A flat blade-type BDU device for electric vehicles

Abstract

The utility model discloses a flat blade-type BDU device for electric vehicles, including an L-shaped support member, a reserved installation space in the front of the L-shaped support member, and the longitudinal section of the L-shaped support member is L-shaped, and the L-shaped support member is an elongated frame structure as a whole; an electrical component assembled and fixed in the installation space of the L-shaped support member; and an L-shaped blister cover assembled and fixed on the front side of the L-shaped support member and enclosing the electrical component in the installation space; an interface matching the corresponding electrical component inside is reserved on the upper part of the L-shaped blister cover. The BDU device of the utility model adopts a flat, blade-type design, which can increase the space utilization rate in the battery pack, and the space that is conventionally considered unusable becomes available, greatly improving the convenience of battery module system design.

Description

Technical Field

[0001] The utility model relates to the technical field of on-off devices for electric vehicle battery packs, in particular to a flat blade-type BDU device for electric vehicles. Background Art

[0002] The high voltage on-off device for electric vehicle battery packs is also called BDU module. Because electric vehicle battery packs have high DC voltage, for safety reasons, main positive, main negative, pre-charge, and fast-charge relays are usually set in the battery pack to ensure the on and off of the circuit of the battery pack's external interface, plus current sensors, fuses, and power supply, communication control and other circuits of all the above electrical parts to achieve the overall function. See Figure 1 shown.

[0003] With the development of technology and consumers' demand for longer pure electric driving range of electric vehicles, the current power battery system design is moving towards higher space utilization. This means that as many batteries as possible should be installed in the battery pack, which seriously compresses the layout space of other components, and the space left for electrical components such as BDU is becoming increasingly narrow and irregular. The traditional "box" BDU is difficult to arrange.

[0004] In the prior art, two methods are generally used to solve the above problems, namely, split BDU and specially customized special-shaped BDU;

[0005] The split BDU of the prior art, that is, according to the location of the high-voltage interface of the whole vehicle and the available layout space of the battery pack, the original complete BDU is functionally split to realize that the BDU occupies two smaller spaces instead of one whole larger space.

[0006] See also Figure 2 As shown, for split-type BDU, because the pre-charging circuit is closely related to the main positive circuit, the two are usually not separated, but the relay or fuse of the main negative circuit or fast charging circuit is separated separately. Therefore, the main negative circuit or fast charging circuit is usually a high-power circuit, which has a high current requirement for the electrical connection copper busbar in the circuit. Therefore, this method cannot avoid long-distance high-power electrical connection, which will inevitably lead to the appearance of long copper busbars, and the increase in the amount of copper busbars is very unfavorable for the cost and weight control of the entire battery pack.

[0007] The specially customized special-shaped BDU of the prior art usually prioritizes the arrangement of battery modules that occupy more than 60% of the volume ratio in the battery pack, and the remaining "corner areas" where battery modules cannot be arranged are used to arrange other component modules such as thermal management inlet and outlet pipes, BMS or OBC / DCDC. Because the thermal management inlet and outlet pipes have related fixed models or sizes, the related circuits and layouts of other component modules such as BMS or OBC / DCDC basically have relatively fixed space requirements and are usually arranged as a whole. Therefore, the space left for BDU and its electrical components is more scattered and special-shaped.

[0008] See also Figure 3 As shown in the figure, the specially customized special-shaped BDU is difficult to develop and takes a long time. Secondly, due to the large number of special-shaped or customized parts, the related mold costs are high and the mold opening cycle is long, resulting in high costs. Only when the battery pack to which the BDU belongs has a huge shipment volume can the R&D and production costs be spread out through economies of scale.

[0009] Therefore, based on the above technical problems, technicians in this field urgently need to develop a flat blade-type electric vehicle BDU device. Utility Model Content

[0010] The purpose of the utility model is to provide a flat blade-type BDU device for electric vehicles. The BDU device is redesigned into a flat "blade-type" structure, which effectively avoids the problems of weight and cost increase caused by the increase in the amount of long copper bars caused by the separate arrangement of high-power circuits in the prior art one; at the same time, the flat "blade-type" structure can reduce development and material costs, and avoid the problems of high mold cost and long mold opening cycle caused by customized non-standard special-shaped parts in the prior art two.

[0011] In order to achieve the above purpose, the utility model provides the following technical solutions:

[0012] The utility model discloses a flat blade-type BDU device for an electric vehicle, the BDU device comprising:

[0013] An L-shaped support member, wherein a mounting space is reserved in the front of the L-shaped support member, and the longitudinal cross-section of the L-shaped support member is L-shaped, and the L-shaped support member is an elongated frame structure as a whole;

[0014] Assembling and fixing the electrical components in the mounting space of the L-shaped support member; and

[0015] An L-shaped blister cover is assembled and fixed to the front side of the L-shaped support member and seals the electrical component in the installation space;

[0016] The upper part of the L-shaped blister cover is reserved with an interface matching the corresponding internal electrical components.

[0017] Furthermore, a plurality of relay mounting nuts are provided at the bottom of the mounting space of the L-shaped support member;

[0018] The electrical component has a plurality of relays arranged at intervals, and the relays are assembled and fixed to the corresponding relay mounting nuts through relay mounting screws and the L-shaped support member;

[0019] The electrical component also includes a fuse and a pre-charge resistor;

[0020] The fuse is fixed to one end of the L-shaped support member in the length direction and is fixedly connected to the back plate of the L-shaped support member;

[0021] The pre-charging resistor is fixed to the other end of the L-shaped support member in the length direction and is fixedly connected to the bottom plate of the L-shaped support member.

[0022] Furthermore, the back plate of the L-shaped support member is provided with a plurality of L-shaped support member horizontal mounting holes in a direction perpendicular to the back plate;

[0023] The bottom plate of the L-shaped support member and the back plate are both provided with a plurality of L-shaped support member vertical mounting holes in a direction parallel to the back plate.

[0024] Furthermore, snap-on windows are provided on the side and the bottom of the L-shaped blister cover;

[0025] A buckle structure can be embedded in the buckle window;

[0026] The L-shaped blister cover is snap-connected with the L-shaped support member via the snap-fit ​​structure.

[0027] Further, the interface is divided into an input interface and an output interface;

[0028] A plurality of output interfaces are provided at the middle position of the upper portion of the L-shaped blister cover, and the opening direction of the plurality of output interfaces is direction A;

[0029] One side of the upper portion of the L-shaped blister cover has a first input interface, and the other side of the upper portion of the L-shaped blister cover has a second input interface;

[0030] The opening direction of the first input interface is direction B, and the opening direction of the second input interface is direction A;

[0031] The A direction is perpendicular to the B direction.

[0032] Further, the BDU device is arranged in the front space of the battery module in the battery pack;

[0033] The BDU device is assembled and fixed to the battery pack box through the vertical mounting hole of the L-shaped support to form a vertical arrangement.

[0034] Furthermore, the BDU device is arranged in a flat space above the battery module in the battery pack;

[0035] The BDU device is assembled and fixed to the BDU bracket in the battery pack through the horizontal mounting hole of the L-shaped support member to form a horizontal arrangement.

[0036] Furthermore, the flat space is located between the battery pack cover and the battery module.

[0037] In the above technical solution, the utility model provides a flat blade-type electric vehicle BDU device, which has the following beneficial effects:

[0038] The BDU device of the utility model is redesigned into a flat "blade-type" structure, which effectively avoids the problems of weight and cost increase caused by the increase in the amount of long copper bars due to the separate arrangement of high-power circuits in the prior art one; at the same time, the flat "blade-type" structure can reduce development and material costs, and avoid the problems of high mold costs and long mold opening cycles caused by customized non-standard special-shaped parts in the prior art two. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings required for use in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present utility model. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0040] Figure 1 It is a circuit schematic diagram of a pre-charging circuit component in the prior art;

[0041] Figure 2 A circuit schematic diagram of a pre-charging circuit assembly of prior art 1;

[0042] Figure 3 It is a structural schematic diagram of a special-shaped BDU device of the second prior art;

[0043] Figure 4 This is a schematic structural diagram of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0044] Figure 5 This is a structural exploded diagram of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0045] Figure 6 Schematic diagram of the arrangement structure of the electrical components of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application Figure 1 ;

[0046] Figure 7 Schematic diagram of the arrangement structure of the electrical components of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application Figure 2 ;

[0047] Figure 8 A schematic diagram of mounting holes on the back of an L-shaped support member of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0048] Fig. 9 A schematic diagram of a mounting hole at the bottom of an L-shaped support member of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0049] Fig.10 A schematic diagram of a snap-on window of an L-shaped blister cover of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0050] Fig.11 A schematic diagram of the connection structure of an L-shaped support member and an L-shaped blister cover of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0051] Fig.12 It is a structural schematic diagram of a first interface arrangement form of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0052] Fig.13 It is a structural schematic diagram of a second interface arrangement form of a flat blade-type electric vehicle BDU device disclosed in an embodiment of the present application;

[0053] Fig.14 A schematic diagram of the arrangement of a first embodiment of a flat blade-type electric vehicle BDU device and a battery pack disclosed in an embodiment of the present application;

[0054] Fig.15 This is a schematic diagram of the layout of a second embodiment of a flat blade-type electric vehicle BDU device and a battery pack disclosed in an embodiment of the present application.

[0055] Description of reference numerals:

[0056] 10. BDU device; 20. Battery pack;

[0057] 1. L-shaped support; 2. L-shaped blister cover; 3. Electrical components;

[0058] 101. L-shaped support member vertical mounting hole; 102. L-shaped support member horizontal mounting hole; 103. Buckle structure;

[0059] 201, snap-on window;

[0060] 301, relay mounting screw; 302, relay mounting nut; 303, relay; 304, fuse; 305, pre-charging resistor;

[0061] 11. Output interface; 12. First input interface; 13. Second input interface;

[0062] 21. Battery pack box; 22. Battery module; 23. Battery pack cover; 24. BDU bracket. DETAILED DESCRIPTION

[0063] In order to enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below in conjunction with the accompanying drawings.

[0064] See also Figures 4 to 15 As shown;

[0065] This embodiment discloses a flat blade-type BDU device for electric vehicles. The BDU device 10 includes:

[0066] An L-shaped support member 1, a mounting space is reserved in the front of the L-shaped support member 1, and the longitudinal section of the L-shaped support member 1 is L-shaped, and the L-shaped support member 1 is an elongated frame structure as a whole;

[0067] An electrical component 3 is assembled and fixed in the installation space of the L-shaped support member 1; and

[0068] An L-shaped blister cover 2 is assembled and fixed to the front side of the L-shaped support member 1 and seals the electrical component 3 in the installation space;

[0069] An interface matching the corresponding electrical component 3 inside is reserved on the upper part of the L-shaped blister cover 2 .

[0070] Specifically, the present embodiment discloses a flat blade-shaped electric vehicle BDU device 10, which mainly includes an L-shaped support member 1, an electrical component 3 integrated at a corresponding position of the L-shaped support member 1, and an L-shaped blister cover 2. The L-shaped support member 1 and the L-shaped blister cover 2 of the present embodiment are mainly long and flat in design. Therefore, the electric vehicle BDU device 10 with a flat blade-shaped structure formed after assembly can adapt to the installation area requirements of the battery pack 20 with limited space.

[0071] Preferably, a plurality of relay mounting nuts 302 are provided at the bottom of the mounting space of the L-shaped support member 1 of this embodiment;

[0072] The electrical component 3 has a plurality of relays 303 arranged at intervals, and the relays 303 are assembled and fixed to the corresponding relay mounting nuts 302 through relay mounting screws 301 and the L-shaped support member 1;

[0073] The electrical component 3 also includes a fuse 304 and a pre-charging resistor 305;

[0074] The fuse 304 is fixed to one end of the L-shaped support member 1 in the length direction and is fixedly connected to the back plate of the L-shaped support member 1;

[0075] The pre-charging resistor 305 is fixed to the other end of the L-shaped support member 1 in the length direction and is fixedly connected to the bottom plate of the L-shaped support member 1 .

[0076] The back plate of the L-shaped support member 1 of this embodiment is provided with a plurality of L-shaped support member horizontal mounting holes 102 in a direction perpendicular to the back plate;

[0077] The bottom plate and the back plate of the L-shaped support member 1 are both provided with a plurality of L-shaped support member vertical mounting holes 101 in a direction parallel to the back plate.

[0078] First, this embodiment further defines the structure of the L-shaped support. The L-shaped support 1 of this embodiment is the structural bearing body of the entire BDU, and multiple installation positions are preset for each electrical component according to the electrical components included in the electrical assembly 3. Among them, the relay 303 is firmly locked on the L-shaped support 1 through the combined action of the relay mounting screw 301 and the relay mounting nut 302 embedded in the L-shaped support 1. The fuse 304 and the pre-charging resistor 305 are also locked in the corresponding position using a similar structure, or installed by a plastic buckle.

[0079] In addition, the L-shaped support member 1 of this embodiment itself has two installation methods in the battery module system of the battery pack, namely, it can be installed upright through the L-shaped support member upright mounting hole 101, and it can also be installed horizontally through the L-shaped support member horizontal mounting hole 102 to match the available space in different battery module systems.

[0080] Preferably, the side and lower part of the L-shaped blister cover 2 of this embodiment are provided with snap-on windows 201;

[0081] The buckle structure 103 can be embedded in the buckle window 201;

[0082] The L-shaped blister cover 2 is snap-fitted to the L-shaped support member 1 via the snap-fit ​​structure 103 .

[0083] Among them, the interface of this embodiment is divided into an input interface and an output interface 11;

[0084] A plurality of output interfaces 11 are provided at the middle of the upper portion of the L-shaped blister cover 2, and the opening direction of the plurality of output interfaces 11 is direction A;

[0085] One side of the upper portion of the L-shaped blister cover 2 has a first input interface 12 , and the other side of the upper portion of the L-shaped blister cover 2 has a second input interface 13 ;

[0086] The opening direction of the first input interface 12 is direction B, and the opening direction of the second input interface 13 is direction A;

[0087] Direction A is perpendicular to direction B.

[0088] At the same time, as an extended implementation, according to wiring requirements, the direction of the output interface 11 of this embodiment can be changed to open in direction B. Similarly, the directions of the first input interface 12 and the second input interface 13 can also be changed.

[0089] This embodiment further defines the structure of the L-shaped blister cover 2, which mainly plays the role of insulation protection and high-voltage finger-proof IPXXB. It adopts a contour design to fit the various electrical components inside the BDU, which are snapped with the L-shaped support member 1 through the snap window 201 and the snap structure 103 on the L-shaped blister cover 2, and this embodiment exposes the electrodes or contacts to be connected through the electrical connection window of the L-shaped blister cover 2, so as to connect the main positive and negative electrodes of the battery pack, the positive and negative electrodes of the external output of the battery, etc., to realize the BDU function.

[0090] As shown in the figure, the first embodiment discloses a first installation form of the BDU device 10 of the present application:

[0091] The BDU device 10 in the first embodiment is arranged in the front space of the battery module 22 in the battery pack 20;

[0092] The BDU device 10 is assembled and fixed to the battery pack box 21 through the L-shaped support vertical mounting hole 101 to form a vertical arrangement.

[0093] The first embodiment of the present invention discloses a first arrangement form of the BDU device 10 of the present application, which is mainly arranged in the narrow and long space in front of the battery module 22 system, and the narrow and long space can only be arranged inside by placing the BDU device 10 upright. After being placed vertically, the fasteners in the L-shaped support upright mounting hole 101 of the L-shaped support 1 of the BDU device 10 are assembled and fixed to the corresponding position of the battery pack case 21.

[0094] As shown in the figure, the second embodiment discloses a second installation form of the BDU device 10 of the present application:

[0095] The BDU device 10 of the second embodiment is arranged in a flat space above the battery module 22 in the battery pack 20;

[0096] The BDU device 10 is assembled and fixed to the BDU bracket 24 in the battery pack 20 through the L-shaped support horizontal installation hole 102 to form a horizontal arrangement.

[0097] The flat space in the second embodiment is located between the battery pack cover 23 and the battery module 22 .

[0098] The BDU device 10 of the second embodiment is mainly arranged in the flat space above the battery in the battery module system. Due to the limitation of the flat space, the BDU device 10 can only be placed in the flat space in a horizontal form. Therefore, during installation, the BDU device 10 is assembled and fixed to the BDU bracket 24 through the fasteners in the L-shaped support horizontal mounting hole 102 of the L-shaped support 1 of the BDU device 10.

[0099] In the above technical solution, the utility model provides a flat blade-type electric vehicle BDU device, which has the following beneficial effects:

[0100] The BDU device 10 of the utility model is redesigned into a flat "blade-type" structure, which effectively avoids the problems of weight and cost increase caused by the increase in the amount of long copper bars due to the separate arrangement of high-power circuits in the prior art one; at the same time, the flat "blade-type" structure can reduce development and material costs, and avoid the problems of high mold costs and long mold opening cycles caused by customized non-standard special-shaped parts in the prior art two.

[0101] The BDU device 10 of the present invention adopts a flat, blade-like design, which can increase the space utilization rate in the battery pack 20. Space that is conventionally considered unusable becomes usable, greatly improving the convenience of battery module 22 system design.

[0102] The BDU device 10 of the present invention adopts a flat, blade-like design, which can be widely adapted to different battery module 22 systems, forming standardized applications, reducing development and material costs, and achieving rapid development and rapid matching.

[0103] The above only describes some exemplary embodiments of the present invention by way of illustration. It is undoubted that those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the above drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A flat blade-type electric vehicle BDU device, characterized in that: The BDU device (10) comprises: An L-shaped support member (1), wherein a mounting space is reserved in the front of the L-shaped support member (1), and the longitudinal cross-section of the L-shaped support member (1) is L-shaped, and the L-shaped support member (1) as a whole is a long strip frame structure; An electrical component (3) is assembled and fixed in the installation space of the L-shaped support member (1); and An L-shaped blister cover (2) is assembled and fixed to the front side of the L-shaped support member (1) and seals the electrical component (3) in the installation space; The upper part of the L-shaped blister cover (2) is reserved with an interface matching the corresponding internal electrical component (3).

2. A flat blade-type electric vehicle BDU device according to claim 1, characterized in that: A plurality of relay mounting nuts (302) are arranged at the bottom of the mounting space of the L-shaped support member (1); The electrical component (3) has a plurality of relays (303) arranged at intervals, and the relays (303) are assembled and fixed to the corresponding relay mounting nuts (302) through relay mounting screws (301) and the L-shaped support member (1); The electrical component (3) further comprises a fuse (304) and a pre-charging resistor (305); The fuse (304) is fixed to one end of the L-shaped support member (1) in the length direction and is fixedly connected to the back plate of the L-shaped support member (1); The pre-charging resistor (305) is fixed to the other end of the L-shaped support member (1) in the length direction and is fixedly connected to the bottom plate of the L-shaped support member (1).

3. A flat blade-type electric vehicle BDU device according to claim 2, characterized in that: The back plate of the L-shaped support member (1) is provided with a plurality of L-shaped support member horizontal installation holes (102) in a direction perpendicular to the back plate; The bottom plate of the L-shaped support member (1) and the back plate are both provided with a plurality of L-shaped support member vertical mounting holes (101) in a direction parallel to the back plate.

4. A flat blade-type electric vehicle BDU device according to claim 2, characterized in that: The side and lower part of the L-shaped blister cover (2) are both provided with snap-on windows (201); The buckle structure (103) can be embedded in the buckle window (201); The L-shaped blister cover (2) is snap-fitted to the L-shaped support member (1) via the snap-fit ​​structure (103).

5. A flat blade-type electric vehicle BDU device according to claim 4, characterized in that: The interface is divided into an input interface and an output interface (11); A plurality of output interfaces (11) are provided at the middle position of the upper part of the L-shaped blister cover (2), and the opening direction of the plurality of output interfaces (11) is direction A; One side of the upper part of the L-shaped blister cover (2) is provided with a first input interface (12), and the other side of the upper part of the L-shaped blister cover (2) is provided with a second input interface (13); The opening direction of the first input interface (12) is direction B, and the opening direction of the second input interface (13) is direction A; The A direction is perpendicular to the B direction.

6. A flat blade-type electric vehicle BDU device according to any one of claims 3 to 5, characterized in that: The BDU device (10) is arranged in the front space of the battery module (22) in the battery pack (20); The BDU device (10) is assembled and fixed to the battery pack box (21) through the L-shaped support member vertical mounting hole (101) to form a vertical arrangement.

7. A flat blade-type electric vehicle BDU device according to any one of claims 3 to 5, characterized in that: The BDU device (10) is arranged in a flat space above a battery module (22) in a battery pack (20); The BDU device (10) is assembled and fixed to the BDU bracket (24) in the battery pack (20) through the horizontal installation hole (102) of the L-shaped support member to form a horizontal arrangement.

8. The flat blade-type electric vehicle BDU device according to claim 7, characterized in that: The flat space is located between the battery pack upper cover (23) and the battery module (22).

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