Power supply distribution unit and power supply assembly

Abstract

The embodiment of the utility model discloses a power supply distribution unit and a power supply assembly, and relates to the technical field of automobile parts. The power distribution unit comprises a shell, a copper bar and a capacitor assembly. The shell is provided with a body part and an accommodating groove. A part of the copper bar is arranged on the body part along a first preset plane. The capacitor assembly is arranged in the accommodating groove along a second preset direction, and the capacitor assembly is connected with the copper bar; wherein the plane where the second preset direction is located intersects with the first preset plane. According to the power supply distribution unit, the capacitor assemblies are integrated, and the capacitor assemblies and the copper bars are arranged in an intersected manner, so that spaces in multiple orientations (X, Y and Z orientations) are utilized, the product is ensured to have a filtering integration function, the space utilization rate can be improved, and the applicability of the power supply distribution unit is enhanced.

Description

Technical Field

[0001] The utility model relates to the technical field of automobile parts, in particular to a power distribution unit and a power component. Background Art

[0002] In current new energy vehicle (NEV) systems, the power distribution unit (PDU), inverter, and onboard charging unit are independent components. With increasing market demand for low cost and miniaturization, all-in-one solutions that integrate the inverter, onboard charging unit, and power bridge within a common housing are becoming a trend. However, in the development of new parts, connecting the power flows of different components within the housing while ensuring the reliability of the electrical connections under mechanical shock and vibration conditions becomes a key issue. The power distribution unit used in all-in-one solutions can effectively reduce the complexity of power transfer within the controller, simplify assembly, and improve product reliability and stability.

[0003] At present, PDU is mainly composed of fuses, PCB boards, arc extinguishers, connectors, copper bars, etc. Figure 1 As shown. The solutions in the related art usually adopt a tiled structure, which is Figure 1 However, as product space requirements become increasingly stringent, along with filtering requirements, filters require more capacitors. The filters and power distribution units are independent of each other, making it difficult to effectively utilize the Z-axis space. This results in larger product dimensions in the XY directions, lower space utilization, and poorer product applicability. Summary of the Invention

[0004] In view of the above shortcomings of the prior art, the purpose of the present invention is to provide a power distribution unit and a power supply component. The power distribution unit can integrate capacitor components and arrange the capacitor components and copper busbars in an intersecting manner, thereby utilizing space in multiple directions. While ensuring that the product has an integrated filtering function, it can improve space utilization and enhance the applicability of the power distribution unit.

[0005] The present invention discloses a power distribution unit, comprising:

[0006] The housing comprises a main body and a receiving groove;

[0007] a copper busbar, a portion of which is arranged on the main body along a first preset plane;

[0008] A capacitor assembly, the capacitor assembly being arranged in the receiving groove along a second preset direction and connected to the copper busbar;

[0009] The plane of the second preset direction intersects with the first preset plane.

[0010] Further, the plane of the second preset direction is perpendicular to the first preset plane.

[0011] Further, the capacitor assembly is glued in the accommodating groove.

[0012] Further, another part of the copper bar is arranged along a second preset direction on the body part, and the copper bar is riveted with the body part.

[0013] Further, the power distribution unit further comprises a heat-conducting gasket, which is glued with the copper bar.

[0014] Further, the body part comprises at least a mounting step and a wing plate, the wing plate itself is surrounded to form a hollow leading-out cavity, the heat-dissipating end of the copper bar is located in the leading-out cavity, and the outer surface of the heat-dissipating end is covered with the heat-conducting gasket.

[0015] Further, the heat-conducting gasket comprises a flash part and a heat-dissipating part, the heat-dissipating part is a sheet structure, and the heat-dissipating part is completely covered in the heat-conducting gasket, the flash part is located on the outer side of the heat-dissipating part in the circumferential direction, and the flash part is bent to connect the wing plate.

[0016] Further, the power distribution unit further comprises a fuse, the shell further comprises a storage groove with an opening on one side, the opening direction of the storage groove is perpendicular to the opening direction of the accommodating groove, and the fuse is arranged in the storage groove.

[0017] Further, the fuse is arranged in the storage groove along the second preset direction.

[0018] Further, the fuse is arranged in the storage groove along the first preset plane.

[0019] The utility model discloses an embodiment further discloses a power supply assembly comprising the power distribution unit.

[0020] The power distribution unit provided by the utility model has the following beneficial effects, including but not limited to:

[0021] 1) the power distribution unit integrates the capacitor assembly in the shell, replaces the traditional filter mode and realizes the fifth level filter integration function, and optimizes the electromagnetic compatibility (Electro Magnetic Compatibility, EMC) performance.

[0022] 2) The power distribution unit can make full use of the space in multiple directions by integrating the capacitor assembly and arranging the capacitor assembly with the copper bar, thereby improving the space utilization and the applicability of the power distribution unit;

[0023] 3) The power distribution unit can reduce the risk of vibration caused by the excessively long traditional copper bar path by riveting the copper bar into the body part;

[0024] 4) The power distribution unit improves the heat conduction performance by arranging the heat conduction pad and directly bonding it with the copper bar, while saving the cost of the traditional assembly type component external support;

[0025] 5) The power distribution unit can avoid the influence of additional holes punched in the upper cover plate on the overall noise, vibration, and harshness (NVH) performance by arranging the fuse and enabling it to be removed from the side. At the same time, the distance between the fuse and the shell disassembly surface is shortened, reducing the possibility of the fuse falling into the shell during the disassembly process, thereby optimizing the potential failure risk caused by human factors. BRIEF DESCRIPTION OF DRAWINGS

[0026] The present specification will be further illustrated in the form of exemplary embodiments, which will be described in detail with reference to the accompanying drawings. These embodiments are not limiting, and in these embodiments, the same numbers represent the same structures, wherein:

[0027] Figure 1 A planar arrangement diagram of a power distribution unit provided by the related art;

[0028] Figure 2 A structure schematic view of a power distribution unit provided by the embodiment of the present application;

[0029] Figure 3 A structure schematic view of a power distribution unit provided by the embodiment of the present application;

[0030] Figure 4 A structure schematic view of a power distribution unit provided by the embodiment of the present application;

[0031] Figure 5 A front view of a power distribution unit provided by the embodiment of the present application;

[0032] Figure 6 A structure schematic view of a heat conduction pad provided by the embodiment of the present application;

[0033] Figure 7 Another structure schematic view of a power distribution unit provided by the embodiment of the present application;

[0034] Figure 8 This is another structural schematic diagram of the power distribution unit provided in an embodiment of the present utility model.

[0035] Icons: 100-power distribution unit; 11-housing; 111-accommodation groove; 112-main body; 1121-installation step; 1122-fender; 1123-export cavity; 113-storage slot; 12-copper busbar; 121-flat part; 122-lap part; 13-capacitor assembly; 14-thermal gasket; 141-flash part; 142-heat dissipation part; 15-fuse. DETAILED DESCRIPTION

[0036] The following describes the embodiments of the present invention through specific examples. Those skilled in the art will readily understand the other advantages and benefits of the present invention from the disclosure herein. The present invention may also be implemented or applied through various other specific embodiments, and the details in this specification may be modified or altered based on different perspectives and applications without departing from the spirit of the present invention. It should be noted that the following embodiments and features within these embodiments may be combined with one another, unless they conflict.

[0037] It should be noted that the illustrations provided in the following embodiments are merely schematic illustrations of the basic concept of the present invention. Therefore, the illustrations only show components related to the present invention and are not drawn according to the number, shape, and size of components in actual implementation. In actual implementation, the type, quantity, and proportion of each component may be changed at will, and the component layout may also be more complex.

[0038] Please refer to Figure 1 , the power distribution unit 100 in the related art is mainly composed of a fuse, a PCB board, an arc extinguisher, a connector, a copper busbar 12, etc. This solution usually adopts a flat structure, but as the product's requirements for space become more and more stringent, the traditional solution takes up more space in the XY direction (i.e., the flat direction in the figure); in addition, the connection between the copper busbar 12 and the shell 11 is fixed with screws, the material cost is high, and the production cycle is slow. At the same time, as the requirements for filtering functions become more and more stringent, the filter requires a larger number of capacitors. The filter and the power distribution unit 100 are independent of each other, and the Z-direction space of the product cannot be effectively utilized, resulting in a larger product size in the XY direction; in addition, the fuse 15 of the traditional solution adopts a flat method, which takes up more space in the XY direction. In terms of replacing the fuse 15, it is necessary to disassemble the large cover from the Z direction first. The internal electrical components will be completely exposed to the disassembly environment, and there is a risk that external impurities or conductive particles will enter the product and affect the reliability of the electrical connection.

[0039] Please refer to Figure 2-Figure 8The present invention provides a power distribution unit 100, which includes a housing 11, a copper busbar 12, and a capacitor assembly 13. The housing 11 has a main body 112 and a receiving groove 111. A portion of the copper busbar 12 is arranged in the main body 112 along a first preset plane. The capacitor assembly 13 is arranged in the receiving groove 111 along a second preset direction, and the capacitor assembly 13 is connected to the copper busbar 12; wherein the plane of the second preset direction intersects with the first preset plane.

[0040] It is worth noting that the second preset direction can refer to Figure 5 The direction shown in the shear head, that is, for Figure 5 For the front view of the power distribution unit 100 provided, the second preset direction refers to the Z-axis direction. Similarly, the first preset plane refers to the plane where the X-axis and the Y-axis are located, and one of the directions of the first preset plane shown in the figure refers to the X-axis direction. It is understandable that the power distribution unit 100 can utilize space in multiple directions (X, Y, and Z directions) by integrating the capacitor component 13 and arranging the capacitor component 13 and the copper bus 12 in an intersecting manner. While ensuring that the product has a filtering integrated function, it can improve space utilization and enhance the applicability of the power distribution unit 100.

[0041] It is also worth mentioning that if Figure 2 As shown, part of the copper busbar 12 is arranged on the main body 112 along the first preset plane, which means that the flat portion 121 of the copper busbar 12 is arranged on the main body 112 along the first preset plane, and the flat portion 121 can be clamped in the clamping slot of the main body 112 to further improve the structural stability of the copper busbar 12 after being fixed.

[0042] In this embodiment, the plane where the second preset direction is located is perpendicular to the first preset plane.

[0043] It is worth noting that the mutually perpendicular arrangement further reduces the occupied area on the first predetermined plane, freeing up more space for other components or functional modules. Furthermore, by vertically distributing the copper busbars 12 and capacitor assembly 13, more modules can be accommodated without increasing the volume of the outer shell 11, thereby achieving more complex functions. This makes the power distribution unit 100 easier to integrate into small or space-constrained devices.

[0044] In this embodiment, the capacitor assembly 13 is glued into the receiving groove 111. It will be appreciated that gluing can securely fix the capacitor assembly 13 in the receiving groove 111, preventing displacement or loosening of the capacitor assembly 13 during vibration, impact, or transportation, thereby improving the overall structural stability of the power distribution unit 100. Depending on the specific implementation environment, the capacitor assembly 13 can also be snap-fitted or bolted into the receiving groove 111.

[0045] In this embodiment, another portion of the copper busbar 12 is placed on the main body 112 along the second preset direction, and the copper busbar 12 and the main body 112 are riveted together. Figure 2 The other part of the copper bus 12 refers to the overlapping portion 122 of the copper bus 12. In this embodiment, the copper bus 12 and the main body 112 are riveted together by a hot riveting process, which can reduce the vibration risk caused by the long path of the copper bus 12.

[0046] Please refer again Figure 3 and Figure 4 The power distribution unit 100 further includes a thermally conductive gasket 14 , which is glued to the copper bus 12 .

[0047] It is worth noting that the thermal pad 14 is directly bonded to the copper bus 12, which can further improve the thermal conductivity of the copper bus 12. At the same time, the thermal pad 14 can also be bonded to the shell 11 to save the cost of the traditional assembled component external bracket.

[0048] Please refer again Figure 3 The main body 112 includes at least a mounting step 1121 and a fender 1122. The fender 1122 itself encloses a hollow outlet cavity 1123. The heat dissipation end of the copper bus 12 is located in the outlet cavity 1123, and the outer surface of the heat dissipation end is covered with a thermal pad 14.

[0049] It is worth noting that the hollow outlet cavity 1123 forms a good air circulation space, which allows the heat from the heat dissipation end of the copper busbar 12 to be conducted and dissipated to the external environment more quickly. The thermal pad 14 is tightly wrapped around the outer surface of the heat dissipation end of the copper busbar 12, further enhancing the efficiency of heat conduction from the copper busbar 12 to the cavity, thereby making the heat dissipation faster and more efficient. At the same time, the cavity formed by the fender 1122 acts as a heat insulator between the heat dissipation end of the copper busbar 12 and other internal components, preventing heat from diffusing to areas that do not require heat dissipation, thereby reducing the temperature accumulation inside the power distribution unit 100, preventing other components from performing poorly due to heat, and extending the life of the equipment. In addition, the design of the mounting step 1121 and the fender 1122 not only provides fixed support for the copper busbar 12, but also ensures the integrity and stability of the outlet cavity 1123, making it less likely that the heat dissipation end of the copper busbar 12 will shift or shake in the cavity, thereby enhancing the stability of the overall structure.

[0050] In this embodiment, if Figure 6 As shown, the thermal pad 14 includes a burr portion 141 and a heat dissipation portion 142. The heat dissipation portion 142 is a sheet-like structure and is completely covered by the thermal pad 14. The burr portion 141 is located on the outer circumference of the heat dissipation portion 142 and is bent to connect to the fender 1122.

[0051] It is worth noting that, compared with the traditional plate-shaped thermal pad 14 , the heat dissipation portion 142 of the thermal pad 14 is less compressed, which can prevent the copper busbar 12 from being pushed out during the actual assembly process.

[0052] In this embodiment, the power distribution unit 100 further includes a fuse 15. The housing 11 includes a storage slot 113 having an opening on one side. The opening of the storage slot 113 is perpendicular to the opening of the receiving slot 111. The fuse 15 is arranged in the storage slot 113. Specifically, the opening of the storage slot 113 is perpendicular to the opening of the receiving slot 111, that is, the storage slot opens toward the side (not the top) as shown in the figure.

[0053] Please refer again Figure 7 In one implementation of this embodiment, the fuse 15 is arranged in the storage slot 113 along the second preset direction. Specifically, the vertical placement of the fuse 15 is suitable for boundaries with relatively compact XY dimensions. This can avoid the impact of additional openings in the cover plate punched from above on the overall NVH performance. At the same time, it shortens the distance between the fuse 15 and the removal surface of the housing 11, reducing the possibility of the fuse 15 falling into the housing 11 during removal, thereby optimizing the potential failure risk caused by human error.

[0054] Please refer again Figure 8 In another implementation of this embodiment, the fuse 15 is arranged along the first preset plane in the storage slot 113. It can be understood that the lateral placement of the fuse 15 is suitable for the boundary of the Z-direction space glue.

[0055] In summary, the power distribution unit 100 can be assembled by the following steps:

[0056] The housing 11 is embedded with injection-molded studs, and the capacitor assembly 13 is inserted into the accommodating groove 111 and secured with glue at the bottom. The copper busbar 12 is then installed into the housing 11 and hot-riveted with the plastic, forming a single unit with the housing 11. Finally, the fuse 15 is assembled, and a thermally conductive pad 14 is wrapped around the heat-dissipating end of the copper busbar 12. The negative copper busbar 12 is led out from the side to connect to external filtering, connectors, and other modules.

[0057] This embodiment also includes a power supply assembly, including the power distribution unit 100 as described above, and having all its beneficial effects.

[0058] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Anyone skilled in the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by one of ordinary skill in the art without departing from the spirit and technical principles disclosed in the present invention are intended to be covered by the claims of the present invention.

[0059] In the description herein, many specific details, such as examples of components and / or methods, are provided to provide a complete understanding of the embodiments of the present invention. However, those skilled in the art will recognize that embodiments of the present invention can be practiced without one or more of the specific details or with other devices, systems, components, methods, components, materials, parts, etc. In other cases, well-known structures, materials, or operations are not specifically shown or described in detail to avoid obscuring aspects of the embodiments of the present invention.

[0060] Reference throughout this specification to "one embodiment," "an embodiment," or "a specific embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention, and not necessarily in all embodiments. Thus, various appearances of the phrases "in one embodiment," "in an embodiment," or "in a specific embodiment" in different places throughout this specification are not necessarily referring to the same embodiment. Furthermore, the particular features, structures, or characteristics of any specific embodiment of the invention may be combined with one or more other embodiments in any suitable manner. It should be understood that other variations and modifications of the embodiments of the invention described herein and shown are possible in light of the teachings herein and are considered part of the spirit and scope of the invention.

[0061] It should also be understood that one or more of the elements shown in the figures may also be implemented in a more separate or more integrated manner, or even removed because they are inoperable in certain circumstances or provided because they may be useful depending on the application.

[0062] In addition, unless otherwise expressly indicated, any marking arrows in the drawings should be regarded as illustrative only and not limiting. Furthermore, unless otherwise indicated, the term "or" as used herein is generally intended to mean "and / or." Where a term is unclear in providing separation or combination capabilities, the combination of components or steps will also be considered as indicated.

[0063] As used in the description herein and throughout the claims that follow, “a,” “an,” and “the” include plural references unless otherwise indicated. Likewise, as used in the description herein and throughout the claims that follow, the meaning of “in” includes “in” and “on” unless otherwise indicated.

[0064] The above description of the illustrated embodiments of the present invention (including the content in the Abstract) is not intended to be exhaustive or to limit the present invention to the precise form disclosed herein. Although specific embodiments of the present invention and examples of the present invention are described herein for illustrative purposes only, as those skilled in the art will recognize and understand, various equivalent modifications are possible within the spirit and scope of the present invention. As noted, these modifications can be made to the present invention in accordance with the above description of the embodiments of the present invention, and these modifications will be within the spirit and scope of the present invention.

[0065] The systems and methods have been generally described herein in detail to facilitate understanding of the present invention. In addition, various specific details have been given to provide an overall understanding of the embodiments of the present invention. However, those skilled in the relevant art will recognize that the embodiments of the present invention can be practiced without one or more of the specific details, or can be practiced using other devices, systems, accessories, methods, components, materials, parts, etc. In other cases, well-known structures, materials, and / or operations are not specifically shown or described in detail to avoid confusing various aspects of the embodiments of the present invention.

Claims

1. A power distribution unit, characterized in that: include: The housing comprises a main body and a receiving groove; a copper busbar, a portion of which is arranged on the main body along a first preset plane; A capacitor assembly, the capacitor assembly being arranged in the receiving groove along a second preset direction and connected to the copper busbar; The plane where the second preset direction is located intersects with the first preset plane.

2. The power distribution unit according to claim 1, wherein: The plane where the second preset direction is located is perpendicular to the first preset plane.

3. The power distribution unit according to claim 1 or 2, characterized in that: The capacitor component is glued into the accommodating groove.

4. The power distribution unit according to claim 1, wherein: Another portion of the copper bar is laid on the main body along a second preset direction, and the copper bar and the main body are riveted together.

5. The power distribution unit according to claim 1, wherein: The power distribution unit further includes a thermally conductive gasket, which is glued to the copper busbar.

6. The power distribution unit according to claim 5, characterized in that: The main body includes at least a mounting step and a fender. The fender itself encloses a hollow outlet cavity. The heat dissipation end of the copper bus is located in the outlet cavity, and the outer surface of the heat dissipation end is covered with the thermal pad.

7. The power distribution unit according to claim 6, characterized in that: The thermally conductive gasket includes a flash portion and a heat dissipation portion. The heat dissipation portion is a sheet-like structure and is completely covered by the thermally conductive gasket. The flash portion is located on the outer circumference of the heat dissipation portion and is bent to connect to the fender.

8. The power distribution unit according to claim 1, wherein: The power distribution unit further includes a fuse, and the shell further includes a storage slot with an opening on one side, the opening direction of the storage slot and the opening direction of the accommodating slot are perpendicular to each other, and the fuse is arranged in the storage slot.

9. The power distribution unit according to claim 8, characterized in that: The fuse is arranged in the storage slot along the second preset direction.

10. The power distribution unit according to claim 8, characterized in that: The fuse is arranged in the storage slot along the first preset plane.

11. A power supply assembly, characterized in that: Comprising a power distribution unit as described in any one of claims 1-10.

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