BDU structure with internal injection-molded copper bar

Abstract

The utility model provides a BDU structure with an internal injection-molded copper bar, and belongs to the field of new energy batteries. The structure comprises a box body, a box cover, a busbar assembly, an electric appliance assembly, a relay assembly, a power interface and an output interface, the box body is of a rectangular structure, the box cover covers the box body, the busbar assembly, the electric appliance assembly and the relay assembly are arranged in the box body, and the electric appliance assembly, the relay assembly, the power interface and the output interface are connected through the busbar assembly. The relay assembly comprises a main positive relay, a fast-charging relay and a main negative relay, and the main positive relay, the fast-charging relay and the main negative relay are evenly and horizontally arranged at intervals in the length direction of the box body. By adopting the BDU structure with the internal injection-molded copper bar provided by the embodiment of the utility model, the problems of large occupied space and difficulty in assembly in the prior art can be solved.

Description

Technical Field

[0001] The utility model relates to the field of new energy batteries, in particular to a BDU structure with an internal injection-molded copper busbar. Background Art

[0002] The BDU (Battery Disconnect Unit), also known as the battery disconnect unit, is a critical component in the high-voltage circuit of new energy batteries, controlling the charging and discharging process. As demands for battery pack power and energy density increase, the number of cells must be increased to meet these requirements within a limited envelope. The BDU is typically placed within the remaining space along the length of the battery pack, aligning the length of the battery pack with the width of the BDU.

[0003] Existing BDU structures typically arrange electrical components in two rows within the housing, resulting in a large footprint in both width and height. Currently, most battery pack modules are secured by box beams, with the module output terminals secured to the beams. If the BDU's height exceeds the beams, routing the module's total positive and negative high-voltage busbars becomes difficult.

[0004] The BDU structure in the prior art adopts a double-row arrangement, which occupies a large space and is difficult to assemble. Utility Model Content

[0005] The present invention provides a BDU structure with an internal injection-molded copper busbar, which can solve the problems of large space occupation and difficult assembly in the prior art. The technical solution is as follows:

[0006] A BDU structure with internal injection-molded copper busbar, including: box body, box cover, busbar assembly, electrical assembly, relay assembly, power interface and output interface,

[0007] The box body is a rectangular structure, the box cover is arranged on the box body, the bus assembly, electrical assembly, and relay assembly are arranged in the box body, the electrical assembly, relay assembly, power interface and output interface are connected through the bus assembly, and the relay assembly includes a main positive relay, a fast charging relay and a main negative relay. The main positive relay, fast charging relay and main negative relay are evenly spaced and arranged horizontally along the length direction of the box body.

[0008] Optionally, the output interface includes a P+ interface, a P- interface, an FC+ interface and an FC- interface, the main positive relay is connected to the P+ interface, the fast charging relay is connected to the FC+ interface, and the main negative relay is connected to the P- interface and the FC- interface.

[0009] Optionally, the P+ interface, P- interface, FC+ interface and FC- interface are located on the same side of the box body.

[0010] Optionally, the P+ interface, P- interface, FC+ interface and FC- interface are arranged to protrude from the outside of the box body.

[0011] Optionally, the power interface includes a B+ interface and a B- interface, and the electrical component includes a Hall sensor, a high-voltage acquisition connector, a low-voltage control connector, a pre-charge relay, a pre-charge resistor and a main fuse. The Hall sensor is connected to the B+ interface, and the Hall sensor is electrically connected to the high-voltage acquisition connector, the low-voltage control connector, the pre-charge relay, the pre-charge resistor and the main fuse.

[0012] Optionally, a limiting groove is provided in the box body, the pre-charging resistor is provided in the limiting groove, and elastic clips are provided at both ends of the limiting groove, and the elastic clips are used to fix the pre-charging resistor in the limiting groove.

[0013] Optionally, the electrical component further includes a diverter, and the diverter is connected to the B-interface.

[0014] Optionally, a mark is provided on the box cover, and the mark matches the power interface and the output interface.

[0015] The beneficial effects of the technical solution provided by the embodiment of the utility model include at least:

[0016] An embodiment of the present invention provides a BDU structure with an internal injection-molded copper busbar, which comprises a busbar assembly, an electrical assembly, a relay assembly, a power interface and an output interface to form the basic circuit of the BDU structure. In the BDU structure, the relay assembly is the component that occupies the largest space. By horizontally arranging the main positive relay, the fast-charging relay and the main negative relay in the box body, the width of the box body is only related to the length of each relay and the thickness of the box body, and the height of the box body is only related to the thickness of each relay, thereby maximally compressing the width and height of the entire BDU structure, thereby reducing the space occupied by the BDU structure and effectively solving the problem of large space occupation and difficult assembly in the prior art. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0018] Figure 1This is a schematic diagram of the overall structure provided by an embodiment of the present utility model;

[0019] Figure 2 This is a schematic diagram of the overall structure of the embodiment of the utility model after the box cover is removed;

[0020] Figure 3 This is a schematic diagram of the reverse side of the overall structure after the box cover and box body are removed provided by an embodiment of the utility model;

[0021] Figure 4 This is a circuit connection diagram provided by an embodiment of the present utility model.

[0022] In the figure: 1-box body; 11-limiting groove; 12-elastic buckle; 2-box cover; 21-mark; 3-bus assembly; 31-first bus; 32-second bus; 33-third bus; 34-fourth bus; 35-fifth bus; 36-sixth bus; 37-seventh bus; 38-eighth bus; 4-electrical component; 41-Hall sensor; 42-high voltage acquisition connector; 43-low voltage control connector; 44-pre-charge relay; 45-pre-charge resistor; 46-main fuse; 47-shunt; 5-relay assembly; 51-main positive relay; 52-fast charge relay; 53-main negative relay; 6-power interface; 61-B+ interface; 62-B- interface; 7-output interface; 71-P+ interface; 72-P- interface 72; 73-FC+ interface; 74-FC- interface; DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the present invention more clear, the embodiments of the present invention will be further described in detail below with reference to the accompanying drawings.

[0024] Figure 1 This is a schematic diagram of the overall structure provided by an embodiment of the present utility model; Figure 2 This is a schematic diagram of the overall structure of the embodiment of the utility model after the box cover is removed; Figure 3 This is a schematic diagram of the reverse side of the overall structure after the box cover and box body are removed provided by an embodiment of the utility model; Figure 4 This is a schematic diagram of the circuit connection provided by the embodiment of the utility model. Figures 1 to 4The BDU structure of an internal injection-molded copper busbar shown in the figure includes: a box body 1, a box cover 2, a bus assembly 3, an electrical assembly 4, a relay assembly 5, a power interface 6 and an output interface 7. The box body 1 is a rectangular structure, the box cover 2 is arranged on the box body 1, the bus assembly 3, the electrical assembly 4, the relay assembly 5 are arranged in the box body 1, the electrical assembly 4, the relay assembly 5, the power interface 6 and the output interface 7 are connected through the bus assembly 3, the relay assembly 5 includes a main positive relay 51, a fast charging relay 52 and a main negative relay 53, and the main positive relay 51, the fast charging relay 52 and the main negative relay 53 are arranged horizontally and evenly spaced along the length direction of the box body 1.

[0025] For example, in an embodiment of the present invention, the busbar assembly 3 includes a first busbar 31, a second busbar 32, a third busbar 33, a fourth busbar 34, and a seventh busbar 37. One end of the first busbar 31 is connected to the power interface 6, and the other end is connected to the second busbar 32. The second busbar 32 and the third busbar 33 are connected to the electrical component 4 to form a basic circuit. One end of the third busbar 33 is connected to the main positive relay 51. One end of the fourth busbar 34 is connected to the main positive relay 51, and the other end is connected to the fast charging relay 52. ​​The main negative relay 53 is connected to the power interface 6 through the seventh busbar 37. When the box body 1 is produced, the busbar assembly 3 is pre-injected into the box body 1 by injection molding. During assembly, the electrical component 4 and the relay assembly 5 are installed in the corresponding positions to form the entire circuit. By injection molding, it can be ensured that the electrical clearance and creepage distance meet the requirements, and no other insulation protection measures are required. In the BDU structure, the relay assembly 5 is the component that occupies the largest space. The length direction of the main positive relay 51, the fast charging relay 52 and the main negative relay 53 are kept consistent with the width direction of the box body 1, and the width direction of the main positive relay 51, the fast charging relay 52 and the main negative relay 53 are kept consistent with the height direction of the box body. They are arranged in a single row in the box body 1, so that the main positive relay 51, the fast charging relay 52 and the main negative relay 53 are evenly spaced and arranged horizontally along the length direction of the box body 1, thereby reducing the width and height space of the box body 1 occupied by the relay assembly 5, thereby reducing the occupied space and reducing the difficulty of assembly.

[0026] An embodiment of the present invention provides a BDU structure with an internal injection-molded copper busbar, which comprises a busbar assembly 3, an electrical assembly 4, a relay assembly 5, a power interface 6 and an output interface 7 to form a basic circuit of the BDU structure. In the BDU structure, the relay assembly 5 is the component that occupies the largest space. By horizontally arranging the main positive relay 51, the fast charging relay 52 and the main negative relay 53 in the box body 1, the width of the box body 1 is only related to the length of each relay and the thickness of the box body 1, and the height of the box body 1 is only related to the thickness of each relay. Compared with the conventional scheme, the total height can be reduced by 30%, thereby maximally compressing the width and height of the entire BDU structure, thereby reducing the space occupied by the BDU structure, and effectively solving the problem of large space occupation and difficult assembly in the prior art.

[0027] Optionally, the output interface 7 includes a P+ interface 71, a P- interface 72, an FC+ interface 73 and an FC- interface 74, the main positive relay 51 is connected to the P+ interface 71, the fast charging relay 52 is connected to the FC+ interface 73, and the main negative relay 53 is connected to the P- interface 72 and the FC- interface 74.

[0028] For example, in the embodiment of the present invention, the busbar assembly 3 further includes a fifth busbar 35 and a sixth busbar 36. The main positive relay 51 is connected to the P+ interface 71 via the fourth busbar 34, the fast charge relay 52 is connected to the FC+ interface 73 via the fifth busbar 35, and the main negative relay 53 is connected to the P- interface 72 and the FC- interface 74 via the sixth busbar 36. This structure allows the BDU structure to be connected to the external circuit via the output interface 7. Since the busbar assembly 3 is connected to the output interface 7, there is no need to connect other wires in the internal circuit for connection, thereby reducing production costs and preventing internal circuit clutter.

[0029] Optionally, the P+ interface 71 , the P− interface 72 , the FC+ interface 73 , and the FC− interface 74 are located on the same side of the box body 1 .

[0030] For example, in an embodiment of the present invention, the P+ interface 71, the P- interface 72, the FC+ interface 73 and the FC- interface 74 are arranged on the same side of the box body 1, which can facilitate the connection of the external circuit to the BDU structure on the same side, thereby reducing the operation of external circuit wiring, improving the overall assembly efficiency, and improving the operational convenience of the BDU structure.

[0031] Optionally, the P+ interface 71 , the P− interface 72 , the FC+ interface 73 and the FC− interface 74 are arranged to protrude from the outside of the box body 1 .

[0032] For example, in an embodiment of the present invention, when the output interface 7 is connected to an external device, it is usually necessary to connect an additional adapter bus. Protruding the P+ interface 71, P- interface 72, FC+ interface 73 and FC- interface 74 outside the box body 1 can reduce the material when the BDU structure is connected to the external device, reduce material and assembly costs, facilitate the connection between the BDU structure and the external device, and further improve the operational convenience of the BDU structure.

[0033] Optionally, the power interface 6 includes a B+ interface 61 and a B- interface 62, and the electrical component 4 includes a Hall sensor 41, a high-voltage acquisition connector 42, a low-voltage control connector 43, a pre-charge relay 44, a pre-charge resistor 45 and a main fuse 46. The Hall sensor 41 is connected to the B+ interface 61, and the Hall sensor 41 is electrically connected to the high-voltage acquisition connector 42, the low-voltage control connector 43, the pre-charge relay 44, the pre-charge resistor 45 and the main fuse 46.

[0034] For example, in the embodiment of the present invention, the B+ interface 61 and the B- interface 62 are also protruded from the outside of the box body 1 and are arranged at both ends of the box body 1. Figure 4 As shown, it is a circuit diagram provided by this embodiment. One end of the first bus 31 is connected to the B+ interface 61, one end of the second bus 32 is connected to one end of the main fuse 46, the other end of the main fuse 46 is connected to one end of the third bus 33, and the other end of the third bus 33 is connected to the fourth bus 34. The Hall sensor 41 is installed on the second bus 32 by bolts. Both ends of the Hall sensor 41 are provided with bosses with anti-rotation design, which can save the installation bracket space. The pre-charge relay 44 and the pre-charge resistor 45 are connected in parallel at both ends of the main positive relay 51 through a wiring harness. The main fuse 46 and the relay assembly 5 are installed and fastened with bolts, and the connection with the bus assembly 3 is also fastened with bolts. The Hall sensor 41 is used to monitor the current in the circuit to ensure the safety of the circuit in the BDU structure. The low-voltage control connector 43 is used to power each relay, power and communicate with the Hall sensor 41, and collect the voltage drop and temperature of the shunt 47. The high-voltage collection connector 42 is used to Figure 4 The voltage is collected at points V1, V2, V3, V4, and V5.

[0035] Optionally, a limiting groove 11 is provided in the box body 1, and the pre-charging resistor 45 is provided in the limiting groove 11. Elastic clips 12 are provided at both ends of the limiting groove 11, and the elastic clips 13 are used to fix the pre-charging resistor 45 in the limiting groove 11.

[0036] For example, in an embodiment of the present invention, by setting a limiting groove 11, the pre-charging resistor 45 can be restricted and fixed in the limiting groove 11. At the same time, by adding an elastic clip 12, the pre-charging resistor 45 can be further fixed in the limiting groove 11, thereby improving the stability of the BDU structure.

[0037] Optionally, the electrical component 4 further includes a diverter 47 , which is connected to the B-interface 62 .

[0038] For example, in the embodiment of the present invention, the busbar assembly 3 further includes an eighth busbar 38. One end of the seventh busbar 37 is connected to the main negative relay 53, and the other end is connected to the shunt 47. One end of the eighth busbar 38 is connected to the shunt 47, and the other end is connected to the B-interface 62. By providing the shunt 47, it can be used in conjunction with the Hall sensor 41 to jointly monitor the current in the circuit, further ensuring the safety of the circuit in the BDU structure.

[0039] Optionally, a mark 21 is provided on the box cover 2 , and the mark 21 matches the power interface 6 and the output interface 7 .

[0040] For example, in an embodiment of the present utility model, corresponding marks 21 are provided at corresponding positions of the power interface 6 and the output interface 7 on the box cover 2. By setting the marks 21, the operator can quickly distinguish each interface when using this BDU structure, thereby further improving the operational convenience of this BDU structure.

[0041] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by persons of ordinary skill in the field to which the present invention belongs. The terms "first", "second" and similar words used in the specification and claims of the present invention do not indicate any order, quantity or importance, but are only used to distinguish different components. Similarly, terms such as "a" or "an" do not indicate a quantity limitation, but rather indicate the presence of at least one. Terms such as "include" or "comprising" mean that the elements or objects appearing before "include" or "comprising" include the elements or objects listed after "include" or "comprising" and their equivalents, and do not exclude other elements or objects. Terms such as "connected" or "connected" are not limited to physical or mechanical connections, but may include electrical connections, whether direct or indirect. Terms such as "upper", "lower", "left", and "right" are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may also change accordingly.

[0042] The above description is only an optional embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A BDU structure with internal injection-molded copper busbar, characterized in that: include: Box body (1), box cover (2), busbar assembly (3), electrical assembly (4), relay assembly (5), power interface (6) and output interface (7), The box body (1) is a rectangular structure. The box cover (2) is arranged on the box body (1). The busbar assembly (3), the electrical assembly (4), and the relay assembly (5) are arranged in the box body (1). The electrical assembly (4), the relay assembly (5), the power interface (6), and the output interface (7) are connected via the busbar assembly (3). The relay assembly (5) comprises a main positive relay (51), a fast charging relay (52), and a main negative relay (53). The main positive relay (51), the fast charging relay (52), and the main negative relay (53) are evenly spaced and arranged horizontally along the length direction of the box body (1).

2. The BDU structure of the internal injection-molded copper busbar according to claim 1, characterized in that: The output interface (7) includes a P+ interface (71), a P- interface (72), an FC+ interface (73) and an FC- interface (74); the main positive relay (51) is connected to the P+ interface (71); the fast charge relay (52) is connected to the FC+ interface (73); and the main negative relay (53) is connected to the P- interface (72) and the FC- interface (74).

3. The BDU structure of the internal injection-molded copper busbar according to claim 2, characterized in that: The P+ interface (71), the P- interface (72), the FC+ interface (73) and the FC- interface (74) are located on the same side of the box body (1).

4. The BDU structure of the internal injection-molded copper busbar according to claim 2, characterized in that: The P+ interface (71), the P- interface (72), the FC+ interface (73) and the FC- interface (74) are arranged to protrude from the outside of the box body (1).

5. The BDU structure of the internal injection-molded copper busbar according to claim 1, characterized in that: The power interface (6) includes a B+ interface (61) and a B- interface (62); the electrical component (4) includes a Hall sensor (41), a high-voltage collection connector (42), a low-voltage control connector (43), a pre-charge relay (44), a pre-charge resistor (45), and a main fuse (46); the Hall sensor (41) is connected to the B+ interface (61); and the Hall sensor (41) is electrically connected to the high-voltage collection connector (42), the low-voltage control connector (43), the pre-charge relay (44), the pre-charge resistor (45), and the main fuse (46).

6. The BDU structure of the internal injection-molded copper busbar according to claim 5, characterized in that: A limiting groove (11) is provided in the box body (1), the pre-charging resistor (45) is provided in the limiting groove (11), and elastic buckles (12) are provided at both ends of the limiting groove (11), and the elastic buckles (12) are used to fix the pre-charging resistor (45) in the limiting groove (11).

7. The BDU structure of the internal injection-molded copper busbar according to claim 5, characterized in that: The electrical component (4) further comprises a diverter (47), and the diverter (47) is connected to the B-interface (62).

8. The BDU structure of the internal injection-molded copper busbar according to claim 1, characterized in that: The box cover (2) is provided with a mark (21), and the mark (21) matches the power interface (6) and the output interface (7).

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