Battery pack circuit breaking unit
By adopting wireless beam structure and efficient heat dissipation design in the battery pack circuit breaker unit, the problems of line chaos, poor heat dissipation and high manufacturing costs in the prior art are solved, and the goals of high integration, lightweight and low cost are achieved.
Patent Information
- Application Number
- CN202421990028.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-08-16
- Publication Date
- 2025-06-03
- Estimated Expiration
- 2034-08-16
AI Technical Summary
The internal circuits of the existing battery pack circuit breaker unit are chaotic, inconvenient for maintenance, poor heat dissipation performance, and high manufacturing cost.
The wireless beam structure is realized by low-pressure copper strips and double-head connectors, replacing traditional wiring harness connections, improving integration and automated production efficiency, and partially projecting the shell surface through the high-pressure copper strips, combining liquid-cooled plates and thermal pads to assist in heat dissipation, reducing the cross-section and cost of copper strips.
The goals of high integration, lightweight and low cost are achieved, the heat dissipation efficiency and automated production convenience of battery pack circuit breaker units are improved, and manufacturing costs are reduced.
Smart Images
Figure CN222939857U_ABST
Abstract
Description
Technical Field
[0001] The utility model relates to a battery pack disconnect unit, belonging to the technical field of battery packs. Background Art
[0002] With the development of the new energy industry, the requirements for the integration and failure rate of battery packs are getting higher and higher. As the core component in the battery pack, the technical state and quality state of the BDU (Battery Disconnect Unit) are directly related to the performance of the battery pack. Low cost, high integration, high quality and lightweight have become the current main trends. At present, the internal circuits of BDU products are relatively chaotic, which is not convenient for maintenance and the heat dissipation performance is also poor. Content of the Utility Model
[0003] The technical problem to be solved by the utility model is to overcome the defects of the prior art and provide a battery pack disconnect unit. A wire-free harness solution is realized by using a low-voltage copper busbar and a double-headed connector, replacing the connection of devices by using wire harnesses in traditional BDU. The wire-free harness solution housing improves the integration of the BDU, is convenient for automated production at the same time, and reduces the manufacturing cost of the BDU. The high-voltage copper busbar of the BDU protrudes partially from the housing surface, and auxiliary heat dissipation is carried out by means of a liquid cooling plate and a heat conduction pad, which can effectively reduce the cross-section of the copper busbar, reduce the cost, and achieve the goals of high integration, lightweight and low cost.
[0004] In the first aspect, the utility model provides a battery pack disconnect unit, including an upper housing, a lower housing, a high-voltage copper busbar, a low-voltage copper busbar, a double-headed connector and internal devices. The upper housing is fixedly connected to the lower housing. The high-voltage copper busbar is fixedly arranged inside the lower housing. A plurality of heat dissipation through holes for cooperating with the high-voltage copper busbar are opened on the lower housing, and a part of the high-voltage copper busbar extends out of the heat dissipation through holes. The low-voltage copper busbar is connected to the internal devices through the double-headed connector. The use of the low-voltage copper busbar and the double-headed connector to realize a wire-free harness structure is beneficial to automated production and replaces the connection of devices by using wire harnesses in traditional BDU. The wire-free harness solution housing improves the integration of the BDU, is convenient for automated production at the same time, and reduces the manufacturing cost of the BDU. The high-voltage copper busbar of the BDU protrudes partially from the housing surface, and auxiliary heat dissipation is carried out by means of a liquid cooling plate and a heat conduction pad, which can effectively reduce the cross-section of the copper busbar, reduce the cost of the device, achieve the goals of high integration, lightweight and low cost, and can realize a wire-free harness and high heat conduction efficiency.
[0005] In the embodiment of the present application, the low-voltage copper busbar is injection-molded integrally with any one of the upper housing or the lower housing.
[0006] In the embodiment of the present application, the internal devices include an active fuse, a passive fuse and a current sensor. The active fuse, the passive fuse and the current sensor are fixedly arranged between the upper housing and the lower housing. The low-voltage copper busbar is connected to the active fuse, the passive fuse and the current sensor through the double-headed connector.
[0007] In the embodiment of the present application, it includes a contactor, which is fixedly arranged between the upper shell and the lower shell, and the connection mode of the coil of the contactor adopts a plug-in type.
[0008] In the embodiment of the present application, the lower shell is provided with a first lower convex plate, a second lower convex plate, a third lower buckle, a fourth lower convex plate, a fifth lower convex plate, a sixth lower buckle, a seventh lower convex plate, an eighth tooth, a ninth lower buckle, a tenth tooth, an eleventh convex plate, a twelfth buckle, and a thirteenth convex plate arranged in sequence. The upper shell is provided with a first upper groove matching the first lower convex plate, a second upper groove matching the second lower convex plate, a third upper convex plate matching the third lower buckle, a fourth upper groove matching the fourth lower convex plate, a fifth upper groove matching the fifth lower convex plate, a sixth upper convex plate matching the sixth lower buckle, a seventh upper groove matching the seventh lower convex plate, an eighth convex plate matching the eighth tooth, a ninth upper convex plate matching the ninth lower buckle, a tenth convex plate matching the tenth tooth, an eleventh groove matching the eleventh convex plate, a twelfth convex plate matching the twelfth buckle, and a thirteenth groove matching the thirteenth convex plate.
[0009] In the embodiment of the present application, the lower shell is provided with a first rear lower convex plate, a second rear lower buckle, a third rear lower convex plate, a fourth rear lower buckle, a fifth rear lower convex plate, a sixth rear lower tooth, an eighth rear lower buckle, an eighth rear lower groove, a ninth rear lower buckle, and a tenth convex plate arranged in sequence.
[0010] The upper shell is provided with a first rear lower groove matching the first rear lower convex plate, a second rear lower convex plate matching the second rear lower buckle, a third rear lower groove matching the third rear lower convex plate, a fourth rear lower convex plate matching the fourth rear lower buckle, a fifth rear lower groove matching the fifth rear lower convex plate, a sixth rear lower convex plate matching the sixth rear lower tooth, an eighth rear lower convex plate matching the eighth rear lower buckle, an eighth rear lower convex plate matching the eighth rear lower groove, a ninth rear lower convex plate matching the ninth rear lower buckle, and a tenth groove matching the tenth convex plate arranged in sequence.
[0011] The beneficial effects achieved by the present utility model:
[0012] The utility model adopts a low-voltage copper busbar and a double-headed connector to realize a wire harness-free structure, which is beneficial to automated production and replaces the connection of devices by wire harnesses in traditional BDU. The wire harness-free scheme housing improves the integration of the BDU, facilitates automated production, and reduces the manufacturing cost of the BDU. The high-voltage copper busbar of the BDU protrudes partially from the surface of the housing, and with the assistance of a liquid cooling plate and a heat conduction pad for heat dissipation, the cross-section of the copper busbar can be effectively reduced, the cost of the device can be reduced, and the goals of high integration, light weight, and low cost can be achieved, and a wire harness-free and high heat conduction efficiency can be realized. The utility model relies on a high heat conduction efficiency to reduce the cost of internal devices and the cross-section of the high-voltage copper busbar. This device integrally injects the low-voltage copper busbar and the upper and lower housings, improving the precision and reducing the difficulty of automated production. Description of the Drawings
[0013] In order to more clearly illustrate the technical solutions of the present application, the drawings required for use in the embodiments will be briefly introduced below. Obviously, for those of ordinary skill in the art, without creative efforts, other drawings can also be obtained based on these drawings.
[0014] Figure 1 is an exploded view of some embodiments of the present application;
[0015] Figure 2 is a front view of some embodiments of the present application;
[0016] Figure 3 is a top view of some embodiments of the present application;
[0017] Figure 4 is a bottom view of some embodiments of the present application;
[0018] Figure 5 is a left view of some embodiments of the present application;
[0019] Figure 6 is a structural diagram of some embodiments of the present application;
[0020] Meanings of the reference numerals: 1 - upper housing; 2 - lower housing; 3 - high-voltage copper busbar; 4 - low-voltage copper busbar; 5 - double-headed connector; 6 - connector; 7 - first lower convex plate; 8 - second lower convex plate; 9 - third lower buckle; 10 - fourth lower convex plate; 11 - fifth lower convex plate; 12 - sixth lower buckle; 13 - seventh lower convex plate; 14 - eighth tooth; 15 - ninth lower buckle; 16 - tenth tooth; 17 - eleventh convex plate; 18 - twelfth buckle; 19 - thirteenth convex plate; 21 - first rear lower convex plate; 22 - second rear lower buckle; 23 - third rear lower convex plate; 24 - fourth rear lower buckle; 25 - fifth rear lower convex plate; 26 - sixth rear lower tooth; 27 - seventh rear lower buckle; 28 - eighth rear lower groove; 29 - ninth rear lower buckle; 30 - tenth convex plate. Detailed implementation manners
[0021] For the convenience of describing the technical solutions of the application, some concepts related to the present application will be described first below.
[0022] It should be noted that if there are directional indications (such as up, down, left, right, front, back...) in the embodiments of the present utility model, they are only used to explain the relative positional relationship and movement conditions between components in a specific posture. If the specific posture changes, the directional indications will also change accordingly.
[0023] In addition, if the descriptions such as "first" and "second" are involved in the present utility model, they are only for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include at least one such feature. In addition, the technical solutions between various embodiments can be combined with each other, but it must be based on the fact that those of ordinary skill in the art can implement them. When the combination of technical solutions results in contradictions or cannot be implemented, it should be considered that such a combination of technical solutions does not exist and is not within the protection scope required by the present utility model.
[0024] See Figure 1, this application discloses a battery pack disconnection unit, which includes an upper housing 1, a lower housing 2, a high-voltage copper bar 3, a low-voltage copper bar 4, a double-headed connector 5 and internal components. The upper housing 1 is fixedly connected to the lower housing 2. The high-voltage copper bar 3 is fixedly arranged inside the lower housing 2. A plurality of heat dissipation through holes matching the high-voltage copper bar 3 are opened on the lower housing 2, and a part of the high-voltage copper bar 3 extends out of the heat dissipation through holes. The low-voltage copper bar 4 is connected to the internal components through a double-headed connector 65. The upper housing 1 and the lower housing 2 are combined to form a box structure. In this device, the low-voltage copper bar, the upper housing and the lower housing are injection-molded into one body, and the high-voltage copper bar partially protrudes from the lower surface of the lower housing; the contactors are arranged in a horizontal manner to facilitate reducing the occupied space in the height direction. The connection method of the coils of the contactors adopts a plug-in type to avoid using wire harnesses inside the battery pack disconnection unit BDU. A large number of double-headed connectors (double-headed plug springs) are used inside the battery pack disconnection unit BDU to realize the connection between the low-voltage copper bar embedded in the upper housing and the internal components. The connector for the external connection of the battery pack disconnection unit BDU and the upper housing or the lower housing of the battery pack disconnection unit BDU are injection-molded into one body and integrated with the internal low-voltage copper bar, which helps to reduce costs. The described connector, upper housing, and lower housing are integrated together and injection-molded as a whole, without the need to design fixing devices for secondary assembly, avoiding product failure caused by additional assembly and reducing costs at the same time. The contour of the connector housing is designed to match the connector at the wire harness end of the battery pack. The terminals inside the connector are replaced with low-voltage copper bars and are formed together during the injection molding process, reducing the assembly workload. The described high-voltage copper bar is used to connect high-voltage components inside the BDU including contactors, active fuses, and passive fuses, and carries the charge and discharge current inside the battery pack. Since the charge and discharge current ratio inside the battery pack is relatively large, the temperature rise of the internal components of the BDU is relatively high. Usually, it is necessary to increase the cross-section of the copper bar or use devices with greater current-carrying capacity, resulting in an increase in cost. The high-voltage copper bar inside the BDU protrudes from the housing locally and is connected to the box body or the liquid cooling plate through a heat conduction pad to assist in heat dissipation, realizing rapid heat transfer, which can effectively reduce the cross-section of the copper bar and reduce the cost of the device. Both ends of the described double-headed connector can be connected to plug terminals. One end of the double-headed connector is connected to the low-voltage copper bar, and the other end of the double-headed connector can be connected to the plug terminals on the contactor.
[0025] In the embodiment of the present application, the low-voltage copper bar 4 is injection-molded integrally with any one of the upper housing 1 and the lower housing 2. The low-voltage copper bar is arranged inside the BDU and injection-molded together with the upper and lower housings, replacing the wire harness of the traditional BDU to realize the transmission of the control signal and the acquisition signal of the internal device. One end of the low-voltage copper bar is integrated with the connector on the housing, and the other end is connected to positions such as the contactor, pre-charge resistor, and voltage detection. The adjacent low-voltage copper bars are connected before injection molding and the connection is cut off after injection molding. The purpose of this is to improve the accuracy of the copper bar in the housing and avoid the assembly failure of the copper bar and the device due to position deviation. The cross-section of the low-voltage copper bar is determined by the actual current-carrying capacity and the size of the connector terminals on the housing. If the size of the BDU is too large, in order to reduce costs, the low-voltage copper bar is usually divided by region.
[0026] In the embodiment of the present application, the internal devices include an active fuse, a passive fuse, and a current sensor. The active fuse, the passive fuse, and the current sensor are fixedly arranged between the upper housing 1 and the lower housing 2. The low-voltage copper bar 4 is connected to the active fuse, the passive fuse, and the current sensor through a double-headed connector 65.
[0027] In the embodiment of the present application, a contactor is included. The contactor is fixedly arranged between the upper housing 1 and the lower housing 2, and the connection mode of the coil of the contactor adopts a plug-in type.
[0028] In the embodiment of the present application, the lower housing 2 is provided with a first lower convex plate 7, a second lower convex plate 8, a third lower buckle 9, a fourth lower convex plate 10, a fifth lower convex plate 11, a sixth lower buckle 12, a seventh lower convex plate 13, an eighth tooth 14, a ninth lower buckle 15, a tenth tooth 16, an eleventh convex plate 17, a twelfth buckle 18, and a thirteenth convex plate 19 arranged in sequence. The upper housing 1 is provided with a first upper groove matching the first lower convex plate 7, a second upper groove matching the second lower convex plate 8, a third upper convex plate matching the third lower buckle 9, a fourth upper groove matching the fourth lower convex plate 10, a fifth upper groove matching the fifth lower convex plate 11, a sixth upper convex plate matching the sixth lower buckle 12, a seventh upper groove matching the seventh lower convex plate 13, an eighth upper convex plate matching the eighth tooth 14, a ninth upper convex plate matching the ninth lower buckle 15, a tenth upper convex plate matching the tenth tooth 16, an eleventh groove matching the eleventh convex plate 17, a twelfth upper convex plate matching the twelfth buckle 18, and a thirteenth groove matching the thirteenth convex plate 19. The third upper convex plate, the sixth upper convex plate, the eighth upper convex plate, the ninth upper convex plate, the tenth upper convex plate, the twelfth upper convex plate, the first lower convex plate 7, the second lower convex plate 8, the fourth lower convex plate 10, the fifth lower convex plate 11, the seventh lower convex plate 13, the eleventh convex plate 17, and the thirteenth convex plate 19 can be flat plates, and the third lower buckle 9, the sixth lower buckle 12, the ninth lower buckle 15, and the twelfth buckle 18 can be flat plates with a square through hole opened.
[0029] In an embodiment of the present application, the lower housing 2 is provided with a first rear lower convex plate 21, a second rear lower buckle 22, a third rear lower convex plate 23, a fourth rear lower buckle 24, a fifth rear lower convex plate 25, a sixth rear lower notch 26, an eighth rear lower buckle 27, an eighth rear lower groove 28, a ninth rear lower buckle 29, and a tenth convex plate 30 arranged in sequence. The upper housing 1 is provided with a first rear lower groove for mating with the first rear lower convex plate 21, a second rear lower convex plate for mating with the second rear lower buckle 22, a third rear lower groove for mating with the third rear lower convex plate 23, a fourth rear lower convex plate for mating with the fourth rear lower buckle 24, a fifth rear lower groove for mating with the fifth rear lower convex plate 25, a sixth rear lower convex plate for mating with the sixth rear lower notch 26, an eighth rear lower convex plate for mating with the eighth rear lower buckle 27, an eighth rear lower convex plate for mating with the eighth rear lower groove 28, a ninth rear lower convex plate for mating with the ninth rear lower buckle 29, and a tenth groove for mating with the tenth convex plate 30. The second rear lower convex plate, the fourth rear lower convex plate, the sixth rear lower convex plate, the eighth rear lower convex plate, the eighth rear lower convex plate, the first rear lower convex plate 21, the ninth rear lower convex plate, the third rear lower convex plate 23, the fifth rear lower convex plate 25, and the tenth convex plate 30 may be flat plates, and the second rear lower buckle 22, the fourth rear lower buckle 24, the sixth rear lower notch 26, the eighth rear lower buckle 27, and the ninth rear lower buckle 29 may be flat plates with a square through-hole opened therein.
[0030] There are many types of contactors, double-headed connectors, active fuses, passive fuses, and current sensors that can be used in the prior art. Those skilled in the art can select according to actual needs, and no examples are given in this embodiment.
[0031] Each embodiment in this specification is described in a progressive manner. The same or similar parts between each embodiment can be referred to each other, and the differences between each embodiment and other embodiments are emphasized.
[0032] Those skilled in the art will easily think of other implementation schemes of the present invention after considering the specification and practicing the present invention here. This application aims to cover any variations, uses, or adaptive changes of the present invention, and these variations, uses, or adaptive changes follow the general principles of the present invention and include common general knowledge or conventional technical means in the technical field that the present invention has not invented. The specification and embodiments are only regarded as exemplary, and the true scope and spirit of the present invention are pointed out by the following claims.
[0033] The above specific embodiments have further elaborated in detail the purpose, technical solution and beneficial effects of the present application. It should be understood that the above are only specific embodiments of the present application and are not used to limit the protection scope of the present application. Any modifications, equivalent substitutions, improvements, etc. made on the basis of the technical solution of the present application shall be included within the protection scope of the present application.
Claims
1. A battery pack disconnect unit, characterized in that: The invention comprises an upper shell (1), a lower shell (2), a high-voltage copper busbar (3), a low-voltage copper busbar (4), a double-head connector (5) and internal components. The upper shell (1) is fixedly connected to the lower shell (2). The high-voltage copper busbar (3) is fixedly arranged inside the lower shell (2). The lower shell (2) is provided with a plurality of heat dissipation through holes matching the high-voltage copper busbar (3). The high-voltage copper busbar (3) partially extends out of the heat dissipation through holes. The low-voltage copper busbar (4) is connected to the internal components via the double-head connector (5).
2. A battery pack disconnect unit according to claim 1, characterized in that: The low-voltage copper busbar (4) is integrally formed by injection molding with either the upper shell (1) or the lower shell (2).
3. A battery pack disconnect unit according to claim 1, characterized in that: The internal components include an active fuse, a passive fuse and a current sensor. The active fuse, the passive fuse and the current sensor are fixedly arranged between the upper shell (1) and the lower shell (2). The low-voltage copper busbar (4) is connected to the active fuse, the passive fuse and the current sensor via a double-head connector (5).
4. A battery pack disconnect unit according to claim 1, characterized in that: It comprises a contactor, which is fixedly arranged between an upper shell (1) and a lower shell (2), and the connection method of the coil of the contactor adopts a plug-in type.
5. A battery pack disconnect unit according to claim 1, characterized in that: The lower shell (2) is provided with a first lower raised plate (7), a second lower raised plate (8), a third lower buckle (9), a fourth lower raised plate (10), a fifth lower raised plate (11), a sixth lower buckle (12), a seventh lower raised plate (13), an eighth tooth opening (14), a ninth lower buckle (15), a tenth tooth opening (16), an eleventh raised plate (17), a twelfth buckle (18), and a thirteenth raised plate (19) which are arranged in sequence, and the upper shell (1) is provided with a first upper groove for matching the first lower raised plate (7), a second upper groove for matching the second lower raised plate (8), and a third upper groove for matching the third lower raised plate (19). a third upper raised plate of the buckle head (9), a fourth upper groove matched with the fourth lower raised plate (10), a fifth upper groove matched with the fifth lower raised plate (11), a sixth upper raised plate matched with the sixth lower buckle head (12), a seventh upper groove matched with the seventh lower raised plate (13), an eighth raised plate matched with the eighth tooth opening (14), a ninth upper raised plate matched with the ninth lower buckle head (15), a tenth raised plate matched with the tenth tooth opening (16), an eleventh groove matched with the eleventh raised plate (17), a twelfth raised plate matched with the twelfth buckle head (18), and a thirteenth groove matched with the thirteenth raised plate (19).
6. A battery pack disconnect unit according to claim 1, characterized in that: The lower shell (2) is provided with a first rear lower raised plate (21), a second rear lower buckle (22), a third rear lower raised plate (23), a fourth rear lower buckle (24), a fifth rear lower raised plate (25), a sixth rear lower tooth opening (26), an eighth rear lower buckle (27), an eighth rear lower groove (28), a ninth rear lower buckle (29) and a tenth raised plate (30) which are arranged in sequence. The upper shell (1) is provided with a first rear lower groove matched with the first rear lower protruding plate (21), a second rear lower protruding plate matched with the second rear lower buckle (22), a third rear lower groove matched with the third rear lower protruding plate (23), a fourth rear lower protruding plate matched with the fourth rear lower buckle (24), a fifth rear lower groove matched with the fifth rear lower protruding plate (25), a sixth rear lower protruding plate matched with the sixth rear lower tooth mouth (26), an eighth rear lower protruding plate matched with the eighth rear lower buckle (27), an eighth rear lower protruding plate matched with the eighth rear lower groove (28), a ninth rear lower protruding plate matched with the ninth rear lower buckle (29), and a tenth groove matched with the tenth protruding plate (30).