An electrical connector and a BDU distribution box

Abstract

The utility model proposes an electrical connector and a BDU distribution box, including an integrated wiring harness and an insulating sleeve, wherein the integrated wiring harness is located in the insulating sleeve, the integrated wiring harness and the insulating sleeve are integrally injection molded, and the insulating sleeve is provided with a reinforcement groove along the direction of the integrated wiring harness; the integrated wiring harness passes through the insulating sleeve, the integrated wiring harness is a metal plate, and a connection hole is provided at one end of the integrated wiring harness. The present application forms an electrical connector by providing an integrated wiring harness and an insulating sleeve, and the integrated wiring harness is a metal plate, and a reinforcement groove is also provided on the insulating sleeve, which makes the electrical connector easy to bend and easy to shape, so as to adapt to the structural layout of the BDU, and there will be no problem of messy wiring harness; at the same time, the insulating sleeve is also provided with a reinforcement groove along the direction of the integrated wiring harness, which can improve the anti-bending ability of the electrical connector in the area that does not require bending, thereby improving the stability of the application.

Description

Technical Field

[0001] The utility model relates to the technical field of new energy vehicles, and in particular to an electric connector and a BDU distribution box. Background Art

[0002] BDU is a module in the PDU of new energy vehicles. It is used to protect the battery module in the battery box of new energy vehicles. It is an important protection module of the high-voltage circuit system of electric vehicles and an important part of the vehicle control system of electric vehicles. In order to achieve high-voltage sampling and low-voltage control of BDU, the internal part of BDU usually adopts wiring harness connection, PCB board connection or FPC connection to make electrical connection of high and low voltage signals.

[0003] The existing utility model patent with authorization announcement number CN206841188U discloses a high-voltage distribution box for power supply of the power system, including a positive circuit and a negative circuit. The positive circuit is provided with a main positive high-voltage contactor and a traction contactor. The pre-charging resistor is connected in series with the pre-charging high-voltage contactor and then connected in parallel to both ends of the main positive high-voltage contactor. As can be seen from this scheme, there are usually several electrical components in the distribution box of electric vehicles, so it is necessary to set up a sampling harness to monitor the battery system to ensure the normal operation of the battery system;

[0004] The utility model patent with the existing authorization announcement number CN210535755U discloses a high-voltage sampling harness wiring fixing structure of a distribution box, including a blister cover, snaps, a high-voltage sampling harness, a high-voltage harness connector, a harness fixing tray, a copper bus, a contactor, a current sensor, a low-voltage control harness, a low-voltage harness connector, and a lower box; each component is correspondingly assembled in the lower box, the high-voltage sampling harness is fixed on the harness fixing tray, the harness fixing tray is encapsulated on the lower box, and the blister cover is mounted on the harness fixing tray;

[0005] As in the above scheme, several sampling wire harnesses are used, but in order to avoid the problem of messy wire harnesses, a wire harness fixing tray is used to organize the wire harnesses. The setting of the wire harness fixing tray will take up too much space, affecting the compactness and structural layout of the BDU, which will in turn affect the structural layout of the entire battery pack in the electric vehicle and make the assembly steps cumbersome. Utility Model Content

[0006] In view of this, the utility model proposes an electrical connector and a BDU distribution box with a simple structure, easy assembly and reliable application, so as to solve the problem of the clutter of the sampling harness in the existing BDU and the problem that the use of harness fixings affects the BDU structural layout.

[0007] The technical solution of the utility model is achieved in this way:

[0008] In one aspect, the utility model provides an electrical connector, comprising an integrated wiring harness and an insulating sleeve, wherein:

[0009] The integrated wiring harness is located in the insulating sleeve, the integrated wiring harness and the insulating sleeve are integrally injection molded, and the insulating sleeve is provided with a reinforcement groove along the direction of the integrated wiring harness;

[0010] The integrated wiring harness passes through the insulating sleeve, is a metal plate, and one end of the integrated wiring harness is provided with a connection hole.

[0011] On the basis of the above technical solution, preferably, the insulating sleeve comprises a body and an end block, wherein:

[0012] A plurality of end blocks are arranged on the side of the body, and reinforcement grooves are arranged on the body and the end blocks;

[0013] The integrated wiring harness passes through the body and the end block, and the integrated wiring harness extends out through the end block.

[0014] On the basis of the above technical solution, preferably, both ends of the integrated wiring harness are provided with connection holes.

[0015] On the basis of the above technical solution, preferably, the integrated wiring harness includes a high-voltage sampling signal control line and a pre-charge signal control line.

[0016] On the other hand, the utility model provides a BDU distribution box, including the above-mentioned electrical connector.

[0017] On the basis of the above technical solution, preferably, it further comprises a lower shell and an upper shell, wherein:

[0018] The lower shell is used to accommodate electrical components, and the integrated wiring harness is used to connect the electrical components;

[0019] The upper shell is buckled on the lower shell, and the side of the upper shell is connected to the lower shell through buckles.

[0020] On the basis of the above technical solution, preferably, it further includes a top cover and a first circuit board, wherein:

[0021] The top cover is arranged on the outer side of the upper shell;

[0022] The first circuit board is arranged between the top cover and the upper shell.

[0023] On the basis of the above technical solution, preferably, it further includes a second circuit board, which is arranged between the lower shell and the upper shell, and the second circuit board is electrically connected to the first circuit board and the integrated wiring harness;

[0024] The top cover is provided with a first wiring port corresponding to the first circuit board;

[0025] The upper shell is provided with a second wiring port corresponding to the second circuit board.

[0026] On the basis of the above technical solution, preferably, the electrical component includes a relay, one end of the integrated wiring harness is connected to the relay, and the other end is connected to the second circuit board;

[0027] The relays include a main positive relay, a main negative relay and a fast charging relay.

[0028] On the basis of the above technical solution, preferably, it also includes a temperature sensing sampling line, and the temperature sensing sampling line is electrically connected to the integrated wiring harness;

[0029] The second circuit board is integrated with a high-voltage communication interface and a low-voltage communication interface;

[0030] The temperature sensing sampling line is integrated with a low-voltage communication interface.

[0031] The electrical connector and BDU distribution box of the utility model have the following beneficial effects compared with the prior art:

[0032] (1) The electrical connector is formed by arranging an integrated wiring harness and an insulating sleeve, and the integrated wiring harness is a metal plate, and a reinforcing groove is also provided on the insulating sleeve, so that the electrical connector has the advantage of being easy to bend and easy to shape, so as to adapt to the structural layout of the BDU, and there will be no problem of messy wiring harness; at the same time, the insulating sleeve is also provided with a reinforcing groove along the direction of the integrated wiring harness, so that the anti-bending ability of the electrical connector in the area that does not need to be bent can be improved, thereby improving the stability of application;

[0033] (2) The insulating sleeve includes a body and an end block, and there are a plurality of end blocks, so that a plurality of metal plates can be integrated into the body to form an integrated wiring harness, and a plurality of metal plate connectors extend outward through the end block to realize the connection of multiple electrical components;

[0034] (3) In the BDU distribution box, the electrical connector is connected to the second circuit board and the relay, and information is transmitted through the communication interface on the second circuit board. At the same time, a temperature sensing sampling line is provided for sampling, and the temperature sensing sampling line itself integrates a communication interface, thereby optimizing the overall structural layout, making the layout of the wiring harness and the electrical components in the BDU compact, and improving space utilization. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0036] Figure 1 It is a three-dimensional diagram of the electrical connector of the utility model;

[0037] Figure 2 It is a three-dimensional diagram of the BDU power distribution box of the utility model;

[0038] Figure 3 This is a three-dimensional diagram of the first circuit board assembly of the BDU power distribution box of the utility model;

[0039] Figure 4 This is a three-dimensional diagram of the second circuit board assembly of the BDU power distribution box of the utility model;

[0040] Figure 5 This is a stereogram of the integrated wiring harness assembly of the BDU power distribution box of the utility model;

[0041] Figure 6 For the utility model Figure 5 A magnified view of the structure at point A;

[0042] Figure 7 It is a three-dimensional diagram of the temperature sensing sampling line of the BDU distribution box of the utility model;

[0043] In the figure: 1. Integrated wiring harness; 11. High-voltage sampling signal control line; 12. Pre-charge signal control line; 101. Connection hole; 2. Insulation sleeve; 21. Main body; 22. End block; 201. Reinforcement groove; 3. Lower shell; 4. Upper shell; 41. Buckle; 401. Second wiring port; 5. Top cover; 501. First wiring port; 6. First circuit board; 7. Second circuit board; 8. Relay; 9. Temperature sensing sampling line. DETAILED DESCRIPTION

[0044] The following will be combined with the implementation of the utility model to clearly and completely describe the technical solutions in the implementation of the utility model. Obviously, the described implementation is only a part of the implementation of the utility model, not all of the implementations. Based on the implementation of the utility model, all other implementations obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0045] like Figures 1 to 7 As shown, the electrical connector of the utility model comprises an integrated wiring harness 1 and an insulating sleeve 2;

[0046] The BDU power distribution box of the utility model includes the above-mentioned electrical connector, and also includes a lower shell 3, an upper shell 4, a top cover 5, a first circuit board 6, a second circuit board 7, a relay 8 and a temperature sensing sampling line 9.

[0047] like Figure 1 As shown, the integrated wiring harness 1 is located in the insulating sleeve 2, the integrated wiring harness 1 and the insulating sleeve 2 are integrally injection molded, and the insulating sleeve 2 is provided with a reinforcement groove 201 along the direction of the integrated wiring harness 1; the integrated wiring harness 1 passes through the insulating sleeve 2, the integrated wiring harness 1 is a metal plate, and one end of the integrated wiring harness 1 is provided with a connection hole 101;

[0048] As shown in the above structure, the electrical connector has the integrated wiring harness 1 disposed inside the insulating sleeve 2. Specifically, during molding, the integrated wiring harness 1 and the insulating sleeve 2 are integrally molded by injection molding;

[0049] The integrated wiring harness 1 is a metal plate. By virtue of the plasticity of the integrated wiring harness 1, the integrated wiring harness 1 and the insulating sleeve 2 can be bent at the same time to adapt to the layout of the electrical components in the BDU. This not only ensures convenient assembly, but also avoids clutter, and does not require auxiliary fixing components to avoid excessive occupation of the internal space in the BDU.

[0050] At the same time, a reinforcement groove 201 is provided on the insulating sleeve 2 along the direction of the integrated wiring harness 1, so that the anti-bending ability of the area where the electrical connector does not need to be bent can be improved, thereby improving the stability of the application;

[0051] Preferably, the integrated wiring harness 1 is made of metals such as copper and aluminum with good electrical conductivity.

[0052] like Figure 1 As shown, the insulating sleeve 2 includes a body 21 and an end block 22, wherein a plurality of end blocks 22 are arranged on the side of the body 21, and a reinforcement groove 201 is arranged on the body 21 and the end block 22; the integrated wiring harness 1 passes through the body 21 and the end block 22, and the integrated wiring harness 1 extends out through the end block 22;

[0053] As shown in the above structure, the insulating sleeve 2 includes two parts, wherein the main body 21 accommodates the middle section of the integrated wiring harness 1, and the end block 22 is used for the end of the integrated wiring harness 1 to extend out, so that the end of the integrated wiring harness 1 can be guided to avoid bending problems;

[0054] In order to ensure the stability of the structure of the insulating sleeve 2 , a reinforcement groove 201 is provided on the body 21 and the end block 22 .

[0055] Specifically, the integrated wiring harness 1 is a sampling wiring harness, which integrates a high-voltage sampling signal control line 11 and a pre-charge signal control line 12;

[0056] The electrical connector is used in the BDU distribution box. The integrated wiring harness 1 is used for sampling electrical components. When connecting, the connection hole 101 at the end of the integrated wiring harness 1 is used to connect the electrical components, which can be connected in series with bolts.

[0057] In some embodiments, both ends of the integrated wiring harness 1 are provided with connection holes 101;

[0058] In some embodiments, the two ends of the integrated wiring harness 1 are not provided with connection holes 101 , but are connected to the electrical components by welding, clamping, etc.

[0059] like Figures 2 to 4As shown, the lower shell 3 is used to accommodate electrical components, and the integrated wiring harness 1 is used to connect the electrical components; the upper shell 4 is buckled on the lower shell 3, and the side of the upper shell 4 is connected to the lower shell 3 through the buckle 41;

[0060] As in the above structure, the lower shell 3 is used to install electrical components, and the upper shell 4 is buckled with the lower shell 3 using a buckle 41, thereby improving the convenience of connecting the lower shell 3 and the upper shell 4.

[0061] like Figure 2 and Figure 3 As shown, the top cover 5 is arranged on the outside of the upper shell 4; the first circuit board 6 is arranged between the top cover 5 and the upper shell 4;

[0062] As shown in the above structure, a circuit board is integrated in the BDU for signal processing and control of electrical components. In the BDU distribution box, the first circuit board 6 is integrated between the upper shell 4 and the top cover 5, thereby realizing the separation of the first circuit board 6 from the electrical components inside the lower shell 3, and the upper shell 4 is relatively flat, which is suitable as the installation base of the first circuit board 6, and can improve the convenience of molding.

[0063] like Figure 4 and Figure 5 As shown, the second circuit board 7 is arranged between the lower shell 3 and the upper shell 4, and the second circuit board 7 is electrically connected to the first circuit board 6 and the integrated wiring harness 1; the top cover 5 is provided with a first wiring port 501 corresponding to the first circuit board 6; the upper shell 4 is provided with a second wiring port 401 corresponding to the second circuit board 7;

[0064] As in the above structure, the second circuit board 7 is used for signal feedback. When the integrated wiring harness 1 is connected to the electrical components, the integrated wiring harness 1 is also connected to the second circuit board 7 to achieve signal communication.

[0065] Specifically, the second circuit board 7 and the first circuit board 6 can be divided into two parts to manage the high voltage circuit and the low voltage circuit respectively;

[0066] Meanwhile, in this structure, the top cover 5 is provided with a first wiring port 501, and the upper shell 4 is provided with a second wiring port 401, which are used to connect the integrated wiring harness 1 and various wiring harnesses to the circuit board;

[0067] Specifically, when setting the wiring port, it is opened on the ends of the upper shell 4 and the top cover 5 facing the same direction to facilitate the integration of the wiring harness.

[0068] like Figure 5 As shown, the electrical component includes a relay 8, one end of the integrated wiring harness 1 is connected to the relay 8, and the other end is connected to the second circuit board 7; the relay 8 includes a main positive relay, a main negative relay and a fast charging relay;

[0069] As described above, the integrated wiring harness 1 is connected to the relay 8 to implement sampling;

[0070] The circuit structure of an electric vehicle usually includes a positive circuit connecting the positive electrode of the battery and the positive electrode of the traction motor, a negative circuit connecting the negative electrode of the battery and the negative electrode of the traction motor, a fast charging positive circuit connecting the positive electrode of the battery and the positive electrode of the charging interface, a fast charging negative circuit connecting the negative electrode of the battery and the negative electrode of the charging interface, and a boost circuit connecting the positive electrode of the battery and the boost positive electrode. The positive circuit is provided with a current sensor and a fuse connected in series with the positive high-voltage contactor of the main road, and a pre-charging resistor is connected in series with the pre-charging high-voltage contactor and then connected in parallel to both ends of the positive high-voltage contactor of the main road; the negative circuit is provided with a shunt and a negative high-voltage contactor of the main road. The fast charging contactor is connected in series with the negative electrode of the positive contactor of the main road to form a fast charging circuit. The boost contactor is connected in series with the negative electrode of the positive contactor of the fast charging circuit to form a boost circuit;

[0071] When performing sampling detection, the integrated wiring harness 1 is connected to the terminals of the relay.

[0072] like Figures 5 to 7 As shown, the temperature sensing sampling line 9 is electrically connected to the integrated wiring harness 1; the second circuit board 7 is integrated with a high-voltage communication interface and a low-voltage communication interface; the temperature sensing sampling line 9 is integrated with a low-voltage communication interface;

[0073] As in the above structure, during detection, the integrated wiring harness 1 is used for high-voltage signal sampling, and the temperature sensing sampling line 9 is used for temperature sensing sampling. The integrated wiring harness 1 provides information feedback through the communication interface of the second circuit board 7, while the temperature sensing sampling line 9 relies on its own integrated low-voltage communication interface for information feedback.

[0074] Specific implementation steps:

[0075] First, the integrated wiring harness 1 and the insulating sleeve 2 are integrated into an integrated structure, and then the integrated wiring harness 1 is bent according to the layout of the electrical components in the BDU distribution box, and then the integrated wiring harness 1 is connected to the relay 8 and the second circuit board 7, and the temperature sensing sampling line 9 is connected to the terminal of the relay 8;

[0076] During specific assembly, the terminals of the relay 8 are connected to the copper busbar, and the temperature sensing sampling line 9 and the integrated wiring harness 1 are electrically connected to the copper busbar.

[0077] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. An electrical connector, characterized in that: It comprises an integrated wiring harness (1) and an insulating sleeve (2), wherein: The integrated wiring harness (1) is located inside the insulating sleeve (2), the integrated wiring harness (1) and the insulating sleeve (2) are integrally injection-molded, and the insulating sleeve (2) is provided with a reinforcement groove (201) along the direction of the integrated wiring harness (1); The integrated wiring harness (1) passes through the insulating sleeve (2); the integrated wiring harness (1) is a metal plate; and a connection hole (101) is provided at one end of the integrated wiring harness (1).

2. The electrical connector according to claim 1, characterized in that: The insulating sleeve (2) comprises a body (21) and an end block (22), wherein: A plurality of the end blocks (22) are arranged on the side of the body (21), and the reinforcement grooves (201) are arranged on both the body (21) and the end blocks (22); The integrated wire harness (1) passes through the body (21) and the end block (22), and the integrated wire harness (1) extends out through the end block (22).

3. The electrical connector according to claim 1, wherein: The connecting holes (101) are provided at both ends of the integrated wiring harness (1).

4. The electrical connector according to claim 1, characterized in that: The integrated wiring harness (1) comprises a high-voltage sampling signal control line (11) and a pre-charging signal control line (12).

5. A BDU distribution box, characterized in that: The invention comprises the electrical connector as claimed in any one of claims 1 to 3.

6. The BDU distribution box according to claim 5, characterized in that: It also includes a lower shell (3) and an upper shell (4), wherein: The lower shell (3) is used to accommodate electrical components, and the integrated wiring harness (1) is used to connect the electrical components; The upper shell (4) is buckled onto the lower shell (3), and the side of the upper shell (4) is connected to the lower shell (3) via a buckle (41).

7. The BDU distribution box according to claim 6, characterized in that: It also includes a top cover (5) and a first circuit board (6), wherein: The top cover (5) is arranged on the outer side of the upper shell (4); The first circuit board (6) is arranged between the top cover (5) and the upper shell (4).

8. The BDU distribution box according to claim 7, characterized in that: It also includes a second circuit board (7), the second circuit board (7) is arranged between the lower shell (3) and the upper shell (4), and the second circuit board (7) is electrically connected to the first circuit board (6) and the integrated wiring harness (1); The top cover (5) is provided with a first wiring port (501) corresponding to the first circuit board (6); The upper shell (4) is provided with a second wiring port (401) corresponding to the second circuit board (7).

9. The BDU distribution box according to claim 8, characterized in that: The electrical component comprises a relay (8), one end of the integrated wiring harness (1) is connected to the relay (8), and the other end is connected to the second circuit board (7); The relay (8) comprises a main positive relay, a main negative relay and a fast charging relay.

10. The BDU distribution box according to claim 9, characterized in that: It also includes a temperature sensing sampling line (9), wherein the temperature sensing sampling line (9) is electrically connected to the integrated wiring harness (1); The second circuit board (7) is integrated with a high-voltage communication interface and a low-voltage communication interface; The temperature sensing sampling line (9) is integrated with a low-voltage communication interface.

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