trunk and branch high voltage (HV) power distribution cables

Abstract

Trunk and branch high voltage (HV) power distribution cables are disclosed. A trunk and branch high voltage power distribution system for a vehicle is provided. The system includes a trunk cable extending along a length of a high voltage power distribution system in the vehicle, and a plurality of branch cables, each of the plurality of branch cables extending from the trunk cable along a width of the high voltage power distribution system to a corresponding one of a plurality of electrical components to be powered by or for supplying electrical power.

Description

Technical Field

[0001] This disclosure generally relates to high-voltage (HV) power distribution systems for vehicles, and more specifically to HV power distribution cables for trunk branches. Background Technology

[0002] Existing HV power distribution architectures use a "spider" structure, where the power distribution box is the central location (spider body) and branches out (spider legs) to various power storage and accessory components. Unfortunately, this type of system has numerous electrical connection points that can easily degrade electrical efficiency and increase the likelihood of loose connections. Standard HV power cables have a very limited bending radius, which creates difficult encapsulation constraints for design engineers. The cost of this HV power distribution architecture is also extremely high, as the power distribution box alone currently ranges in the tens of thousands of dollars. Therefore, there is a need for an improved HV power distribution architecture. Summary of the Invention

[0003] According to a first aspect, a trunk-branch high-voltage power distribution system for a vehicle includes: a trunk cable extending along the length of the high-voltage power distribution system in the vehicle; and a plurality of branch cables, each of the plurality of branch cables extending along the width of the high-voltage power distribution system from the trunk cable to a corresponding electrical component among a plurality of electrical components for which electrical power is to be distributed or for supplying electrical power.

[0004] In an embodiment of the first aspect, each of the trunk cable and branch cables includes a high-voltage conductor contained within an inner insulator and a shield between the inner and outer insulators, the area of ​​the trunk cable being larger than the area of ​​any of the branch cables. In an embodiment of the first aspect, the high-voltage conductor, shield, and inner and outer insulators are arranged coaxially. In an embodiment of the first aspect, the high-voltage conductor of the trunk cable is continuous with the high-voltage conductor of each of the plurality of branch cables. In yet another embodiment of the first aspect, the outer insulator of the trunk cable is continuous with the outer insulator of each of the plurality of branch cables. In yet another embodiment of the first aspect, the trunk cable is fixedly orthogonal to each of the plurality of branch cables. In yet another embodiment of the first aspect, the trunk cable is continuous with each of the plurality of branch cables. In yet another embodiment of the first aspect, a motor inverter is connected to an end of the trunk cable. In another embodiment of the first aspect, a high-voltage battery is connected to an end of at least one of the plurality of branch cables to supply electrical power. In another embodiment of the first aspect, each of the trunk cable and branch cables is configured to transmit high-voltage power above 60 volts.

[0005] According to a second aspect of this disclosure, a trunk-branch high-voltage power distribution system for a vehicle includes: a trunk cable extending along the length of the high-voltage power distribution system in the vehicle; and a plurality of branch cables, each of the plurality of branch cables extending directly from the trunk cable to a corresponding electrical component among a plurality of electrical components for which electrical power is to be distributed or for supplying electrical power.

[0006] In an embodiment of the second aspect, each of the trunk cable and branch cables includes a high-voltage conductor contained within an inner insulator and a shield between the inner and outer insulators, the area of ​​the trunk cable being larger than the area of ​​any of the branch cables. In an embodiment of the second aspect, the high-voltage conductor, shield, and inner and outer insulators are arranged coaxially. In an embodiment of the second aspect, the high-voltage conductor of the trunk cable is continuous with the high-voltage conductor of each of the plurality of branch cables. In another embodiment of the second aspect, the outer insulator of the trunk cable is continuous with the outer insulator of each of the plurality of branch cables. In yet another embodiment of the second aspect, the trunk cable is fixedly orthogonal to each of the plurality of branch cables. In yet another embodiment of the second aspect, the trunk cable is continuous with each of the plurality of branch cables. In yet another embodiment of the second aspect, a motor inverter is connected to an end of the trunk cable. In yet another embodiment of the second aspect, a high-voltage battery is connected to an end of at least one of the plurality of branch cables to supply electrical power. In yet another embodiment of the second aspect, each of the trunk cable and branch cables is configured to transmit high-voltage power above 60 volts. Attached Figure Description

[0007] The foregoing and other features of this disclosure will become more apparent from the following description and the appended claims, taken in conjunction with the accompanying drawings. These drawings depict only a few embodiments according to this disclosure and should therefore not be considered as limiting the scope of this disclosure.

[0008] Figure 1 The diagram illustrates a prior art HV power distribution architecture using a spider structure.

[0009] Figure 2 The diagram illustrates a trunk branch HV power distribution architecture according to a representative embodiment of the present disclosure.

[0010] Figure 3 The diagram illustrates a trunk branch positive side cable according to a representative embodiment of the present disclosure.

[0011] In the following detailed description, various embodiments are described with reference to the accompanying drawings. Those skilled in the art will appreciate that the drawings are illustrated for simplicity and clarity, and therefore may not be drawn to scale and may not include well-known features; the order in which actions or steps occur may differ from the described order or may be performed simultaneously, unless otherwise specified; and the terms and expressions used herein have the meanings understood by those skilled in the art, unless otherwise assigned different meanings herein. Throughout the text, similar reference numerals refer to similar elements or components. Therefore, it is not necessarily true that similar elements or components will be described in detail with respect to every drawing. Detailed Implementation

[0012] This disclosure relates to a trunk-branch HV power distribution architecture using novel and inventive cables designed for encapsulation of HV electrical components in a vehicle. The trunk is a central cable running the length of the HV system, and the branches are “T”-shaped branches leading to each of the HV electrical components within the HV system. Because the trunk-branch cables are specifically designed to correspond to the HV components on the vehicle, bends in the cable can be part of the cable design, allowing for a tighter encapsulation. Since the trunk-to-branch connection is integrated into the cable, no additional connection points exist, thus improving electrical efficiency and eliminating the possibility of loose electrical connections. Furthermore, costs are reduced due to fewer items in the system—i.e., no distribution boxes and fewer connection points.

[0013] exist Figure 1 The image shows a prior art HV power distribution system 100 in a vehicle. System 100 uses a "spider" structure, with a distribution box 102 at the center (spider body). Distribution box 102 includes multiple connection points for connecting to various power storage / batteries and electronic accessory components. Charger box 104, motor 1 inverter 106, and motor 2 inverter 108 are connected to distribution box 102 via cables 110, 112, and 114, respectively. Fans 116 and 118, and DC-DC converters 120 and 122 are connected to distribution box 102 via cables 124, 126, 128, and 130, respectively. HV batteries 132, 134, 136, 138, and 140, which supply power to the remaining components, are further connected to distribution box 102 via cables 142, 144, 146, 148, and 150. All cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 are separated from distribution box 102 and wired to power storage components (i.e., batteries) or electrical accessory components that require power. This results in a complex arrangement with many electrical connection points, which reduces electrical efficiency and increases the possibility of loose connections.

[0014] although Figure 1 The diagram shows all cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 laid out in straight lines. However, the actual cabling is constrained by the available space inside the vehicle, the actual lengths of cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 across all the various connection points, and the location constraints of various power storage and accessory components within the vehicle. In reality, because cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 are cabled throughout the vehicle, this spider-like architecture results in numerous bends, turns, twists, drops, etc.

[0015] For clarity, each of cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 is described herein as a single-power line; however, it should be understood that all or many cables of 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 are further classified as positive-power lines and negative-power lines. Cables 110, 112, 114, 124, 126, 128, 130, 142, 144, 146, 148, and 150 have different cross-sectional areas, such as... Figure 1 As shown in Figure 152, standard HV power cables have a very limited bending radius, especially cables with a larger cross-section, such as battery cables 142, 144, 146, 148, 150 (e.g., 70 mm). 2 ) and motor inverter cables 112 and 114 (50 mm) 2 This imposes challenging constraints on vehicle power distribution systems.

[0016] Figure 2 The illustration depicts a trunk-branch HV power distribution system 200 according to a representative embodiment of this disclosure. System 200 uses a trunk cable 202, which is a central cable extending along the length of system 200. Various branch cables branch off from trunk cable 202 (similar to branches on a tree trunk) to each of the electrical components within the HV system. Trunk-to-branch connections are integrated directly into the cables, rather than as... Figure 1 The existing technical architecture described herein uses cabling via distribution boxes.

[0017] Charger box 204, motor 1 inverter 206, and motor 2 inverter 208 are connected to main cable 202 via branch cables 210, 212, and 214, respectively. Fans 216 and 218, and DC-DC converters 220 and 222 are connected to main cable 202 via branch cables 224, 226, 228, and 230, respectively. HV batteries 232, 234, 236, 238, and 240, which supply power to the remaining components, are further connected to main cable 202 via branch cables 242, 244, 246, 248, and 250. All branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248, and 250 branch directly from main cable 202 to a corresponding electrical component among the multiple electrical components to which power is distributed or used to supply power.

[0018] The length of each of the branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248, and 250 can correspond to the physical dimensions of the location within the vehicle in which they are designed for use (such as the compartment behind the driver's cab or under the hood). The length of the main cable 202 can also correspond to the physical dimensions of the location within the vehicle in which it is designed for use (such as the compartment behind the driver's cab). Therefore, the bending, twisting, turning, descent, etc., required in existing power distribution architectures can be minimized.

[0019] For clarity, each of trunk cable 202 and branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248 and 250 is described herein as a single power line; however, it should be understood that all or many of the cables in trunk cable 202 and branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248 and 250 are further divided into positive power lines and negative power lines.

[0020] Main cable 202 and branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248 and 250 have different cross-sectional areas, such as Figure 2 As shown in Figure 252. The trunk cable 202 has a length of 100 mm. 2 The area of ​​the trunk cable. In other embodiments, the trunk cable may have a larger or smaller area. However, the area of ​​the trunk cable should be larger than the area of ​​any of the branch cables. This architecture allows the charger box branch cable 210 and the motor inverter branch cables 212 and 214 to have 50mm² area. 2The area. Battery branch cables 242, 242, 246, 248 and 250 have a diameter of 25 mm. 2 The area is [missing information], while the accessory components under the hood have only 5 mm [missing information]. 2 Branch cables of area 224, 226, 228 and 230.

[0021] System 200 includes an accessory distribution box 252. The accessory distribution box 252 may include circuit breakers and fuses for lower-power accessories only, such as fans 216, 218 and DC-DC converters 220, 222. Because the accessory distribution box 252 handles lower-power accessories, the wiring entering and leaving the accessory distribution box 252 can be much smaller than HV wiring.

[0022] Still referencing Figure 2 Each of the mainline cable 202 and branch cables 210, 212, 214, 224, 226, 228, 230, 242, 244, 246, 248, and 250 has a conductor contained within an insulation body. The conductor may be multiple conductive metal (e.g., copper or aluminum) wires bundled together in a high-voltage (HV) conductor core and surrounded by an inner insulation body, and further surrounded by another protective layer, which may be a shield. The shield may be inserted between the inner and outer insulation bodies. The HV conductor, shield, and inner and outer insulation bodies may be arranged coaxially. The multilayer insulation prevents HV current from escaping from the inner conductive core to the external environment.

[0023] Figure 3 The illustration shows a trunk branch cable 300 according to a representative embodiment of the present disclosure. For clarity, Figure 3 Only the positive side of the trunk branch cable 300 is shown in the illustration, but it should be understood that the negative / grounded side of the trunk branch cable 300 should also exist, and therefore this description also applies to the corresponding negative / grounded side trunk branch cable (not shown).

[0024] The trunk branch cable 300 includes a trunk cable 302 and a plurality of branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352, and 354, each of which extends directly from the trunk cable 302 without passing through a power distribution box. The end of the trunk cable 302 is connected to a motor inverter. A high-voltage battery is connected to the end of each of the first set of branch cables 342, 344, 346, 348, 350, 352, and 354 to supply electrical power to other components connected to the trunk cable 302. An HV DC-DC converter and an HV compressor are connected to the end of each of the second set of branch cables 304, 306, 320, and 322 to be supplied with electrical power. These components are examples. In other embodiments, alternative and / or additional electrical components may be connected to the ends of the branch cables. Each of the main cable 302 and branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352 and 354 is configured to transmit HV electrical power of at least 60 volts or higher.

[0025] like Figure 3 As seen in the diagram, trunk cable 302 is continuous with each of the multiple branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352, and 354. The HV conductor of trunk cable 302 is continuous with the HV conductor of each of the multiple branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352, and 354. The outer insulation of trunk cable 302 is continuous with the outer insulation of each of the multiple branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352, and 354. The trunk cable 302 is fixedly orthogonal to each of the multiple branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352 and 354, and each trunk-branch node is T-shaped.

[0026] In an alternative embodiment, each trunk-branch node is connected by a T-connector; instead of the conductor and insulation layers being continuous along trunk cable 302 and branch cables 304, 306, 320, 322, 342, 344, 346, 348, 350, 352 and 354.

[0027] While this disclosure and its contents have been described in a manner that establishes ownership and enables those skilled in the art to make and use them, and which is currently considered the best mode thereof, it will be understood and appreciated that many equivalents exist for the selected embodiments described herein and that numerous modifications and variations can be made thereto without departing from the scope and spirit of this disclosure, which is not limited to the embodiments described herein but rather to the appended claims and their equivalents. For example, various components of the embodiments may be interchanged, added, or replaced in other embodiments.

Claims

1. A trunk branch high-voltage power distribution system for vehicles, comprising: Trunk cable, which extends along the length of a high-voltage power distribution system in a vehicle; as well as Multiple branch cables, each of which extends along the width of the high-voltage power distribution system from the main cable to a corresponding electrical component among a plurality of electrical components to which the electrical power is to be distributed or to supply the electrical power.

2. The system according to claim 1, wherein, Each of the trunk cable and the branch cables includes a high-voltage conductor contained within an inner insulator and a shield between the inner and outer insulators, wherein the area of ​​the trunk cable is larger than the area of ​​any of the branch cables.

3. The system according to claim 2, wherein, The high-voltage conductor, the shielding component, the inner insulator, and the outer insulator are arranged coaxially.

4. The system according to claim 3, wherein, The high-voltage conductor of the main cable is continuous with the high-voltage conductor of each of the plurality of branch cables.

5. The system according to claim 3, wherein, The outer insulation of the trunk cable is continuous with the outer insulation of each of the plurality of branch cables.

6. The system according to claim 1, wherein, The trunk cable is fixedly orthogonal to each of the plurality of branch cables.

7. The system according to claim 6, wherein, The trunk cable and each of the plurality of branch cables are continuous.

8. The system according to claim 6, wherein, The motor inverter is connected to the end of the main cable.

9. The system according to claim 8, wherein, A high-voltage battery is connected to the end of at least one of the plurality of branch cables to supply the electrical power.

10. The system according to claim 1, wherein, Each of the trunk cable and the branch cable is configured to transmit high-voltage power above 60 volts.

11. A trunk branch high-voltage power distribution system for vehicles, comprising: Trunk cable, which extends along the length of a high-voltage power distribution system in a vehicle; as well as Multiple branch cables, each of which extends directly from the main cable to a corresponding electrical component among a plurality of electrical components to which electrical power is to be distributed or used to supply the electrical power.

12. The system according to claim 11, wherein, Each of the trunk cable and the branch cables includes a high-voltage conductor contained within an inner insulator and a shield between the inner and outer insulators, wherein the area of ​​the trunk cable is larger than the area of ​​any of the branch cables.

13. The system according to claim 12, wherein, The high-voltage conductor, the shielding component, the inner insulator, and the outer insulator are arranged coaxially.

14. The system according to claim 13, wherein, The high-voltage conductor of the main cable is continuous with the high-voltage conductor of each of the plurality of branch cables.

15. The system according to claim 13, wherein, The outer insulation of the trunk cable is continuous with the outer insulation of each of the plurality of branch cables.

16. The system according to claim 11, wherein, The trunk cable is fixedly orthogonal to each of the plurality of branch cables.

17. The system according to claim 16, wherein, The trunk cable and each of the plurality of branch cables are continuous.

18. The system according to claim 16, wherein, The motor inverter is connected to the end of the main cable.

19. The system according to claim 18, wherein, A high-voltage battery is connected to the end of at least one of the plurality of branch cables to supply the electrical power.

20. The system according to claim 11, wherein, Each of the trunk cable and the branch cable is configured to transmit high-voltage power above 60 volts.

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