Power distribution module, battery pack, and powered device

Abstract

The application discloses a power distribution module, a battery pack and a power utilization device, and relates to the technical field of power batteries. The power distribution module comprises a shell, a main circuit board and a plurality of electrical devices. The shell has a first opening in a first direction. The main circuit board covers the first opening. The plurality of electrical devices are arranged on both sides of the main circuit board in the first direction. The plurality of electrical devices respectively form a battery disconnect unit, a power distribution unit and a signal acquisition unit. At least the battery disconnect unit is arranged on the inner side of the shell. The technical scheme provided by the application makes full use of the space on both sides of the main circuit board, reasonably arranges a plurality of electrical devices with different sizes, improves the integration of the power distribution module, and reduces the space occupied by the power distribution module in the battery pack.

Description

Technical Field

[0001] This invention relates to the field of power battery technology, and in particular to a power distribution module, a battery pack, and electrical equipment. Background Technology

[0002] In the field of electric vehicles and energy storage systems, the battery pack, as the core energy carrier, has an internal power distribution module that undertakes many important tasks, including power distribution, signal acquisition, and circuit protection. However, current power distribution modules require a large amount of internal space in the battery pack, limiting the improvement of battery pack energy density. Summary of the Invention

[0003] The main objective of this invention is to provide a power distribution module, a battery pack, and an electrical device, aiming to improve the problem that current power distribution modules require a large amount of internal space in the battery pack.

[0004] To achieve the above objectives, the present invention proposes a power distribution module for a battery pack, the power distribution module comprising:

[0005] The housing has a first opening in a first direction; The main circuit board is disposed over the first opening; and, Multiple electrical components are respectively disposed on both sides of the main circuit board in the first direction. The multiple electrical components respectively form a battery disconnection unit, a power distribution unit and a signal acquisition unit, wherein at least the battery disconnection unit is disposed on the inner side of the housing.

[0006] In one embodiment, a support portion is provided inside the housing; The plurality of electrical components include a plurality of first electrical components located in the inner cavity of the housing, and at least a portion of the first electrical components are disposed in the support portion.

[0007] In one embodiment, the support portion is formed with a plurality of first through holes extending along a first direction; The plurality of first electrical components include a plurality of first relays, which are respectively disposed through a plurality of first through holes and are detachably connected to the carrier portion; The battery disconnection unit includes a plurality of the first relays.

[0008] In one embodiment, the housing further has a second opening opposite to the first opening; The first relay has a connecting protrusion at the middle of the first direction. The connecting protrusion is located on the side of the bearing portion near the second opening and is threaded to the bearing portion.

[0009] In one embodiment, the end of the first relay facing away from the main circuit board is provided with an input terminal and an output terminal; The input terminal and the output terminal are respectively connected to copper busbars, which are configured to be connected in series with two adjacent first relays, or electrically connected to the energy storage unit of the battery pack.

[0010] In one embodiment, the support portion is formed with a plurality of second through holes extending along a first direction; The plurality of copper busbars include a plurality of external copper busbars, which are respectively inserted through a plurality of second vias and protrude from the housing through the first opening.

[0011] In one embodiment, the input terminals and output terminals of a plurality of first relays are arranged sequentially along a second direction, and the plurality of first relays include a main positive relay and a fast charging relay distributed along a third direction; The copper busbar includes a series copper busbar that connects the main positive relay and the fast charging relay in series. The series copper busbar has a middle section that is bent toward the bearing portion and is located between the main positive relay and the fast charging relay. The first direction, the second direction, and the third direction intersect each other.

[0012] In one embodiment, a mounting bracket is provided on the side of the support portion away from the main circuit board; The plurality of the first electrical components also include a first fuse, one end of which is mounted on the mounting bracket and the other end of which is connected to the input terminal of the main positive relay; The battery disconnection unit includes the first fuse.

[0013] In one embodiment, a first buffer pad is provided on the side of the support portion near the main circuit board; The plurality of first electrical components include a plurality of second relays, and the plurality of second relays are disposed in contact with the first buffer pad; The power distribution unit includes a plurality of the second relays.

[0014] In one embodiment, a second buffer pad is provided on the side of the support portion near the main circuit board, wherein: The plurality of the first electrical components include a first pre-charge resistor disposed on the second buffer pad, and the battery disconnection unit includes the first pre-charge resistor; and / or, The plurality of the first electrical components include a second pre-charge resistor disposed on the second buffer pad, and the power distribution unit includes the second pre-charge resistor.

[0015] In one embodiment, the main circuit board has a plurality of through holes extending along a first direction; At least a portion of the first electrical device has a plug-in terminal in a first direction, the plug-in terminal being plugged into a corresponding plug-in through hole.

[0016] In one embodiment, the housing has a mounting sidewall in a third-party orientation; The signal acquisition unit includes an acquisition circuit board, which is mounted on the mounting sidewall and connected to the main circuit board via pin headers. Wherein, the first direction intersects with the third direction.

[0017] In one embodiment, the plurality of electrical components include a plurality of second fuses disposed on the side of the main circuit board opposite to the housing; The power distribution unit includes a plurality of the second fuses.

[0018] To achieve the above objectives, the battery pack proposed in this invention includes the aforementioned power distribution module.

[0019] To achieve the above objectives, the electrical device proposed in this invention includes the aforementioned battery pack.

[0020] The technical solution provided by this invention integrates multiple electrical components from the battery disconnection unit, power distribution unit, and signal acquisition unit onto the main circuit board, endowing the power distribution module with multiple functions such as circuit protection, power distribution, and signal acquisition. Furthermore, these multiple electrical components are also respectively arranged on both sides of the main circuit board, making full use of the space on both sides. Multiple different types of electrical components can be rationally arranged according to their own size specifications, reducing the area of ​​the main circuit board, improving the integration of the power distribution module, reducing the space occupied by the power distribution module within the battery pack, and contributing to the improvement of the battery pack's energy density. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of an embodiment of the power distribution module proposed in this invention; Figure 2 for Figure 1 Top view of the central power distribution module; Figure 3 for Figure 2 A structural diagram of the intermediate power distribution module (excluding the main circuit board); Figure 4 for Figure 1 A bottom-view structural diagram of the central power distribution module; Figure 5 for Figure 4 Three-view drawing of the series-connected copper busbar; Figure 6 for Figure 1 A structural schematic diagram of the power distribution module (excluding the housing) from another perspective.

[0023] Explanation of icon numbers: 100. Power distribution module; 1. Housing; 1a. First opening; 1b. Second opening; 11. Supporting part; 11a. First through hole; 11b. Second through hole; 111. Mounting bracket; 112. First buffer pad; 113. Second buffer pad; 12. Mounting sidewall; 2. Main circuit board; 3. Electrical components; 31. First electrical component; 31a. Plug-in terminal; 311. First relay; 3111. Connecting protrusion; 3112. Input terminal; 3113. Output terminal; 311a. Main positive relay; 311b. Fast charging relay; 311c. Main negative relay; 312. Second relay; 313. First fuse; 314. First pre-charge resistor; 315. Second pre-charge resistor; 32. Second fuse; 33. Acquisition circuit board; 3a. Battery disconnection unit; 3b. Power distribution unit; 3c. Signal acquisition unit; 4. Copper busbar; 41. External copper busbar; 411. Input copper busbar; 412. Output copper busbar; 42. Series copper busbar; 421. Intermediate section; 422. Connecting section; X, first direction; Y, second direction; Z, third direction.

[0024] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] It should be noted that if the embodiments of the present invention involve directional indication, the directional indication is only used to explain the relative positional relationship and movement of the components in a certain specific posture. If the specific posture changes, the directional indication will also change accordingly.

[0027] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0028] In the field of electric vehicles and energy storage systems, the battery pack, as the core energy carrier, has an internal power distribution module that undertakes many important tasks, including power distribution, signal acquisition, and circuit protection. Currently, common battery pack power distribution modules typically adopt an integrated design, integrating functional units such as power distribution units, signal acquisition units (such as voltage and temperature detection circuits), and battery disconnection units (such as relay and fuse drive circuits) onto the same integrated circuit board. Furthermore, multiple functional units are often arranged in a partitioned layout and concentrated on one side of the circuit board.

[0029] However, the partitioned layout requires a large area of ​​integrated circuit boards, which limits the integration density of the power distribution modules. This means the power distribution modules typically occupy a significant amount of installation space within the battery pack. This not only reduces the space available for accommodating more cells or improving structural strength but also indirectly affects the overall energy density and lightweighting of the battery pack. Furthermore, the increased circuit board size leads to higher material costs, reduced mechanical stability, and decreased electrical connection reliability under vibration. As battery systems continue to evolve towards higher integration and higher energy density, the current layout of power distribution modules has become a major factor restricting the optimization of internal space and the improvement of overall performance within the battery pack. Therefore, how to achieve a higher degree of integration within a limited space, effectively reduce module size, and improve layout compactness has become a pressing technical problem to be solved in this field.

[0030] In view of this, the present invention proposes a power distribution module and a battery pack, which can at least improve the problem that current power distribution modules require a large amount of internal space in the battery pack. To facilitate understanding of the power distribution module provided by the present invention, the following description is provided in conjunction with the accompanying drawings, wherein... Figure 1 This is a schematic diagram of the structure of an embodiment of the power distribution module proposed in this invention; Figure 2 for Figure 1 Top view of the central power distribution module; Figure 3 for Figure 2 A structural diagram of the intermediate power distribution module (excluding the main circuit board); Figure 4 for Figure 1 A bottom-view structural diagram of the central power distribution module; Figure 5 for Figure 4 Three-view drawing of the series-connected copper busbar; Figure 6 for Figure 1 A structural schematic diagram of the power distribution module (excluding the housing) from another perspective.

[0031] Please see Figure 1 and Figure 6 The power distribution module 100 proposed in this invention is used for a battery pack. In one embodiment, the power distribution module 100 includes a housing 1, a main circuit board 2, and a plurality of electrical components 3. The housing 1 has a first opening 1a in a first direction X. The main circuit board 2 covers the first opening 1a. The plurality of electrical components 3 are respectively disposed on both sides of the main circuit board 2 in the first direction X. The plurality of electrical components 3 respectively form a battery disconnection unit 3a, a power distribution unit 3b, and a signal acquisition unit 3c. At least the battery disconnection unit 3a is disposed on the inner side of the housing 1.

[0032] The function of "casing 1" is to provide a mounting base for the main circuit board 2, and it is also mounted on the internal mounting structure of the battery pack. The material of casing 1 is usually an insulating material. Various connection circuits and control circuits are usually arranged on the "main circuit board 2" to ensure the electrical connection between the interconnected electrical components 3 and the control of the related electrical components 3. "Multiple electrical components 3 are respectively set on both sides of the main circuit board 2 in the first direction X" means that under the premise that multiple electrical components 3 are electrically connected to the main circuit board 2, some electrical components 3 are set inside casing 1, and the rest of the electrical components 3 are set outside casing 1.

[0033] The "Battery Disconnection Unit 3a" is mainly responsible for the switching on and off of the high-voltage circuit and safety protection. It typically includes main positive relay 311a, main negative relay 311c, fast charging relay 311b, battery disconnection fuse, main positive pre-charge resistor, and other electrical components 3. The "Power Distribution Unit 3b" is mainly responsible for the precise distribution and management of high-voltage power, distributing the high-voltage power output from the battery pack to high-voltage loads such as drive motors, DC-DC converters, air conditioning compressors, and heaters through the power distribution interface. It typically includes power distribution relays, power distribution fuses, power distribution pre-charge resistors, and other electrical components 3. The "Signal Acquisition Unit 3c" is mainly responsible for high-voltage signal acquisition, insulation detection, and current detection, providing core data support for the former two. The coordinated action of the Battery Disconnection Unit 3a, Power Distribution Unit 3b, and Signal Acquisition Unit 3c directly determines the safety and stability of the battery pack system.

[0034] The technical solution provided by this invention integrates multiple electrical components 3 from the battery disconnection unit 3a, power distribution unit 3b, and signal acquisition unit 3c onto the main circuit board 2, giving the power distribution module 100 multiple functions such as circuit protection, power distribution, and signal acquisition. Furthermore, the multiple electrical components 3 are also respectively arranged on both sides of the main circuit board 2, making full use of the space on both sides of the main circuit board 2. Multiple different types of electrical components 3 can be rationally arranged according to their own size specifications, reducing the area of ​​the main circuit board 2, improving the integration of the power distribution module 100, reducing the space occupied by the power distribution module 100 inside the battery pack, and contributing to the improvement of the battery pack's energy density. Moreover, the multiple electrical components 3 in the battery disconnection unit 3a typically need to be directly connected to the energy storage unit inside the battery pack, and are high-voltage electrical components 3. By placing the multiple electrical components 3 in the battery disconnection unit 3a inside the housing 1, the housing 1 can provide high-voltage isolation for the battery disconnection unit 3a.

[0035] Please see Figures 2 to 4 In one embodiment, a support portion 11 is provided inside the housing 1; the plurality of electrical components 3 include a plurality of first electrical components 31 located in the inner cavity of the housing 1, and at least some of the first electrical components 31 are disposed in the support portion 11.

[0036] In the above technical solution, a support part 11 is provided inside the housing 1, and at least some of the multiple electrical components 3 are provided in the support part 11. The support part 11 can distribute the weight of the part of the electrical components 3, thereby reducing the load pressure on the main circuit board 2 and improving the reliability of the connection between the electrical components 3 and the main circuit board 2.

[0037] Please see Figure 3 and Figure 4 In one embodiment, the support portion 11 is formed with a plurality of first through holes 11a extending along a first direction X; the plurality of first electrical devices 31 include a plurality of first relays 311, which are respectively disposed in the plurality of first through holes 11a and are detachably connected to the support portion 11; wherein, the battery disconnection unit 3a includes a plurality of first relays 311.

[0038] The multiple first relays 311 typically include a main positive relay 311a, a main negative relay 311c, and a fast charging relay 311b; since the first relays 311 are part of the battery disconnection unit 3a, they typically have a larger size along the first direction X (compared to the power distribution relays of the power distribution unit 3b).

[0039] There are several ways to make the first relay 311 detachably connected to the support part 11. For example, the top of the first electrical component 31 is connected to the main circuit board 2, the bottom is set through the first through hole 11a, and a protruding structure is set in the middle. The first relay 311 can abut against the support part 11 by means of the protruding structure in the middle, so that the support part 11 bears the weight of the first electrical component 31.

[0040] In the above technical solution, a plurality of first through holes 11a are provided on the support part 11, which are through the first through holes 11a to allow the larger first relay 311 in the battery disconnection unit 3a to pass through, thereby providing a support foundation for the smaller first electrical device 31.

[0041] Please see Figure 4 In one embodiment, the housing 1 also has a second opening 1b opposite to the first opening 1a; the first relay 311 is provided with a connecting protrusion 3111 at the middle of the first direction X, the connecting protrusion 3111 is provided on the side of the support portion 11 near the second opening 1b, and is threadedly connected to the support portion 11.

[0042] In the above technical solution, the first relay 311 is threaded to the side of the bearing part 11 near the second opening 1b through the connecting protrusion 3111 in its middle. According to the principle of the second opening 1b and the setting of the main circuit board 2, during the assembly of the power distribution module 100, the first relay 311, which has a larger size and greater weight, can be threaded to the bearing part 11 through the second opening 1b first, and then the first relay 311 is electrically connected to the main circuit board 2. Compared with the solution where the first relay 311 is pre-installed on the main circuit board 2 and then mounted on the housing 1 by the main circuit board 2, so that the first relay 311 is supported by the bearing part 11, the above technical solution can significantly reduce the stress on the main circuit board 2 and protect it during the assembly process.

[0043] For the layout scheme of "connecting protrusion 3111", please refer to [link / reference]. Figure 4 In one embodiment, the plurality of first relays 311 include a main negative relay 311c and a fast charging relay 311b that are spaced apart along the second direction Y. The negative relays and the fast charging relays 311b are respectively provided with connecting protrusions 3111 on the side that are close to each other. The two connecting protrusions 3111 are located in the gap formed between the main negative relay 311c and the fast charging relay 311b, and are arranged along the third direction Z.

[0044] Specifically, the multiple first relays 311 have the same model and specifications, and the first relays 311 are provided with connecting protrusions 3111 on both sides of the second direction Y. The two connecting protrusions 3111 are symmetrically distributed with respect to the first relays 311 on the central axis of the first direction X.

[0045] Please see Figure 4 In one embodiment, the first relay 311 is provided with an input terminal 3112 and an output terminal 3113 at the end opposite to the main circuit board 2; wherein the input terminal 3112 and the output terminal 3113 are respectively connected to a copper busbar 4, and the copper busbar 4 is configured to connect two adjacent first relays 311 in series, or to be electrically connected to the energy storage unit of the battery pack.

[0046] The “energy storage unit of the battery pack” can also be called a cell, battery cell or battery module; there are usually direct or indirect electrical connections between multiple first relays 311. Therefore, the copper busbar 4 is usually used to connect two adjacent first relays 311 in series, or to connect to the energy storage unit of the battery pack. The former belongs to the series copper busbar 42, and the latter belongs to the external copper busbar 41.

[0047] The copper busbar 4 and the first relay 311 are generally electrically connected by bolts. Due to the presence of bolts, the copper busbar 4 and the first relay 311 have a high connection strength.

[0048] In the above technical solution, the copper busbar 4 is used to electrically connect two adjacent first relays 311 or to the energy storage unit of the battery pack. On the one hand, the copper busbar 4 has high structural strength, which can increase the connection strength of the two adjacent first relays 311 when they are connected in series. On the other hand, the use of the copper busbar 4 eliminates the traditional connection method of wire harness and connector, which improves the problems of electrical signal interference and transmission delay.

[0049] Please see Figure 2 and Figure 4 In one embodiment, the support portion 11 is formed with a plurality of second through holes 11b extending along the first direction X; the plurality of copper busbars 4 include a plurality of external copper busbars 41, which are respectively disposed in the plurality of second through holes 11b and extend out of the housing 1 from the first opening 1a.

[0050] In the above technical solution, the end of the housing 1 near the input terminal 3112 and output terminal 3113 of the first relay 311 is usually used for the mounting structure inside the battery pack. Multiple second through holes 11b are provided on the support part 11, and multiple external copper busbars 41 can pass through the corresponding second through holes 11b respectively and extend out of the housing 1 from the first opening 1a. This solution can provide sufficient connection space for the outer end of the external copper busbar 41, and the setting of the second through holes 11b can provide a limiting basis for the external copper busbar 41 to ensure the structural stability of the external copper busbar 41.

[0051] Please see Figure 4 and Figure 5 In one embodiment, the input terminals 3112 and output terminals 3113 of a plurality of first relays 311 are arranged sequentially along the second direction Y. The plurality of first relays 311 include a main positive relay 311a and a fast charging relay 311b distributed along the third direction Z. The copper busbar 4 includes a series copper busbar 42 of the main positive relay 311a and the fast charging relay 311b connected in series. The series copper busbar 42 has a middle section 421, which is bent toward the bearing portion 11 and is located between the main positive relay 311a and the fast charging relay 311b. The first direction X, the second direction Y and the third direction Z intersect.

[0052] "The input terminals 3112 and output terminals 3113 of the multiple first relays 311 are sequentially distributed along the second direction Y" means that for each first relay 311, the input terminal 3112 is always located on the same side of the output terminal 3113 along the second direction Y. For example Figure 4 As shown, input terminal 3112 is located to the left of output terminal 3113.

[0053] Based on the above structure of the series copper busbar 42, the series copper busbar 42 can be formed by bending. For example, first bend a straight copper busbar 4 from the middle to obtain two connecting segments 422 that are parallel along the width direction of the straight copper busbar 4, so as to connect the middle segment 421 of the two connecting segments 422. Then bend the two connecting segments 422 to both sides along the thickness direction of the straight copper busbar 4 to obtain the above structure of the series copper busbar 42.

[0054] Because the input terminal 3112 and the output terminal 3113 are distributed along the second direction Y, and the main positive relay 311a and the fast charging relay 311b are distributed along the third direction Z, there is a misalignment between the output terminal 3113 of the main positive relay 311a and the input terminal 3112 of the fast charging relay 311b. In the above technical solution, the two connecting sections 422 of the series copper busbar 42 are respectively connected to the output terminal 3113 of the main positive relay 311a and the input terminal 3112 of the fast charging relay 311b. Based on this, the series copper busbar 42 has a middle section 421, and the middle section 421 faces the bearing. The bent configuration of the carrier 11 serves two purposes. Firstly, the presence of the intermediate section 421 allows the two connecting sections 422 of the series copper busbar 42 to maintain sufficient current carrying capacity to cope with high-voltage scenarios. Secondly, the intermediate section 421 is bent toward the carrier 11 and located between the main positive relay 311a and the fast charging relay 311b. This allows full utilization of the space between the main positive relay 311a and the fast charging relay 311b along the first direction X, enabling the main positive relay 311a and the fast charging relay 311b to be arranged more compactly in the third direction Z, thereby increasing the layout density of multiple first electrical components 31.

[0055] In one specific implementation, the power distribution module 100 includes a housing 1, a main circuit board 2, and multiple electrical components 3; the housing 1 has a first opening 1a in a first direction X; the main circuit board 2 covers the first opening 1a; the multiple electrical components 3 are respectively disposed on both sides of the main circuit board 2 in the first direction X, and the multiple electrical components 3 respectively form a battery disconnection unit 3a, a power distribution unit 3b, and a signal acquisition unit 3c, wherein at least the battery disconnection unit 3a is disposed inside the housing 1; the multiple electrical components 3 include multiple first relays 311 located in the inner cavity of the housing 1, for battery disconnection... Unit 3a includes a plurality of first relays 311; the input terminals 3112 and output terminals 3113 of the plurality of first relays 311 are arranged sequentially along the second direction Y, and the plurality of first relays 311 include a main positive relay 311a and a fast charging relay 311b arranged along the third direction Z; the copper busbar 4 includes a series copper busbar 42 of the main positive relay 311a and the fast charging relay 311b connected in series, the series copper busbar 42 has a middle section 421, the middle section 421 is bent toward the bearing part 11 and is located between the main positive relay 311a and the fast charging relay 311b.

[0056] Please see Figure 4 In one embodiment, a mounting bracket 111 is provided on the side of the support portion 11 away from the main circuit board 2; the plurality of first electrical components 31 also include a first fuse 313, one end of the first fuse 313 is mounted on the mounting bracket 111, and the other end of the first fuse 313 is connected to the input terminal 3112 of the main positive relay 311a; wherein, the battery disconnection unit 3a includes the first fuse 313.

[0057] In the first direction X, the height of the mounting bracket 111 relative to the support portion 11 is generally equal to the height of the input terminal 3112 of the main positive relay 311a relative to the support portion 11.

[0058] Although the main positive relay 311a is an active switch, its contacts may weld together due to electric arc when encountering an extreme short-circuit current far exceeding its breaking capacity, leading to the expansion of the fault or even a fire. In the above technical solution, the first fuse 313, as a passive protection element, is characterized by permanently and physically cutting off the fault circuit by melting the fuse element after the current exceeds the set threshold and continues for a certain period of time. This series layout ensures that even if the main positive relay 311a fails, the first fuse 313 can still directly cut off the power output from the positive source of the battery pack, thereby isolating the fault inside the battery pack and preventing catastrophic consequences such as thermal runaway. Moreover, the mounting bracket 111 ensures that the two ends of the first fuse 313 can be installed flush, guaranteeing the stability of the mounting structure of the first fuse 313.

[0059] Please see Figure 3 In one embodiment, a first buffer pad 112 is provided on the side of the support portion 11 near the main circuit board 2; a plurality of first electrical components 31 include a plurality of second relays 312, and the plurality of second relays 312 are disposed abutting against the first buffer pad 112; wherein, the power distribution unit 3b includes a plurality of second relays 312.

[0060] Based on the fact that "multiple second relays 312" belong to the power distribution unit 3b, multiple second relays 312 are usually used to control the power supply and power cut-off of high-voltage loads such as drive motors, DC-DC converters, air conditioning compressors, and heaters.

[0061] In the above technical solution, the first buffer pad 112 can provide a buffer base and shock absorption support for multiple second relays 312, which can effectively improve their vibration resistance and ensure the reliability of the electrical connection between the second relays 312 and the main circuit board 2.

[0062] Please see Figure 3 In one embodiment, a second buffer pad 113 is provided on the side of the support portion 11 near the main circuit board 2, and a plurality of first electrical components 31 include a first pre-charge resistor 314, the first pre-charge resistor 314 is disposed on the second buffer pad 113, and the battery disconnection unit 3a includes the first pre-charge resistor 314.

[0063] The "first pre-charge resistor 314" belongs to the battery disconnection unit 3a. The main function of the first pre-charge resistor 314 is to limit the current, protect the relays and high-voltage loads with higher value, and ensure that the high-voltage system can establish power supply smoothly and safely.

[0064] In the above technical solution, the second buffer pad 113 can provide a buffer base and shock-absorbing support for the first pre-charge resistor 314, which can effectively improve its shock resistance and ensure the reliability of the electrical connection between the first pre-charge resistor 314 and the main circuit board 2.

[0065] Please see Figure 3 In another embodiment, a second buffer pad 113 is provided on the side of the support portion 11 near the main circuit board 2, and a plurality of first electrical components 31 include a second pre-charge resistor 315, the second pre-charge resistor 315 is disposed on the second buffer pad 113, and the power distribution unit 3b includes the second pre-charge resistor 315.

[0066] Since the "second pre-charge resistor 315" belongs to the power distribution unit 3b, the second pre-charge resistor 315 is usually used to limit the current and protect higher-value relays (e.g., relays in the power distribution unit 3b) and high-voltage loads (e.g., power supply for high-voltage loads such as superstructures, PTC, AC, DC-DC, BDCAC, battery liquid heating, air conditioning, etc.), ensuring that the high-voltage system establishes power supply smoothly and safely.

[0067] In the above technical solution, the second buffer pad 113 can provide a buffer base and shock absorption support for the second pre-charge resistor 315, which can effectively improve its vibration resistance and ensure the reliability of the electrical connection between the second pre-charge resistor 315 and the main circuit board 2.

[0068] It should be noted that the two parallel technical features, "first pre-charge resistor 314" and "second pre-charge resistor 315", can be set individually or simultaneously. Obviously, setting them simultaneously is more effective.

[0069] Please see Figure 1 and Figure 2 In one embodiment, the main circuit board 2 has a plurality of through holes extending along the first direction X; at least a portion of the first electrical components 31 have plug terminals 31a located in the first direction X, and the plug terminals 31a are plugged into the corresponding through holes.

[0070] In the above technical solution, the first electrical component 31 is plugged into the plug-in through hole on the main circuit board 2 through the plug-in terminal 31a, thereby realizing electrical connection. On the one hand, the plug-in method allows the first electrical component 31 to be installed on the main circuit board 2 after the main circuit board 2 is installed on the housing 1, giving the power distribution module 100 more convenient operation methods. On the other hand, the plug-in through hole can also provide precise positioning for the plug-in terminal 31a, ensuring that the first electrical component 31 is in the correct position after the electrical connection is completed.

[0071] Specifically, the multiple first electrical components 31 include a first relay 311 with a larger size and a second relay 312 with a smaller size. The second relay 312 can be pre-inserted into the main circuit board 2 through the plug-in terminal 31a, while the first relay 311 needs to wait for the main circuit board 2 to be installed before being inserted into the main circuit board 2. Alternatively, the first relay 311 can be pre-installed into the housing 1, and the main circuit board 2 can be positioned relative to the housing 1 by means of the positioning connection between the plug-in terminal 31a and the plug-in through hole.

[0072] Please see Figure 1 and Figure 4 In one embodiment, the housing 1 has a mounting sidewall 12 located in the third direction Z; the signal acquisition unit 3c includes an acquisition circuit board 33, which is mounted on the outside of the mounting sidewall 12 and connected to the main circuit board 2 via pin headers; wherein the first direction X intersects with the third direction Z.

[0073] The “acquisition circuit board 33” is connected to the main circuit board 2 via pin headers. The main circuit board 2 can input the voltage, current, temperature and other signals it acquires into the acquisition circuit board 33. The acquisition circuit board 33 can perform logical operations such as insulation monitoring, fault diagnosis, charge and discharge control and thermal management. The acquisition circuit board 33 is generally equipped with a communication interface to communicate with the vehicle VCU to realize the overall intelligent control and safety monitoring of the high voltage system.

[0074] In the above technical solution, the battery disconnection unit 3a is located inside the housing 1, while the acquisition circuit board 33 is installed on the outside of the mounting side wall 12. The insulating housing 1 can achieve electrical isolation between high voltage and low voltage, ensuring the accuracy of the data acquired by the acquisition circuit board 33.

[0075] Please see Figure 1 and Figure 2 In one embodiment, the plurality of electrical components 3 include a plurality of second fuses 32, which are disposed on the side of the main circuit board 2 away from the housing 1; the power distribution unit 3b includes a plurality of second fuses 32.

[0076] For the power distribution unit 3b, since there are many power distribution targets, multiple second fuses 32 are usually needed to protect multiple distribution circuits respectively. At the same time, the specifications of the multiple second fuses 32 are usually low and the size is small. In the above technical solution, the multiple second fuses 32 are set on the side of the main circuit board 2 away from the housing 1, which can make full use of the characteristics of small size and high density of the second fuses 32, and make full use of the outer mounting space of the main circuit board 2.

[0077] The battery pack provided by the present invention includes the power distribution module 100 described above. The specific structure of the power distribution module 100 is as described in the above embodiments. Since the battery pack adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be described in detail here.

[0078] The electrical device provided by this invention includes the battery pack described above. The specific structure of the battery pack is as described in the above embodiments. Since the electrical device adopts all the technical solutions of all the above embodiments, it has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be elaborated here. The electrical device includes, but is not limited to, new energy vehicles, drones, etc.

[0079] In one specific implementation, the accessory module also includes a main positive pre-charge relay. The following describes the working logic of the power distribution module 100 when the electrical equipment is a vehicle: When the vehicle starts, the signal acquisition unit 3c receives the VCU command through the communication interface and issues a closing command to control the main positive precharge relay and the main negative relay 311c to engage and connect the high voltage circuit to precharge the high voltage components such as the motor and electronic control. When the downstream high voltage reaches the set voltage value, the main positive precharge relay is disconnected and the main positive relay 311a is engaged, and the high voltage of the whole vehicle is successfully powered on. After the power distribution module 100 is successfully powered on, it supplies power to the superstructure, PTC, AC, DC-DC, BDCAC, battery liquid heating, air conditioning and other high-voltage loads through the second relay 312 and the second fuse 32. The power distribution module 100 collects information such as voltage, bus current and insulation value of the input and output terminals of these relays through the acquisition circuit board 33, and sends this information to the external controller through CAN signal for relay adhesion, insulation judgment and other vehicle control. When the vehicle is fast charging, after confirming that the charging conditions are met, the BMS sends a control signal to the power distribution module 100 to close the main positive relay 311a, the main negative relay 311c and the fast charging relay 311b. When the main positive relay 311a, the main negative relay 311c and the fast charging relay 311b are normally engaged, the vehicle begins to enter the fast charging mode.

[0080] The above are merely preferred embodiments of the present invention and do not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention specification and drawings under the concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A power distribution module for a battery pack, characterized in that, The power distribution module includes: The housing has a first opening in a first direction; The main circuit board is disposed over the first opening; and, Multiple electrical components are respectively disposed on both sides of the main circuit board in the first direction. The multiple electrical components respectively form a battery disconnection unit, a power distribution unit and a signal acquisition unit, wherein at least the battery disconnection unit is disposed on the inner side of the housing.

2. The power distribution module as described in claim 1, characterized in that, The housing is provided with a support component inside; The plurality of electrical components include a plurality of first electrical components located in the inner cavity of the housing, and at least a portion of the first electrical components are disposed in the support portion.

3. The power distribution module as described in claim 2, characterized in that, The bearing portion is formed with a plurality of first through holes extending along a first direction; The plurality of first electrical components include a plurality of first relays, which are respectively disposed through a plurality of first through holes and are detachably connected to the carrier portion; The battery disconnection unit includes a plurality of the first relays.

4. The power distribution module as described in claim 3, characterized in that, The housing also has a second opening opposite to the first opening; The first relay has a connecting protrusion at the middle of the first direction. The connecting protrusion is located on the side of the bearing portion near the second opening and is threaded to the bearing portion.

5. The power distribution module as described in claim 3, characterized in that, The first relay has an input terminal and an output terminal at the end opposite to the main circuit board. The input terminal and the output terminal are respectively connected to copper busbars, which are configured to be connected in series with two adjacent first relays, or electrically connected to the energy storage unit of the battery pack.

6. The power distribution module as described in claim 5, characterized in that, The supporting part is formed with a plurality of second through holes extending along the first direction; The plurality of copper busbars include a plurality of external copper busbars, which are respectively inserted through a plurality of second vias and protrude from the housing through the first opening.

7. The power distribution module as described in claim 5, characterized in that, The input terminals and output terminals of the plurality of first relays are arranged sequentially along the second direction, and the plurality of first relays include a main positive relay and a fast charging relay arranged along the third direction; The copper busbar includes a series copper busbar that connects the main positive relay and the fast charging relay in series. The series copper busbar has a middle section that is bent toward the bearing portion and is located between the main positive relay and the fast charging relay. The first direction, the second direction, and the third direction intersect each other.

8. The power distribution module as described in claim 7, characterized in that, A mounting bracket is provided on the side of the support portion away from the main circuit board; The plurality of the first electrical components also include a first fuse, one end of which is mounted on the mounting bracket and the other end of which is connected to the input terminal of the main positive relay; The battery disconnection unit includes the first fuse.

9. The power distribution module as described in claim 2, characterized in that, A first buffer pad is provided on the side of the support part near the main circuit board; The plurality of first electrical components include a plurality of second relays, and the plurality of second relays are disposed in contact with the first buffer pad; The power distribution unit includes a plurality of the second relays.

10. The power distribution module as described in claim 2, characterized in that, A second buffer pad is provided on the side of the support portion near the main circuit board, wherein: The plurality of the first electrical components include a first pre-charge resistor disposed on the second buffer pad, and the battery disconnection unit includes the first pre-charge resistor; and / or, The plurality of the first electrical components include a second pre-charge resistor disposed on the second buffer pad, and the power distribution unit includes the second pre-charge resistor.

11. The power distribution module as described in any one of claims 1 to 10, characterized in that, The main circuit board has a plurality of through holes extending along a first direction; At least a portion of the first electrical device has a plug-in terminal in a first direction, the plug-in terminal being plugged into a corresponding plug-in through hole.

12. The power distribution module as described in any one of claims 1 to 10, characterized in that, The housing has a mounting sidewall facing a third direction; The signal acquisition unit includes an acquisition circuit board, which is mounted on the outside of the mounting sidewall and connected to the main circuit board via pin headers. Wherein, the first direction intersects with the third direction.

13. The power distribution module as described in any one of claims 1 to 10, characterized in that, The plurality of electrical components include a plurality of second fuses disposed on the side of the main circuit board away from the housing; The power distribution unit includes a plurality of the second fuses.

14. A battery pack, characterized in that, Includes the power distribution module as described in any one of claims 1 to 13.

15. An electrical appliance, characterized in that, Includes the battery pack as described in claim 14.

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