High-voltage distribution box, battery pack and vehicle

Abstract

The utility model belongs to the technical field of vehicles, and discloses a high-voltage distribution box, a battery pack and a vehicle, the high-voltage distribution box comprises a box body and an electrical element, the box body further comprises a first shell and a second shell, the first shell and the second shell jointly enclose to form a first accommodating cavity, and the first shell is provided with a mounting groove with a notch facing the second shell; the electrical element comprises a relay, the relay is clamped and limited in the mounting groove, and the relay is a shell-free relay. According to the high-voltage distribution box, the battery pack comprising the high-voltage distribution box and the vehicle comprising the high-voltage distribution box, the back-twist risk caused by fixing the relay through bolts is avoided, and the space utilization rate is high.

Description

Technical Field

[0001] The utility model relates to the technical field of vehicles, in particular to a high-voltage distribution box, a battery pack and a vehicle. Background Art

[0002] With the continuous development of automotive technology, there are more and more electrical devices on vehicles, especially new energy vehicles. To ensure the power supply of each electrical load on the vehicle, a high-voltage distribution box is provided on the vehicle. The relays in the existing high-voltage distribution box are usually fixed to the box body by bolts. To provide an installation position for the bolts, at least two fixing feet are usually provided on the relay, resulting in a large space occupied by the relay as a whole, which also affects the development of the battery pack towards miniaturization and integration. Moreover, there is a risk of overheating caused by abnormal internal resistance of the electrical connection point due to torque attenuation of the bolts used to fix the relay. Summary of the Utility Model

[0003] One of the purposes of the utility model is to provide a high-voltage distribution box to solve the problems of large space occupied by the relay and bolt detwisting; the second and third purposes of the utility model are to provide a battery pack and a vehicle to solve the problems of large space occupied by the battery pack and the risk of overheating.

[0004] To achieve this purpose, the utility model adopts the following technical solutions:

[0005] In a first aspect, an embodiment of the utility model provides a high-voltage distribution box. The high-voltage distribution box includes a box body and electrical components. The box body includes a first housing and a second housing. The first housing and the second housing jointly enclose a first accommodation cavity. The first housing is provided with an installation groove with an opening facing the second housing; the electrical components include a relay. The relay is clamped and limited in the installation groove, and the relay adopts a shell-less relay.

[0006] In one embodiment, a clamping member is provided on the relay, and a clamping groove is formed on the groove wall of the installation groove. The relay is limited in the installation groove through the mutually matching clamping member and the clamping groove, or the mutually matching clamping member and the clamping hole.

[0007] In one embodiment, the high-voltage distribution box further includes an electrical connection piece. The electrical connection piece is welded to the electrical components forming the high-voltage circuit in the high-voltage distribution box, and the electrical connection pieces are welded to each other.

[0008] In one embodiment, the high-voltage distribution box includes a low-voltage interface;

[0009] The relay is connected to the low-voltage interface through a lead frame, or the relay is connected to the low-voltage interface through a printed circuit.

[0010] In one embodiment, the high-voltage power distribution box includes a high-voltage sampling interface;

[0011] The high-voltage sampling point on the high-voltage line in the high-voltage power distribution box is connected to the high-voltage sampling interface through a lead frame, or the high-voltage sampling point on the high-voltage line in the high-voltage power distribution box is connected to the high-voltage sampling interface through a printed circuit.

[0012] In one embodiment, the lead frame or the printed circuit is located on a side of the first housing facing away from the second housing.

[0013] In one embodiment, the box body further includes a third housing, the third housing is located on a side of the first housing facing away from the second housing, and the third housing and the second housing enclose a second accommodation cavity, and the lead frame or the printed circuit is located in the second accommodation cavity.

[0014] In one embodiment, the first housing includes a mounting groove seat, the mounting groove is formed in the mounting groove seat, and the bottom of the mounting groove seat protrudes from a side of the first housing facing the third housing.

[0015] In one embodiment, potting glue is filled in the gap between the mounting groove and the relay.

[0016] In a second aspect, an embodiment of the present invention provides a battery pack, including the high-voltage power distribution box described in any of the above embodiments.

[0017] In a third aspect, an embodiment of the present invention provides a vehicle, including the above battery pack.

[0018] Advantages of the present invention:

[0019] For the high-voltage power distribution box, battery pack and vehicle provided by the present invention, the outer shell in the existing relay is cancelled, a mounting groove for accommodating the relay is provided on the box body, and the relay is snap-fitted and fixed in the mounting groove. This not only avoids the risk of bolt back-twisting that may be caused by bolt connection, but also saves space because there is no need to set fixed feet for fixing bolts, which is beneficial to improving the space utilization rate of the high-voltage power distribution box, and also promotes the development of the battery pack towards miniaturization and integration. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is an exploded structural schematic diagram of the high-voltage power distribution box in an embodiment of the present invention;

[0021] Figure 2 is an internal structural schematic diagram of the high-voltage power distribution box in an embodiment of the present invention;

[0022] Figure 3It is a cross-sectional view of the high-voltage distribution box in the embodiment of the present utility model;

[0023] Figure 4 It is a schematic structural diagram of the lead frame in the embodiment of the present utility model;

[0024] Figure 5 It is a schematic structural diagram of the relay in the embodiment of the present utility model;

[0025] Figure 6 It is a cross-sectional view when the relay is assembled in the installation groove in the embodiment of the present utility model;

[0026] Figure 7 It is a schematic diagram of the high-voltage line principle in the high-voltage distribution box in the related art.

[0027] In the figure:

[0028] 10. Box body; 11. First shell; 12. Second shell; 13. Third shell; 14. Installation groove seat; 141. Installation groove; 142. Clamping groove; 20. Relay; 21. Clamping part; 30. Lead frame; 40. Pre-charge resistor; 50. Fuse; 60. Electric connection piece. Specific embodiments

[0029] The present utility model will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the present utility model, rather than limiting the present utility model. In addition, it should be noted that for the convenience of description, only the parts related to the present utility model are shown in the drawings, rather than all the structures.

[0030] In the description of the present utility model, unless otherwise clearly defined and limited, the terms "connected", "connected", and "fixed" shall be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or integrated; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two elements or the interaction relationship between two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present utility model can be understood according to specific situations.

[0031] In the present utility model, unless otherwise clearly specified and defined, the first feature being "above" or "below" the second feature may include direct contact between the first and second features, or may include the situation where the first and second features are not in direct contact but are in contact through additional features therebetween. Moreover, the first feature being "above", "over" and "on top of" the second feature includes the first feature being directly above and obliquely above the second feature, or simply indicating that the horizontal height of the first feature is higher than that of the second feature. The first feature being "below", "beneath" and "underneath" the second feature includes the first feature being directly below and obliquely below the second feature, or simply indicating that the horizontal height of the first feature is lower than that of the second feature.

[0032] In the description of this embodiment, the orientation or positional relationships such as "above", "below", "right", etc. are based on the orientation or positional relationships shown in the drawings. It is only for the convenience of description and simplifying the operation, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0033] Referring to Figures 1-7 As shown, in an embodiment of the present utility model, a high-voltage distribution box is proposed, which includes a box body 10 and electrical components. The box body 10 further includes a first housing 11 and a second housing 12. The first housing 11 and the second housing 12 jointly enclose a first accommodation cavity. The first housing 11 and the second housing 12 are fixedly connected, for example, by bolts. The first housing 11 is integrally arranged in a groove-like structure to cooperate with the second housing 12 to form the first accommodation cavity. An installation groove base 14 is provided on the first housing 11. An installation groove 141 with an opening facing the second housing 12 is formed on the installation groove base 14. The electrical components include a relay 20. The relay 20 is snap-fitted and limited in the installation groove 141, and the relay 20 adopts a non-enclosed relay. It can be understood that the non-enclosed relay 20 refers to a relay device without a housing. This relay device includes all functional components of the relay in the prior art except the housing, such as a base, a coil, a yoke, contact terminals, etc. The connection relationships between the various functional components will not be elaborated here. In order to achieve the snap-fitting and limiting of the relay 20 and the installation groove base 14, a first snap-fitting structure is provided on the relay 20, for example, on the yoke of the relay 20 or on the base of the relay 20. A second snap-fitting structure is provided in the installation groove base 14. The relay 20 and the installation groove base 14 are limited and fixed through the mutually cooperating first snap-fitting structure and second snap-fitting structure.

[0034] The above high-voltage distribution box cancels the housing of relay 20, sets an installation groove 141 on the first housing 11 with the same size as the housing of the existing relay 20, and fixes the housingless relay 20 in the installation groove 141 by means of snap connection, which not only protects the relay 20 in the same way, but also saves the fixing feet for installation bolts, achieving the purpose of saving space. At the same time, there is no risk of untwisting, avoiding the overheating risk caused by bolt untwisting.

[0035] Reference Figure 5 and Figure 6 As shown, in one embodiment, the first snap connection structure includes a snap connection member 21 protruding from the relay 20, and the second snap connection structure includes a snap connection groove 142 or a snap connection hole that cooperates with the snap connection member 21. Specifically, two snap connection members 21 are respectively arranged on opposite sides of the housingless relay 20. Correspondingly, two snap connection grooves 142 or two snap connection holes are respectively arranged on two opposite groove side walls of the installation groove 141. Of course, in other embodiments, three or four or more snap connection members 21 can also be arranged. The snap connection member 21 can specifically be a snap connection block or a snap connection hook, and no specific limitation is made here.

[0036] When the housingless relay 20 is placed in the installation groove 141, the snap connection member 21 is embedded into the snap connection groove 142 or the snap connection hole to fix the housingless relay 20. It should be emphasized that the installation groove seat 14 or the snap connection member 21 has a certain elasticity to enable the snap connection member 21 to be smoothly snapped into the snap connection groove 142 or the snap connection hole. For example, the installation groove seat 14 is an injection molded part integrally injection molded with the first housing 11, reducing the processing difficulty of the high-voltage distribution box.

[0037] In other embodiments, the first snap connection structure can also be a snap connection groove 142 or a snap connection hole, and the second snap connection structure can be a snap connection member 21.

[0038] At the same time, in order to further provide the connection stability between the relay 20 and the installation groove seat 14, in some embodiments, the gap between the installation groove 141 and the relay 20 is filled with potting glue. The potting glue can not only reinforce the relay 20 and the installation groove seat 14, but also has good heat conduction performance, and can timely dissipate the heat generated by the relay 20.

[0039] It can be understood that the high-voltage distribution box can be a BDU and a PDU according to different functions. Among them, the BDU is also called the battery disconnect unit and is located inside the battery module. It is the working unit for high-voltage distribution, disconnection, and short-circuit protection of the battery system. The PDU is also called the power distribution unit and is located outside the battery module. Its main function is to distribute the high-voltage power of the power battery to each high-voltage electrical equipment, such as the motor controller, drive motor, electric air-conditioning compressor, PTC heater, etc. Relays are provided in both the BDU and the PDU to control the on / off of the circuit.

[0040] Taking the high-voltage distribution box as an example of using it as a BDU, the following is a further description.

[0041] In one embodiment, the relay 20 in the high-voltage distribution box includes a main positive relay, a main negative relay, and a pre-charge relay. The main positive relay, the main negative relay, and the pre-charge relay are all fixed on the first housing 11 through the mounting slot base 14. The electrical components in the high-voltage distribution box further include a fuse 50 and a pre-charge resistor 40. The fuse 50 and the pre-charge resistor 40 cooperate with the relay 20 to jointly form a high-voltage circuit. The high-voltage circuit is used for high-voltage large-circuit current-carrying and can connect the external battery input and the load output. The pre-charge resistor 40 is also fixed on the first housing 11, and specifically, it can adopt methods including but not limited to snap connection or bolt connection.

[0042] Refer to Figure 7 As shown, in the high-voltage circuit of the related art, the main positive relay is connected in series with the fuse 50 and can be connected to the positive pole of the battery. The main negative relay can be connected to the negative pole of the battery. The pre-charge relay is connected in series with the pre-charge resistor 40 and then connected in parallel with the main positive relay. It should be emphasized that when forming the high-voltage circuit, between the relay 20 and the fuse 50, between the relay 20 and the relay 20, and between the relay 20 and the pre-charge resistor 40, they are all connected through an electrical connection piece 60, such as a copper bar. The electrical connection piece 60 is welded to each of the above electrical components and between the connected electrical connection pieces 60. Compared with threaded connection or plug connection, it can avoid problems such as back-twisting (threaded connection) or large contact resistance caused by dirty contact surfaces (plug connection), improving the stability and reliability of the connection internal resistance. Moreover, due to the use of the welding connection method, the contact lead-out end of the relay 20 for connecting the electrical connection piece 60 can adopt a smooth-surface cylindrical structure, reducing the processing difficulty of the relay 20.

[0043] In addition to forming the high-voltage circuit, the relay 20 can also be connected to the low-voltage interface provided on the box body 10, and then connected to the external BMS system to form a low-voltage circuit. The low-voltage circuit is used to control the on-off of the relay 20. In the related art, the relay 20 and the low-voltage interface are connected by a low-voltage wire harness. The low-voltage wire harness is cross-arranged with each electrical component in the high-voltage distribution box, and is prone to failure due to reasons such as fixed stress and wear, further causing risks such as abnormal power-off of the vehicle and even short-circuit fire. Based on this, in some embodiments, the high-voltage distribution box connects the relay 20 and the low-voltage interface through a lead frame 30 or a printed circuit. The lead frame 30 or the printed circuit replaces the original low-voltage wire harness in the high-voltage distribution box and connects the above electrical components, making the internal circuit of the high-voltage distribution box neat and beautiful, saving more space than the low-voltage wire harness, and enabling fully automated production. Specifically, the lead frame 30 or the printed circuit is connected to the coil lead-out end of the relay 20 by welding.

[0044] Taking the example of using a lead frame 30 to replace the low-voltage harness to connect the relay 20 and the low-voltage interface, in one embodiment, in order to avoid interference between the high-voltage circuit and the low-voltage circuit, the lead frame 30 and the electrical connection piece 60 are respectively located on opposite sides of the first housing 11. Specifically, the contact lead-out end of the relay 20 is arranged in the first accommodation cavity, and the electrical connection piece 60 is welded to the contact lead-out end in the first accommodation cavity, while the coil lead-out end of the relay 20 for connecting the lead frame 30 (low-voltage harness) is arranged outside the first accommodation cavity, that is, on the side of the first housing 11 facing away from the second housing 12. It can be understood that the first housing 11 is provided with a through hole for the coil lead-out end to pass through.

[0045] On this basis, referring to Figure 1 As shown, the box body 10 further includes a third housing 13. The third housing 13 is located on the side of the first housing 11 facing away from the second housing 12. The third housing 13 is fixedly connected to the first housing 11 by means including but not limited to bolt connection or snap connection and encloses to form a second accommodation cavity. The third housing 13 is specifically a trough-shaped structure with an open side facing the second housing 12. The lead frame 30 is located in the second accommodation cavity, thereby forming protection for the lead frame 30.

[0046] Similarly, a lead frame 30 for high-voltage sampling or a printed circuit for high-voltage sampling is also provided in the high-voltage distribution box, which is used to connect the high-voltage sampling point in the high-voltage line and the high-voltage sampling interface provided on the box body 10. The high-voltage sampling point can include the front / back end of the main positive relay, the front / back end of the main negative relay, the front / back end of the fuse 50, etc., which are not specifically limited herein. However, it should be emphasized that the lead frame 30 for high-voltage sampling or the printed circuit for high-voltage sampling is also located in the second accommodation cavity to make rational use of space, and the first housing 11 is also provided with a through hole for the electrical connection piece 60 to pass through. The lead frame 30 for high-voltage sampling or the printed circuit is welded to the electrical connection piece 60.

[0047] Referring to Figure 6 As shown, based on the setting of the third housing 13, in order to improve the space utilization rate of the high-voltage distribution box and thus improve the integration degree, the bottom of the mounting groove seat 14 protrudes from the side of the first housing 11 facing the third housing 13, that is, at least part of the relay 20 in the mounting groove seat 14 is located in the second accommodation cavity. Specifically, the side of the mounting groove seat 14 where the slot opening is provided is flush with the surface of the first housing 11 facing the second housing 12, and part of the relay 20 passes out of the mounting groove seat 14 through the slot opening of the mounting groove seat 14 and is in the first accommodation cavity.

[0048] In one embodiment, the pre-charge resistor 40 is also arranged in the second accommodation cavity to further improve the space utilization rate.

[0049] In an embodiment of the present utility model, a battery pack is further provided, which includes a battery module and the high-voltage distribution box in any of the above embodiments, and the high-voltage distribution box is electrically connected to the battery module.

[0050] In an embodiment of the present utility model, a vehicle is further provided, which includes the battery pack in the above embodiment, and the vehicle can be any type of power battery.

[0051] For the battery pack and the vehicle in the above embodiments, the high-voltage distribution box installs the relay in the high-voltage distribution box without the shell and replaces the low-voltage wire harness and / or the high-voltage sampling wire harness with a lead frame or a printed circuit, reducing the volume of the high-voltage distribution box by 20%; moreover, the relay without the shell and the electrical connection piece are welded and connected to achieve fully automated production, reducing the cost by 20% and increasing the production efficiency by 20%.

[0052] Obviously, the above embodiments of the present utility model are merely examples for clearly illustrating the present utility model, rather than limiting the implementation manners of the present utility model. For those of ordinary skill in the art, various obvious changes, re-adjustments and substitutions can be made without departing from the protection scope of the present utility model. It is not necessary and impossible to enumerate all the implementation manners here. Any modifications, equivalent substitutions and improvements made within the spirit and principle of the present utility model shall be included in the protection scope of the claims of the present utility model.

Claims

1. High-voltage power distribution box, characterized in that, The high-voltage power distribution box includes: A box body (10), the box body (10) includes a first housing (11) and a second housing (12), the first housing (11) and the second housing (12) jointly enclose a first accommodation cavity, and the first housing (11) is provided with a mounting groove (141) with a notch facing the second housing (12); Electrical components, the electrical components include a relay (20), the relay (20) is snap-fitted and limited in the mounting groove (141), and the relay (20) is a shell-less relay.

2. The high-voltage power distribution box according to claim 1, wherein, A snap-fitting member (21) is provided on the relay (20), a snap-fitting groove (142) or a snap-fitting hole is formed on the groove wall of the mounting groove (141), and the relay (20) is limited in the mounting groove (141) through the mutually cooperating snap-fitting member (21) and the snap-fitting groove (142), or, the mutually cooperating snap-fitting member (21) and the snap-fitting hole.

3. The high-voltage power distribution box according to claim 1, characterized in that The high-voltage power distribution box further includes an electrical connection piece (60), the electrical connection piece (60) is welded to the electrical components forming the high-voltage circuit in the high-voltage power distribution box, and the connected electrical connection pieces are welded to each other.

4. The high-voltage power distribution box according to claim 1, characterized in that, The high-voltage power distribution box includes a low-voltage interface; The relay (20) is connected to the low-voltage interface through a lead frame (30), or, the relay (20) is connected to the low-voltage interface through a printed circuit.

5. The high-voltage power distribution box according to claim 1, wherein The high-voltage power distribution box includes a high-voltage sampling interface; The high-voltage sampling point on the high-voltage circuit in the high-voltage power distribution box is connected to the high-voltage sampling interface through a lead frame (30), or, the high-voltage sampling point on the high-voltage circuit in the high-voltage power distribution box is connected to the high-voltage sampling interface through a printed circuit.

6. The high-voltage power distribution box according to claim 4 or 5, characterized in that, The lead frame (30) or the printed circuit is located on the side of the first housing (11) facing away from the second housing (12).

7. The high-voltage power distribution box according to claim 6, characterized in that, The box body (10) further includes a third housing (13), the third housing (13) is located on the side of the first housing (11) facing away from the second housing (12), and the third housing (13) and the second housing (12) enclose a second accommodation cavity, and the lead frame (30) or the printed circuit is located in the second accommodation cavity.

8. The high-voltage power distribution box according to claim 7, characterized in that, The first housing (11) includes a mounting groove seat (14), the mounting groove (141) is formed in the mounting groove seat (14), and the bottom of the mounting groove seat (14) protrudes from the side of the first housing (11) facing the third housing (13).

9. The high-voltage power distribution box according to any one of claims 1-5, characterized in that, The gap between the mounting groove (141) and the relay (20) is filled with potting glue.

10. Battery pack, characterized in that, Including the high-voltage power distribution box according to any one of claims 1-9.

11. A vehicle, characterized in that, Including the battery pack according to claim 10.

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