A high-pressure dispensing unit and a method of assembling a high-pressure dispensing unit

Abstract

The application provides a high-voltage distribution unit and an assembling method of the high-voltage distribution unit. The high-voltage distribution unit comprises a shell, at least one relay fixed to the bottom of the shell, the relay being provided with one end of a high-voltage contact facing the bottom of the shell, and a circuit board vertically fixed to the shell, the board surface of the circuit board being opposite to the side surface of one side of the relay, the circuit board being electrically connected to the opposite end of the relay through a connecting sheet, and the connecting sheet being made of flexible metal material. The high-voltage distribution unit provided by the application will not cause fatigue fracture or slight wear problems due to position deviation or stress during the assembling process, and the height of the high-voltage distribution unit can be further reduced, and the utilization rate of the board surface of the circuit board can be improved.

Description

Technical Field

[0001] This invention relates to the field of automobile batteries, and more particularly to a high-voltage distribution unit and a method for assembling the high-voltage distribution unit. Background Technology

[0002] The high-voltage distribution unit is a key component in the high-voltage electrical design of electric vehicles. It includes a main relay, main fuse, high-voltage pre-charge circuit, and active discharge circuit, and its primary function is to disconnect the electric vehicle's battery system, ensuring its safety under normal conditions and in emergency situations. Furthermore, the high-voltage distribution unit can also transfer electrical energy between battery cells, charging stations, and electrical appliances.

[0003] From the perspective of reducing costs and achieving high integration, the current research trend is to integrate the battery management controller into the high-voltage distribution unit and realize the wireless connection between the battery management controller and the relays in the high-voltage distribution unit.

[0004] Figure 1 This diagram illustrates a prior art method of achieving wireless connection via male-female terminal plugging. In the prior art, the battery management controller and relays are respectively fixed to the housing of the high-voltage distribution unit. Electrical connection is achieved by plugging the female terminal on the battery management controller and the male terminal on the relay into the housing. However, there are assembly tolerances between the female terminal on the battery management controller, the male terminal on the relay, and the housing of the high-voltage distribution unit. During the assembly of multiple relays, it is difficult to guarantee the accuracy of the mating positions of so many mating terminals. Furthermore, even if the high-voltage distribution unit is assembled successfully, the assembly stress between the male terminal on the relay and the female terminal on the battery management controller can lead to fatigue fracture or abnormal fretting wear during subsequent driving.

[0005] In another prior art, the low-voltage terminal of the relay is connected to the circuit board by soldering it to a connecting piece. The laser-welded surfaces of the connecting piece and the relay are below the circuit board. The high-voltage distribution unit, including the relay, connecting piece, and circuit board in the vertical direction, results in a relatively high height, making it difficult to meet the increasingly stringent height requirements of battery packs. Furthermore, the circuit board requires multiple holes to be cut out for laser transmission to facilitate soldering between the connecting piece and the relay, leading to insufficient and fragmented space for hardware layout within the circuit board, resulting in very low utilization efficiency of the circuit board surface.

[0006] In order to overcome the above-mentioned defects of the existing technology, there is an urgent need in the field for a high voltage distribution unit that will not suffer from fatigue fracture or fretting wear due to positional deviation or stress during the assembly process, and can further reduce the height of the high voltage distribution unit and improve the board surface utilization rate. Summary of the Invention

[0007] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0008] In order to overcome the above-mentioned defects of the existing technology, the present invention provides a high voltage distribution unit and a high voltage distribution unit assembly method, which will not cause fatigue fracture or fretting wear due to position deviation or stress during the assembly process, and can further reduce the height of the high voltage distribution unit and improve the board surface utilization rate of the circuit board.

[0009] Specifically, the battery distribution unit provided according to the first aspect of the present invention includes: a housing; at least one relay fixed to the bottom of the housing, the end of the relay having a high-voltage contact facing the bottom of the housing; and a circuit board vertically fixed to the housing, the surface of the circuit board facing the side of the relay, the circuit board being electrically connected to the mating terminal of the relay via a connecting piece, the connecting piece being made of a flexible metal material.

[0010] Preferably, in one embodiment of the present invention, the connecting piece includes a first connecting portion and a second connecting portion. The first connecting portion extends vertically from both sides to form an extension portion. The first connecting portion and the extension portion are provided with pins. After the pins are inserted into the circuit board, the end face of the extension portion abuts against the circuit board. At least a portion of the pins is tin-plated. The second connecting portion is soldered to the mating terminal of the relay.

[0011] Preferably, in one embodiment of the present invention, the top end of the second connecting portion is bent to form a guide portion with a guide angle, the guide portion being configured to guide the connecting piece.

[0012] Preferably, in one embodiment of the present invention, the connecting piece further includes a body portion connecting the first connecting portion and the second connecting portion, the body portion being used to compensate for the positional deviation of the mating end of the relay during the assembly process of the connecting piece and the mating end of the relay.

[0013] Preferably, in one embodiment of the present invention, the width of the second connecting portion is greater than the width of the main body portion.

[0014] Preferably, in one embodiment of the present invention, the mating terminal of the relay includes a low-voltage drive terminal, which is disposed on the side opposite to the circuit board.

[0015] Preferably, in one embodiment of the present invention, the width of the second connection portion is greater than the width of the low-voltage drive terminal.

[0016] Preferably, in one embodiment of the present invention, the mating terminal of the relay further includes a copper busbar connected to the high-voltage contact of the relay, one end of the copper busbar being electrically connected to the circuit board via a connecting piece, and the other end being connected to a battery cell, a charging device, or a power device.

[0017] Preferably, in one embodiment of the present invention, the high-voltage distribution unit further includes a shunt; the shunt is connected to the connection terminal of a floating connector on the circuit board via a pin, and the housing of the floating connector is provided with a gap for the connection terminal to move.

[0018] Preferably, in one embodiment of the present invention, the circuit board is a battery management controller.

[0019] Furthermore, the assembly method of the battery distribution unit provided by the second aspect of the present invention includes the steps of: fixing a relay in a housing, with one end of the relay having a high-voltage contact facing downwards; vertically embedding a circuit board with a connecting piece attached into the housing, with the surface of the circuit board facing the side of the relay; and welding the connecting piece to the mating end of the relay after overlapping, so as to obtain the high-voltage distribution unit provided in any of the above embodiments. Attached Figure Description

[0020] The above-described features and advantages of the present invention will be better understood after reading the following detailed description of embodiments of the present disclosure in conjunction with the accompanying drawings. In the drawings, components are not necessarily drawn to scale, and components having similar related characteristics or features may have the same or similar reference numerals.

[0021] Figure 1 This diagram illustrates a prior art method for achieving wireless beam-free connection through male-female terminal plugging.

[0022] Figure 2 A schematic diagram of the top of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown;

[0023] Figure 3 A schematic diagram of the top of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown;

[0024] Figure 4 A schematic diagram of a relay provided according to some embodiments of the present invention is shown;

[0025] Figure 5 A schematic diagram of a circuit board provided according to some embodiments of the present invention is shown;

[0026] Figure 6 A schematic diagram of a circuit board and relay connection according to some embodiments of the present invention is shown;

[0027] Figure 7 A schematic diagram of a connecting piece provided according to some embodiments of the present invention is shown;

[0028] Figure 8 A schematic diagram of a connecting piece guiding a low-voltage drive terminal is shown according to some embodiments of the present invention;

[0029] Figure 9 A schematic diagram of a relay provided according to some embodiments of the present invention is shown;

[0030] Figure 10 A schematic diagram of the bottom of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown;

[0031] Figure 11 A schematic diagram of the connection between a copper busbar and a relay according to some embodiments of the present invention is shown;

[0032] Figure 12 A schematic diagram of the connection between a copper busbar and a relay according to some embodiments of the present invention is shown;

[0033] Figure 13 A schematic diagram of the top of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown;

[0034] Figure 14 A schematic diagram of a shunt provided according to some embodiments of the present invention is shown; and

[0035] Figure 15 A schematic diagram of a shunt assembly with a floating connector provided according to some embodiments of the present invention is shown.

[0036] Figure label:

[0037] 200: High-voltage distribution unit;

[0038] 201: Bolt;

[0039] 210: Shell;

[0040] 211: Side of the shell;

[0041] 220: Bronze busbar;

[0042] 221: Stepped surface;

[0043] 222: Extended structure;

[0044] 230: Copper busbar;

[0045] 300: High-voltage distribution unit;

[0046] 400: Relay;

[0047] 401: Side view;

[0048] 410: Low-voltage drive terminal;

[0049] 411: Receiving tank;

[0050] 412: Support base;

[0051] 421: Positioning rib;

[0052] 422: Buckle;

[0053] 430: High-voltage contact thread;

[0054] 500: Circuit board;

[0055] 510: Connecting piece;

[0056] 511: First connecting part;

[0057] 5111: Extension;

[0058] 512: Second connecting part;

[0059] 513: Pin;

[0060] 514: Guiding section;

[0061] 515: Ontology;

[0062] 516: Convex hull structure;

[0063] 520: Connecting piece;

[0064] 530: Floating connector;

[0065] 900: Relay;

[0066] 910: Positioning ribs;

[0067] 1200: Relay;

[0068] 1210: High-voltage contact;

[0069] 1400: Diverter;

[0070] 1410: Groove;

[0071] 1420: Insert pin;

[0072] 1430: Resistor; and

[0073] 1440: Bronze busbar. Detailed Implementation

[0074] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. It should be noted that the aspects described below with reference to the accompanying drawings and specific embodiments are merely exemplary and should not be construed as limiting the scope of protection of the present invention in any way.

[0075] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0076] Furthermore, the terms "upper," "lower," "left," "right," "top," "bottom," "horizontal," and "vertical" used in the following description should be understood as the orientations shown in the relevant paragraphs and accompanying drawings. These relative terms are for illustrative purposes only and do not imply that the described apparatus must be manufactured or operated in a specific orientation, and therefore should not be construed as limiting the invention.

[0077] It is understood that although terms such as "first," "second," and "third" may be used herein to describe various components, regions, layers, and / or parts, these components, regions, layers, and / or parts should not be limited by these terms, and these terms are only used to distinguish different components, regions, layers, and / or parts. Therefore, the first components, regions, layers, and / or parts discussed below may be referred to as second components, regions, layers, and / or parts without departing from some embodiments of the present invention.

[0078] As mentioned above, when existing integrated battery management controllers achieve wireless connection of the high-voltage distribution unit through male-female plug-in, it is difficult to guarantee the accuracy of the mating position, and fatigue fracture or abnormal fretting wear may occur due to assembly stress. When wireless connection is achieved by welding with connecting pieces, it is difficult to meet the height requirements of the battery pack; moreover, in order to achieve laser welding under the circuit board, multiple holes need to be cut into the circuit board for laser transmission, resulting in insufficient space for hardware layout and fragmentation, and very low board surface utilization efficiency.

[0079] In order to overcome the above-mentioned defects of the existing technology, the present invention provides a high voltage distribution unit and a high voltage distribution unit assembly method, which will not cause fatigue fracture or fretting wear due to position deviation or stress during the assembly process, and can further reduce the height of the high voltage distribution unit and improve the board surface utilization rate of the circuit board.

[0080] The following will refer to Figures 2 to 15 Describe the high-voltage distribution unit in detail.

[0081] Figure 2 and Figure 3 A schematic diagram of the top of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown.

[0082] The high-voltage distribution unit 200 may include a housing 210, and a circuit board vertically fixed to the housing 210 may be provided on the housing side 211. In some embodiments, the circuit board may be a battery management controller.

[0083] At least one relay 400 can be fixed to the bottom of the housing 210 of the high-voltage distribution unit 200. Figure 2 In the illustrated embodiment, the high-voltage distribution unit 200 may be equipped with two relays 400. For example... Figure 3 As shown, the high-voltage distribution unit 300 can be equipped with 4 relays 400.

[0084] Figure 4 A schematic diagram of a relay provided according to some embodiments of the present invention is shown.

[0085] Figure 4 The relay 400 shown is in the inverted state. For example... Figure 2 , Figure 3 and Figure 4 The relay 400 can be fixed in an inverted state at the bottom of the housing 210, that is, the end with the high-voltage contact is facing the bottom of the housing 210.

[0086] Figure 5 A schematic diagram of a circuit board according to some embodiments of the present invention is shown. The circuit board 500 may be provided with a plurality of connecting pieces 510 and 520 for electrical connection with the mating terminals of the relay 400, the connecting pieces 510 and 520 being made of flexible metal material.

[0087] Figure 6 A schematic diagram of a circuit board and relay connection provided according to some embodiments of the present invention is shown. Figure 6 The housing 210 is hidden, but it can be seen that the circuit board 500 is vertically fixed to the housing 210, and the surface of the circuit board 500 is opposite to one side of the relay 400.

[0088] The following will take the low-voltage drive terminal 410 of the relay 400 as an example to further describe the connecting piece 510 and the electrical connection between the circuit board 500 and the connecting piece 400 through the connecting piece 510.

[0089] like Figure 4 and Figure 6As shown, the mating terminals of relay 400 may include two side-mounted low-voltage drive terminals 410. The low-voltage drive terminals 410 may be located on the sides of relay 400 opposite to circuit board 500. Connecting piece 510 corresponds to the position of the low-voltage drive terminals 410 of relay 400, and is electrically connected to the low-voltage drive terminals 410 of relay 400 via the connecting piece 510 on circuit board 500.

[0090] The connecting piece 510 can be made of a flexible metal material used for electrical connections. In some embodiments, the connecting piece 510 is a flexible metal material that is easy to weld, such as nickel, nickel alloy, or pure copper. When the circuit board 500 is inserted into the housing 210 on the side 401 of the relay 400 where the low-voltage drive terminal 410 is located, the flexible connecting piece 510 can eliminate stress generated during assembly.

[0091] Figure 7 A schematic diagram of a connecting piece provided according to some embodiments of the present invention is shown. Figure 8 A schematic diagram of a connecting piece guiding a low-voltage drive terminal is shown, according to some embodiments of the present invention.

[0092] like Figure 7 As shown, the connecting piece 510 may include a first connecting portion 511 and a second connecting portion 512.

[0093] The first connecting part 511 extends from both sides towards Figure 6 The extension 5111 extends vertically in the Z-axis direction as shown. The first connecting portion 511 and the extension 5111 are provided with pins 513 for support and conduction.

[0094] After pin 513 is inserted into circuit board 500, the end face of extension 5111 abuts against circuit board 500, and then the first connecting part 511 of connecting piece 510 is fixed to circuit board 500 by reflow soldering or other methods. Pin 513 is tin-plated in at least a portion to improve adhesion when it is mounted.

[0095] The connecting piece 510 is welded to the low-voltage drive terminal 410 of the relay 400 via the second connecting part 512.

[0096] exist Figure 6 In the case of the high voltage distribution unit 200, the second connecting part 512 of the connecting piece 510 and the low voltage drive terminal 410 can be welded from the top of the housing 210, thereby realizing the electrical connection between the low voltage drive terminal 410 of the relay 400 and the circuit board 500.

[0097] In some embodiments, the welding method used for the second connecting portion 512 of the welding connector 510 and the low-voltage drive terminal 410 may include laser welding, resistance welding or ultrasonic welding.

[0098] By connecting the low-voltage drive terminal 410 and the connecting piece 510 by welding, a certain assembly error can be allowed during the assembly process.

[0099] In some embodiments, the top end of the second connecting portion 512 may be bent to form a guide portion 514 with a guide angle, the guide portion 514 being configured to guide the connecting piece 510.

[0100] The horizontally positioned connecting piece 510, through the bent guide portion 514 and the flexible deformation of the connecting piece 510 itself, can achieve a guiding function, eliminating interference tolerances in the vertical direction of the Z-axis during assembly. Furthermore, based on the arrangement of the guide portion 514, the high-voltage distribution unit 200 can tolerate greater assembly errors during assembly.

[0101] For example, such as Figure 8 As shown, the upwardly bent guide portion 514 can be used to guide the connecting piece 510 to the upper side of the low-voltage drive terminal 410. During the assembly of the circuit board 500 to the housing 210 where the relay 400 is fixed, there may be a vertical positional deviation between the connecting piece 510 and the low-voltage drive terminal 410. In this case, the horizontally positioned connecting piece 510 can be smoothly guided to the low-voltage drive terminal 410 by the upwardly bent guide portion 514 and the flexible deformation of the connecting piece 510 itself, eliminating the interference tolerance between the connecting piece 510 and the low-voltage drive terminal 410 in the vertical direction of the housing 210 during the assembly process.

[0102] Accordingly, such as Figure 4 and Figure 8 As shown, the upper end of the low-voltage drive terminal 410 of the relay 400 may also be provided with a receiving groove 411 for the guide portion 514 of the connecting piece 510 to avoid the guide portion 514. The receiving groove 411 is notched to accommodate the guide portion 514, thereby avoiding the guide portion 514 during welding.

[0103] The connecting piece 510 may also include a body portion 515 that connects the first connecting portion 511 and the second connecting portion 512. The body portion 515 may deform during the assembly process of the connecting piece 510 and the mating end of the relay 400 to compensate for the positional deviation of the mating end of the relay 400.

[0104] The width of the second connecting portion 512 can be greater than the width of the main body portion 515. When assembly stress is generated due to the mating of the connecting piece 510 and the low-voltage drive terminal 410, the main body portion 515, with its narrower width, can better accommodate the deformation of the connecting piece 510, thereby eliminating the assembly stress through deformation.

[0105] In some embodiments, the width of the second connection portion 512 may be greater than the width of the low-voltage drive terminal 410.

[0106] like Figure 6 As shown, when there is a positional deviation in the Y-axis direction during the assembly and mating process of the connecting piece 510 and the low-voltage drive terminal 410, the second connecting portion 512 can ensure sufficient welding area in the overlapping area of ​​the connecting piece 510 and the low-voltage drive terminal 410 by having a wider covering surface relative to the width of the low-voltage drive terminal 410. Thus, high assembly precision is not required between the connecting piece 510 and the low-voltage drive terminal 410 during assembly.

[0107] Preferably, such as Figure 7 As shown, the connecting piece 510 may also include a convex hull structure 516 that provides auxiliary support on the downward side of the first connecting portion 511.

[0108] Because the guide portion 514 bends upward and the extension portion 5111 extends upward, the center of gravity of the connecting piece 510 may shift, causing the connecting piece 510 to tip over. By providing the convex hull structure 516 on the downward-facing side of the first connecting portion 511, the reverse tipping of the connecting piece 510 can be effectively suppressed.

[0109] Please continue to refer to this. Figure 4 In some embodiments, the relay 400 may further include a support base 412 that is close to and located below the low-voltage drive terminal 410. The support base 412 may be made of plastic. During the welding process between the second connecting portion 512 of the connecting piece 510 and the low-voltage drive terminal 410, the support base 412 can prevent overpressure from damaging the low-voltage drive terminal 410 of the relay 400.

[0110] In addition, to facilitate the fixing and positioning of the relay 400 in the high-voltage distribution unit 200, the relay 400 may also be provided with a positioning rib 421 for guidance and a latch 422 for fixing. The positioning rib 421 can be located on both sides of the side 401 of the relay 400 for precise positioning of the relay 400 during assembly of the high-voltage distribution unit 200. The latch 422 can be located at the middle position of the side 401 and the middle position of the opposite side of the side 401. During assembly of the high-voltage distribution unit 200, the latch 422 can fasten the relay 400 to the housing 210 of the high-voltage distribution unit 200.

[0111] It is understood that the positioning rib 421 and the snap fastener 422 are merely specific solutions provided by the present invention that are easy to implement. Based on the above concept and relevant knowledge in the field, those skilled in the art can use other equivalent methods to achieve the same technical effect. For example, the relay 400 can also be guided by the housing contour positioning, and bolts can also be used to fix the relay 400.

[0112] Figure 9 A schematic diagram of a relay according to some embodiments of the present invention is shown. In some preferred embodiments, the relay 900 may include a reduced positioning rib 910. During the assembly of the high-voltage distribution unit, the reduced positioning rib 910 precisely positions the relay 900 and reduces the distance between adjacent relays 900, thereby further reducing the length dimension of the high-voltage distribution unit.

[0113] In addition to the low-voltage drive terminal 410, the mating terminals of the relay 400 may also include a copper busbar 220 connected to the high-voltage contacts of the relay 400.

[0114] Figure 10 A schematic diagram of the bottom of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown. Figure 10 The housing 210 is hidden, but it can be seen from the bottom of the housing of the high voltage distribution unit 200 that the high voltage distribution unit 200 may also include a copper busbar 220.

[0115] One end of the copper busbar 220 is electrically connected to the circuit board 500 via a connecting piece 520, and the other end is connected to the battery cell, charging device, or power device.

[0116] The connecting piece 520 has the same structure as the connecting piece 510, but is arranged in the opposite direction. The extension of the first connecting portion of the connecting piece 520 can face the bottom of the housing, and the guide portion of the connecting piece 520 can be bent towards the bottom of the housing.

[0117] The copper busbar 220 can be soldered to the second connection part of the connecting piece 520 of the circuit board 500. The circuit board 500 is electrically connected to the high-voltage contacts of the relay 400 through the connecting piece 520 and the copper busbar 220, thereby realizing high-voltage sampling to collect the voltage difference of the relay 400 and thus determine the switching state of the relay.

[0118] Figure 11 and Figure 12 A schematic diagram illustrating the connection between a copper busbar and a relay according to some embodiments of the present invention is shown. Figure 6 and Figure 11 As shown, one end of the copper busbar 220 that is electrically connected to the circuit board 500 can be connected to the high-voltage contact thread 430 of the relay 400 by bolt 201, so that the copper busbar 220 and the relay 400 are electrically connected, and the relay 400 is more securely fixed in the housing 210.

[0119] like Figure 12 As shown, in another preferred embodiment, the relay fixed to the housing 210 is relay 1200. Relay 1200 can be omitted. Figure 11In the illustrated embodiment, the high-voltage contact thread 430 of the relay 400 directly welds the copper busbar 220 to the high-voltage contact 1210 of the relay 1200. This ensures reliable connection between the relay 1200 and the copper busbar 220 while synergizing with the welding process between the connecting piece 520 and the copper busbar 220, reducing the number of process steps.

[0120] In addition, one end of the high-voltage contact thread 430 of the copper busbar 220 and the relay 400 may also include a stepped surface 221, which can contact the water-cooling plate of the battery pack to achieve heat dissipation of the high-voltage distribution unit 200.

[0121] The copper busbar 220 may also include an extension structure extending upward toward the housing to form one end of the copper busbar 220 that connects to the battery cell, charging device or power device.

[0122] like Figure 2 and Figure 11 As shown, the extension structure of the copper busbar 220 can directly cross the relay 400 in the vertical direction and be located at the end of the relay 400 facing the housing 210.

[0123] Considering that the height of the high voltage distribution unit 200 should be as low as possible, for battery packs with stricter height restrictions, the extension structure of the copper busbar 220 can be located on both sides of the side 401 of the relay 400 which is provided with the low voltage drive terminal 410.

[0124] Figure 13 A schematic diagram of the top of the housing of a high-voltage distribution unit provided according to some embodiments of the present invention is shown.

[0125] like Figure 13 As shown, one end of the copper busbar 220 connected to the high-voltage contacts of the relay 400 is led to the side of the relay 400 via a connecting post or similar means, and then the extension structure 222 extends upwards towards the housing 210. The height of the extension structure 222 does not exceed the height of the relay 400; therefore, the overall height of the copper busbar 220 does not increase the vertical height of the high-voltage distribution unit 200. Through this preferred arrangement of the copper busbar 220, the height of the high-voltage distribution unit 200 can be further reduced.

[0126] like Figure 5 As shown, the circuit board 500 may also be provided with an onboard floating connector 530. The floating connector 530 can be connected to a shunt fixed in the housing 210.

[0127] Figure 14 A schematic diagram of a shunt provided according to some embodiments of the present invention is shown. The shunt 1400 may be a pin-type shunt.

[0128] The copper busbar of the shunt 1400 may include four grooves 1410, which can be used to engage with the positioning ribs of the housing 210 to precisely position the shunt 1400 and the housing 210 during assembly.

[0129] The shunt 1400 may also be provided with a pin 1420 for connection to the floating connector 530. The pin 1420 is an electrical connection PIN. The shunt 1400 is electrically connected to the circuit board 500 by connecting the pin 1420 to the connection terminal in the floating connector 530.

[0130] Shunt 1400 may also include resistor 1430 and copper busbars 1440 located on both sides of resistor 1430.

[0131] One side copper busbar 1440 of the shunt 1400 can be connected to the copper busbar connected to the high-voltage contacts of the relay. For example... Figure 10 As shown, on the relay 400 near the floating connector 530, the copper busbar 230 connected to the high-voltage contact on the side near the floating connector 530 may be threaded. This copper busbar 230 can be bolted to the copper busbar 1440 of the shunt 1400. Those skilled in the art will understand that the bolted connection is merely a convenient implementation method provided by this invention, and based on the above concept and relevant knowledge in the art, other equivalent methods can be used to achieve the same technical effect.

[0132] The copper busbar 1440 on the other side of the shunt 1400 can be connected to the battery cell. Thus, the shunt 1400 can be used to monitor the current of the high-voltage distribution unit 200 and the switching status of the relay 400.

[0133] Figure 15 A schematic diagram of a shunt and floating connector assembly according to some embodiments of the present invention is shown. The housing of the floating connector 530 may include connecting terminals. Within the housing of the floating connector 530, gaps may be provided around the connecting terminals to allow them to move, enabling the connecting terminals to move back and forth and left and right within the housing of the floating connector 530. This eliminates assembly stress between the shunt 1400 and the circuit board 500 and compensates for assembly tolerances during the assembly process.

[0134] Thus, the connection between the mating ends of the circuit board 500 and the relay 400 is achieved by welding connecting pieces 510 and 520, and the connection with the shunt 1400 is achieved by the floating connector 530, eliminating the mechanical stress of the existing male-female terminal plug-in connection. Furthermore, since the circuit board 500 and the relay 400 are arranged opposite each other, in the vertical direction, the battery distribution power supply 200 only includes the height of the relay 400 itself, better meeting the height requirements of the battery pack and achieving a thinner and lighter battery pack.

[0135] The high-voltage distribution unit 200 will be further described below in conjunction with its assembly method. Those skilled in the art will understand that the embodiments of the assembly method for the high-voltage distribution unit 200 provided are merely non-limiting implementations of the present invention, intended to clearly demonstrate the main concepts of the invention and provide specific solutions convenient for public implementation, rather than limiting all functions or operating modes of the high-voltage distribution unit 200. Similarly, the high-voltage distribution unit 200 is also only one non-limiting implementation of the present invention and does not limit the executing entity or execution order of each step in the assembly method of the high-voltage distribution unit 200.

[0136] During assembly, the copper busbar 220 is first fixed to the housing 210, and then the relay 400 is fixed to the copper busbar 220, so that the relay 400 and the copper busbar 220 are embedded in the housing 210. The end of the relay 400 with the high-voltage contact faces downward.

[0137] Connecting tabs 510 and 520 can be mounted on the circuit board 500. Connecting tabs 510 and 520 can be mounted and fixed on the circuit board 500 by means of reflow soldering or other methods.

[0138] Next, the circuit board 500 is embedded in the housing 210. The surface of the circuit board 500 is opposite to one side of the relay 400. The low-voltage drive terminal 410 of the relay 400 may be located on the side 401 opposite to the circuit board 500.

[0139] The connecting piece is welded to the mating terminal of the relay after being overlapped, in order to obtain the high voltage distribution unit.

[0140] Specifically, as the circuit board 500 is inserted, the connecting piece 510 is guided by the guide portion 514 to the upper side of the low-voltage drive terminal 410, thereby attaching the connecting piece 510 to the upper side of the low-voltage drive terminal 410. Similarly, as the circuit board 500 is inserted, the connecting piece 520 can be attached to the lower side of the copper busbar 220.

[0141] Then, connecting tabs 510 and low-voltage drive terminals 410 are soldered from the top of housing 210 to connect the low-voltage drive terminals 410 of circuit board 500 and relay 400. Connecting tabs 520 and copper busbars 220 are soldered from the bottom of housing 210 to connect the high-voltage contacts of circuit board 500 and relay 400. A shunt 1400 may also be fixed inside housing 210. As circuit board 500 is inserted, pins 1420 of shunt 1400 are inserted into onboard floating connectors 530 configured on circuit board 500. The connecting terminals in floating connector 530 for inserting pins 1420 can move within the housing of floating connector 530 to relieve assembly stress between circuit board 500 and shunt 1400.

[0142] Since the circuit board 500 and the relay 400 are positioned opposite each other, the connecting pieces 510 and 520 between them can be soldered vertically. Therefore, there is no need to cut holes in the circuit board 500 for laser transmission. Compared to existing high-voltage distribution units, the high-voltage distribution unit 200 has a higher board surface utilization rate and a more rational hardware layout.

[0143] The high-voltage distribution unit 200 obtained according to the above assembly method can be configured in the battery pack to disconnect the battery system under normal conditions or emergency situations, and to transfer electrical energy between the battery cells, charging piles and electrical appliances.

[0144] In summary, the high-voltage distribution unit and its assembly method provided by this invention can achieve electrical connection between the circuit board and the relay through connecting pieces, eliminating positional deviations and stresses during the male and female terminal plug-in assembly process, as well as the resulting fretting wear problems; by using a side-mounted circuit board and an inverted relay, the height of the high-voltage distribution unit is reduced, and the utilization rate of the circuit board surface is improved.

[0145] Although the methods described above are illustrated and depicted as a series of actions for the sake of simplicity, it should be understood and appreciated that these methods are not limited by the order of the actions, as some actions may occur in a different order and / or concurrently with other actions from the illustrations and descriptions herein or not illustrated and described herein but which may be understood by those skilled in the art, according to one or more embodiments.

[0146] The prior description of this disclosure is provided to enable any person skilled in the art to make or use this disclosure. Various modifications to this disclosure will be apparent to those skilled in the art, and the general principles defined herein may be applied to other variations without departing from the spirit or scope of this disclosure. Therefore, this disclosure is not intended to be limited to the examples and designs described herein, but should be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A high-voltage distribution unit, characterized in that, include: case; At least one relay is fixed to the bottom of the housing, with one end of the relay having a high-voltage contact facing the bottom of the housing; as well as The circuit board is vertically fixed to the housing, and the surface of the circuit board is opposite to the side of the relay. The circuit board is electrically connected to the mating terminal of the relay through a connecting piece, which is made of flexible metal material.

2. The high-voltage distribution unit as described in claim 1, characterized in that, The connecting piece includes a first connecting portion and a second connecting portion. The first connecting portion extends vertically from both sides to form an extension portion. The first connecting portion and the extension portion are provided with pins. After the pins are inserted into the circuit board, the end face of the extension portion abuts against the circuit board. At least a portion of the pins is tin-plated. The second connection part is welded to the mating terminal of the relay.

3. The high-voltage distribution unit as described in claim 2, characterized in that, The top end of the second connecting portion is bent to form a guide portion with a guide angle, the guide portion being configured to guide the connecting piece.

4. The high-voltage distribution unit as described in claim 2, characterized in that, The connecting piece also includes a body portion that connects the first connecting portion and the second connecting portion. The body portion is used to compensate for the positional deviation of the mating end of the relay during the assembly process of the connecting piece and the mating end of the relay.

5. The high-voltage distribution unit as described in claim 4, characterized in that, The width of the second connecting part is greater than the width of the main body part.

6. The high-voltage distribution unit as described in claim 2, characterized in that, The relay's mating terminal includes a low-voltage drive terminal, which is located on the side opposite to the circuit board.

7. The high-voltage distribution unit as described in claim 6, characterized in that, The width of the second connection portion is greater than the width of the low-voltage drive terminal.

8. The high-voltage distribution unit as described in claim 1, characterized in that, The relay's mating terminal also includes a copper busbar connected to the high-voltage contact of the relay. One end of the copper busbar is electrically connected to the circuit board via a connecting piece, and the other end is connected to the battery cell, charging device, or power device.

9. The high-voltage distribution unit as described in claim 1, characterized in that, The high-voltage distribution unit also includes a shunt; The shunt is connected to the connection terminal of the floating connector on the circuit board via a pin, and the housing of the floating connector has a gap for the connection terminal to move.

10. The high-voltage distribution unit as described in any one of claims 1 to 9, characterized in that, The circuit board is a battery management controller.

11. A method for assembling a high-voltage distribution unit, characterized in that, Including the following steps: The relay is fixed in the housing, with the end of the relay having a high-voltage contact facing downwards; A circuit board with mounting tabs is vertically embedded into the housing, with the surface of the circuit board facing the side of the relay; and The connecting piece is welded to the mating terminal of the relay to obtain the high-voltage distribution unit as described in any one of claims 1 to 10.

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