Battery pack circuit breaking unit with grounding structure

Abstract

The utility model discloses a battery pack circuit breaking unit with grounding structure, including insulating casing, a plurality of electric components of setting in insulating casing, PCB board and grounding structure, PCB board is installed on insulating casing, and a plurality of electric components are electrically connected in PCB board, grounding structure includes conducting row, and conducting row is installed on insulating casing, and one end of conducting row is electrically connected in common ground on PCB board, and its other end is set as the lead-out end for the contact with the metal shell of external device. The utility model discloses setting the grounding structure containing conducting row, constructs low impedance ground discharge path for PCB board and electric component, can effectively shield external noise, reduce the influence of electromagnetic interference to voltage sampling signal, and prevent high voltage surge and electrostatic damage chip on PCB board, improve the electromagnetic compatibility and work reliability of battery pack circuit breaking unit, guarantee vehicle dynamic control signal stability.

Description

Technical Field

[0001] This utility model relates to the technical field of high-voltage control boxes for new energy power battery packs, and in particular to a battery pack circuit breaker unit with a grounding structure. Background Technology

[0002] In the field of new energy vehicles, the high-voltage control box in the power battery pack is the core component for realizing functions such as high-voltage circuit on / off control and overload protection. The battery pack circuit breaker unit in the high-voltage control box generally integrates electrical components such as relays, fuses, and pre-charge resistors.

[0003] However, traditional battery pack circuit breaker units lack a specially designed grounding structure, leading to serious electromagnetic interference and protection issues in practical applications. On one hand, various signal interference sources exist in the external environment; on the other hand, the electric arc and electromagnetic radiation generated when the high-current contactor inside the battery pack engages or disengages can also cause interference during product use, resulting in a series of adverse consequences: 1. Abnormal voltage sampling: Interference noise is mixed into the voltage sampling signal, causing the collected battery voltage signal to be unstable. This causes the vehicle dynamic control system to make a deviation in judging the battery status, which can easily trigger false faults and affect the reliability of the vehicle's power control.

[0004] 2. High sensitivity to electromagnetic interference. The chips on the circuit board have weak resistance to electromagnetic interference. External or internal electromagnetic interference can easily lead to circuit logic confusion and signal distortion. In severe cases, it can directly disrupt the normal control function of the high-voltage box.

[0005] 3. High voltage surge and electrostatic discharge damage: Due to the lack of a low impedance discharge path, the energy of high voltage surge and electrostatic discharge cannot be conducted away in time, directly impacting the chip, causing chip breakdown, performance degradation or even damage, and greatly shortening the service life of the circuit board.

[0006] 4. Electromagnetic compatibility is not up to standard. Traditional structures, due to the lack of effective grounding design, cannot meet the stringent electromagnetic compatibility requirements of high-voltage components in new energy vehicles. The low pass rate of electromagnetic compatibility tests restricts the market application of the products.

[0007] Therefore, there is an urgent need to design a special grounding structure for the battery pack circuit breaker unit to improve the circuit's anti-interference capability and meet the high reliability requirements of new energy power battery systems. Utility Model Content

[0008] The problem to be solved by this utility model is to provide a battery pack circuit breaker unit with a grounding structure, so as to overcome the defect of existing battery pack circuit breaker units that are susceptible to electromagnetic interference due to the lack of a grounding structure, resulting in reduced reliability.

[0009] The technical solution adopted by this utility model to solve its technical problem is: a battery pack circuit breaker unit with a grounding structure, comprising: an insulating shell, a plurality of electrical components disposed within the insulating shell, a PCB board and a grounding structure, wherein the PCB board is mounted on the insulating shell, and the plurality of electrical components are electrically connected to the PCB board; the grounding structure includes a conductive busbar, the conductive busbar is mounted on the insulating shell, and one end of the conductive busbar is electrically connected to a common grounding terminal on the PCB board, and the other end is configured as a lead-out terminal for contacting the metal casing of an external device.

[0010] As a further improvement of this utility model, the grounding structure further includes a grounding wire, one end of which is soldered to a common grounding terminal on the PCB board, and the other end of which is provided with a plug-in terminal, which is plugged into one end of the conductive busbar.

[0011] As a further improvement of this utility model, the conductive busbar and the insulating shell are integrally formed by insert injection molding.

[0012] As a further improvement of this utility model, the conductive bar is fixedly inserted into the insulating shell.

[0013] As a further improvement of this utility model, the conductive bus includes a plug-in section, the insulating housing is provided with a slot, the plug-in section is inserted into the slot and stopped by a limiting step at the end of the slot, and the plug-in section is provided with a plug-in piece extending out of the slot.

[0014] As a further improvement of this utility model, serrated protrusions are integrally formed on both thin walls of the plug-in section, and the side of the protrusion facing the plug-in direction of the plug-in section is an inclined guide slope, and the protrusion is tightly fitted to the inner wall of the slot; symmetrically arranged outwardly inclined elastic locking feet are provided on both sides of the plug-in section, and a stop is provided in the slot, with both elastic locking feet abutting against the stop.

[0015] As a further improvement of this utility model, the conductive bus also includes a lead-out section integrally connected to the plug-in section. The lead-out section is arranged at the bottom of the insulating housing, and the bottom of the insulating housing is provided with a positioning groove for positioning the lead-out section. The end of the lead-out section away from the plug-in section is designated as the lead-out end.

[0016] As a further improvement of this utility model, the bottom of the insulating shell is provided with a support surface, and the lead-out end protrudes downward from the support surface.

[0017] As a further improvement of this utility model, the insulating shell is provided with mounting feet, and a metal insert is fixed on the mounting feet, with the lead end abutting against the bottom surface of the metal insert.

[0018] As a further improvement of this utility model, some of the electrical components are electrically connected to the PCB board via wires, while other electrical components are directly soldered onto the PCB board.

[0019] The beneficial effects of this utility model are as follows: This utility model provides a battery pack circuit breaker unit with a grounding structure. By setting a grounding structure including a conductive busbar, a low-impedance grounding discharge path is constructed for the PCB board and electrical components. This can effectively shield external noise, reduce the influence of electromagnetic interference on signals such as voltage sampling, and prevent high-voltage surges and electrostatic damage to chips on the PCB board. It also improves the electromagnetic compatibility and operational reliability of the battery pack circuit breaker unit and ensures the stability of vehicle dynamic control signals. At the same time, the lead-out end of the conductive busbar contacts the metal casing of external equipment, simplifying the grounding design and enhancing grounding stability and convenience. Attached Figure Description

[0020] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a perspective view of the battery pack circuit breaker unit with grounding structure of this utility model; Figure 2 This is a cross-sectional view of the battery pack circuit breaker unit with grounding structure of this utility model; Figure 3 This is a perspective view of the battery pack circuit breaker unit with grounding structure of this utility model from another angle. Figure 4 This is a perspective view of the conductive busbar in the battery pack circuit breaker unit with grounding structure of this utility model.

[0022] Referring to the accompanying drawings, the following explanations are provided: 1. Insulating housing; 101. Slot; 102. Limiting step; 103. Stop; 104. Positioning groove; 105. Support surface; 106. Mounting foot; 2. PCB board; 3. Conductive busbar; 31. Plug section; 311. Plug piece; 312. Locking protrusion; 313. Flexible locking foot; 32. Lead-out section; 321. Lead-out end; 4. Grounding wire; 5. Plug terminal; 6. Metal insert. Detailed Implementation

[0023] The present application will now be described in detail with reference to the accompanying drawings and specific embodiments.

[0024] The following specific examples illustrate the implementation of this application. Those skilled in the art can easily understand other advantages and effects of this application from the content disclosed in this specification. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. This application can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of this application. It should be noted that, in the absence of conflict, the following embodiments and features in the embodiments can be combined with each other. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0025] It should be noted that various aspects of embodiments within the scope of the appended claims are described below. It will be apparent that the aspects described herein can be embodied in a wide variety of forms, and any particular structure and / or function described herein is merely illustrative. Based on this application, those skilled in the art will understand that one aspect described herein can be implemented independently of any other aspect, and two or more of these aspects can be combined in various ways. For example, any number and aspects set forth herein can be used to implement the device and / or practice the method. Additionally, this device and / or method can be implemented using structures and / or functionalities other than one or more of the aspects set forth herein.

[0026] It should also be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of this application. The illustrations only show the components related to this application and are not drawn according to the number, shape and size of the components in actual implementation. In actual implementation, the form, quantity and proportion of each component can be arbitrarily changed, and the layout of the components may also be more complex.

[0027] Additionally, specific details are provided in the following description to facilitate a thorough understanding of the examples. However, those skilled in the art will understand that practice can be carried out without these specific details.

[0028] The technical solutions provided by the various embodiments of this application are described below with reference to the accompanying drawings.

[0029] See Figures 1 to 4This utility model provides a battery pack circuit breaker unit with a grounding structure, including an insulating housing 1 and several electrical components disposed within the insulating housing 1. These electrical components can be, but are not limited to, one or more of a main contactor, a negative contactor, a pre-charge contactor, a heating relay, a current sensor, and a fuse; these are known prior art technologies in the field of new energy power batteries. Specifically, the main contactor and negative contactor can control the on / off state of the high-voltage main circuit of the battery pack; the pre-charge contactor can cooperate with related components to complete the pre-charging process of the high-voltage circuit to suppress inrush current; the heating relay is used to control the on / off state of the battery pack heating circuit; the current sensor can detect the circuit current, thereby monitoring overcurrent and other conditions; and the fuse can provide protection by melting when the circuit experiences overload or short circuit. Through the cooperation of these existing electrical components, the battery pack circuit breaker unit can achieve its intended functions, such as controlling the on / off state of the high-voltage circuit, monitoring current, and providing fault protection, thus providing fundamental support for the safe and stable operation of the battery pack.

[0030] As a significant improvement of this invention, the battery pack circuit breaker unit with a grounding structure also includes a PCB board 2 and a grounding structure. The PCB board 2 is mounted on an insulating housing 1, and several electrical components are electrically connected to the PCB board 2. The grounding structure includes a conductive busbar 3, which is mounted on the insulating housing 1. One end of the conductive busbar 3 is electrically connected to the common ground terminal (GND) on the PCB board, and the other end is set as a lead-out terminal 321 for contact with the metal casing of external equipment. By setting a grounding structure including the conductive busbar 3, this invention constructs a low-impedance grounding discharge path for the PCB board 2 and electrical components, effectively shielding external noise, reducing the impact of electromagnetic interference on voltage sampling and other signals, and preventing high-voltage surges and electrostatic discharge from damaging the chips on the PCB board 2. This improves the electromagnetic compatibility and operational reliability of the battery pack circuit breaker unit and ensures the stability of vehicle dynamic control signals. At the same time, the lead-out terminal 321 of the conductive busbar 3 contacts the metal casing of external equipment, simplifying the grounding design and enhancing grounding stability and convenience.

[0031] In this invention, some electrical components are electrically connected to the PCB board 2 via wires, while others are directly soldered onto the PCB board 2. By mounting the PCB board 2 on the insulating housing 1, this invention serves two purposes: firstly, it acts as a core carrier, providing an integrated mounting base for several electrical components. Through electrical connections with each component, it enables circuit continuity and stable transmission of electrical signals and currents, ensuring the coordinated operation of all components and supporting the battery pack circuit breaker unit in achieving its intended functions such as on / off control and status monitoring. Secondly, it serves as a connection base for the grounding structure, providing a key node for dissipating interference and noise, and assisting the grounding structure in playing its anti-interference and protective roles.

[0032] In this embodiment, the functions of PCB board 2 include, but are not limited to, the following: 1) It executes a precise strategy. After receiving the power-on or power-off command, it can autonomously and accurately execute complex power-on and power-off timing control. In particular, during the pre-charging process, it can monitor the voltage across the pre-charging resistor in real time, determine the voltage difference between the bus and the load capacitor, and close the main / negative contactor at the appropriate time to avoid instantaneous inrush current burning out the main contactor.

[0033] 2) Highly integrated design: PCB board 2 serves as the structural component and circuit carrier, carrying low-voltage control circuits, integrating small-sized fuses and pre-charge contactors, heating relays, current sensors, etc., reducing the overall structure. Compared with traditional wire harness connections, it can eliminate the three-dimensional space occupied by wire harnesses and terminals. All connections are completed within the two-dimensional plane of PCB board 2, achieving high power density design.

[0034] 3) Current sensors, fuses, etc. generate a lot of heat when they are working. By welding them onto a large area of ​​copper foil, the excellent thermal conductivity of the copper foil itself can quickly conduct the heat to other areas, thus quickly dissipating the heat.

[0035] Furthermore, such as Figure 1 and Figure 2 As shown, the grounding structure also includes a grounding wire 4. One end of the grounding wire 4 is soldered to the common grounding terminal, i.e., the GND terminal, on the PCB board 2. The other end of the grounding wire 4 is provided with a plug-in terminal 5. The plug-in terminal 5 is inserted into the plug-in piece 311 at one end of the conductive bus 3, realizing a detachable and convenient electrical connection between the common grounding terminal of the PCB board 2 and the conductive bus 3, which facilitates assembly and subsequent maintenance. The combination of soldering and plugging ensures the reliability of the electrical connection and reduces the assembly difficulty and error rate.

[0036] Preferably, the plug-in terminal 5 is fitted with a protective sleeve. The solder joint between the grounding wire 4 and the PCB board 2 can be protected with hot melt adhesive.

[0037] In this embodiment, the conductive busbar 3 is specifically fixed to the insulating housing 1 by plugging in.

[0038] See Figure 2 and Figure 4 The conductive busbar 3 includes a plug-in section 31, which is distributed vertically. A slot 101 is provided vertically inside the insulating housing 1. The plug-in section 31 is inserted into the slot 101 from bottom to top and is stopped by a limiting step 102 at the end of the slot 101. At the same time, the upper end of the plug-in section 31 is provided with a plug-in piece 311 extending out of the slot 101 for plugging into the plug-in terminal 5.

[0039] Furthermore, the two sides of the insertion section 31 are symmetrically provided with outwardly inclined elastic locking feet 313. The elastic locking feet 313 are formed by bending the lower end outward after partially cutting the body of the insertion section 31, and have the ability to elastically deform towards the outside of the insertion section 31. The slot 101 is provided with a stop 103. During the insertion process of the conductive busbar 3, as the insertion section 31 is continuously inserted into the slot 101, the inclined surfaces of the two elastic locking feet 313 slide into contact with the stop 103, and are pushed inward by the stop 103 to undergo elastic deformation until the elastic locking feet 313 pass the stop 103, and then return to their natural state and abut against the stop 103 under their own elastic force. At this time, the insertion section 31 is also stopped by the limiting step 102. This utility model uses the elastic locking foot 313 to cooperate with the stop 103, and the limiting step 102 to stop and limit the connection section 31 of the conductive busbar 3, thereby accurately positioning and axially stopping the connection section 31, ensuring accurate installation position.

[0040] Meanwhile, serrated protrusions 312 are integrally formed on both sides of the thin wall of the plug section 31, and the side of the protrusions 312 facing the plug section 31 insertion direction is an inclined guide slope. When the plug section 31 is inserted into the slot 101, the protrusions 312 on both sides fit tightly against the inner wall of the slot 101, making the installation more stable and improving the vibration and impact resistance of the overall structure.

[0041] See Figure 3 and Figure 4 The conductive busbar 3 also includes an L-shaped lead-out section 32 integrally connected to the plug-in section 31. The lead-out section 32 is distributed horizontally. The lead-out section 32 is located at the bottom of the insulating housing 1, and the bottom of the insulating housing 1 is provided with a positioning groove 104 for positioning the lead-out section 32. The end of the lead-out section 32 away from the plug-in section 31 is designated as the lead-out end 321. By arranging the lead-out section 32 at the bottom of the insulating housing 1, this utility model can optimize the spatial layout of the grounding structure, making the overall structure more compact and reasonable, and facilitating accurate contact with external grounding components. By using the lead-out section 32 in cooperation with the positioning groove 104, the lead-out portion of the conductive busbar 3 is positioned, ensuring the positional accuracy of the lead-out end 321.

[0042] Optionally, the conductive busbar 3 can be a copper busbar or an aluminum busbar, etc.

[0043] Of course, in other embodiments of this utility model, the conductive busbar 3 and the insulating shell 1 can also be integrally molded by insert injection molding, so that the two are more firmly combined, avoiding displacement and loosening of the conductive busbar 3 during use, and improving structural stability; at the same time, it simplifies the assembly process, improves production efficiency and reduces assembly costs.

[0044] It is worth mentioning that the bottom of the insulating housing 1 is provided with a support surface 105, and the lead-out end 321 is set to protrude slightly downward from the support surface 105, which can ensure full contact with the external metal shell (or grounding carrier), avoid the support surface 105 from obstructing the grounding connection, improve the reliability and effectiveness of grounding, and ensure that interference noise is discharged smoothly.

[0045] See Figure 1 The insulating housing 1 is provided with mounting feet 106, and an annular metal insert 6 is fixed on the mounting feet 106. The metal insert 6 and the insulating housing 1 are integrally formed by insert injection molding. The lead-out end 321 is attached to the bottom surface of the metal insert 6, and the lead-out end 321 is provided with a through hole corresponding to the inner hole of the metal insert 6. The inner hole of the metal insert 6 and the through hole of the lead-out end 321 allow bolts to pass through, thereby fixing the insulating housing 1 to the external metal housing (or grounding carrier) and connecting the lead-out end 321 to the external metal housing (or grounding carrier).

[0046] Therefore, the battery pack circuit breaker unit with grounding structure of this utility model can shield external noise intrusion, obtain a stable battery voltage signal, reduce sensitivity to external or internal electromagnetic interference, greatly reduce false faults caused by abnormal voltage sampling, prevent high voltage surges and electrostatic discharge from damaging the chip, improve the durability and lifespan of PCB board 2, and also improve the pass rate of electromagnetic compatibility test.

[0047] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A battery pack circuit breaker unit with a grounding structure, comprising an insulating housing (1) and a plurality of electrical components disposed within the insulating housing (1), characterized in that, The battery pack circuit breaker unit also includes a PCB board (2) and a grounding structure. The PCB board (2) is mounted on the insulating housing (1), and several electrical components are electrically connected to the PCB board (2). The grounding structure includes a conductive bus (3), which is mounted on the insulating housing (1). One end of the conductive bus (3) is electrically connected to a common grounding terminal on the PCB board, and the other end is set as a lead-out terminal (321) for contacting the metal casing of an external device.

2. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, The grounding structure also includes a grounding wire (4), one end of which is soldered to a common grounding terminal on the PCB board (2), and the other end of which is provided with a plug-in terminal (5), which is plugged into one end of the conductive bus (3).

3. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, The conductive bus (3) and the insulating shell (1) are integrally formed by insert injection molding.

4. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, The conductive bus (3) is fixedly inserted into the insulating housing (1).

5. The battery pack circuit breaker unit with grounding structure according to claim 4, characterized in that, The conductive bus (3) includes a plug section (31), and the insulating housing (1) is provided with a slot (101). The plug section (31) is inserted into the slot (101) and stopped by a limiting step (102) at the end of the slot (101). At the same time, the plug section (31) is provided with a plug piece (311) extending out of the slot (101).

6. The battery pack circuit breaker unit with grounding structure according to claim 5, characterized in that, The two thin walls of the insertion section (31) are integrally formed with serrated protrusions (312), and the side of the protrusions (312) facing the insertion direction of the insertion section (31) is an inclined guide slope. The protrusions (312) are tightly fitted to the inner wall of the slot (101). The two sides of the insertion section (31) are symmetrically provided with outwardly inclined elastic feet (313). The slot (101) is provided with a stop (103), and the two elastic feet (313) abut against the stop (103).

7. The battery pack circuit breaker unit with grounding structure according to claim 5, characterized in that, The conductive bus (3) also includes a lead-out section (32) integrally connected to the plug-in section (31). The lead-out section (32) is arranged at the bottom of the insulating housing (1), and the bottom of the insulating housing (1) is provided with a positioning groove (104) for positioning the lead-out section (32). The end of the lead-out section (32) away from the plug-in section (31) is designated as the lead-out end (321).

8. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, The bottom of the insulating housing (1) is provided with a support surface (105), and the lead-out end (321) protrudes downward from the support surface (105).

9. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, The insulating housing (1) is provided with mounting feet (106), and a metal insert (6) is fixed on the mounting feet (106). The lead-out end (321) is attached to the bottom surface of the metal insert (6).

10. The battery pack circuit breaker unit with grounding structure according to claim 1, characterized in that, Some of the electrical components are electrically connected to the PCB board (2) via wires, while other electrical components are directly soldered onto the PCB board (2).

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