Bdu unit and battery pack

Abstract

This utility model belongs to the field of new energy battery technology and discloses a BDU unit and battery pack. The BDU unit includes a housing, electrical components, a busbar, and a heat dissipation module. The housing includes a base plate; the electrical components are installed inside the housing and disposed on the base plate; the busbar is disposed on the base plate and electrically connected to the electrical components, and the busbar and base plate are integrally formed; the heat dissipation module is disposed on the housing and is heat-transfer connected to the busbar. Because the busbar is integrally formed on the base plate, the installation difficulty of the busbar on the housing is reduced, allowing the base plate to provide stable support for the busbar, enhancing the overall structural rigidity of the busbar, and avoiding problems such as vibration and fatigue caused by the busbar being suspended. Moreover, placing the busbar on the base plate can save internal space of the housing, simplify the layout design and wiring process of the electrical components in the cavity, reduce production difficulty, and thus improve the production efficiency and operational stability of the BDU unit and battery pack.

Description

Technical Field

[0001] This utility model relates to the field of new energy battery technology, and in particular to a BDU unit and battery pack. Background Technology

[0002] Currently, the design of BDU (Battery Disconnect Unit) mainly selects devices with corresponding rated current based on the current magnitude. With the increasing market demand for high-current fast charging, the proportion of high-rated current and high-specification current devices in the battery pack has increased. In order to maintain the same range, the overall size of the battery pack has to be increased, which increases the production and installation costs of the battery pack. Moreover, the heat dissipation performance of the current devices has decreased significantly, affecting the safety and stability of the battery pack.

[0003] To meet market demands for high-current fast charging in situations with limited electrical space, existing technologies offer a liquid-cooled BDU module. This module incorporates a liquid-cooling module within the BDU housing, ensuring close contact between the module and the corresponding copper busbar. This allows for cooling of the internal copper busbar, maintaining its current-carrying capacity and avoiding the use of high-rated-current, high-specification electrical components. However, because the liquid-cooling module is mounted on the housing, ensuring close contact requires suspending the copper busbar within the BDU module. This can lead to vibration and fatigue issues, reducing heat dissipation and significantly increasing the difficulty of busbar installation and layout with other electrical components. Ultimately, this impacts the BDU module's production efficiency and operational stability.

[0004] Therefore, it is necessary to design a BDU unit and battery pack to solve the problems existing in the prior art. Utility Model Content

[0005] The purpose of this utility model is to provide a BDU unit and battery pack, which optimizes the layout design of the liquid cooling module in the BDU unit, improves the stability of the copper busbar, reduces the difficulty of copper busbar installation and layout between the copper busbar and various electrical components, ensures the high-efficiency output and stable use of the BDU unit, thereby improving the production efficiency and quality of the battery pack.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] The BDU unit includes: a housing, including a base plate; electrical components, installed inside the housing and disposed on the base plate; a busbar, disposed on the base plate and electrically connected to the electrical components, and the busbar and the base plate are integrally formed; and a heat dissipation module, disposed on the base plate and heat-transfer connected to the busbar.

[0008] Preferably, the electrical component includes a current device and a locking element. The current device is electrically connected to the busbar and has a connection portion. The locking element is used to lock the connection portion and the busbar so that the current device is locked onto the busbar.

[0009] Preferably, the base plate is provided with an embedding groove and a first clearance hole. The busbar is integrally formed and disposed in the embedding groove. The embedding groove has a heat dissipation port on the side facing the heat dissipation module. The busbar is connected to the heat dissipation module through the heat dissipation port. The first clearance hole is connected to the embedding groove and is correspondingly disposed in the connecting part. The locking member passes through the busbar and the first clearance hole and is locked and connected to the connecting part.

[0010] Preferably, the busbar has a recessed groove on the side facing the heat dissipation module, and a connecting through hole is opened at the bottom of the recessed groove. The connecting through hole is directly opposite the first clearance hole. The end of the locking member facing the connecting part passes through the connecting through hole and the first clearance hole and is locked to the connecting part. The end of the locking member facing the heat dissipation module is recessed in the recessed groove.

[0011] Preferably, the locking component is a locking bolt, the connecting part is provided with a threaded hole, the threaded hole is directly opposite to the connecting through hole and the first clearance hole, the threaded part of the locking bolt passes through the connecting through hole and the first clearance hole and is threadedly connected to the threaded hole, and the end cap of the locking bolt is recessed in the groove.

[0012] Preferably, the heat dissipation module includes a liquid cooling plate and a thermally conductive layer. The liquid cooling plate is positioned directly opposite the heat dissipation port, and the thermally conductive layer is tightly fitted between the busbar and the liquid cooling plate, so that the liquid cooling plate is connected to the busbar through heat transfer via the thermally conductive layer; and / or,

[0013] The thermally conductive layer is a structural adhesive curing layer. The heat dissipation port has an annular adhesive-blocking edge protruding from the periphery of the opening end facing the liquid cooling plate. The annular adhesive-blocking edge surrounds the busbar to form a filling space, and the filling space is filled with the structural adhesive curing layer.

[0014] Preferably, the current device includes a relay, the relay having relay contacts, and the relay contacts being configured as the connection portion;

[0015] The current device includes a main fuse, and a conductive support post is connected to the outside of the main fuse. The conductive support post is configured as the connection part.

[0016] Preferably, the periphery of the housing is provided with a BDU interface, which includes a BDU positive input interface, a BDU positive output interface, a BDU negative input interface, and a BDU negative output interface; the relay includes a main positive relay and a main negative relay; the busbar includes a first copper busbar, a second copper busbar, a third copper busbar, and a fourth copper busbar, wherein:

[0017] The conductive support post on one side of the main fuse is connected to the positive input interface of the BDU;

[0018] One end of the first copper busbar is connected to the conductive support column on the other side of the main fuse, and the other end of the first copper busbar is connected to one end of the main positive relay;

[0019] One end of the second copper busbar is connected to the other end of the main positive relay, and the other end of the second copper busbar extends to be connected to the positive output interface of the BDU;

[0020] One end of the third copper busbar is connected to the negative input interface of the BDU, and the other end of the third copper busbar is connected to one end of the main negative relay; one end of the fourth copper busbar is connected to the other end of the main negative relay, and the other end of the fourth copper busbar extends to connect to the negative output interface of the BDU.

[0021] Preferably, the housing is provided with a BDU interface on its periphery, the bottom plate is provided with a second clearance hole, and at least two mounting grooves are provided, with at least one mounting groove corresponding to the second clearance hole;

[0022] The busbar includes a first busbar and a second busbar. The first busbar is integrally formed in the mounting groove and has a connection through hole. The second busbar is bent and one end is connected to the first busbar through the second clearance hole. The other end of the second busbar is connected to the BDU interface.

[0023] The battery pack includes module cells and the aforementioned BDU unit, wherein the module cells are electrically connected to the BDU unit.

[0024] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0025] In the BDU unit provided in this embodiment, since the busbar is integrally molded and mounted on the base plate, the installation difficulty of the busbar on the housing is effectively reduced, and the base plate can be fixedly connected to the busbar. This allows the base plate to provide stable support for the busbar, thereby enhancing the overall structural rigidity of the busbar and avoiding problems such as vibration and fatigue caused by the busbar being suspended. This ensures that the busbar is not prone to vibration and deformation during the operation of electrical components. Moreover, mounting the busbar on the base plate saves internal space in the housing, simplifies the layout design and wiring process of electrical components in the cavity, reduces production difficulty, and thus effectively improves the production efficiency and operational stability of the BDU unit. Attached Figure Description

[0026] Figure 1 This is the general assembly drawing of the BDU unit provided in this embodiment of the utility model;

[0027] Figure 2 This is an exploded view of the BDU unit provided in this embodiment of the present invention;

[0028] Figure 3 yes Figure 1 A magnified view of a section at point A in the middle;

[0029] Figure 4 This is a top view of the BDU unit with the hidden cover plate provided in this embodiment of the utility model;

[0030] Figure 5 It is along Figure 4 Sectional view at point BB;

[0031] Figure 6 It is along Figure 4 Sectional view at CC;

[0032] Figure 7 This is a bottom view of the BDU unit with the hidden cover plate provided in this embodiment of the utility model;

[0033] Figure 8 It is along Figure 7 Sectional view at point DD;

[0034] Figure 9 yes Figure 8 A magnified view of a section at point E in the middle;

[0035] Figure 10 yes Figure 9 A schematic diagram of the structure behind the hidden locking components and busbar;

[0036] Figure 11 yes Figure 7 A magnified view of a section at point F in the middle;

[0037] Figure 12This is a schematic diagram of the structure of the electrical components and busbars after assembly according to an embodiment of the present invention;

[0038] Figure 13 This is a top view of the electrical components and busbars assembled according to the embodiment of the utility model.

[0039] In the picture:

[0040] 10. BDU Unit;

[0041] 1. Housing; 11. Base plate; 111. Mounting groove; 1111. Heat dissipation vent; 112. First clearance hole; 113. Annular adhesive retaining edge; 1131. Filling space; 12. Side wall plate; 121. Locking protrusion; 122. Mounting ear; 13. Cover plate; 131. Snap-fit ​​structure; 141. BDU positive input interface; 142. BDU positive output interface; 143. BDU negative input interface; 144. BDU negative output interface; 1451. Fast charging positive interface; 1452. Fast charging negative interface; 1461. Range extender positive interface; 1462. Range extender negative interface;

[0042] 2. Electrical components; 2101. Threaded hole; 211. Relay; 2111. Relay contact; 2112. Main positive relay; 2113. Main negative relay; 2114. Fast charging positive relay; 2115. Fast charging negative relay; 212. Main fuse; 2121. Conductive support post; 213. Precharge relay; 214. Precharge resistor; 215. Current sensor; 216. NTC; 217. HMU; 218. DC-DC fuse; 22. Locking components;

[0043] 3. Busbar; 301. Recessed groove; 302. Connecting through hole; 310. First busbar; 320. Second busbar; 31. First copper busbar; 32. Second copper busbar; 33. Third copper busbar; 34. Fourth copper busbar; 35. Fifth copper busbar; 36. Sixth copper busbar;

[0044] 4. Heat dissipation module. Detailed Implementation

[0045] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, not the entire structure.

[0046] In the description of this utility model, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0047] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0048] In the description of this embodiment, the terms "upper," "lower," "right," and "left," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first" and "second" are only used for distinction in description and have no special meaning.

[0049] The technical solution provided by this utility model will be described below with reference to the accompanying drawings and specific embodiments.

[0050] Combination Figures 1 to 13 As shown, this embodiment provides a BDU unit 10 for a battery pack. The BDU unit 10 includes a housing 1, an electrical component 2, a busbar 3, and a heat dissipation module 4. The housing 1 includes a base plate 11. The electrical component 2 is installed within a cavity of the housing 1 and disposed on the base plate 11. The busbar 3 is disposed on the base plate 11 and electrically connected to the electrical component 2, and the busbar 3 is integrally formed with the base plate 11. The heat dissipation module 4 is disposed on the base plate 11 and thermally connected to the busbar 3.

[0051] In the above configuration, since the busbar 3 is integrally formed on the base plate 11, the installation difficulty of the busbar 3 on the housing 1 is effectively reduced, and the base plate 11 can be fixedly connected to the busbar 3. This allows the base plate 11 to provide stable support for the busbar 3, thereby enhancing the overall structural rigidity of the busbar 3 and avoiding problems such as vibration and fatigue caused by the busbar 3 being suspended. This ensures that the busbar 3 is not prone to vibration and deformation during the operation of the electrical components 2. Moreover, placing the busbar 3 on the base plate 11 saves internal space in the housing 1, simplifies the layout design and wiring process of the electrical components 2 in the cavity, reduces production difficulty, and thus effectively improves the production efficiency and operational stability of the BDU unit 10.

[0052] In this embodiment, the busbar 3 is made of a conductive metal material, such as copper or aluminum, to ensure good conductivity and heat dissipation. The base plate 11 is manufactured using a high-strength composite insulating material, such as plastic, which not only effectively isolates the electrical components 2 from the housing 1 but also possesses excellent mechanical strength, ensuring the overall structural stability. Preferably, the busbar 3 and the base plate 11 are fixedly connected by integral injection molding, that is, the base plate 11 is directly injection molded during production. Specifically, the housing 1 provided in this embodiment also includes a side wall plate 12, which is connected to the base plate 11 to form a receiving cavity. The side wall plate 12 and the base plate 11 are preferably fixedly connected by integral injection molding, that is, the base plate 11, the side wall plate 12, and the busbar 3 are directly injection molded into an integral connection during production.

[0053] More specifically, the housing 1 also includes a cover plate 13, which, after being sealed onto the side wall plate 12, forms a closed receiving cavity to insulate and isolate the internal electrical components 2 from the external environment, ensuring the safety of the electrical components 2 in use. Preferably, the cover plate 13 is made of plastic sheet, so that the housing 1 can insulate and enclose the electrical components 2 within the mounting cavity.

[0054] The cover plate 13 and the side wall plate 12 are fixedly connected by clips or screws to ensure sealing and firmness, and also to facilitate the disassembly and assembly of the cover plate 13, making it convenient for maintenance and upkeep of the electrical components 2 inside the mounting cavity. One embodiment of this invention is as follows, referring to... Figure 3 As shown, the housing 1 is generally square. The cover plate 13 has snap-fit ​​structures 131 around its perimeter, and corresponding latching protrusions 121 are provided on the side wall panels 12. After the cover plate 13 is placed on the side wall panels 12, the snap-fit ​​structures 131 can be locked onto the latching protrusions 121, thus achieving a sealed fixation of the cover plate 13 and the side wall panels 12. After the snap-fit ​​structures 131 are released from the latching protrusions 121, the cover plate 13 can be easily opened for inspection or replacement of the internal electrical components 2.

[0055] Furthermore, to prevent the electrical component 2 from interfering with the installation of the cover plate 13 due to assembly tolerance issues, a mating gap is reserved between the snap-fit ​​structure 131 and the snap protrusion 121 in the horizontal direction. It is understood that this mating gap is typically small, ensuring a sealed connection even if there is relative horizontal displacement between the cover plate 13 and the side wall plate 12. By setting this mating gap, assembly tolerances of the side wall plate 12, electrical component 2, and cover plate 13 can be effectively absorbed, thereby ensuring the installation efficiency of the cover plate 13.

[0056] Optionally, the outer side wall of the side wall panel 12 is provided with a plurality of mounting ears 122 for assembling the BDU unit 10. In this embodiment, six mounting ears 122 are provided, with three mounting ears 122 in a group, and two groups of mounting ears 122 are provided on opposite sides of the side wall panel 12. The center of the mounting ears 122 is provided with a bolt through hole. By using the mounting ears 122 in conjunction with bolts, the housing 1 of the BDU unit 10 can be fixed in the battery pack.

[0057] In one embodiment, the electrical component 2 includes a current device and a locking member 22. The current device is electrically connected to the busbar 3 and has a connecting portion. When the busbar 3 is integrally formed on the base plate 11, the locking member 22 can lock the connecting portion and the busbar 3, so that the current device can be locked and fixed on the busbar 3. Exemplarily, in this embodiment, referring to... Figure 5 As shown, the current device includes a relay 211, which has relay contacts 2111. The relay contacts 2111 are configured as connecting parts, and a locking member 22 fixes the relay contacts 2111 to the busbar 3, allowing the relay 211 to be directly fixed in the mounting cavity via the locking member 22. Compared to the conventional design, which involves embedding a nut in the housing 1, locking the mounting feet of the relay 211 to the housing 1, and then locking the relay contacts 2111 to the busbar 3 via a fastener, this design eliminates the need for the nut on the housing 1. In this embodiment, the busbar 3 serves not only as a current carrier and heat conductor but also as a fixator for the relay 211, resulting in lower installation costs and higher efficiency.

[0058] It should also be noted that, in this embodiment, the current device further includes a main fuse 212, as shown in the reference. Figure 6 As shown, a conductive support post 2121 is connected to each side of the main fuse 212. The conductive support post 2121 is also a connecting part. By locking the conductive support post 2121 to the busbar 3 with the locking part 22, the main fuse 212 can also be directly locked and fixed to the busbar 3, eliminating the need for nuts and other fasteners. This simplifies the installation steps of the main fuse 212 and further improves the installation efficiency of current devices.

[0059] Taking relay 211 as an example, in order to achieve the integral molding of busbar 3 on base plate 11, and at the same time enable locking member 22 to fix busbar 3 and relay 211, in this embodiment, combined with Figures 7 to 10 As shown, during the injection molding process of the base plate 11 and the busbar 3, an insert groove 111 for embedding the busbar 3 can be formed on the base plate 11 at the position of the busbar 3. A heat dissipation port 1111 is provided on the side of the insert groove 111 facing the heat dissipation module 4. After injection molding, the base plate 11 can form a first clearance hole 112 at a preset position that communicates with the insert groove 111. After the relay contact 2111 is set at the preset position, the first clearance hole 112 is correspondingly set at the relay contact 2111. In this way, the locking member 22 can pass through the busbar 3 and the first clearance hole 112 in sequence and connect with the relay contact 2111, thereby achieving the purpose of locking the busbar 3 integrally formed with the base plate 11.

[0060] Preferably, such as Figure 9 As shown, a recessed groove 301 is provided on the side of the busbar 3 facing the heat dissipation module 4. A connecting through hole 302 is provided at the bottom of the groove 301. The connecting through hole 302 is directly opposite the first clearance hole 112. One end of the locking member 22 facing the connecting part passes through the connecting through hole 302 and the first clearance hole 112 and is locked to the connecting part. The other end of the locking member 22 facing the heat dissipation module 4 is recessed in the recessed groove 301 to prevent the locking member 22 from protruding out of the recessed groove 301 and affecting the use of the BDU unit 10. In this embodiment, the heat dissipation module 4 is installed on the bottom plate 11 of the housing 1, and the heat dissipation module 4 is directly opposite and heat-transferringly connected to the busbar 3. By recessing the locking member 22 in the recessed groove 301, the surface of the busbar 3 facing the heat dissipation module 4 can be kept flat, thereby allowing the busbar 3 and the heat dissipation module 4 to be in close contact and ensuring heat dissipation efficiency.

[0061] More preferably, the locking component 22 is a locking bolt, with a threaded hole 2101 on the connecting part. The threaded hole 2101 is directly opposite to the connecting through hole 302 and the first clearance hole 112. The threaded part of the locking bolt is threadedly connected to the threaded hole 2101 through the connecting through hole 302 and the first clearance hole 112. At the same time, the end cap of the locking bolt is recessed in the recess 301, so that the locking bolt fixes the busbar 3 and the relay contact 2111, thereby achieving the effect of stable locking and fixing of the relay 211 and the busbar 3. By selecting a locking bolt, the reliability of the connection between the relay 211 and the busbar 3 can be ensured, and the relay 211 can be disassembled and assembled on the busbar 3 by turning the locking bolt, thus facilitating the maintenance and replacement of the relay 211.

[0062] Specifically, in this embodiment, the heat dissipation module 4 includes a liquid cooling plate and a heat-conducting layer. The liquid cooling plate is positioned directly opposite the heat dissipation port 1111, and the heat-conducting layer is tightly bonded between the busbar 3 and the liquid cooling plate, allowing the liquid cooling plate to be connected to the busbar 3 via heat transfer through the heat-conducting layer. The heat-conducting layer optimizes the heat transfer path of the relay 211 to relay contact 2111 - busbar 3 - heat-conducting layer - liquid cooling plate. The heat generated by the relay contact 2111 during operation is absorbed by the busbar 3 and then effectively transferred to the liquid cooling plate via the heat-conducting layer. The liquid cooling medium within the liquid cooling plate then carries the heat away, ensuring the cooling effect of the heat dissipation module 4 on the busbar 3. Furthermore, the heat-conducting layer spatially isolates the busbar 3 and the liquid cooling plate, preventing direct contact between them. This ensures that even if the insulating varnish of the liquid cooling plate is damaged, causing insulation failure, the busbar 3 will not directly contact the liquid cooling plate, thus eliminating the risk of leakage.

[0063] Considering that the thicker the thermal conductive layer, the worse its thermal conductivity, this invention specifies a minimum thermal conductive layer thickness of 1 mm. In this embodiment, the thermal conductive layer thickness is set to 1.7 mm.

[0064] Preferably, the thermally conductive layer is a structural adhesive cured layer in which thermally conductive gel solidifies in the area of ​​the busbar 3. By using thermally conductive gel to form the thermally conductive layer, the thermally conductive layer has good thermal conductivity and adhesion, ensuring a tight connection between the thermally conductive layer and the busbar 3 and the liquid cooling plate, and effectively reducing the risk of poor contact caused by vibration or temperature changes, thereby further improving the stability and reliability of the heat dissipation module 4.

[0065] Further, refer to Figure 11 As shown, the heat dissipation vent 1111 has an annular adhesive-blocking edge 113 protruding from its circumferential side facing the liquid cooling plate. The annular adhesive-blocking edge 113 surrounds the busbar 3 to form a filling space 1131. Thermally conductive gel fills this filling space 1131, forming a uniform thermally conductive layer and effectively preventing the thermally conductive gel from overflowing. It is understood that the height of the annular adhesive-blocking edge 113 (from the plane of the busbar 3 to the adhesive surface), combined with the busbar 3 tolerance (base plate 11 tolerance ±0.2mm + busbar 3 flatness 0.5mm), needs to be higher than the busbar 3 to meet the thickness requirements of the formed thermally conductive layer. Preferably, in this embodiment, the height of the annular adhesive-blocking edge 113 is equal to the thickness of the thermally conductive layer, i.e., 1.7mm.

[0066] For example, based on the superior heat dissipation performance of the BDU unit 10 in this application, the specifications of the relay 211, main fuse 212, and bus 3 inside the BDU module can be reduced. For instance, a 250A relay 211 can be used instead of a 600A relay 211, a 550A main fuse 212 can be used instead of a 1200A main fuse 212, and the bus 3 can be 30*2mm. 2 The specification replaces 40*3mm 2 That is, the BDU unit 10 proposed in this application can realize the downgraded use of the internal relay 211, main fuse 212 and bus 3, thereby reducing production costs, reducing the size of internal components, and ensuring structural strength while also allowing for reasonable layout of internal components.

[0067] In this embodiment, a BDU interface is provided on the periphery of the housing 1. The BDU interface is a plug-in window that is opened on the side wall panel 12 and exposes the end of the corresponding busbar 3. The bottom of the plug-in window forms a fixing part for the busbar 3, and one end of the busbar 3 extends and is fixed to the bottom of the plug-in window, thereby forming different BDU interfaces at different plug-in windows for different busbars 3.

[0068] In this embodiment, reference Figure 12 and Figure 13 As shown, the BDU interface includes a BDU positive input interface 141, a BDU positive output interface 142, a BDU negative input interface 143, and a BDU negative output interface 144. The relay 211 includes a main positive relay 2112 and a main negative relay 2113. The busbar 3 includes a first copper busbar 31, a second copper busbar 32, a third copper busbar 33, and a fourth copper busbar 34. One conductive support post 2121 on one side of the main fuse 212 is connected to the BDU positive input interface 141; one end of the first copper busbar 31 is connected to the conductive support post 2121 on the other side of the main fuse 212, and the other end of the first copper busbar 31 is connected to one end of the main positive relay 2112; one end of the second copper busbar 32 is connected to the other end of the main positive relay 2112, and the other end of the second copper busbar 32... One end extends to connect to the positive output interface 142 of the BDU; one end of the third copper busbar 33 is connected to the negative input interface 143 of the BDU, and the other end of the third copper busbar 33 is connected to one end of the main negative relay 2113; one end of the fourth copper busbar 34 is connected to the other end of the main negative relay 2113, and the other end of the fourth copper busbar 34 extends to connect to the negative output interface 144 of the BDU, thereby enabling the cells in the battery pack to make conductive connections with external electrical equipment through the BDU unit 10, and when a fault occurs, the main fuse 212 can quickly disconnect the circuit to protect the cells and equipment.

[0069] refer to Figure 11As shown, the current device also includes a precharge relay 213, a precharge resistor 214, a current sensor 215, an NTC (negative temperature coefficient thermistor) 216, an HMU (high voltage acquisition unit) 217, and a DC-DC (voltage converter) fuse located in the mounting cavity.

[0070] The precharge relay 213 and the precharge resistor 214 are connected in series and then in parallel with the main positive relay 2112. The precharge process is provided through the precharge resistor 214 and the precharge relay 213. The precharge relay 213 and the precharge resistor 214 form a precharge circuit. The precharge relay 213 can control the opening and closing of the precharge circuit, while the precharge resistor 214 plays a current limiting role.

[0071] One end of the current sensor 215 is connected in series with the main negative relay 2113, and the other end is electrically connected to the negative terminal of the module cell, used to test the current value in the circuit. Preferably, the current sensor 215 is a Hall sensor.

[0072] The NTC216 is located inside the mounting cavity and is connected in series with the main negative relay 2113. It is used to collect the highest temperature range of the BDU, which is used as a basis for judging whether the liquid cooling heat dissipation has failed.

[0073] One end of the HMU217 is connected in series with the main negative relay 2113, and the other end is connected to the negative output interface 144 of the BDU. It is used to monitor the voltage of the BDU unit 10 in real time to ensure the safe operation of the high-voltage circuit in the BDU unit 10.

[0074] The DC-DC fuse 218 is connected to the positive output interface 142 of the BDU and serves as an overcurrent protection device. When an abnormal voltage or temperature occurs at the positive output interface 142 of the BDU, the DC-DC fuse 218 will cut off the current to prevent damage to the module cells and the BDU unit 10.

[0075] It should be noted that the BDU interface provided in this embodiment also includes a fast charging interface, which includes a fast charging positive interface 1451 and a fast charging negative interface 1452; the relay 211 also includes a fast charging positive relay 2114 and a fast charging negative relay 2115; the busbar 3 also includes a fifth copper busbar 35 and a sixth copper busbar 36. The fast-charging positive relay 2114 is connected in parallel to one side of the main positive relay 2112. One end of the fast-charging positive relay 2114 and the other end of the main positive relay 2112 are both connected to the second copper busbar 32. The other end of the fast-charging positive relay 2114 is connected to one end of the fifth copper busbar 35. The other end of the fifth copper busbar 35 is connected to the fast-charging positive interface 1451. The fast-charging negative relay 2115 is connected in parallel to one side of the main negative relay 2113. The fast-charging negative relay 2115 and the main negative relay 2113 are both connected to one end of the fourth copper busbar 34. One end of the sixth copper busbar 36 is connected to the fast-charging negative interface 1452. The other end of the sixth copper busbar 36 is connected to the fast-charging negative relay 2115. This allows the high-voltage electricity from the charging element to be directly connected to the battery pack through the BDU unit 10, achieving the purpose of high-current fast charging.

[0076] Optionally, the BDU interface provided in this embodiment also includes a range extender interface, which includes a positive range extender interface 1461 and a negative range extender interface 1462. The positive range extender interface 1461 is connected to the positive terminal of the power generation device (e.g., a generator in a vehicle), and the negative range extender interface 1462 is connected to the negative terminal of the power generation device. When the power generation device is connected to the battery pack through the above connection method, the module cells can be powered by selecting the power generation device, solving the problem that the vehicle cannot continue to drive when the module cells are low on power and there is no charging station nearby, thereby improving the range of the electrical equipment.

[0077] Preferably, the BDU unit 10 provided in this embodiment is equipped with both the fast charging interface and the range extender interface, making it suitable for range-extended / plug-in hybrid vehicles. This allows users to choose low-cost fast charging or pre-extended range, balancing charging speed and enhanced range. Of course, it is understood that different types of vehicles have different needs. For example, for battery electric vehicles (BEVs) and plug-in hybrid electric vehicles (PHEVs), a fast charging interface is sufficient on the BDU unit 10; while for range-extended electric vehicles (REEVs), range extension is the primary means of extending range, and fast charging is not a necessary requirement for this type of vehicle, so a range extender interface is sufficient on the BDU unit 10.

[0078] Specifically, in order to connect the busbar 3 to the BDU interface, in this embodiment, the base plate 11 is also provided with a second clearance hole, and six mounting grooves 111 are provided, corresponding to the first copper busbar 31, the second copper busbar 32, the third copper busbar 33, the fourth copper busbar 34, the fifth copper busbar 35 and the sixth copper busbar 36, respectively, wherein at least one mounting groove 111 is correspondingly provided in the second clearance hole; the busbar 3 specifically includes a first busbar 310 and a second busbar 320, wherein the first busbar 310 is flat and is integrally connected to the base plate 11 by being embedded in the mounting groove 111, and the second busbar 320 is bent, one end of the second busbar 320 can be connected to the first busbar 310 by bolt through the second clearance hole, and the other end of the second busbar 320 is bent and extended to the plug-in window and connected to the BDU interface. By designing the busbar 3 as a split structure, the busbar 3 can simultaneously simplify the fixed installation of electrical components 2 such as relays 211 and fuses, and extend to the plug-in window to connect to the BDU interface. Moreover, by first injection molding the first busbar 310 and the base plate 11 as a single unit, and then fixing the second busbar 320 to the first busbar 310 with bolts, the operation difficulty of fixing the busbar 3 to the base plate 11 can be effectively reduced, thereby ensuring high assembly efficiency.

[0079] For example, in this embodiment, the second copper busbar 32, the fourth copper busbar 34, the fifth copper busbar 35, and the sixth copper busbar 36 are all split structures, and each includes the aforementioned first busbar 310 and second busbar 320. The first busbar 310 of the second copper busbar 32 is T-shaped, with one end connected to the other end of the main positive relay 2112. The remaining two ends of the second copper busbar 32 are each provided with a second busbar 320, one of which is used to connect to the BDU positive output interface 142, and the other is used to connect to the range extender positive interface 1461.

[0080] The first busbar 310 of the fourth copper busbar 34 is L-shaped. One extension of the first busbar 310 is connected to the other end of the main negative relay 2113. A second busbar 320 is provided at each end of the other extension of the first busbar 310. One of the second busbars 320 is used to connect to the negative output interface 144 of the BDU, and the other busbar is used to connect to the range extender negative interface 1462.

[0081] The first busbar 310 of the fifth copper busbar 35 is in the shape of an "I". One end of the first busbar 310 is connected to the other end of the fast charging positive relay 2114, and the other end of the first busbar 310 is connected to the second busbar 320. The second busbar 320 is used to connect to the fast charging positive interface 1451.

[0082] The first busbar 310 of the sixth copper busbar 36 is L-shaped, and one extension of the first busbar 310 is connected to the fast charging negative relay 2115. The other extension of the first busbar 310 is connected to the second busbar 320, which is used to connect to the fast charging negative interface 1452.

[0083] Another embodiment of this utility model provides a battery pack, which includes modular cells and the BDU unit 10 described in the above embodiment. The modular cells are electrically connected to the BDU unit 10. By using this BDU unit 10, not only can the heat dissipation module 4 heat the electrical components 2 such as the relay 211 and fuse, as well as the busbar 3, but the heat dissipation effect of the electrical components 2 and fuse and the busbar 3 can be enhanced, reducing the size of the electrical components 2 and the busbar 3 and lowering the cost of use; moreover, by integrally molding the busbar 3 onto the bottom plate 11 of the housing 1, the layout of the busbar 3 can be optimized, enhancing the safety and stability of the busbar 3 in use. At the same time, it can save internal space of the housing 1, simplify the layout design of the electrical components 2, reduce wiring and production difficulty, thereby effectively improving the production efficiency and safety and stability of the battery pack.

[0084] The above-mentioned battery pack is a CTP type battery pack. In other parallel embodiments, when the battery pack is a traditional modular battery pack, the battery pack also includes an integrated housing. The BDU unit 10 and the module cells are all installed in the integrated housing to complete the assembly of the battery pack.

[0085] In the description of this specification, references to terms such as "some embodiments," "other embodiments," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0086] Obviously, the above embodiments of this utility model are merely examples for clearly illustrating the present utility model, and are not intended to limit the implementation of the present utility model. Those skilled in the art can make various obvious changes, readjustments, and substitutions without departing from the protection scope of this utility model. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this utility model should be included within the protection scope of the claims of this utility model.

Claims

1. A BDU unit characterized by include: The shell (1) includes a base plate (11); Electrical components (2) are installed inside the housing (1) and disposed on the base plate (11); Busbar (3) is disposed on the base plate (11) and electrically connected to the electrical component (2), and the busbar (3) and the base plate (11) are integrally formed; The heat dissipation module (4) is disposed on the base plate (11) and is heat-transfer connected to the busbar (3).

2. The BDU unit of claim 1, wherein, The electrical component (2) includes a current device and a locking element (22). The current device is electrically connected to the busbar (3) and the current device is provided with a connection part. The locking element (22) is used to lock the connection part and the busbar (3) so that the current device is locked onto the busbar (3).

3. The BDU unit of claim 2, wherein, The base plate (11) is provided with an embedding groove (111) and a first clearance hole (112). The busbar (3) is integrally formed and disposed in the embedding groove (111). The embedding groove (111) is provided with a heat dissipation port (1111) on the side facing the heat dissipation module (4). The busbar (3) is connected to the heat dissipation module (4) through the heat dissipation port (1111). The first clearance hole (112) is connected to the embedding groove (111). The first clearance hole (112) is correspondingly disposed in the connecting part. The locking member (22) passes through the busbar (3) and the first clearance hole (112) and is locked and connected to the connecting part.

4. The BDU unit of claim 3, wherein, The busbar (3) has a recessed groove (301) on the side facing the heat dissipation module (4). A connecting through hole (302) is opened at the bottom of the recessed groove (301). The connecting through hole (302) is directly opposite to the first clearance hole (112). The locking member (22) is inserted through the connecting through hole (302) and the first clearance hole (112) at one end facing the connecting part, and is locked to the connecting part. The locking member (22) is recessed in the recessed groove (301) at one end facing the heat dissipation module (4).

5. The BDU unit of claim 4, wherein, The locking component (22) is a locking bolt. The connecting part is provided with a threaded hole (2101). The threaded hole (2101) is directly opposite to the connecting through hole (302) and the first clearance hole (112). The threaded part of the locking bolt passes through the connecting through hole (302) and the first clearance hole (112) and is threadedly connected to the threaded hole (2101). The end cap of the locking bolt is recessed in the countersunk groove (301).

6. The BDU unit of claim 3, wherein, The heat dissipation module (4) includes a liquid cooling plate and a heat-conducting layer. The liquid cooling plate is positioned directly opposite the heat dissipation port (1111), and the heat-conducting layer is tightly fitted between the busbar (3) and the liquid cooling plate, so that the liquid cooling plate is connected to the busbar (3) through the heat-conducting layer for heat transfer; and / or, The thermally conductive layer is a structural adhesive curing layer. The heat dissipation port (1111) has an annular adhesive-blocking edge (113) protruding on the periphery of the opening end facing the liquid cooling plate. The annular adhesive-blocking edge (113) surrounds the busbar (3) to form a filling space (1131). The filling space (1131) is filled with the structural adhesive curing layer.

7. The BDU unit of claim 4, wherein, The current device includes a relay (211), the relay (211) is provided with relay contacts (2111), and the relay contacts (2111) are configured as the connection part; The current device includes a main fuse (212), and a conductive support post (2121) is connected to the outside of the main fuse (212), and the conductive support post (2121) is configured as the connection part.

8. The BDU unit of claim 7, wherein, The housing (1) is provided with a BDU interface on its periphery, the BDU interface including a BDU positive input interface (141), a BDU positive output interface (142), a BDU negative input interface (143), and a BDU negative output interface (144); the relay (211) includes a main positive relay (2112) and a main negative relay (2113); the busbar (3) includes a first copper busbar (31), a second copper busbar (32), a third copper busbar (33), and a fourth copper busbar (34), wherein: The conductive support post (2121) on one side of the main fuse (212) is connected to the positive input interface (141) of the BDU; One end of the first copper busbar (31) is connected to the conductive support column (2121) on the other side of the main fuse (212), and the other end of the first copper busbar (31) is connected to one end of the main positive relay (2112). One end of the second copper busbar (32) is connected to the other end of the main positive relay (2112), and the other end of the second copper busbar (32) extends to be connected to the positive output interface (142) of the BDU; One end of the third copper busbar (33) is connected to the negative input interface (143) of the BDU, and the other end of the third copper busbar (33) is connected to one end of the main negative relay (2113); One end of the fourth copper busbar (34) is connected to the other end of the main negative relay (2113), and the other end of the fourth copper busbar (34) extends to be connected to the negative output interface (144) of the BDU.

9. The BDU unit of claim 7, wherein, The housing (1) is provided with a BDU interface on its periphery, the bottom plate (11) is provided with a second clearance hole, and at least two mounting grooves (111) are provided, with at least one mounting groove (111) corresponding to the second clearance hole; The busbar (3) includes a first busbar (310) and a second busbar (320). The first busbar (310) is integrally formed in the mounting groove (111) and has the connecting through hole (302) formed on it. The second busbar (320) is bent. One end of the second busbar (320) is connected to the first busbar (310) through the second clearance hole, and the other end of the second busbar (320) is connected to the BDU interface.

10. A battery pack, characterized by, It includes a module battery cell and a BDU unit (10) according to any one of claims 1-9, wherein the module battery cell is electrically connected to the BDU unit (10).

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