High-voltage aluminum bar arrangement structure and new energy vehicle

Abstract

The utility model provides a kind of high pressure aluminum row arrangement structure and new energy automobile, belong to new energy automobile technical field. Including vehicle body rear floor, fuel tank and high pressure aluminum row, fuel tank is installed in the bottom of the chassis suspension rear side of vehicle body outside and is set on the chassis suspension rear side of vehicle body, high pressure aluminum row includes the first paragraph in the vehicle body outside and the second paragraph in the vehicle body inside, the first paragraph is connected with the second paragraph by the via hole communicated in vehicle body rear floor, the first paragraph is used to extend from battery pack to via hole, the second paragraph is used to extend from via hole to charging port;The first paragraph is partially located between vehicle body rear floor and fuel tank on arrangement path;Second paragraph is attached in the vehicle body rear floor inside and extends along the wheel base direction of vehicle body. It can solve the technical problem of process forming difficulty and high manufacturing cost caused by the defect of aluminum row arrangement scheme in existing new energy automobile.

Description

Technical Field

[0001] This utility model relates to the field of new energy vehicle technology, and in particular to a high-pressure aluminum busbar arrangement structure and a new energy vehicle. Background Technology

[0002] In new energy vehicles, especially pure electric and plug-in hybrid electric vehicles, lightweighting and efficiency improvement of high-voltage power transmission systems are among the core technological development trends. To connect the vehicle to an external power source, the charging port is connected to the battery pack located at the bottom of the vehicle body via a high-voltage conductor. Traditional solutions often use large-section cable harnesses for connection, but these suffer from disadvantages such as heavy weight, irregular wiring, and high cost. Therefore, the industry is gradually adopting lightweight and highly conductive aluminum busbars (high-voltage aluminum busbars) to replace some sections of the high-voltage charging harnesses for direct connection between the charging port and the battery pack. This helps achieve lightweighting goals and improves production and assembly efficiency.

[0003] In existing vehicle layouts, the high-voltage aluminum busbar connecting the charging port and the battery pack typically needs to be arranged along the lower space of the vehicle chassis. To cope with the complex operating environment under the vehicle, this aluminum busbar structure generally requires corresponding protection and fixing solutions. For example, in publicly available technical solutions, an insulating sleeve is usually added to the aluminum busbar or it is partially encapsulated in a protective groove. At the same time, it is fixed to specific positions on the longitudinal beams, transverse beams, or floor of the vehicle body using clamps, brackets, and other connectors. This avoids direct contact and short circuits between the aluminum busbar and the vehicle body and ensures its stability under vehicle vibration conditions.

[0004] However, placing the high-voltage aluminum busbar on the exterior of the vehicle chassis has significant drawbacks. Due to the extremely compact space of the vehicle chassis and the need to accommodate various other components, such as fuel / cooling pipes, brake lines, parking cables, and various sensor harnesses, the routing of the high-voltage aluminum busbar must be circuitous and detour to avoid these existing chassis components. This forced avoidance directly results in the high-voltage aluminum busbar requiring multiple and complex spatial bends to achieve connection. Each bend increases the difficulty of the aluminum busbar stamping process, reduces production consistency, and the circuitous path also increases the overall length of the aluminum busbar, raising not only the material cost of the busbar itself but also the corresponding fixing and protection costs, which is detrimental to overall vehicle cost control. Utility Model Content

[0005] This utility model embodiment provides a high-pressure aluminum busbar arrangement structure, which can solve the technical problems of difficult forming and high manufacturing cost caused by the defects of existing aluminum busbar arrangement schemes in new energy vehicles. The technical solution is as follows: In a first aspect, this utility model embodiment provides a high-pressure aluminum busbar arrangement structure, including: a rear floor of the vehicle body, a fuel tank, and a high-pressure aluminum busbar. The fuel tank is installed outside the rear floor of the vehicle and located on the rear side of the chassis suspension on the vehicle body. The high-voltage aluminum busbar includes a first section located outside the vehicle body and a second section located inside the vehicle body. The first section and the second section are connected through a through hole in the rear floor of the vehicle body. The first section is used to extend from the battery pack to the through hole, and the second section is used to extend from the through hole to the charging port. The first segment is partially located between the rear floor of the vehicle and the fuel tank in the arrangement path; The second segment is fitted inside the rear floor of the vehicle body and extends along the wheelbase direction of the vehicle body.

[0006] Optionally, the fuel tank has an avoidance groove on one edge near the rear floor of the vehicle.

[0007] Optionally, the clearance groove is provided with a clearance notch with a width matching that of the first segment.

[0008] Optionally, a sealing sleeve is provided at the location where the high-pressure aluminum busbar passes through the rear floor of the vehicle body.

[0009] Optionally, the second segment is disposed on one side edge of the rear floor of the vehicle body.

[0010] Optionally, the length of the first paragraph is less than the length of the second paragraph.

[0011] Secondly, this utility model embodiment also provides a new energy vehicle, including the high-pressure aluminum exhaust arrangement structure described in the first aspect, and also includes an exhaust pipe, which is disposed outside the rear floor of the vehicle body and is arranged at a distance from the first section.

[0012] Optionally, the horizontal distance between the first segment and the exhaust pipe is greater than 100 mm.

[0013] The beneficial effects of the technical solution provided by this utility model embodiment include at least the following: This invention innovatively divides a high-pressure aluminum busbar into a first section outside the vehicle body and a second section inside the vehicle body, connecting the two through a through-hole in the rear floor. Utilizing its double-sided arrangement, it effectively avoids various components at the bottom of the vehicle body along the traditional path, significantly shortening the busbar length and reducing the number of bends. By placing the first section behind the fuel tank and utilizing the space between the rear floor and the fuel tank, the most complex area—the chassis suspension system—is avoided, allowing the first section to extend in an almost straight line. The reduced number of bends allows for a simpler two-dimensional bending process for the aluminum busbar, lowering mold costs, processing time, and the defect rate. The second section extends along the wheelbase direction, conforming to the inner surface of the rear floor, fully utilizing the thin space within the rear floor while being protected by the vehicle structure from internal collisions and harsh external environments, thus improving service life and reliability. This effectively solves the technical problems of difficult forming and high manufacturing costs caused by the defects in existing aluminum busbar layout schemes in new energy vehicles. Attached Figure Description

[0014] 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.

[0015] Figure 1 This is a three-dimensional structural diagram of the high-pressure aluminum busbar arrangement structure provided in this embodiment of the utility model; Figure 2 This is a bottom view schematic diagram of the high-pressure aluminum busbar arrangement structure provided in this embodiment of the utility model; Figure 3 This is a schematic diagram showing the relative relationship between the fuel tank and the high-pressure aluminum busbar in an embodiment of this utility model; Figure 4 This is a schematic diagram of the structure of the fuel tank provided in an embodiment of the present invention; Figure 5 This is a structural schematic diagram of the high-pressure aluminum busbar and sealing sleeve provided in an embodiment of this utility model.

[0016] In the diagram: 1-Rear floor of the vehicle; 2-Fuel tank; 3-High-pressure aluminum exhaust pipe; 4-Sealing sleeve; 5-Exhaust pipe; 21-Avoidance groove; 22-Avoidance notch; 31-First section; 32-Second section; m-Chassis suspension. Detailed Implementation

[0017] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be described in further detail below with reference to the accompanying drawings.

[0018] Figure 1 This is a three-dimensional structural diagram of the high-pressure aluminum busbar arrangement structure provided in this embodiment of the utility model; Figure 2 This is a bottom view schematic diagram of the high-pressure aluminum busbar arrangement structure provided in this embodiment of the utility model; Figure 3 This is a schematic diagram showing the relative relationship between the fuel tank and the high-pressure aluminum busbar in an embodiment of this utility model. Figure 4 This is a schematic diagram of the structure of the fuel tank provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of the high-pressure aluminum busbar and sealing sleeve provided in an embodiment of this utility model. Figures 1 to 5 As shown, this utility model embodiment provides a high-pressure aluminum busbar arrangement structure, aiming to solve the technical problems existing in the prior art where high-pressure aluminum busbars are arranged outside the vehicle chassis, such as circuitous paths, numerous bends, increased length, and increased costs. It includes: a rear floor of the vehicle body 1, a fuel tank 2, and a high-pressure aluminum busbar 3.

[0019] The fuel tank 2 is installed outside the rear floor 1 of the vehicle body and located behind the chassis suspension m on the vehicle body. The high-pressure aluminum busbar 3 includes a first section 31 located outside the vehicle body and a second section 32 located inside the vehicle body. The first section 31 and the second section 32 are connected by a through hole in the rear floor 1. The first section 31 extends from the battery pack to the through hole, and the second section 32 extends from the through hole to the charging port. The first section 31 is partially located between the rear floor 1 and the fuel tank 2 in its arrangement path. The second section 32 is fitted inside the rear floor 1 and extends along the wheelbase direction of the vehicle body.

[0020] In this embodiment of the invention, the fuel tank 2 is installed outside the rear floor 1 of the vehicle body and located behind the chassis suspension m on the vehicle body. Specifically, the fuel tank 2 is located below the chassis of the vehicle body, in the area behind the rear suspension system (including rear suspension crossbeams, shock absorbers, control arms, etc.). This arrangement provides a spatial basis for the optimized routing of the high-pressure aluminum busbar 3. The high-pressure aluminum busbar 3 includes a first section 31 located outside the vehicle body and a second section 32 located inside the vehicle body. The first section 31 and the second section 32 are connected by a through hole in the rear floor 1 of the vehicle body. In a specific implementation, a through hole is pre-drilled in the rear floor 1 of the vehicle body, and the size of the through hole is slightly larger than the cross-sectional size of the high-pressure aluminum busbar 3 (for example, 2-5 mm larger) so that the high-pressure aluminum busbar 3 can pass through smoothly. The first section 31 and the second section 32 are continuous structures formed by bending the same aluminum busbar material through the rear floor 1 of the vehicle body. In the arrangement path, the first section 31 is partially located between the rear floor 1 of the vehicle body and the fuel tank 2. In other words, the first segment 31 overlaps with the fuel tank 2 in the horizontal projection direction, and at least a portion of the wiring path of the first segment 31 lies within the interlayer space between the lower surface of the rear floor 1 and the upper surface of the fuel tank 2. This arrangement makes full use of the available space above the fuel tank 2. The second segment 32 extends from the through-hole to the charging port. The charging port is typically located on the side or rear of the vehicle body, somewhere inside the rear floor 1 (i.e., the vehicle's cabin or trunk area). After the second segment 32 enters the vehicle through the through-hole in the rear floor 1, it extends along the inner side of the rear floor 1 to the installation position of the charging port and is electrically connected to the terminal block of the charging port. The second segment 32 fits snugly against the interior of the rear floor 1 and extends along the wheelbase direction of the vehicle body. Specifically, "fitting snugly" means that the second segment 32 is arranged close to the inner surface of the rear floor 1 (i.e., the side facing the interior of the vehicle body), and "extending along the wheelbase direction of the vehicle body" means that the main direction of the second segment 32 is parallel or substantially parallel to the longitudinal direction of the vehicle (i.e., the vehicle's longitudinal direction). The first section 31 utilizes the space between the rear floor 1 and the fuel tank 2, avoiding the chassis suspension m; the second section 32 utilizes the thin layer of space on the inner surface of the rear floor 1; the two sections are connected by a through-hole, achieving efficient connection between the interior and exterior spaces; the entire solution integrates previously unusable fragmented spaces, forming an efficient high-voltage power transmission channel. Simultaneously, because the second section 32 is located inside the vehicle body, avoiding other components at the bottom of the vehicle body in conventional setups, the high-voltage aluminum busbar 3 experiences fewer bends, reducing stress concentration points and lowering the risk of fatigue fracture under vibration conditions; the shorter length of the aluminum busbar and the smaller spacing between fixing points result in better vibration resistance. It is protected from harsh environmental factors such as road splashes, mud, and stone impacts, increasing its service life; it avoids high-temperature components such as exhaust pipes, reducing the risk of insulation aging due to excessive temperature.

[0021] Optionally, a clearance groove 21 is provided on the edge of the fuel tank 2 near the rear floor 1 of the vehicle body. Exemplarily, in this embodiment of the invention, the clearance groove 21 is a groove-shaped structure formed by an inward recess in the upper surface or upper edge region of the fuel tank 2. Specifically, the fuel tank 2 is typically a hollow plastic or metal container, and during its design phase, a stepped groove region is reserved on the side near the rear floor 1 (near the rear of the vehicle body). The depth of this groove is determined according to the extension path of the first segment 31. The clearance groove 21 allows the first segment 31 to be partially embedded in the upper surface region of the fuel tank 2, further shortening the vertical distance between the first segment 31 and the rear floor 1 of the vehicle body, achieving a more compact arrangement. Without the clearance groove 21, the first segment 31 may directly press against the upper surface of the fuel tank 2. Under vehicle vibration and bumpy conditions, the two may rub or collide, causing wear or even cracking of the surface of the fuel tank 2, or wear of the insulating sleeve of the aluminum strip 3. The clearance groove 21 provides a certain safety gap (usually 10-20mm) between the two, avoiding hard contact and improving the overall service life.

[0022] Optionally, the clearance groove 21 is provided with a clearance notch 22 whose width matches that of the first segment 31. Exemplarily, in this embodiment of the invention, the clearance notch 22 is a notch structure formed by further indenting the edge of the clearance groove 21 at the turning point of the first segment 31. The clearance notch 22 serves to guide and position the first segment 31. During vehicle assembly, when the first segment 31 is installed along a predetermined path, the edge of the clearance notch 22 restricts the lateral movement of the first segment 31, ensuring it is accurately positioned according to the design and avoiding installation deviations. The depth of the clearance notch 22 is typically deeper than that of the clearance groove 21 (increasing by 20-40mm), allowing the first segment 31 to be embedded more deeply into the structure of the fuel tank 2, further lowering the bottom position of the first segment 31 and providing more leeway for vehicle ground clearance.

[0023] Optionally, a sealing sleeve 4 is provided at the location where the high-pressure aluminum busbar 3 passes through the rear floor 1 of the vehicle body. Exemplarily, in this embodiment of the invention, the sealing sleeve 4 is an elastic sealant fitted onto the outer surface of the high-pressure aluminum busbar 3, filling the gap between the high-pressure aluminum busbar 3 and the through-hole in the rear floor 1. The sealing sleeve 4 is typically made of highly elastic, aging-resistant, and temperature-resistant materials such as rubber, silicone, thermoplastic elastomer (TPE), or polyurethane (PU). When a car is driven through water, washed, or in rainy conditions, the exterior of the vehicle body comes into contact with water. If the through-hole is not sealed, water will seep into the vehicle, causing problems such as water accumulation on the floor, wet carpets, and corrosion of electrical components. The sealing sleeve 4 forms a watertight seal at the through-hole, preventing water from seeping into the vehicle from the outside and meeting the overall vehicle waterproofing requirements. When a vehicle is driven on dirt roads, construction sites, or other similar environments, a large amount of dust will be kicked up from the bottom of the vehicle body. If the through-hole is not sealed, dust will enter the vehicle through the through-hole, affecting the air quality inside the vehicle. The sealing sleeve 4 prevents dust intrusion. The rear floor 1 of the vehicle body vibrates during driving due to road surface excitation. If the passage is not sealed, the vibration will be transmitted to the surrounding area centered on the passage, generating resonance noise. The sealing sleeve 4 is elastic and can absorb some vibration energy, reducing the transmission of vibration into the vehicle and lowering interior noise. Although the outer surface of the high-voltage aluminum busbar 3 is usually covered with an insulating sleeve, the sealing sleeve 4 provides an additional insulating layer, further reducing the risk of short circuit between the aluminum busbar and the vehicle body metal structure, and improving the safety of the high-voltage system.

[0024] Optionally, the second segment 32 is disposed on one side edge of the rear floor 1 of the vehicle body. Exemplarily, in this embodiment of the invention, "one side edge" refers to the left or right edge area of ​​the rear floor 1 in the vehicle width direction (lateral direction), typically within a range of 100-300mm from the side panel. This side arrangement ensures that the path of the second segment 32 from the through-hole to the charging port is nearly straight, eliminating the need to cross the middle of the vehicle body, avoiding unnecessary lateral wiring, and further shortening the length of the aluminum busbar. Simultaneously, the side-arranged second segment 32 allows for easy access to the aluminum busbar by simply removing one side of the seat or interior panel during maintenance or replacement, without requiring extensive disassembly of the interior trim, thus improving maintenance convenience.

[0025] Optionally, the length of the first segment 31 is less than the length of the second segment 32. Exemplarily, in this embodiment of the invention, this length relationship indicates that most of the length of the high-voltage aluminum busbar 3 (typically 60-70%) is located inside the vehicle body, with only a small portion located outside. The environment inside the vehicle body is relatively stable with minimal temperature changes, so there is no need to consider issues such as waterproofing, dustproofing, or stone impact protection; therefore, the length can be appropriately increased. However, the external environment of the vehicle body is harsh, so the length should be minimized to reduce exposure risks. Placing the longer second segment 32 inside the vehicle protects it from the harsh external environment, improving the overall reliability and service life of the high-voltage system.

[0026] This utility model also provides a new energy vehicle, including, for example: Figures 1 to 5 The high-pressure aluminum exhaust pipe arrangement shown also includes an exhaust pipe 5, which is located outside the rear floor 1 of the vehicle body and spaced apart from the first section 31. For plug-in hybrid electric vehicles (PHEVs) or range-extended electric vehicles, the vehicle is equipped with an internal combustion engine, and the exhaust system of the internal combustion engine includes the exhaust pipe 5. The exhaust pipe 5 is usually led out from the exhaust manifold of the internal combustion engine, extends rearward along the undercarriage of the vehicle body, passes through components such as the three-way catalytic converter and muffler, and finally exits from the rear of the vehicle. The position of the exhaust pipe 5 under the undercarriage of the vehicle body is usually near the centerline of the vehicle body or off to one side. The spaced arrangement means that the first section 31 and the exhaust pipe 5 maintain a certain distance in space, and the two do not contact or intersect. In specific implementation, the routing path of the first section 31 is reasonably planned so that it is staggered from the exhaust pipe 5 in the horizontal (lateral or longitudinal) or vertical direction. The temperature of the exhaust pipe 5 can reach 400-800℃ when the internal combustion engine is working. If the first section 31 is arranged close to the exhaust pipe 5, the high temperature will be transferred to the aluminum exhaust pipe through radiation and convection, causing the aluminum exhaust pipe temperature to rise. The insulating sheath on the outer surface of aluminum busbars is usually made of plastic or rubber. Prolonged exposure to temperatures above 100°C accelerates aging, hardening, and even melting, leading to decreased insulation performance and increasing the risk of high-voltage leakage or short circuits. This invention, through spaced arrangement, maintains a sufficient distance between the first section 31 and the exhaust pipe 5. The temperature of the first section 31 can be controlled below 60°C, allowing the insulating sheath to function normally without requiring any additional thermal protection measures, thus achieving cost savings and weight reduction.

[0027] Furthermore, the horizontal distance between the first segment 31 and the exhaust pipe 5 is greater than 100mm. The horizontal distance refers to the shortest distance projected onto the horizontal plane between the outer surfaces of the first segment 31 and the exhaust pipe 5. During measurement, the first segment 31 and the exhaust pipe 5 are orthographically projected onto a horizontal plane (i.e., a plane parallel to the ground), and the shortest distance between the two projected contours is measured. Through thermal simulation analysis and real-vehicle testing, it was found that when the horizontal distance between the first segment 31 and the exhaust pipe 5 is greater than 100mm, the thermal radiation from the exhaust pipe 5 has a negligible impact on the first segment 31. Specific data are as follows: at a distance of 50mm, the surface temperature of the first segment 31 can reach 95-110℃; at a distance of 80mm, the surface temperature is approximately 75-85℃; at a distance of 100mm, the surface temperature is approximately 60-70℃; and at a distance of 120mm or more, the surface temperature is approximately 50-60℃, close to the ambient temperature, and the thermal influence of the exhaust pipe is essentially eliminated.

[0028] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning understood by one of ordinary skill in the art to which this utility belongs. The terms “first,” “second,” and similar terms used in this utility patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Similarly, the terms “an” or “a” and similar terms do not indicate a quantity limitation, but rather indicate the presence of at least one. The terms “comprising” or “including” and similar terms mean that the elements or objects preceding “comprising” or “including” encompass the elements or objects listed following “comprising” or “including” and their equivalents, and do not exclude other elements or objects. The terms “connected” or “linked” and similar terms are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. “Above,” “below,” “left,” “right,” etc., are used only to indicate relative positional relationships; when the absolute position of the described objects changes, the relative positional relationship may also change accordingly.

[0029] The above description is only an optional embodiment of this utility model and is not intended to limit this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-pressure aluminum busbar arrangement structure, installed on the body of a new energy vehicle, characterized in that, include: The rear floor of the vehicle body (1), the fuel tank (2) and the high-pressure aluminum busbar (3). The fuel tank (2) is installed outside the rear floor (1) of the vehicle body and located on the rear side of the chassis suspension (m) on the vehicle body. The high-pressure aluminum busbar (3) includes a first section (31) located outside the vehicle body and a second section (32) located inside the vehicle body. The first section (31) and the second section (32) are connected through a through hole in the rear floor (1) of the vehicle body. The first section (31) is used to extend from the battery pack to the through hole, and the second section (32) is used to extend from the through hole to the charging port. The first segment (31) is partially located between the rear floor (1) of the vehicle body and the fuel tank (2) in the arrangement path; The second segment (32) fits inside the rear floor (1) of the vehicle body and extends along the wheelbase direction of the vehicle body.

2. The high-pressure aluminum busbar arrangement structure according to claim 1, characterized in that, The fuel tank (2) has an avoidance groove (21) on one side edge near the rear floor (1) of the vehicle body.

3. The high-pressure aluminum busbar arrangement structure according to claim 2, characterized in that, The clearance groove (21) is provided with a clearance notch (22) whose width matches that of the first segment (31).

4. The high-pressure aluminum busbar arrangement structure according to claim 1, characterized in that, A sealing sleeve (4) is provided at the position where the high-pressure aluminum busbar (3) passes through the rear floor (1) of the vehicle body.

5. The high-pressure aluminum busbar arrangement structure according to claim 1, characterized in that, The second segment (32) is located on one side edge of the rear floor (1) of the vehicle body.

6. The high-pressure aluminum busbar arrangement structure according to claim 1, characterized in that, The length of the first paragraph (31) is less than the length of the second paragraph (32).

7. A new energy vehicle, comprising the high-voltage aluminum busbar arrangement structure as described in any one of claims 1 to 6, characterized in that, It also includes an exhaust pipe (5), which is located outside the rear floor (1) of the vehicle body and is spaced apart from the first segment (31).

8. The new energy vehicle according to claim 7, characterized in that, The horizontal distance between the first segment (31) and the exhaust pipe (5) is greater than 100 mm.

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