BDU zero wire harness transmission structure and BDU zero wire harness connection structure

Abstract

The utility model relates to the field of new energy automobiles and power batteries, and provides a BDU zero wire harness transmission structure and a BDU zero wire harness connection structure. A BDU zero wire harness transmission structure comprises a metal signal flat cable and a flat cable insulation support, the flat cable insulation support is made through insert injection molding, and the metal signal flat cable serves as an insert and is arranged in the flat cable insulation support; the metal signal flat cable comprises a conductive metal foil and a plurality of first signal ends. A BDU zero wire harness connection structure comprises a BDU zero wire harness transmission structure, an electrical member and a first housing. The metal signal flat cable is used for transmitting a high-voltage acquisition signal or a low-voltage control signal of an electrical part; the first shell comprises one or more parts; the first shell and the flat cable insulation support are fixedly connected to form a shell of the BDU, and the electrical part is arranged in the shell. According to the utility model, a more flexible local space is provided for the BDU, the automatic assembly efficiency is improved, and the manufacturing cost is reduced.

Description

Technical Field

[0001] The utility model relates to the fields of new energy vehicles and power batteries, and particularly to a high-voltage power distribution unit for new energy vehicles. Background Art

[0002] In new energy vehicles, the BDU (high-voltage power distribution unit) is responsible for the power distribution and management of the high-voltage system, and provides functions such as charge and discharge control, overload and short-circuit protection, and high-voltage sampling for the whole vehicle. The BDU mainly consists of components such as high-voltage relays, fuses, pre-charge resistors, pre-charge relays, current sensors / shunts, copper bars, wire harnesses, and housings. The main circuits of the BDU include a main circuit, a pre-charge circuit, a discharge circuit, a charge circuit, a heating circuit, a high-voltage acquisition circuit, a low-voltage control circuit, etc., among which the charge circuit, the heating circuit, etc. can be customized and selected according to different requirements.

[0003] In the related art, the internal connection of the BDU generally adopts the traditional wire harness connection method. The Chinese patent application document CN1697262A discloses a flat wire connected to a connection object, including: a plurality of transmission lines; an insulating layer covering the above transmission lines; and an indicating line formed on one surface of the above insulating layer, at a predetermined distance from one end of the above flat wire. When the above flat wire is inserted into the above connection object at a distance of the above predetermined distance, it is electrically connected to a circuit board or a printed circuit board. In the above related art, FFC (flexible flat cable) is used for electrical connection of components. The disadvantages of the wire harness connection used in the above related art are that the wire harness in the BDU is messy and occupies space, the wire harness connection is required, resulting in low assembly efficiency, the wiring terminals are easy to loosen, and there is a risk of circuit failure and even vehicle fire caused by loose connection of wires and falling off of wire heads. Therefore, it is urgent to solve the problems existing in the BDU due to the need for wire harness connection in this field. Summary of the Utility Model

[0004] The utility model aims to solve the problems existing in the related art, and provides a design scheme of a zero-wire harness BDU with a plastic coating technology route, which provides a flexible local space for the BDU, improves the automation assembly efficiency, reduces the manufacturing cost, and especially after the signal transmission circuit adopts the plastic coating process (insert-molding / over-molding), it can provide a flexible local space for the BDU and significantly improve the automation efficiency.

[0005] In view of the above limitations, the utility model proposes a zero-wire harness transmission structure and a zero-wire harness connection structure for the BDU.

[0006] In a first aspect, the utility model provides a zero-wire harness transmission structure for the BDU, including:

[0007] A metal signal cable for transmitting signals;

[0008] A cable insulation bracket, which is made by insert molding, and the metal signal cable is arranged in the cable insulation bracket as an insert; the cable insulation bracket is a part of the housing of the BDU;

[0009] The metal signal cable includes: a conductive metal foil and a plurality of first signal ends. The conductive metal foil extends in a preset wiring manner, and the first signal ends are arranged on the conductive metal foil and exposed from the cable insulation bracket. The first signal ends are used to connect with external electrical components.

[0010] Further: The signal is a high-voltage acquisition signal or a low-voltage control signal;

[0011] The material of the conductive metal foil is copper or copper alloy. The first signal end is a planar structure, and its shape is circular, rectangular, or circular ring-shaped, or the first signal end is a pin or a claw.

[0012] Further: It also includes: a copper bar and a copper bar insulation bracket;

[0013] The copper bar insulation bracket is formed by insert molding, and the copper bar is arranged in the copper bar insulation bracket as an insert;

[0014] A plurality of first conductive ends are arranged on the copper bar and exposed from the copper bar insulation bracket.

[0015] Further: After the copper bar insulation bracket and the cable insulation bracket are fixedly connected, they jointly serve as a part of the housing of the BDU.

[0016] Further: A first buckle is arranged on the cable insulation bracket, and a second buckle is arranged on the copper bar insulation bracket. The cable insulation bracket and the copper bar insulation bracket are clamped by the first buckle and the second buckle.

[0017] Further: A first fixing hole is arranged on the cable insulation bracket; a second fixing hole is arranged on the copper bar insulation bracket; the cable insulation bracket and the copper bar insulation bracket are connected by fasteners through the first fixing hole and the second fixing hole.

[0018] Further: The cable insulation bracket and the copper bar insulation bracket are connected by a hot melting method.

[0019] In a second aspect, the present invention provides a BDU zero wire harness connection structure, including: the BDU zero wire harness transmission structure, an electrical component, and a first housing;

[0020] The metal signal cable is used to transmit the high-voltage acquisition signal or low-voltage control signal of the electrical component;

[0021] The first housing includes one or more parts; the first housing is fixedly connected to the cable insulation bracket to form the housing of the BDU, and the electrical component is arranged in the housing.

[0022] Further: the first housing includes: an upper cover, a side outer shell;

[0023] The cable insulation bracket embedding the metal signal cable is arranged at the lower part of the side outer shell;

[0024] A shape matching the outer shape of the electrical component is formed in the inner cavity of the side outer shell; the electrical component is placed in the side outer shell and located above the cable insulation bracket;

[0025] The cable insulation bracket is fixedly connected to the side outer shell, and the upper end of the side outer shell is fixedly connected to the upper cover.

[0026] Further: a second signal terminal for transmitting signals is arranged on the electrical component; the second signal terminal is connected to the first signal terminal;

[0027] A second conductive terminal is arranged on the external copper bar of the peripheral device; the second conductive terminal is connected to the first conductive terminal.

[0028] Compared with the related technology, the present utility model has the following advantages:

[0029] The BDU zero-line harness transmission structure provided by the first aspect of the present utility model, through the plastic coating treatment of the metal signal cable pre-made according to the electrical schematic diagram and the electrical component layout design scheme, realizes the electrical connection and signal transmission of the zero-line harness in an integrated and automated manner, thereby saving the BDU space occupied by the harness, providing a more flexible local space for the BDU, improving the automated assembly efficiency, reducing the manufacturing cost, and avoiding problems such as loose wiring terminals, virtual connection of wires, and falling off of wire ends that are prone to occur in the wire harness connection method.

[0030] The BDU zero-line harness connection structure provided by the second aspect of the present utility model, by using the BDU zero-line harness transmission structure, realizes the electrical connection and signal transmission of the zero-line harness in an integrated and automated manner, thereby saving the BDU space occupied by the harness, providing a more flexible local space for the BDU, improving the automated assembly efficiency, reducing the manufacturing cost, and avoiding problems such as loose wiring terminals, virtual connection of wires, and falling off of wire ends that are prone to occur in the wire harness connection method. On the other hand, by using the cable insulation bracket of the BDU zero-line harness transmission structure as a part of the outer shell, the BDU space is further saved and the cost is reduced. Description of the Drawings

[0031] Figure 1 Schematic diagram of the BDU zero wire harness transmission structure according to an embodiment of the present utility model; (a) is a perspective view; (b) is an exploded view;

[0032] Figure 2 Schematic diagram of the BDU zero wire harness transmission structure according to another embodiment of the present utility model; (a) is a top view; (b) is an exploded view;

[0033] Figure 3 Schematic diagram of the BDU zero wire harness connection structure according to an embodiment of the present utility model; (a) is a perspective view; (b) is an exploded view.

[0034] Description of the reference numerals:

[0035] 11 - Metal signal cable; 111 - Conductive metal foil; 112 - First signal terminal; 113 - Positioning structure; 12 - Cable insulation bracket;

[0036] 21 - Copper bar; 211 - First conductive terminal; 22 - Copper bar insulation bracket

[0037] 30 - Electrical component;

[0038] 41 - Upper cover; 42 - Side housing. Detailed implementation manners

[0039] To make the objectives, technical solutions and advantages of the present utility model clearer and more understandable, the present utility model will be further described in detail below. However, it should be understood that the description herein is only used to explain the present utility model and is not intended to limit the scope of the present utility model.

[0040] Unless otherwise defined, all technical terms and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which the present utility model belongs. The terms used in the description of the present utility model herein are only for the purpose of describing specific embodiments and are not intended to limit the present utility model. The characterization means involved herein can refer to the relevant descriptions in the prior art and will not be elaborated herein.

[0041] To further understand the present utility model, the present utility model will be further described in detail below in conjunction with the best embodiments.

[0042] Embodiment 1

[0043] As Figures 1-3 shown, a BDU zero wire harness transmission structure includes:

[0044] A metal signal cable 11 for transmitting signals; the metal signal cable 11 is designed according to the electrical schematic diagram and the arrangement of electrical components to ensure signal transmission;

[0045] The flexible cable insulation bracket 12 is made by insert molding. The metal signal flexible cable 11 is set as an insert in the flexible cable insulation bracket 12. The flexible cable insulation bracket 12 can be a part of the housing of the BDU.

[0046] The metal signal flexible cable 11 includes a conductive metal foil and a plurality of first signal terminals 112. The conductive metal foil extends according to a preset wiring pattern. The first signal terminals 112 are arranged on the conductive metal foil and exposed from the flexible cable insulation bracket 12. The first signal terminals 112 are used to connect with external electrical components 30.

[0047] The metal signal flexible cable 11 further includes a positioning structure 113 for positioning the metal signal flexible cable 11 using a positioning post or the like to prevent its position from shifting. Claws (such as Figure 1 the protruding structure shown) are arranged on the first signal terminals 112 for plugging and mating with the electrical components.

[0048] The metal signal flexible cable 11 is made of copper or copper alloy and can be made by etching on a copper plate or copper alloy plate, stamping the copper plate or copper alloy plate, etc.

[0049] Insert molding (insert - mo ld ing), also known as over - mo ld ing, is a process in which a pre - prepared insert is fixed at a specified position in an injection mold, then injection - molded, and after the mold is opened, the insert is wrapped by the cooled and solidified plastic to obtain a product. First, the metal signal flexible cable 11 is placed at the specified position in the mold, the mold is closed, hot - melt plastic is injected, held under pressure for a certain time, the assembly is formed, the mold is opened, and the flexible cable insulation bracket 12 is taken out, and the insert molding process is completed. The flexible cable insulation bracket 12 is designed within a preset envelope space to play a role in fixing and protecting the metal signal flexible cable 11.

[0050] Different from the existing FFC (Flexible Flat Cable), the metal signal flexible cable 11 of the present utility model is made according to the electrical schematic diagram and the arrangement design of electrical components, without the need for wire harness connection, which can save space inside the BDU and realize automated assembly, thereby improving the assembly and electrical connection efficiency.

[0051] The material of the flexible cable insulation bracket 12 is polytetrafluoroethylene (PTFE), polyvinyl alcohol (PVA), polyimide (PI), polyamide (PA), etc. The above materials have good insulation effects and corrosion - resistance and high - temperature resistance effects, but the present utility model is not limited to the above materials.

[0052] Further: The signal is a high - voltage acquisition signal or a low - voltage control signal;

[0053] The material of the conductive metal foil is copper or copper alloy, and the first signal terminal 112 is arranged at a position on the conductive metal foil where electrical connection is required; the first signal terminal 112 is a planar structure, and its shape is circular, rectangular, or annular, or the first signal terminal 112 is a pin or a claw. The conductive metal foil and the first signal terminal 112 can be made by etching on a copper plate or a copper alloy plate, stamping the copper plate or the copper alloy plate, etc. When the first signal terminal 112 is a pin or a claw, it can also be made by fixing a prefabricated part to the conductive metal foil through welding or bonding.

[0054] Further: it also includes: a copper bar 21 and a copper bar insulating bracket 22;

[0055] The copper bar insulating bracket 22 is formed by insert molding, and the copper bar 21 is arranged in the copper bar insulating bracket 22 as an insert; the function of the copper bar 21 is to carry current and is used to transmit current, mainly for carrying a large current.

[0056] A plurality of first conductive terminals 211 are arranged on the copper bar 21, and the first conductive terminals 211 protrude from the copper bar insulating bracket 22.

[0057] After the copper bar insulating bracket 22 is fixedly connected to the flexible cable insulating bracket 12, they jointly serve as a part of the housing of the BDU; or, the copper bar insulating bracket 22 alone serves as a part of the housing of the BDU. The copper bar insulating bracket 22 and the flexible cable insulating bracket 12 are designed within a preset envelope space to wrap the entire BDU as a housing, thereby further saving the space of the BDU and reducing the cost.

[0058] The insert molding process of the copper bar insulating bracket 22 is as follows: first, place the copper bar 21 at a designated position in the mold, close the mold, inject hot melt plastic, hold the pressure for a certain time, the component is formed, open the mold, and take out the copper bar insulating bracket 22, and the insert molding is completed. The copper bar insulating bracket 22 plays a role in fixing and protecting the copper bar 21.

[0059] Further: a first buckle is arranged on the flexible cable insulating bracket 12, and a second buckle is arranged on the copper bar insulating bracket 22, and the flexible cable insulating bracket 12 and the copper bar insulating bracket 22 are clamped with the first buckle and the second buckle. The number of the first buckle and the second buckle is equal and the positions correspond to each other, and the number is one or more.

[0060] Furthermore: a first fixing hole is provided on the flexible cable insulating bracket 12; a second fixing hole is provided on the copper bar insulating bracket 22; the flexible cable insulating bracket 12 and the copper bar insulating bracket 22 are connected by fasteners through the first fixing hole and the second fixing hole. The number of the first fixing hole and the second fixing hole is equal and the positions correspond to each other, and the number is one or more. The fasteners are bolts, nuts, rivets, etc.

[0061] Furthermore: the flexible cable insulating bracket 12 and the copper bar insulating bracket 22 are connected by a hot melting method. The materials of the flexible cable insulating bracket 12 and the copper bar insulating bracket 22 themselves can be directly used for hot melting to connect the contact surfaces of the two, or another hot melt adhesive can be used to connect the two.

[0062] The solution of the utility model can save about 20% of the BDU space.

[0063] Embodiment 2

[0064] On the basis of Embodiment 1, as Figures 1-3 shown, a BDU zero wire harness connection structure includes: the BDU zero wire harness transmission structure, the electrical component 30, and the first housing;

[0065] The metal signal flexible cable 11 is used to transmit the high-voltage acquisition signal or the low-voltage control signal of the electrical component 30;

[0066] The first housing includes one or more parts; the first housing is fixedly connected to the flexible cable insulating bracket 12 to form the housing of the BDU, and the electrical component 30 is arranged in the housing.

[0067] It can be understood that it can be designed according to needs so that the first housing covers other areas outside the flexible cable insulating bracket 12. Therefore, the first housing can be a whole or can be divided into multiple parts for assembly.

[0068] The copper bar 21 can be embedded in the copper bar insulating bracket 22 for use, and can also be used alone according to needs. As Figure 3 shown, it is the copper bar 21 directly used without plastic coating, but it can also be replaced by the copper bar insulating bracket 22 with the embedded copper bar 21 after plastic coating treatment.

[0069] Furthermore: after the copper bar insulating bracket 22 and the flexible cable insulating bracket 12 are fixedly connected, they jointly serve as a component of the housing of the BDU, and the first housing is fixedly connected to the flexible cable insulating bracket 12;

[0070] Or, the copper bar insulating bracket 22 alone serves as a component of the housing of the BDU, and the first housing is fixedly connected to the flexible cable insulating bracket 12 and the copper bar insulating bracket 22 to form the housing of the BDU.

[0071] Further: The first housing includes: an upper cover 41 and a side outer shell 42;

[0072] The cable insulation bracket 12 embedding the metal signal cable 11 is arranged at the lower part of the side outer shell 42;

[0073] A shape matching the outer shape of the electrical component 30 is formed in the inner cavity of the side outer shell 42; the electrical component 30 is placed in the side outer shell 42 and located above the cable insulation bracket 12;

[0074] The cable insulation bracket 12 is fixedly connected to the side outer shell 42, and the upper end of the side outer shell 42 is fixedly connected to the upper cover 41.

[0075] Further: A second signal terminal for transmitting signals is arranged on the electrical component 30; the second signal terminal is connected to the first signal terminal 112; when the first signal terminal is a pin or a claw, plugging can be performed (as shown in Figure 1 ) or, as a planar structure, made into a ring and connected by fasteners, etc. to achieve signal transmission.

[0076] A second conductive terminal is arranged on an external copper bar (not shown in the figure) of the peripheral device; the second conductive terminal is connected to the first conductive terminal 211.

[0077] Further: The first conductive terminal 211 and the second conductive terminal are round holes, and the two are connected by fasteners to connect the copper bar 21 and the external copper bar; the fasteners are bolts, nuts, buckles, plug-in fasteners, etc.

[0078] In the embodiments of the present invention, the transmission structure and connection structure of the present invention can be used for the BDU. It can be understood that the transmission structure and connection structure are not limited to the above applications, and can also be used in all application scenarios suitable for the inventive concept of the present invention.

[0079] The above are only the preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, or improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A BDU zero-line harness transmission structure, characterized in that, Including: A metal signal cable (11) for transmitting signals; A cable insulation bracket (12), the cable insulation bracket (12) is made by insert molding, and the metal signal cable (11) is disposed as an insert within the cable insulation bracket (12); The metal signal cable (11) includes: a conductive metal foil, and a plurality of first signal terminals (112), the first signal terminals (112) are disposed on the conductive metal foil and exposed from the cable insulation bracket (12), and the first signal terminals (112) are used to connect to an external electrical component (30).

2. The BDU zero line harness transmission structure according to claim 1, wherein: The signal is a high-voltage acquisition signal or a low-voltage control signal; The material of the conductive metal foil is copper or copper alloy, the first signal terminal (112) is a planar structure, and the shape is circular, rectangular, or circular ring-shaped, or the first signal terminal (112) is a pin or a claw.

3. The BDU zero-line harness transmission structure according to claim 1, wherein, Further including: A copper bar (21), a copper bar insulation bracket (22); The copper bar insulation bracket (22) is formed by insert molding, and the copper bar (21) is disposed as an insert within the copper bar insulation bracket (22); A plurality of first conductive terminals (211) are disposed on the copper bar (21), and the first conductive terminals (211) are exposed from the copper bar insulation bracket (22).

4. The BDU zero line harness transmission structure according to claim 3, wherein: A first buckle is disposed on the cable insulation bracket (12), and a second buckle is disposed on the copper bar insulation bracket (22), and the cable insulation bracket (12) and the copper bar insulation bracket (22) are snap-connected by the first buckle and the second buckle.

5. The BDU zero line harness transmission structure according to claim 3, wherein: A first fixing hole is disposed on the cable insulation bracket (12); a second fixing hole is disposed on the copper bar insulation bracket (22); the cable insulation bracket (12) and the copper bar insulation bracket (22) are connected by fasteners through the first fixing hole and the second fixing hole.

6. The BDU zero-line harness transmission structure according to claim 3, characterized in that: The cable insulation bracket (12) and the copper bar insulation bracket (22) are connected by a hot melt method.

7. A BDU zero line harness connection structure, characterized in that, Including: The BDU zero line harness transmission structure according to any one of claims 1-6, an electrical component (30), a first housing; The metal signal cable (11) is used to transmit the high-voltage acquisition signal or the low-voltage control signal of the electrical component (30); The first housing includes one or more parts; the first housing is fixedly connected to the cable insulation bracket (12) to form the housing of the BDU, and the electrical component (30) is disposed in the housing.

8. The BDU zero line harness connection structure according to claim 7, wherein: The first housing includes: an upper cover (41), a side outer shell (42); The cable insulation bracket (12) embedding the metal signal cable (11) is disposed at the lower part of the side outer shell (42); A shape matching the outer shape of the electrical component (30) is formed in the inner cavity of the side housing (42); the electrical component (30) is placed in the side housing (42) and is located above the cable insulating bracket (12). The cable insulating bracket (12) is fixedly connected to the side housing (42), and the upper end of the side housing (42) is fixedly connected to the upper cover (41).

9. The BDU zero cable connection structure according to claim 7, characterized in that: A second signal terminal for transmitting signals is provided on the electrical component (30); the second signal terminal is connected to the first signal terminal (112). A second conductive terminal is provided on the external copper bar of the peripheral device; the second conductive terminal is connected to the first conductive terminal (211).

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