit due to short circuit. Moreover, the wiring operation of other electrical components and the terminal block 500 can be simplified by designing an insertion structure that matches the terminal sleeve 510, so as to meet the technical requirements of automated wiring.

[0037] like Figure 2As shown, the outer surface of the upper housing 100 is provided with an insertion port 130 connecting each installation area 120. The insertion port 130 serves as a channel for the lateral insertion of the encapsulation box 300, and its structural design must simultaneously meet the requirements of ease of assembly and sealing protection. In this embodiment, since the upper housing 100 has four installation areas 120, the number of insertion ports 130 is also four. The shape of the insertion port 130 is adapted to the shape of the encapsulation box 300, both adopting an asymmetrical trapezoidal structure. The asymmetrical trapezoidal structure ensures that the encapsulation box 300 and the insertion port 130 have a unique insertion direction, which can effectively achieve the foolproof function and avoid misalignment of electrical modules. The edge of the insertion port 130 is provided with a groove (not shown in the figure), and a silicone rubber sealing gasket is provided in the groove. The cross-sectional size of the sealing gasket is 3mm×3mm, and it is made of silicone rubber with a Shore hardness of 70, which has good elasticity and aging resistance. When the encapsulation box 300 is fully inserted into the insertion port 130, the mounting plate 310 of the encapsulation box 300 fits tightly with the sealing gasket, so that the installation area 120 forms a sealed space with a protection level of IP67, which can effectively prevent rainwater, dust and other impurities from entering the interior of the installation area 120.

[0038] Although the electrical module is installed inside the enclosure 300, it can be electrically connected to other electrical components via conductive terminals 320 on the outer side of the enclosure 300. That is, regardless of the number of electrical modules installed inside the enclosure 300, all electrical modules inside the enclosure 300 are electrically connected through internal wiring, while the conductive terminals 320 on the outer side of the enclosure 300 serve as the external terminals for this internal wiring. The electrical module is laterally inserted into the corresponding insertion slot 130 of the upper housing 100 through the enclosure 300 until the conductive terminals 320 on the outer side of the enclosure 300 contact the access electrode 400 of the corresponding mounting area 120. After the enclosure 300 is laterally inserted into place, the enclosure 300 is threaded to the surface of the upper housing 100 via its mounting plate 310, thereby fixing the enclosure 300 to the upper housing 100.

[0039] Furthermore, in order to better achieve electrical connection and reduce the probability of poor connection, the conductive terminal 320 on the outer side of the encapsulation box 300 can be a spring member, which relies on elasticity to make contact with the contact 411 of the access electrode 400, thereby improving the reliability of wiring.

[0040] On the other side, the top surface of the upper housing 100 is equipped with multiple indicator lights 140. Each indicator light 140 is controlled by a detector (not shown in the attached diagram) in an installation area 120. The detector is used to detect the connection status between the electrical module inside the enclosure 300 and the access electrode 400, while the indicator lights 140 are used to visually display the connection status between the corresponding enclosure 300 and the access electrode 400. The indicator lights 140 use LED light sources, which are characterized by low power consumption and long lifespan. A total of four indicator lights 140 are set, each corresponding to one of the four installation areas 120. The indicator lights 140 have three working states: solid green indicates that the electrical module inside the enclosure 300 is properly connected to the access electrode 400 and is working stably; flashing yellow indicates that the connection is in a critical state; solid red indicates a connection fault, such as no connection, poor contact, or short circuit. The setting of indicator lights 140 helps to quickly locate the fault location and achieve the purpose of rapid repair.

[0041] Specifically, the detector employs a combination of a contact pressure sensor and a temperature sensor to achieve accurate detection of the connection status. The contact pressure sensor can be a miniature piezoresistive pressure sensor, model Honeywell 481, mounted on the back of the vertical section 410 of the access electrode 400, used to acquire the contact pressure signal between the conductive terminal 320 and the access electrode 400 in real time. The temperature sensor can be a surface-mount NTC thermistor, model EPCOS B57863, mounted on the front of the vertical section 410 of the access electrode 400, used to detect the temperature at the contact point between the conductive terminal 320 and the access electrode 400.

[0042] The detector works as follows: After the electrical module is assembled, the contact pressure sensor detects the contact pressure in real time, and the temperature sensor detects the temperature of the contact area in real time. The detected signals are converted into electrical signals and transmitted to the controller. The controller uses an STM32 series microcontroller as its core chip. It filters, amplifies, and performs A / D conversion on the received pressure and temperature signals, and then judges the connection status according to a preset judgment logic. The judgment logic is set as follows: when the contact pressure is ≥3N and the contact temperature is ≤80℃, the connection is considered normal, and the signal processing module controls the corresponding indicator light 140 to be solid green; when the contact pressure is between 2N and 3N and the temperature is ≤80℃, the connection is considered critical, and the control indicator light 140 flashes yellow; when the contact pressure is <2N or the temperature is >80℃, the connection is considered faulty, the control indicator light 140 is solid red, and the signal processing module transmits the fault signal to the vehicle controller through a low-voltage interface. The vehicle controller issues corresponding alarm prompts according to the fault type, such as displaying the location of the faulty module and the cause of the fault on the vehicle display screen, reminding the driver to perform timely maintenance.

[0043] like Figure 1 and Figure 2As shown, the lower housing 200 is connected to the lower part of the upper housing 100. The connection methods between the two include, but are not limited to, snap-fit ​​connection, magnetic connection, or screw connection. The lower housing 200 is mainly used to accommodate the wire mesh and realize the connection with external components. The lower housing 200 is also made of glass fiber reinforced PA66 material, which is consistent with the material of the upper housing 100, so as to facilitate the connection sealing and thermal expansion coefficient matching between the two and avoid gaps in the connection due to temperature changes. The side of the lower housing 200 is provided with connecting ears 210. The connecting ears 210 are used to install and fix the lower housing 200 in the battery pack. There is a buffer pad between the contact surface of the connecting ears 210 and the battery pack. The buffer pad is made of nitrile rubber with a thickness of 5mm, which can effectively absorb the vibration generated during vehicle driving, reduce the impact of vibration on the internal structure and electrical connection of the BDU, and extend the service life of the BDU.

[0044] Each access electrode 400 has a connection terminal (i.e., lower vertical section 430) inside the lower housing 200, and the connection terminal of each access electrode 400 is inserted into the corresponding wiring sleeve 510 of the wiring board 500. The lower housing 200 contains multiple wires (not shown in the attached diagram). The wires are multi-strand copper core flexible wires, and the cross-sectional area of ​​the copper core is selected according to the operating current of the corresponding electrical module. The cross-sectional area of ​​the wires corresponding to the relay module and the precharge module is 16 mm². 2 The cross-sectional area of ​​the conductors corresponding to the fuse module and the voltage detection module is 6mm². 2 The insulation layer of the conductor is made of cross-linked polyethylene, which has excellent high temperature resistance and insulation strength, and can effectively withstand the electrical stress under the high voltage environment of the vehicle.

[0045] Multiple connection terminals and multiple wires are arranged in a preset wiring layout to form a wire network. The layout of the wire network is optimized using computer-aided design software to ensure that the spacing between wires is ≥10mm, avoiding electromagnetic interference caused by insufficient wire spacing. The wire network is fixed inside the lower housing 200 by wire clips (not shown in the attached diagram). The wire clips are made of nylon to ensure that the wires do not shake during vehicle vibration and to prevent damage to the wire insulation layer due to friction. The layout of the wire network should follow the principle of "separation of strong and weak currents," with high-voltage power lines and low-voltage control lines arranged on opposite sides of the lower housing 200, kept far apart from each other.

[0046] The reason why this technology uses wire mesh instead of a custom PCB board is that wire mesh is more flexible and more applicable than PCB board. Even for small-batch production or pilot production, it will not increase costs. Furthermore, since multiple electrical modules can be set up within a single package 300, the same BDU shell can still be used when customizing different power distribution schemes, without the need to redesign the PCB board, effectively reducing costs.

[0047] According to some embodiments of the present invention, the outer surface of the lower housing 200 is provided with an interface 220 for external connection, and the interface 220 is electrically connected to the wire network. The interface 220 includes four high-voltage interfaces and two low-voltage interfaces. The high-voltage interfaces are used to connect to the battery modules of the battery pack and the high-voltage electrical equipment of the vehicle, adopting a standard MC4 connector structure and having anti-misinsertion function. The low-voltage interfaces are used to connect to the vehicle controller and battery management system, adopting a pin-type connector with 16 pins, used to transmit detector detection signals, indicator light 140 control signals, and wire network status feedback signals. A rubber sealing ring is provided at the connection point between the interface 220 and the lower housing 200. The sealing ring is made of hydrogenated nitrile rubber, which has good oil resistance and aging resistance, ensuring that the protection level of the interface 220 reaches IP67. A dust cover is provided on the outside of the interface 220, which effectively prevents dust from entering the interior of the interface 220 when the interface 220 is not in use, protecting the pins or connectors from contamination.

[0048] With the above structure, the partition 110 of the upper housing 100 provides independent installation space for each electrical module. Combined with the lateral embedding method of the enclosure 300, it replaces the traditional stud-based scattered fixing, resulting in a neat and orderly layout of each module and significantly improving assembly efficiency. The wiring network inside the lower housing 200 forms a unified connection through a pre-set wiring layout, avoiding the problem of messy wire arrangement and structurally reducing electromagnetic interference. The electrical modules and the wiring network are isolated in different spaces, reducing the risk of mutual interference and allowing for direct lateral disassembly of the electrical modules through the enclosure 300 without touching the wiring network area. Furthermore, wiring network maintenance only requires operation on the lower housing 200, greatly improving maintenance convenience.

[0049] Because the vehicle-mounted BDU adopts a modular design, during the maintenance phase, after ruling out wire network faults, if any indicator light 140 shows a red light, then the corresponding encapsulation box 300 should be replaced. The maintenance personnel can take the faulty encapsulation box 300 back to the workshop for disassembly and repair, eliminating the need for on-site repair and greatly improving work efficiency.

[0050] like Figure 5As shown, the mounting plate 310 of the encapsulation box 300, in addition to its fixed connection with the upper housing 100, also integrates a heat dissipation function. A heat pipe unit is installed within the mounting plate 310, allowing heat exchange between the inner cavity of the encapsulation box 300 and the external environment. Specifically, the heat pipe unit includes an outer wall 610, an inner wall 620, and a liquid-absorbing core 630. The outer wall 610 has mounting holes 311 for connecting to the upper housing 100. Since the outer wall 610 faces outwards and the inner wall 620 faces inwards, the outer wall 610 serves as a heat dissipation surface, and the inner wall 620 serves as a heat-receiving surface. The outer wall 610 has a concave plane formed by the boss 611, and the inner wall 620 has a flange that can be embedded in the concave plane. A sealing strip 640 is provided between the flange and the concave plane. The sealing strip 640 is made of high-temperature resistant silicone rubber. It achieves a seal through the pressing force between the inner wall 620 and the outer wall 610, so that the outer wall 610, the inner wall 620 and the sealing strip 640 form a sealed heat pipe cavity 650. When the inner wall 620 is sealed tightly against the concave plane by the sealing strip 640, the position of the inner wall 620 is flush with the position of the boss 611.

[0051] Since the heat pipe unit is not a gravity heat pipe, a wick 630 is provided on the wall of the heat pipe cavity 650. A suitable amount of liquid working fluid 660 is placed inside the heat pipe cavity 650. The wick 630 adopts a porous capillary structure, which can provide stable capillary force and has high permeability, ensuring smooth return of the liquid working fluid 660. To lower the boiling point of the liquid working fluid 660, a vacuum needs to be applied to the heat pipe cavity 650, allowing the liquid working fluid 660 to be placed in the vacuum-enclosed heat pipe cavity 650. Specifically, the wick 630 includes a first wicking part 631 and a second wicking part 632. The first wicking part 631 is fixedly disposed on the inner side of the outer wall 610, and the second wicking part 632 is fixedly disposed on the inner side of the inner wall 620. Both the first wicking part 631 and the second wicking part 632 have a porous capillary structure. Liquid working medium 660 includes, but is not limited to, water or ethanol, and the porous capillary structure needs to be adapted according to the type of liquid working medium 660.

[0052] To allow the liquid working fluid 660 to be injected into the heat pipe cavity 650, a machining hole is provided on the outer wall 610 or the inner wall 620. This machining hole communicates with the heat pipe cavity 650 and serves both as a vacuum pump and a working fluid injection point. During operation, the machining hole is first connected to the vacuum unit and the working fluid storage tank via a pipeline. The vacuum unit is then started to evacuate the heat pipe cavity 650. The vacuum is maintained until the pressure gauge indicates a vacuum level of 10... -3 At the Pa level, maintain a vacuum state and inject a measured amount of liquid working fluid 660 into the heat pipe cavity 650 through the pipeline. After injection, close the pipeline valve and seal the opening of the machined hole using an argon arc welding process. Finally, perform an airtightness test on the welded area to ensure that there is no vacuum leakage in the heat pipe cavity 650, thereby ensuring the long-term stable operation of the heat pipe unit.

[0053] When the electrical module generates heat, the heat is transferred through the inner wall 620 of the heat pipe unit to the inner cavity 650 of the heat pipe, causing the liquid working fluid 660 inside the heat pipe cavity 650 to evaporate. The vapor diffuses along the temperature gradient to the heat dissipation surface of the outer wall 610. Since the temperature of the air outside the box is lower than that of the air inside the box, the vapor exchanges heat with the outside air and condenses. The condensed liquid working fluid 660 flows back under the action of the porous capillary structure, forming a circulating heat dissipation. This heat dissipation structure can reduce the operating temperature of the electrical module by 20°C to 30°C, significantly improving the operational stability and service life of the electrical module.

[0054] In this embodiment, the main components of the mounting plate 310 and the heat pipe unit are made of metal, while the other parts of the encapsulation box 300 are made of plastic. The two are bonded together with adhesive. Before bonding the mounting plate 310, the electrical module must first be installed. During later maintenance, a hot air gun is needed to melt the adhesive on the mounting plate 310 so that the mounting plate 310 can be removed to expose the electrical module.

[0055] This technology achieves precise one-to-one heat dissipation by directly integrating the heat pipe unit into the mounting plate 310 of the encapsulation box 300. The heat generated by the electrical module is directly transferred to the outside through the mounting plate 310 of the encapsulation box 300, resulting in a shorter heat transfer path and higher heat dissipation efficiency. In addition to heat dissipation, the encapsulation box 300 also serves as a modular assembly carrier for the electrical module. The integration of these two functions into the same component effectively reduces the space occupied inside the vehicle BDU, which is a first in the industry.

[0056] This invention also provides a battery pack, including a battery assembly and the aforementioned vehicle-mounted BDU. The battery assembly is a lithium-ion power battery pack, composed of multiple individual cells connected in series. The vehicle-mounted BDU is connected to the output terminal of the battery assembly via a high-voltage interface on the lower housing 200, enabling the distribution and control of the battery assembly's output power. The battery pack's outer shell is made of cold-rolled steel plate, with an internal heat insulation layer and fireproof layer. The vehicle-mounted BDU is installed at the front end inside the battery pack, close to the battery assembly's output terminal, shortening the length of the high-voltage wires and reducing line loss and electromagnetic interference. The battery pack also includes a battery management system (BMS). The BMS connects to a detector and network via the low-voltage interface of the vehicle-mounted BDU, enabling real-time monitoring and control of the vehicle-mounted BDU's operating status. When a connection failure or network abnormality occurs in the vehicle-mounted BDU, the BMS can promptly issue a control signal to cut off the battery assembly's output, ensuring the safe use of the battery pack.

[0057] This invention also provides a new energy vehicle, which includes the aforementioned battery pack. The battery pack is installed under the vehicle chassis and supplies power to the vehicle's motor controller, on-board charger, DC / DC converter, and other high-voltage electrical equipment through the high-voltage interface of the on-board BDU. The low-voltage interface of the on-board BDU is connected to the vehicle controller, enabling the vehicle controller to control and monitor the status of the on-board BDU.

[0058] New energy vehicles can be private cars, such as sedans, SUVs, MPVs, or pickup trucks. They can also be commercial vehicles, such as vans, buses, small trucks, or large semi-trailers. New energy vehicles have an electric motor that acts as a generator to store mechanical energy; they can be hybrid vehicles or pure electric vehicles.

[0059] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A vehicle-mounted BDU, characterized in that, include: The upper housing (100) has multiple installation areas (120) formed inside by partitions (110). Each partition (110) has an access electrode (400) at the position of each installation area (120). The outer surface of the upper housing (100) has an embedding port (130) that connects to each installation area (120). The lower housing (200) is connected below the upper housing (100). Each of the access electrodes (400) is provided with a connection terminal in the lower housing (200). The lower housing (200) is provided with multiple wires. The multiple connection terminals and multiple wires are arranged in a preset wiring layout to form a wire network. Multiple electrical modules are provided and installed inside a packaging box (300). Each electrical module has conductive terminals (320) on the outer side of the packaging box (300). The electrical modules are laterally embedded into the corresponding insertion opening (130) of the upper housing (100) through the packaging box (300) until the conductive terminals (320) of the packaging box (300) contact the access electrode (400) of the corresponding mounting area (120). Multiple electrical modules are electrically connected through a wire mesh, thereby isolating the electrical modules and the wire mesh in different spaces. The packaging box (300) has a mounting plate (310) externally placed in the insertion opening (130). The packaging box (300) is fixedly connected to the upper housing (100) through the mounting plate (310). A heat pipe unit is provided inside the mounting plate (310), allowing heat to pass through the inner cavity of the packaging box (300). The heat pipe unit exchanges heat with the external environment of the box. The heat pipe unit includes an outer wall (610), an inner wall (620), and a liquid absorber (630). The outer wall (610) faces outward, and the inner wall (620) faces inward. The outer wall (610) has a concave plane formed by a boss (611), and the inner wall (620) has a flange that can be embedded in the concave plane. A sealing strip (640) is provided between the flange and the concave plane to allow heat exchange. The outer wall (610), inner wall (620) and sealing strip (640) form a sealed heat pipe cavity (650). The heat pipe cavity (650) is provided with a liquid wick (630) on its wall surface. The liquid wick (630) has a porous capillary structure. An appropriate amount of liquid working fluid (660) is provided inside the heat pipe cavity (650) which is in a vacuum state.

2. The vehicle-mounted BDU according to claim 1, characterized in that: The encapsulation box (300) and the corresponding insertion port (130) have a unique insertion direction.

3. The vehicle-mounted BDU according to claim 1, characterized in that: The inner side of the partition (110) is provided with a plurality of slots (111) that are downwardly connected to the lower housing (200). The slots (111) are used to install the access electrode (400), so that the position of the access electrode (400) in the installation area (120) is adjustable.

4. The vehicle-mounted BDU according to claim 1, characterized in that: Each of the installation areas (120) is equipped with a detector for detecting the connection between the electrical module and the access electrode (400).

5. The vehicle-mounted BDU according to claim 4, characterized in that: The top surface of the upper housing (100) is provided with a plurality of indicator lights (140), each of the indicator lights (140) being controlled by a detector of one of the installation areas (120).

6. The vehicle-mounted BDU according to claim 1, characterized in that: The plurality of electrical modules include at least a precharge module and a relay module.

7. The vehicle-mounted BDU according to claim 1, characterized in that: The outer surface of the lower housing (200) is provided with an interface (220) for external connection, and the interface (220) is electrically connected to the wire mesh.

8. A battery pack, characterized in that, It includes a battery pack and an on-board BDU as described in any one of claims 1-7, wherein the on-board BDU is electrically connected to the battery pack.

9. A new energy vehicle, characterized in that, Includes the battery pack as described in claim 8.

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