High-voltage conductive bar fixing structure and automobile

Abstract

This application discloses a high-voltage busbar fixing structure and an automobile. The high-voltage busbar fixing structure includes: a busbar base, the busbar base including a base housing and a nut fixed to the base housing; and a buckle, the buckle including a first limiting part and a guiding part, the first limiting part cooperating with a first mating limiting part in the busbar base to restrict the relative movement of the busbar base and the buckle in a first direction; the guiding part cooperating with a guide groove in the busbar base to guide the relative movement of the busbar base and the buckle in a second direction. The high-voltage busbar fixing structure according to this application can better fix the high-voltage busbar.

Description

Technical Field

[0001] This application relates to the automotive field, and more specifically, to a high-voltage busbar fixing structure and an automobile having such a high-voltage busbar fixing structure. Background Technology

[0002] With the development of electric vehicle technology, power batteries, as an important component of new energy vehicles, are key to the safe driving of vehicles.

[0003] There is a type of battery pack in which the crossbeam is made of extruded aluminum or die-cast aluminum, and the high-voltage conductor is fixed to the output pole base by bolts. The output pole base is snapped into the crossbeam of the battery pack for fixation.

[0004] During vehicle operation, especially under conditions of rapid acceleration and vibration, the high-voltage busbars are prone to loosening. Loosening can lead to increased contact resistance at electrical connections and abnormally high temperatures. When the temperature exceeds the maximum permissible range for the battery cell, it may trigger thermal runaway, causing battery pack safety issues. In severe cases, loose connections can cause the entire vehicle to lose high voltage, affecting normal vehicle operation. Summary of the Invention

[0005] The main technical problem this application aims to solve is how to better fix high-voltage busbars.

[0006] To solve the above-mentioned technical problems, this application provides a high-voltage busbar fixing structure, which includes: A conductive bus base, the conductive bus base comprising a base housing and a nut fixed to the base housing; The buckle includes a first limiting part and a guiding part. The first limiting part cooperates with a first mating limiting part in the conductive busbar base to restrict the relative movement between the conductive busbar base and the buckle in a first direction. The guiding part cooperates with a guiding groove in the conductive busbar base to guide the relative movement between the conductive busbar base and the buckle in a second direction.

[0007] According to one aspect of this application, the high-voltage busbar fixing structure further includes a high-voltage busbar, a busbar, and a threaded connector. The high-voltage busbar is used to connect to the battery circuit breaker unit, the busbar is used to connect to the cell output terminal, and the threaded connector cooperates with the nut to fix the high-voltage busbar and the busbar to the busbar base.

[0008] According to a high-voltage busbar fixing structure proposed in one aspect of this application, the buckle includes a second limiting part, which can cooperate with a second matching limiting part in the battery pack crossbeam, thereby limiting the relative movement of the buckle and the battery pack crossbeam in a first direction.

[0009] According to a high-voltage busbar fixing structure proposed in one aspect of this application, the guide portion includes an edge, and the guide groove includes a mating edge, the edge engaging with the mating edge to restrict the buckle from rotating relative to the busbar base about a first direction.

[0010] According to a high-voltage busbar fixing structure proposed in one aspect of this application, the buckle includes a buckle body that can engage with an opening in the battery pack crossbeam, thereby restricting the buckle from rotating about a first direction relative to the battery pack crossbeam.

[0011] According to one aspect of the high-voltage busbar fixing structure, the guide portion is plate-shaped, the buckle body is cube-shaped, and the guide portion and the buckle body are connected by a neck.

[0012] According to a high-voltage busbar fixing structure proposed in one aspect of this application, a base plate is provided at the bottom of the guide groove, the upper surface of the base plate is in contact with the lower surface of the guide portion, and the lower surface of the base plate is in contact with the upper surface of the buckle body.

[0013] According to a high-voltage busbar fixing structure proposed in one aspect of this application, the nut and the base housing are injection molded together.

[0014] According to a high-voltage busbar fixing structure proposed in one aspect of this application, at least two flanges are provided at the lower end of the base housing. The flanges are able to contact the battery pack crossbeam across both sides, thereby preventing the base housing from rotating relative to the battery pack crossbeam about a first direction.

[0015] On the other hand, this application provides an automobile that includes the high-voltage busbar fixing structure described in any of the preceding aspects.

[0016] According to the technical solution of this application, the buckle is detachably connected to the conductive bus base by the cooperation of the guide part and the guide groove, and can be directly replaced when the buckle is damaged, making maintenance simple. Attached Figure Description

[0017] The disclosure of this application is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this application. Wherein: Figure 1The schematic diagram illustrates a high-voltage busbar fixing structure according to one embodiment of the present application, wherein a snap-fit ​​is inserted into the busbar base; Figure 2 Schematic representation Figure 1 The high-voltage busbar fixing structure in the middle, wherein the buckle is not inserted into the busbar base; Figure 3 Schematic representation Figure 1 The conductor bus base of the high-voltage conductor bus fixing structure in the middle; Figure 4 A portion of a battery pack according to one embodiment of this application is schematically shown; Figure 5 Schematic representation Figure 4 The battery cells in the battery pack; Figure 6 Schematic representation Figure 4 The high-voltage conductor busbar of the battery pack. Detailed Implementation

[0018] The embodiments of this application will now be described in detail with reference to the accompanying drawings. Those skilled in the art will appreciate that these descriptions are merely descriptive and exemplary and should not be construed as limiting the scope of protection of this application.

[0019] A high-voltage conductor bus fixing structure 100 according to a specific embodiment of this application is used to fix a high-voltage conductor bus 3 inside a battery pack. The high-voltage conductor bus fixing structure 100 includes a conductor bus base 1 and a clip 2.

[0020] The conductor bus base 1 includes a base housing 11 and a nut 12 fixed to the base housing 11. (Reference) Figure 3 As shown, the base housing 11 forms a receiving space for accommodating the busbar 4 and provides a connection point between the high-voltage conductor 3 and the busbar 4. The clip 2 is used to fix the conductor base 1 to the battery pack crossbeam 6.

[0021] For example, the first direction is a vertical direction (e.g., the Z direction) perpendicular to the extension direction of the battery pack beam 6, and the second direction is a horizontal direction (e.g., the X direction) perpendicular to the extension direction of the battery pack beam 6. The first direction and the second direction are perpendicular to each other.

[0022] Through the cooperation of the guide part 21 and the guide groove 13, the buckle 2 is detachably connected to the conductive bus base 1. With this detachable connection method, if the buckle 2 is damaged, the buckle 2 can be directly replaced without replacing the entire conductive bus base 1, reducing maintenance costs; the installation and disassembly process does not require special tools and is easy to operate; the connection strength between the buckle 2 and the conductive bus base 1 is high and it is not easy to loosen under vibration conditions.

[0023] The base housing 11 of the conductive busbar base 1 can adopt a doghouse structure. A doghouse structure is a housing structure with a specific shape, including horizontal and vertical walls that enclose a receiving space. A guide groove 13 is provided in the housing wall, extending along a second direction through the vertical wall. The guide groove 13 has an inlet end and a stop end. The opening size of the inlet end can be larger than that of the stop end, forming a tapered structure to facilitate the entry of the guide part 21; the stop end has a stop surface to limit the sliding stroke of the guide part 21. The cross-section of the guide groove 13 can be rectangular, trapezoidal, or other polygonal, matching the shape of the guide part 21.

[0024] The base housing 11 with this design is compact and can achieve reliable fixation in a limited space; the guide groove 13 makes it easier to install and remove the buckle 2; the shape of the housing helps to protect the internal electrical connection components from external impacts.

[0025] The base housing 11 can be made of insulating materials, such as engineering plastics like PA66, PBT, and PPS, to ensure electrical insulation between the high-voltage conductor 3 and the battery pack crossbeam 6. The base housing 11 can also be made of ceramic or other insulating materials.

[0026] The nut 12 and the base housing 11 can be injection molded together. Specifically, using an insert injection molding process, the nut 12 is pre-positioned in the cavity of the injection mold, and then molten plastic material is injected into the cavity. After the plastic material cools and solidifies, it forms an integral structure with the nut 12. The nut 12 can also be fixed to the base housing 11 by pressing, hot melting, ultrasonic welding, or threaded connection. The base housing 11 may have holes to reduce material consumption, reduce overall weight, and reduce air bubbles during the injection molding process.

[0027] The latch 2 includes a first limiting part and a guide part 21. The guide part 21 cooperates with the guide groove 13 in the conductive bus base 1, thereby guiding the relative movement of the conductive bus base 1 and the latch 2 in the second direction. During installation, the guide part 21 of the latch 2 is inserted from the inlet end of the guide groove 13 and slid along the second direction to the stop end to complete the connection between the latch 2 and the conductive bus base 1. During disassembly, the latch 2 can be removed from the conductive bus base 1 by sliding it in the opposite direction.

[0028] The guide portion 21 can be constructed as a plate. The plate-shaped guide portion 21 structure facilitates smooth sliding in the guide groove 13 and reduces sliding resistance; the upper and lower surfaces of the plate-shaped guide portion 21 cooperate with the wall surface of the guide groove 13 to prevent the conductive bus base 1 from rotating relative to the buckle 2 about a direction perpendicular to the first direction (e.g., the Y direction), thereby improving the stability of the connection.

[0029] The guide portion 21 may include edges, and the guide groove 13 may include mating edges that engage with each other to restrict the buckle 2 from rotating about a first direction relative to the conductive busbar base 1. For example, the guide portion 21 may be constructed as a quadrilateral (such as a rectangle or square), and the guide groove 13 may be constructed as a matching quadrilateral cross-section. Each edge of the quadrilateral guide portion 21 abuts against the mating edges of the inner wall of the guide groove 13 to prevent the buckle 2 from rotating about the first direction within the guide groove 13. The guide portion 21 may also be constructed as a triangle, pentagon, hexagon, or other polygons, and the guide groove 13 may be constructed as a matching shape.

[0030] The first limiting part cooperates with the first paired limiting part in the conductive bus base 1, thereby restricting the relative movement between the conductive bus base 1 and the buckle 2 in the first direction. For example, the first limiting part is constructed as a hook, and the first paired limiting part is constructed as a groove that cooperates with the hook; or the first limiting part is constructed as a boss, and the first paired limiting part is constructed as a groove that cooperates with the boss; or the first limiting part is constructed as a stepped surface, and the first paired limiting part is constructed as a paired stepped surface that cooperates with the stepped surface.

[0031] refer to Figure 1 As shown, a base plate 14 is provided at the bottom of the guide groove 13. The upper surface of the base plate 14 contacts the lower surface of the guide portion 21, and the lower surface of the base plate 14 contacts the upper surface of the snap-fit ​​body 23. In this respect, the first limiting part is the lower surface of the guide portion 21 and the upper surface of the snap-fit ​​body 23, and the first mating limiting part is the base plate 14. The base plate 14 is clamped between the guide portion 21 and the snap-fit ​​body 23, thereby limiting the relative movement of the conductive busbar base 1 and the snap-fit ​​2 in the first direction. This structure uses the base plate 14 of the guide groove 13 as a limiting component, which is simple in structure and does not require additional limiting structure; the base plate 14 simultaneously bears the pressure from the guide portion 21 and the snap-fit ​​body 23, resulting in uniform force distribution and reliable connection.

[0032] refer to Figure 2 As shown, the buckle 2 may include a buckle body 23, which can engage with an opening in the battery pack crossbeam 6 to restrict the buckle 2 from rotating about a first direction relative to the battery pack crossbeam 6.

[0033] The snap-fit ​​body 23 can be constructed as a cube. The cube-shaped snap-fit ​​body 23 has multiple planes that mate with the inner wall of the opening in the battery pack crossbeam 6 to prevent the snap-fit ​​2 from rotating around the first direction. The snap-fit ​​body 23 can also be constructed as a cuboid, prism, or other polygonal prism, the shape of which matches the shape of the opening in the battery pack crossbeam 6.

[0034] The guide portion 21 and the latching body 23 can be connected via a neck 24. The neck 24 is a transition portion connecting the guide portion 21 and the latching body 23, and its cross-sectional dimensions are smaller than those of the guide portion 21 and the latching body 23, thereby forming a stepped structure between the guide portion 21 and the latching body 23. This stepped structure can cooperate with the base plate 14 of the guide groove 13 to achieve limiting in the first direction.

[0035] The buckle 2 may also include a second limiting part 22, which can cooperate with the second matching limiting part in the battery pack beam 6 to limit the relative movement between the buckle 2 and the battery pack beam 6 in the first direction.

[0036] Through the cooperation of the first limiting part and the first mating limiting part, the conductor bus base 1 and the buckle 2 are fixed in the first direction; through the cooperation of the second limiting part 22 and the second mating limiting part, the buckle 2 and the battery pack crossbeam 6 are fixed in the first direction. Therefore, the conductor bus base 1 is indirectly fixed to the battery pack crossbeam 6 in the first direction through the buckle 2, realizing the reliable installation of the high-voltage conductor bus fixing structure 100 in the battery pack.

[0037] The second limiting part 22 can be configured as a wedge-shaped protrusion provided on the buckle body 23. The wedge-shaped protrusion has an inclined guide surface and a vertical limiting surface. The guide surface is inclined toward the direction in which the buckle 2 is inserted into the battery pack crossbeam 6, so as to facilitate the buckle 2 to be smoothly inserted into the opening of the battery pack crossbeam 6; the limiting surface abuts against the second mating limiting part (e.g., the edge of the opening) of the battery pack crossbeam 6 to prevent the buckle 2 from coming out of the opening.

[0038] There can be two second limiting parts 22, respectively disposed on both sides of the buckle body 23. The two second limiting parts 22 are symmetrically arranged, which can make the force on the buckle 2 in the opening of the battery pack crossbeam 6 more balanced and improve the stability of the fixation. The number of second limiting parts 22 can also be one, three, four or more.

[0039] The second matching limiting part can be a stepped surface, groove, or other structure that can cooperate with the second limiting part 22 at the edge of the opening of the battery pack crossbeam 6.

[0040] At least two flanges 15 may be provided at the lower end of the base housing 11. The flanges 15 can cross the two sides of the battery pack crossbeam 6 and contact the battery pack crossbeam 6, thereby preventing the base housing 11 from rotating relative to the battery pack crossbeam 6 about the first direction.

[0041] The flange 15 can be constructed as a right-angle flange, meaning that the flange 15 extends at a right angle to the horizontal wall of the base housing 11. When the base housing 11 is installed on the battery pack crossbeam 6, the flanges 15 on both sides overlap the two side surfaces of the battery pack crossbeam 6, forming a straddling contact with the battery pack crossbeam 6. When the threaded connector 5 is tightened with the nut 12, the tightening torque will generate a tendency for the base housing 11 to rotate around the first direction. The contact between the flange 15 and the two sides of the battery pack crossbeam 6 can resist this rotational tendency, ensuring that the base housing 11 remains stable during the tightening process.

[0042] For example, there are two flanges 15, which are respectively set on opposite sides of the base housing 11 and arranged symmetrically. The material of the flanges 15 is the same as that of the base housing 11, and they can be integrally formed with the base housing 11.

[0043] refer to Figure 4 and Figure 6 As shown, in the battery pack, the high-voltage busbar fixing structure 100 may further include a high-voltage busbar 3, a busbar 4, and a threaded connector 5. The high-voltage busbar 3 is used to connect the battery disconnect unit (BDU) and is an important component of the battery pack's high-voltage circuit. The high-voltage busbar 3 is typically made of copper (hence the name high-voltage copper busbar) to ensure good conductivity and low resistance. The high-voltage busbar 3 has through holes for the threaded connector 5 to pass through.

[0044] refer to Figure 5 As shown, bus 4 is used to connect the output terminals of the battery cells, collecting and conducting the current from multiple battery cells to the high-voltage bus 3. Bus 4 can be made of copper or aluminum. Bus 4 also has through holes, corresponding to the through holes of the high-voltage bus 3.

[0045] The threaded connector 5 engages with the nut 12 to fix the high-voltage busbar 3 and the busbar 4 to the busbar base 1. The threaded connector 5 can be a bolt, screw, or combination bolt. For example, after the bolt passes through the through holes of the high-voltage busbar 3 and the busbar 4, it engages with the nut 12 embedded in the base housing 11. By tightening the bolt, the high-voltage busbar 3 and the busbar 4 are pressed and fixed onto the busbar base 1.

[0046] The complete current path from the battery to the external source is as follows: terminal of cell 7 → aluminum busbar 8 connecting cell → busbar 4 → high voltage busbar 3 (fixed by threaded connector 5) → battery circuit breaker unit → external load. The aluminum busbar 8 connecting cell to the terminal of cell 7 is laser-welded, resulting in high welding strength and low contact resistance; the busbar 4 and the aluminum busbar connecting cell to the 8 are ultrasonically welded, suitable for connecting dissimilar metals such as copper and aluminum, ensuring stable welding quality.

[0047] The overall installation process of the high-voltage conductor bus fixing structure 100 is as follows: The first step is to install the conductive busbar base 1 onto the snap fastener 2. Align the guide groove 13 of the conductive busbar base 1 with the guide portion 21 of the snap fastener 2, and slide the conductive busbar base 1 along the second direction, allowing the guide portion 21 to enter from the inlet end of the guide groove 13 and slide to the stop end. During the sliding process, the edge of the guide portion 21 engages with the mating edge of the guide groove 13, guiding the conductive busbar base 1 to move in the correct direction. When the guide portion 21 reaches the stop end, the first limiting portion engages with the first mating limiting portion, completing the fixation of the conductive busbar base 1 and the snap fastener 2.

[0048] The second step is to install the clip 2 onto the battery pack crossbeam 6. Align the clip body 23 of the clip 2 with the opening on the battery pack crossbeam 6 and press it downwards in the first direction. During the pressing process, the wedge-shaped guide surface of the second limiting part 22 contacts the edge of the opening, generating elastic deformation, allowing the second limiting part 22 to pass through the opening. When the clip body 23 is fully inserted into the opening, the second limiting part 22 elastically recovers and engages with the second mating limiting part of the battery pack crossbeam 6, completing the fixation of the clip 2 to the battery pack crossbeam 6. At this time, the flange 15 of the base housing 11 overlaps the two side surfaces of the battery pack crossbeam 6.

[0049] The third step is to install the busbar 4 and the high-voltage conductor 3. Place the busbar 4 within the receiving space of the conductor base 1, aligning the through hole of the busbar 4 with the nut 12. Stack the high-voltage conductor 3 on top of the busbar 4, aligning the through hole of the high-voltage conductor 3 with the through hole of the busbar 4 and the nut 12.

[0050] Fourth step, tighten the threaded connector 5. Pass the threaded connector 5 through the through holes of the high-voltage busbar 3 and the busbar 4, and engage it with the nut 12. Use a torque wrench or other tools to tighten the threaded connector 5 to the specified torque to complete the fixing of the high-voltage busbar 3 and the busbar 4. During the tightening process, the flange 15 of the base housing 11 contacts both sides of the battery pack crossbeam 6 to prevent the base housing 11 from rotating around the first direction and ensure the reliability of the threaded connection.

[0051] This application also provides a vehicle that includes a high-voltage conductor busbar fixing structure or battery pack according to any of the above embodiments. The vehicle can be a pure electric vehicle, a plug-in hybrid electric vehicle, or other types of electric vehicles. The high-voltage conductor busbar fixing structure is installed inside the vehicle's battery pack and is used to fix the high-voltage conductor busbar connecting the cell output terminal and the battery disconnect unit.

[0052] By adopting the high-voltage conductor fixing structure of this application, the high-voltage connection of the vehicle is more stable and reliable throughout its entire life cycle, avoiding the risk of abnormal temperature rise and thermal runaway caused by the loosening of the high-voltage conductor, thus improving the safety and reliability of electric vehicles.

Claims

1. A high-voltage conductor busbar fixing structure (100), characterized in that, The high-voltage busbar fixing structure (100) includes: Conductive bus base (1), the conductive bus base (1) includes a base housing (11) and a nut (12) fixed to the base housing (11); The buckle (2) includes a first limiting part and a guide part (21). The first limiting part cooperates with the first matching limiting part in the conductive bus base (1) to restrict the relative movement of the conductive bus base (1) and the buckle (2) in a first direction. The guide part (21) cooperates with the guide groove (13) in the conductive bus base (1) to guide the relative movement of the conductive bus base (1) and the buckle (2) in a second direction.

2. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, The high-voltage conductor bus fixing structure (100) also includes a high-voltage conductor bus (3), a busbar (4) and a threaded connector (5). The high-voltage conductor bus (3) is used to connect the battery circuit breaker unit, the busbar (4) is used to connect the battery cell output electrode, and the threaded connector (5) cooperates with the nut (12) to fix the high-voltage conductor bus (3) and the busbar (4) to the conductor bus base (1).

3. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, The buckle (2) includes a second limiting part (22), which can cooperate with a second matching limiting part in the battery pack beam (6) to restrict the relative movement of the buckle (2) and the battery pack beam (6) in a first direction.

4. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, The guide portion (21) includes an edge, and the guide groove (13) includes a mating edge, the edge engaging with the mating edge to restrict the buckle (2) from rotating about a first direction relative to the conductive bus base (1).

5. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, The buckle (2) includes a buckle body (23) which can engage with an opening in the battery pack beam (6) to restrict the buckle (2) from rotating about a first direction relative to the battery pack beam (6).

6. The high-voltage conductor bus fixing structure (100) according to claim 5, characterized in that, The guide part (21) is plate-shaped, the buckle body (23) is cube-shaped, and the guide part (21) and the buckle body (23) are connected by a neck (24).

7. The high-voltage conductor bus fixing structure (100) according to claim 5, characterized in that, A base plate (14) is provided at the bottom of the guide groove (13). The upper surface of the base plate (14) is in contact with the lower surface of the guide part (21), and the lower surface of the base plate (14) is in contact with the upper surface of the buckle body (23).

8. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, The nut (12) and the base housing (11) are injection molded together.

9. The high-voltage conductor bus fixing structure (100) according to claim 1, characterized in that, At least two flanges (15) are provided at the lower end of the base housing (11). The flanges (15) are able to contact the battery pack crossbeam (6) across both sides, thereby preventing the base housing (11) from rotating relative to the battery pack crossbeam (6) about a first direction.

10. A car, characterized in that, It includes a high-voltage busbar fixing structure (100) according to any one of claims 1 to 9.

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