High-voltage tank and vehicle

Abstract

The utility model provides a high-voltage box and vehicle, wherein the high-voltage box comprises a box body, a PDU, a connector and a busbar, the box body is provided with an accommodating cavity, the PDU is arranged in the accommodating cavity, the connector is arranged in the box body in a penetrating manner, the busbar is flexible, the busbar is arranged in the accommodating cavity and comprises a first end and a second end which are opposite to each other, and the first end and the second end are arranged in the accommodating cavity. The first end is connected with the connector, and the second end is connected with the PDU. According to the technical scheme of the utility model, the technical problem that the busbar is snapped is solved.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage box technology, specifically to high-voltage boxes and vehicles. Background Technology

[0002] The vehicle includes a high-voltage box, which includes a box body, a PDU housed within the box body, a connector passing through the box body, and a busbar housed within the box body. The busbar connects the PDU and the connector. The connector of the high-voltage box is connected to other components of the vehicle via a wiring harness, such as connecting to a battery pack or other electrical devices.

[0003] However, during vehicle operation, the wiring harness may shake, causing it to pull on the connectors and subsequently the busbars. This can easily break the busbars and cause the high-voltage box to fail. Utility Model Content

[0004] An embodiment of this utility model provides a high-voltage box and vehicle that can improve the technical problem of busbar breakage.

[0005] In a first aspect, embodiments of the present invention provide a high-voltage box, the high-voltage box comprising:

[0006] The enclosure has a receiving cavity;

[0007] PDU, located within the receiving cavity;

[0008] Connector, passing through the housing; and

[0009] The busbar is flexible and disposed within the receiving cavity, and includes a first end and a second end opposite to each other, the first end being connected to the connector and the second end being connected to the PDU.

[0010] In one embodiment, the bus is configured to be made of soft copper.

[0011] In one embodiment, the busbar further includes a main body segment connecting the first end and the second end, and the outer surface of the main body segment is provided with an insulating film.

[0012] In one embodiment, the main body segment includes a first segment and a second segment connected to each other, the insulating film is disposed in the first segment, and the PDU includes a sensor disposed in the second segment.

[0013] In one embodiment, the outer surface of the second segment is provided with a conductive anti-oxidation layer;

[0014] And / or, the outer surface of the first end is provided with a conductive anti-oxidation layer;

[0015] And / or, the outer surface of the second end is provided with a conductive anti-oxidation layer.

[0016] In one embodiment, the thickness of the conductive anti-oxidation layer is less than or equal to 0.2 mm;

[0017] And / or, the conductive anti-oxidation layer is configured as a nickel layer.

[0018] In one embodiment, the busbar further includes a main body segment connecting the first end and the second end, the main body segment being bent.

[0019] In one embodiment, the first end has a first through hole, the connector has a first connection hole, and the high-voltage box further includes a first bolt, which passes through the first through hole and the first connection hole to connect the first end and the connector.

[0020] And / or, the second end is provided with a second through hole, the PDU is provided with a second connection hole, and the high-voltage box further includes a second bolt, which passes through the second through hole and the second connection hole to connect the second end and the PDU.

[0021] In one embodiment, the depth direction of the first via is consistent with the depth direction of the second via.

[0022] In one embodiment, the first via and / or the second via is configured as an elongated hole.

[0023] In one embodiment, the thickness of the busbar ranges from 2 mm to 3 mm.

[0024] Secondly, an embodiment of the present invention provides a vehicle that includes the aforementioned high-pressure box.

[0025] The beneficial effects of the embodiments of this utility model are as follows:

[0026] In an embodiment of this invention, the busbar inside the high-voltage box is flexible. The busbar includes a first end and a second end opposite to each other. The first end is connected to a connector, and the second end is connected to a PDU. Thus, when the connector is pulled by the wire harness, the flexible busbar has more deformation allowance and is less prone to breakage, thereby making the high-voltage box less likely to fail. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1This is a top view of a high-voltage box provided in an embodiment of the present invention, wherein the top part of the box is hidden;

[0029] Figure 2 yes Figure 1 Front view of the medium and high voltage box;

[0030] Figure 3 yes Figure 1 Rear view of the medium- and high-voltage box;

[0031] Figure 4 yes Figure 1 Left view of the medium- and high-voltage box;

[0032] Figure 5 yes Figure 1 A schematic diagram of a busbar and an insulating film;

[0033] Figure 6 yes Figure 5 Cross-sectional view of the busbar and insulating film.

[0034] 100. High-voltage box; 200. Box body; 210. Receiving cavity; 300. Connector; 400. PDU; 500. Busbar; 510. First end; 511. First through hole; 520. Second end; 521. Second through hole; 530. Main body section; 531. First section; 532. Second section; 600. Insulating film; 710. TMS relay; 720. Heating positive relay; 730. Heating negative relay; 740. Discharge negative relay; 750, Precharge relay; 760, Precharge resistor; 770, Charging relay; 780, Charging fuse; 790, Main fuse; 800, Heating fuse; 810, TMS fuse; 820, Discharge positive connector; 830, Discharge negative connector; 840, Charging positive connector; 850, Charging negative connector; 860, Battery positive connector; 870, Battery negative connector; 880, MSD connector; 890, Sensor. Detailed Implementation

[0035] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present utility model. In addition, it should be understood that the specific embodiments described herein are only for illustration and explanation of the present utility model and are not intended to limit the present utility model. In the present utility model, unless otherwise stated, directional terms such as "upper" and "lower" generally refer to the upper and lower positions of the device in actual use or operation, specifically the drawing directions in the accompanying drawings; while "inner" and "outer" refer to the outline of the device.

[0036] The vehicle includes a high-voltage box, which includes a box body, a PDU housed within the box body, a connector passing through the box body, and a busbar housed within the box body. The busbar connects the PDU and the connector. The connector of the high-voltage box is connected to other components of the vehicle via a wiring harness, such as connecting to a battery pack or other electrical devices.

[0037] However, during vehicle operation, the wiring harness may shake, causing it to pull on the connectors and subsequently the busbars. This can easily break the busbars and cause the high-voltage box to fail.

[0038] Specifically, current busbars are made of rigid copper. Rigid copper is quite hard, and if the wiring harness is pulled by a large force, the rigid copper busbar is prone to breakage, which can cause the high-voltage box to fail.

[0039] Therefore, embodiments of this utility model provide a high-voltage box and vehicle that can improve the technical problem of busbar breakage.

[0040] Reference Figures 1 to 6 In one embodiment of this utility model, the high-voltage box 100 includes a box body 200, a PDU 400 (Power Distribution Unit), a connector 300, and a bus 500. The box body 200 has a receiving cavity 210, within which the PDU 400 is disposed, and the connector 300 passes through the box body 200. The bus 500 is disposed within the receiving cavity 210 and includes a first end 510 and a second end 520, with the first end 510 connected to the connector 300 and the second end 520 connected to the PDU 400. It is understood that the PDU 400 achieves electrical connection with the connector 300 through the bus 500. The bus 500 is flexible. Thus, under the tension of the wiring harness, the bus 500 has a large deformation allowance, making it less prone to breakage, thereby reducing the likelihood of failure of the high-voltage box 100.

[0041] There are many materials that can make the bus 500 flexible. In one embodiment, the bus 500 is made of soft copper. First, soft copper has good ductility and plasticity, which makes the bus 500 flexible. Second, soft copper has good fatigue resistance; it is not prone to cracking or breaking under repeated bending and vibration, thus improving the service life of the bus 500. Soft copper has very high conductivity, which can effectively transmit current, reduce resistance loss and energy loss. Due to its good conductivity, soft copper can reduce the heat generated by resistance, improving the thermal stability of the system.

[0042] However, this design is not limited to this; in some other embodiments, the busbar 500 can also be made of soft aluminum. Soft aluminum also has good ductility and plasticity, which makes the busbar 500 flexible. Secondly, soft aluminum has a low density, which helps to make the high-voltage box 100 lightweight. Furthermore, a dense aluminum oxide film forms on the surface of soft aluminum, which has good corrosion resistance and can effectively prevent further oxidation and corrosion.

[0043] In one embodiment, the bus 500 is made of T2 copper. Choosing T2 copper as the material for the bus 500 has significant advantages. T2 copper has extremely high conductivity, approaching 100% of the International Annealed Copper Standard (IACS), ensuring efficient current transmission and low resistance loss. Its low oxygen content (less than 0.003%) reduces oxidation and impurities, improving the material's purity and corrosion resistance. Simultaneously, T2 copper possesses good mechanical properties and ductility, making it easy to process and install, adapting to complex electrical connection requirements.

[0044] However, this design is not limited to this. In some other embodiments, the bus 500 is made of T1 oxygen-free copper, T3 electrolytic copper, silver-plated copper, phosphorus-containing deoxidized copper, or high-conductivity alloy copper.

[0045] When the wiring harness is stretched, the busbar 500 will deform, meaning its position will change. This makes it easy for the busbar 500 to alter the circuitry of the high-voltage box 100. For example, the high-voltage box 100 contains multiple busbars 500. When stretched by the wiring harness, these multiple busbars 500 may come into direct contact, making the high-voltage box 100 prone to short circuits. Therefore, in one embodiment, the busbar 500 further includes a main body segment 530 connecting the first end 510 and the second end 520. The outer surface of the main body segment 530 is provided with an insulating film 600. Thus, even if the position of the busbar 500 changes under the stretching of the wiring harness, the insulating film 600 effectively reduces the risk of short circuits in the high-voltage box 100.

[0046] The insulating film 600 can be made of various materials. In one embodiment, the insulating film 600 can be made of polyolefin or PVC. It is worth noting that polyolefin and PVC are heat-shrinkable materials, which allows the insulating film 600 to be molded onto the busbar 500 using adhesive heat-shrink tubing. However, this design is not limited to this; in some other embodiments, the insulating film 600 can be made of other materials, which are not limited here, as long as it can achieve the insulating effect.

[0047] In one embodiment, the main body segment 530 includes a first segment 531 and a second segment 532 connected to each other. An insulating film 600 is disposed on the first segment 531, and the PDU 400 includes a sensor 890 disposed on the second segment 532. It is understood that the second segment 532 does not have the insulating film 600, which allows the sensor 890 to more accurately detect the current flowing through the busbar 500 via the second segment 532. In some other embodiments, the insulating film 600 is disposed not only on the first segment 531 but also on the second segment 532 to improve the safety of the high-voltage box 100.

[0048] In one embodiment, sensor 890 is configured as a Hall sensor, with the second end 520 passing through it. Since the second segment 532 does not have an insulating film 600, the process of passing the second segment 532 through the Hall sensor is easier, reducing the possibility of interference between the insulating film 600 and the Hall sensor during this process. In some other embodiments, sensor 890 can be of other types, which are not limited here.

[0049] In one embodiment, the outer surface of the second segment 532 is provided with a conductive anti-oxidation layer. This allows the sensor 890 to detect the current flowing through the busbar 500 more accurately while preventing the second segment 532 from being oxidized.

[0050] In one embodiment, a conductive anti-oxidation layer is provided on the outer surface of the first end 510. In this way, the connection between the first end 510 and the connector 300 has good conductivity, while preventing the first end 510 from being oxidized.

[0051] In one embodiment, a conductive anti-oxidation layer is provided on the outer surface of the second end 520. This ensures good conductivity at the connection between the second end 520 and the PDU400 while preventing the second end 520 from being oxidized.

[0052] In one embodiment, the thickness of the conductive anti-oxidation layer is less than or equal to 0.2 mm. This provides good anti-oxidation protection for the busbar 500 while reducing the amount of material used in the conductive anti-oxidation layer, thus helping to lower the manufacturing cost of the high-voltage box 100.

[0053] In one embodiment, the conductive anti-oxidation layer is configured as a nickel layer. Nickel possesses excellent corrosion resistance and chemical resistance, effectively preventing oxidation and corrosion of the bus 500 and extending its service life. Although its conductivity is slightly lower than that of copper, it still maintains good conductivity, does not affect current transmission efficiency, and has low contact resistance. Nickel also has excellent high-temperature stability and oxidation resistance, making it suitable for high-temperature environments; its high hardness and strong adhesion provide additional mechanical protection against scratches and wear. Furthermore, the nickel coating has a bright and aesthetically pleasing appearance, good welding and bonding performance, and is environmentally friendly and sustainable. These characteristics collectively ensure the long-term stability and reliability of the bus 500 in various applications. Notably, a nickel layer can be formed on a bus 500 made of soft copper by diffusion welding of nickel sheets.

[0054] However, this design is not limited to this. In some other embodiments, the conductive anti-oxidation layer is configured as a tin layer, a silver layer, an aluminum oxide layer, an organic coating, a fluorocarbon coating, etc.

[0055] In one embodiment, the bus 500 further includes a body segment 530 connecting the first end 510 and the second end 520, the body segment 530 being bent. The bus 500 is flexible, making it easy to bend. By bending the body segment 530, the first end 510 of the bus 500 is connected to the connector 300, and the second end 520 is connected to the PDU 400, thereby improving the efficiency of the bus 500 in being installed on the connector 300 and the PDU 400, respectively.

[0056] In one embodiment, the first end 510 has a first through hole 511, the connector 300 has a first connection hole, and the high-voltage box 100 further includes a first bolt, which passes through the first through hole 511 and the first connection hole to connect the first end 510 and the connector 300. Thus, the first end 510 and the connector 300 are connected together by the first bolt. This connection method is easy to install and disassemble, facilitates rapid assembly and maintenance, and supports reuse; it provides reliable connection strength, can withstand high loads and evenly distribute stress, and is suitable for connecting parts of various materials and complex shapes; it is highly economical, with low cost and no need for complex processing, reducing manufacturing and inventory management costs; it has high safety, the connection status is visible, and accidental detachment can be prevented by an anti-loosening device.

[0057] However, this design is not limited to this; in some other embodiments, the first end 510 is welded to the connector 300. This ensures that the first end 510 and the connector 300 remain stable and reliable even in harsh environments; the welded connection has virtually no contact resistance, guaranteeing optimal current transmission efficiency and reducing energy loss and heat generation; due to its permanent and non-removable nature, welding effectively prevents loosening and arcing risks, enhancing safety; furthermore, welding simplifies the design and manufacturing process, reduces the number of parts and space requirements, while improving corrosion resistance and protection levels.

[0058] In one embodiment, the outer surface of the first end 510 is provided with a nickel layer, which makes the head of the first bolt contact the nickel layer when the first bolt passes through the first through hole 511. The nickel layer has a high coefficient of friction, so that the first bolt can connect the first end 510 and the connector 300 more securely.

[0059] And / or, the second end 520 has a second through hole 521, the PDU400 has a second connection hole, and the high-voltage box 100 also includes a second bolt, which passes through the second through hole 521 and the second connection hole to connect the second end 520 and the PDU400. Thus, the second end 520 and the PDU400 are connected together by the first bolt. This connection method is easy to install and disassemble, facilitates rapid assembly and maintenance, and supports reuse; it provides reliable connection strength, can withstand high loads and evenly distribute stress, and is suitable for connecting parts of various materials and complex shapes; it is highly economical, with low cost and no need for complex processing, reducing manufacturing and inventory management costs; it has high safety, the connection status is visible, and accidental detachment can be prevented by anti-loosening devices.

[0060] However, this design is not limited to this; in some other embodiments, the second end 520 is welded to the PDU400. This ensures that the second end 520 and the PDU400 remain stable and reliable even in harsh environments; the welded connection has virtually no contact resistance, guaranteeing optimal current transmission efficiency and reducing energy loss and heat generation; due to its permanent and non-removable nature, welding effectively prevents loosening and arcing risks, enhancing safety; furthermore, welding simplifies the design and manufacturing process, reduces the number of parts and space requirements, while improving corrosion resistance and protection levels.

[0061] In one embodiment, the outer surface of the second end 520 is provided with a nickel layer, which makes the head of the second bolt contact the nickel layer when the second bolt passes through the second through hole 521. The nickel layer has a high coefficient of friction, so that the second bolt can connect the second end 520 and PDU400 more securely.

[0062] In one embodiment, the depth direction of the first via 511 is consistent with the depth direction of the second via 521. This helps to improve the installation efficiency of the bus 500 to the connector 300 and PDU 400, respectively.

[0063] In one embodiment, the first via 511 is configured as an elongated hole. The elongated hole allows for adjustment of the busbar 500's position, providing installation flexibility and absorbing manufacturing tolerance differences to ensure precise alignment; it can disperse stress, reduce stress concentration, and improve vibration resistance, thereby increasing connection stability and lifespan; it simplifies installation and maintenance, reducing operational difficulty and time, and facilitating quick assembly and disassembly; it is compatible with multiple installation methods, providing multiple mounting positions to adapt to different installation needs and future expansion; it can also compensate for thermal expansion, allowing the busbar 500 some movement space during temperature changes, reducing stress damage caused by thermal expansion and contraction. These characteristics collectively improve the reliability and flexibility of the busbar 500 connection, making it suitable for applications requiring high-precision alignment, operating in vibration environments, requiring frequent maintenance, and experiencing significant temperature variations.

[0064] In one embodiment, the second via 521 is configured as an elongated hole. The elongated hole allows for adjustment of the busbar 500's position, providing installation flexibility and absorbing manufacturing tolerance differences to ensure precise alignment; it can disperse stress, reduce stress concentration, and improve vibration resistance, thereby increasing connection stability and lifespan; it simplifies installation and maintenance, reducing operational difficulty and time, and facilitating quick assembly and disassembly; it is compatible with multiple installation methods, providing multiple mounting positions to adapt to different installation needs and future expansion; it can also compensate for thermal expansion, allowing the busbar 500 some movement space during temperature changes, preventing stress damage caused by thermal expansion and contraction. These characteristics collectively improve the reliability and flexibility of the busbar 500 connection, making it suitable for applications requiring high-precision alignment, operating in vibration environments, requiring frequent maintenance, and experiencing significant temperature variations.

[0065] In one embodiment, the first via 511 and / or the second via 521 are configured as elongated holes. Elongated holes allow for position adjustment of the busbar 500, providing installation flexibility and absorbing manufacturing tolerance differences to ensure precise alignment; they can disperse stress, reduce stress concentration, and provide good vibration resistance, improving connection stability and lifespan; they simplify installation and maintenance, reducing operational difficulty and time, and facilitating quick assembly and disassembly; they are compatible with multiple installation methods, providing multiple mounting positions to adapt to different installation needs and future expansion; they can also compensate for thermal expansion, allowing the busbar 500 some movement space during temperature changes, reducing stress damage caused by thermal expansion and contraction. These characteristics collectively improve the reliability and flexibility of the busbar 500 connection, making it suitable for applications requiring high-precision alignment, operating in vibration environments, requiring frequent maintenance, and experiencing significant temperature variations.

[0066] In one embodiment, the thickness of the bus 500 ranges from 2mm to 3mm. An excessively thick bus 500 increases material costs and weight, leading to unnecessary resource waste and potentially occupying too much space, limiting design flexibility. Furthermore, an excessively thick bus 500 may be difficult to handle during bending or installation due to excessive rigidity, increasing construction difficulty. An excessively thin bus 500 may result in insufficient current carrying capacity, increased resistance and heat generation, thereby reducing efficiency and increasing energy loss; it may also break under vibration or external force due to insufficient mechanical strength, affecting the reliability and safety of the system. Therefore, a thickness of 2mm to 3mm for the bus 500 is more suitable. The thickness of the bus 500 is as follows... Figure 6 As shown in H in the diagram.

[0067] In one embodiment, the PDU 400 includes a TMS (Thermal Management System) relay 710, a heating positive relay 720, a heating negative relay 730, a discharge negative relay 740, a pre-charge relay 750, a pre-charge resistor 760, a charging relay 770, a charging fuse 780, a main fuse 790, a heating fuse 800, a TMS fuse 810, and a Hall sensor. Multiple connectors 300 are provided, including a discharge positive connector 820, a discharge negative connector 830, a battery positive connector 860, a battery negative connector 870, a charging positive connector 840, a charging negative connector 850, and an MSD (Manual Service Disconnect) connector 880. Multiple busbars 500 are provided. Each component in the PDU 400 can be connected to its corresponding connector 300 via the busbars 500.

[0068] Secondly, an embodiment of the present invention provides a vehicle that includes the aforementioned high-voltage box 100. The high-voltage box 100 adopts all the technical solutions of all the above embodiments, and therefore has at least all the beneficial effects brought about by the technical solutions of the above embodiments, which will not be repeated here.

[0069] The embodiments of this utility model have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of this utility model. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this utility model. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A high-pressure box, characterized in that, include: The enclosure has a receiving cavity; PDU, located within the receiving cavity; Connector, which passes through the housing; as well as The busbar is flexible and disposed within the receiving cavity, and includes a first end and a second end opposite to each other, the first end being connected to the connector and the second end being connected to the PDU.

2. The high-voltage box according to claim 1, characterized in that, The busbar is made of soft copper.

3. The high-pressure box according to claim 1, characterized in that, The busbar also includes a main body section connecting the first end and the second end, and the outer surface of the main body section is provided with an insulating film.

4. The high-pressure box according to claim 3, characterized in that, The main body segment includes a first segment and a second segment that are interconnected. The insulating film is disposed in the first segment, and the PDU includes a sensor, which is disposed in the second segment.

5. The high-pressure box according to claim 4, characterized in that, The outer surface of the second segment is provided with a conductive anti-oxidation layer; And / or, the outer surface of the first end is provided with a conductive anti-oxidation layer; And / or, the outer surface of the second end is provided with a conductive anti-oxidation layer.

6. The high-voltage box according to claim 5, characterized in that, The thickness of the conductive anti-oxidation layer is less than or equal to 0.2 mm; And / or, the conductive anti-oxidation layer is configured as a nickel layer.

7. The high-voltage box according to claim 1, characterized in that, The busbar also includes a main body segment connecting the first end and the second end, the main body segment being bent.

8. The high-voltage box according to claim 1, characterized in that, The first end has a first through hole, the connector has a first connection hole, and the high-voltage box further includes a first bolt, which passes through the first through hole and the first connection hole to connect the first end and the connector. And / or, the second end is provided with a second through hole, the PDU is provided with a second connection hole, and the high-voltage box further includes a second bolt, which passes through the second through hole and the second connection hole to connect the second end and the PDU.

9. The high-voltage box according to claim 8, characterized in that, The depth direction of the first via is consistent with the depth direction of the second via.

10. The high-pressure box according to claim 8, characterized in that, The first via and / or the second via is configured as an elongated hole.

11. The high-voltage box according to any one of claims 1 to 10, characterized in that, The thickness of the busbar ranges from 2 mm to 3 mm.

12. A vehicle, characterized in that, Includes the high-voltage box as described in any one of claims 1 to 11.

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