A battery pack distribution box, a battery pack, and a vehicle

Abstract

This application discloses a battery pack distribution box, a battery pack, and a vehicle. The battery pack distribution box includes a housing assembly, a guide vane assembly, a relay assembly, a circuit board assembly, and a pre-charge module. The housing assembly includes a bottom shell; the guide vane assembly is disposed on the bottom wall of the bottom shell; the relay assembly is housed within a cavity of the bottom shell, located on the side of the guide vane away from the bottom wall, and includes a main positive relay, a fast-charging positive relay, a main negative relay, and a fast-charging negative relay arranged along a first direction, with each relay's contact portion connected to a guide vane; the main control circuit board and slave board in the circuit board assembly are both located on the side of the relays away from the bottom wall, and a conductive sheet is connected between the slave board and each relay; the pre-charge module is disposed on the side of the slave board facing the bottom wall. This battery pack distribution box has a high degree of integration and can effectively reduce wiring harness connections, facilitating automated production.

Description

Technical Field

[0001] This application relates to the field of vehicle technology, and more particularly to a battery pack distribution box, a battery pack, and a vehicle. Background Technology

[0002] In new energy vehicles, the BDU (Battery Disconnect Unit) refers to the battery disconnection unit or battery circuit breaker unit, which is also a type of distribution box and an important component of the battery pack. As a device for disconnecting and connecting the power battery to high-voltage electricity, the BDU provides functions such as charge and discharge control and single-circuit overload protection for the high-voltage system of new energy vehicles, playing a crucial role in the safety of the battery pack.

[0003] In related technologies, BDUs connect various electrical components through wiring harnesses to achieve control and monitoring. However, this method has problems such as complex wiring and complicated assembly and connection processes, which cannot achieve fully automated assembly and is not conducive to improving production efficiency. Utility Model Content

[0004] This application discloses a battery pack distribution box, a battery pack, and a vehicle, which enables the BDU to have a high degree of integration and can effectively reduce the wiring harness connections in the BDU, which is conducive to the automated production of the BDU and improves production efficiency.

[0005] To achieve the above objectives, in a first aspect, embodiments of this application disclose a battery pack distribution box, comprising:

[0006] A housing assembly, the housing assembly including a bottom shell having a receiving cavity having a bottom wall;

[0007] A flow guide assembly is disposed on the bottom wall, and the flow guide assembly includes a plurality of flow guides;

[0008] A relay assembly is housed within the accommodating cavity and located on the side of the guide bus away from the bottom wall. The relay assembly includes a plurality of relays arranged along a first direction, including a main positive relay, a fast charging positive relay, a main negative relay, and a fast charging negative relay. The contact portion of each relay is connected to one of the guide buses.

[0009] A circuit board assembly, comprising a main control circuit board and a slave board, wherein the main control circuit and the slave board are electrically connected, and both the main control circuit board and the slave board are located on the side of the relay away from the bottom wall. Each slave board is correspondingly arranged with a plurality of the relays, and a conductive sheet is connected between the slave board and each of the relays.

[0010] A pre-charge module is disposed on the side of the plate facing the bottom wall.

[0011] Optionally, the battery pack distribution box further includes a second capacitor, and the relay assembly further includes a boost relay. The second capacitor is disposed on the slave board, and the boost relay is connected to the slave board via the conductive sheet; and / or,

[0012] The battery pack distribution box also includes a third capacitor, and the relay assembly also includes a step-down relay. The third capacitor is disposed on the slave board, and the step-down relay is connected to the slave board through the conductive sheet.

[0013] Optionally, along the first direction, the boost relay and the buck relay are arranged between the fast charging positive relay and the main negative relay.

[0014] Optionally, the bottom shell has an outer bottom surface opposite to the bottom wall in a direction perpendicular to the bottom wall, and a heat sink is attached to the outer bottom surface. In a direction perpendicular to the bottom wall, the side of the flow guide away from the relay assembly is exposed on the outer bottom surface and is attached to the heat sink.

[0015] Optionally, an insulating thermally conductive element is provided between the heat sink and the flow guide.

[0016] Optionally, the contact portion of the main positive relay has a columnar structure, and the outer peripheral wall of the contact portion of the main positive relay is provided with a first ceramic shell. The end of the contact portion of the main positive relay facing the guide bus extends out of the first ceramic shell, and the guide bus connected to the contact portion of the main positive relay is also welded to the first ceramic shell; and / or, the contact portion of the main negative relay has a columnar structure, and the outer peripheral wall of the contact portion of the main negative relay is provided with a second ceramic shell. The end of the contact portion of the main negative relay facing the guide bus extends out of the second ceramic shell, and the guide bus connected to the contact portion of the main negative relay is also welded to the second ceramic shell.

[0017] Optionally, the plurality of the flow guides are integrally injection molded with the bottom shell, or the bottom shell includes a bottom plate and a surrounding plate, the bottom plate and the surrounding plate forming the receiving cavity, and the plurality of the flow guides are vacuum formed with the bottom plate.

[0018] Optionally, the battery pack distribution box further includes a first capacitor, and the relay assembly further includes a capacitor switch relay electrically connected to the first capacitor. The first capacitor and the capacitor switch relay are arranged along the first direction and located between the fast charging positive relay and the main negative relay.

[0019] Optionally, the slave board includes a first sub-slave board and a second sub-slave board, the first sub-slave board and the second sub-slave board are electrically connected, and the first sub-slave board or the second sub-slave board is electrically connected to the main control circuit board;

[0020] The bottom shell includes:

[0021] The first sub-bottom shell, the first sub-slave board, the main positive relay and the fast charging positive relay are all located inside the first sub-bottom shell. The conductive sheet is connected between the first sub-slave board and the main positive relay and the fast charging positive relay. The pre-charge module is disposed on the first sub-slave board.

[0022] The second sub-bottom shell, the first sub-bottom shell and the second sub-bottom shell are arranged sequentially along the first direction, the second sub-slave plate, the main negative relay and the fast charging negative relay are all located inside the second sub-bottom shell, and the conductive sheet is connected between the second sub-slave plate and the main negative relay and the fast charging negative relay.

[0023] Optionally, the slave board further includes a third sub-slave board, wherein the first sub-slave board and the second sub-slave board are respectively connected to the third sub-slave board via flexible circuit boards, and the third sub-slave board is connected to the main control circuit board;

[0024] The bottom shell also includes a third sub-bottom shell. Along the first direction, the third sub-bottom shell is located between the first sub-bottom shell and the second sub-bottom shell. The third sub-slave board, the first capacitor, the capacitor switch relay, and the main control circuit board are all located inside the third sub-bottom shell. The capacitor switch relay is connected to the main control circuit board through the conductive sheet.

[0025] Optionally, the contact portion of at least one of the main positive relay, the fast charging positive relay, the main negative relay, and the fast charging negative relay is disposed facing the bottom wall; the contact portion of the capacitor switch relay is disposed facing the side wall of the accommodating cavity.

[0026] Optionally, it also includes a pulse width modulation chip, which is disposed on the slave board and electrically connected to the main positive relay and / or the main negative relay.

[0027] Secondly, embodiments of this application also disclose a battery pack, comprising:

[0028] Battery housing;

[0029] A battery pack, wherein the battery pack is disposed within the battery housing;

[0030] The battery pack distribution box described in any one of the first aspects is disposed inside the battery box and electrically connected to the battery pack.

[0031] Thirdly, embodiments of this application also disclose a vehicle including the battery pack described in the second aspect.

[0032] Compared with the prior art, the beneficial effects of this application are as follows:

[0033] By placing the flow guide assembly on the bottom wall, housing the relay assembly within the housing cavity and placing it on the side of the flow guide away from the bottom wall, and placing both the main control circuit board and the slave board on the side of the relay away from the bottom wall, and placing the pre-charge module on the side of the slave board facing the bottom wall, the flow guide, relay, and circuit board can be layered within the housing, effectively reducing the number of wiring harness connections in the distribution box, facilitating automated production of the distribution box, and thus effectively improving production efficiency.

[0034] The relay assembly includes multiple relays arranged along a first direction, including a main positive relay, a fast-charging positive relay, a main negative relay, and a fast-charging negative relay. Each relay's contact portion is connected to a current-carrying busbar. When multiple relays are placed in the receiving cavity, the main positive relay, fast-charging positive relay, main negative relay, and fast-charging negative relay can be placed simultaneously in the receiving cavity. Furthermore, the connections between the main positive relay, fast-charging positive relay, main negative relay, and fast-charging negative relay and their corresponding current-carrying busbars can be operated together, facilitating the installation of each relay. This makes it easier to automate the production of the power distribution box, improves production efficiency, and enables the power distribution box to have discharge control and fast-charging control functions for the battery pack, demonstrating a high degree of integration. Attached Figure Description

[0035] To more clearly illustrate the technical solutions in the embodiments of this utility model, the drawings used in 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.

[0036] Figure 1 A perspective view of a battery pack distribution box provided for an embodiment of this utility model;

[0037] Figure 2 An exploded view of a battery pack distribution box provided in an embodiment of this utility model;

[0038] Figure 3 A perspective view of a battery pack distribution box without a top cover, provided for an embodiment of this utility model;

[0039] Figure 4 A perspective view of the battery pack distribution box after it has been rotated a certain angle without a top cover, as provided in this embodiment of the utility model;

[0040] Figure 5 A perspective view of a battery pack distribution box without housing assembly, main control circuit board, first slave board, second slave board, third slave board and heat sink provided for an embodiment of the present utility model;

[0041] Figure 6 for Figure 5 Enlarged view of position D in the middle;

[0042] Figure 7 A perspective view of a battery pack distribution box without a top cover, main control circuit board, first sub-slave board, second sub-slave board and third sub-slave board provided for an embodiment of this utility model;

[0043] Figure 8 for Figure 7 Enlarged view of position A in the middle;

[0044] Figure 9 for Figure 7 Enlarged view of position B in the middle;

[0045] Figure 10 for Figure 7 Enlarged view of position C in the middle;

[0046] Figure 11 A perspective view of a battery pack distribution box without a top cover, heat sink, and insulating heat-conducting components, provided for an embodiment of this utility model;

[0047] Figure 12 A schematic diagram of the structure of a main positive relay connected to a current-carrying busbar is provided for an embodiment of this utility model;

[0048] Figure 13 This is a schematic diagram of another configuration of the main positive relay connected to the busbar, as provided in an embodiment of the present invention.

[0049] Figure 14 A perspective view of a battery pack provided for an embodiment of this utility model;

[0050] Figure 15 This is a structural schematic diagram of a vehicle provided for an embodiment of the present utility model.

[0051] Explanation of reference numerals in the attached figures:

[0052] 1-Shell assembly; 11-Bottom shell; 111-First sub-bottom shell; 1111-Accommodating cavity; 1112-Bottom plate; 11121-Outer bottom surface; 1113-Enclosure plate; 112-Second sub-bottom shell; 113-Third sub-bottom shell; 12-First sub-top cover; 13-Second sub-top cover; 14-Third sub-top cover;

[0053] 2-Flow guide assembly; 21-Flow guide;

[0054] 3-Relay assembly; 31-Main positive relay; 311-Contact; 312-First ceramic housing; 32-Fast charging positive relay; 33-Capacitor switch relay; 34-Main negative relay; 35-Fast charging negative relay; 36-Boost relay; 37-Buck relay;

[0055] 4a - First capacitor; 4b - Second capacitor; 4c - Third capacitor;

[0056] 5-Circuit board assembly; 51-Main control circuit board; 52-Slave board; 521-First slave board; 522-Second slave board; 523-Third slave board; 524-Fourth slave board; 53-Flexible circuit board;

[0057] 6-Pre-charge module;

[0058] 7-Heat dissipation components;

[0059] 8-Insulating and thermally conductive components;

[0060] 9-Conductive sheet;

[0061] 100 - Vehicle; 110 - Battery pack; 10 - Battery pack distribution box; 20 - Battery housing; 30 - Battery group. Detailed Implementation

[0062] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0063] In this invention, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing this invention and its embodiments, and are not intended to limit the indicated device, element, or component to having a specific orientation, or to be constructed and operated in a specific orientation.

[0064] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in some cases to indicate a certain dependency or connection relationship. Those skilled in the art can understand the specific meaning of these terms in this utility model according to the specific circumstances.

[0065] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; 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, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this utility model based on the specific circumstances.

[0066] Furthermore, the terms "first," "second," etc., are primarily used to distinguish different devices, elements, or components (which may be the same or different in specific type and construction), and are not intended to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.

[0067] In related technologies, BDUs connect various electrical components via wiring harnesses. For example, relays are connected via high-voltage wiring harnesses to achieve control and monitoring. However, this method has problems such as complex wiring and assembly connection processes, which makes wiring errors easy to occur and cannot achieve fully automated assembly, thus hindering the improvement of production efficiency.

[0068] In view of the problems described in the background art, the present invention provides a battery pack distribution box, a battery pack, and a vehicle, which enables the BDU to have a high degree of integration and can effectively reduce the wiring harness connections in the BDU, which is conducive to the automated production of the BDU and improves production efficiency.

[0069] The battery will be described in detail below through specific embodiments:

[0070] This application provides a battery pack power distribution box, such as... Figures 1-6 As shown, the system includes a housing assembly 1, a flow guide assembly 2, a relay assembly 3, a circuit board assembly 5, and a pre-charge module 6. The housing assembly 1 includes a bottom shell 11 with a receiving cavity 1111 having a bottom wall. The flow guide assembly 2 is disposed on the bottom wall and includes multiple flow guides 21. The relay assembly 3 is housed within the receiving cavity 1111 and located on the side of the flow guides 21 facing away from the bottom wall. The relay assembly 3 includes flow guides along a first direction (e.g., ...). Figure 2Multiple relays are arranged in the direction shown in the middle (x). The multiple relays include a main positive relay 31, a fast charging positive relay 32, a main negative relay 34, and a fast charging negative relay 35. Each relay's contact portion 311 is connected to a current guide 21. The circuit board assembly 5 includes a main control circuit board 51 and a slave board 52. The main control circuit and the slave board 52 are electrically connected. The main control circuit board 51 and the slave board 52 are both located on the side of the relays away from the bottom wall. The slave board 52 is arranged correspondingly to the multiple relays. A conductive sheet 9 is connected between the slave board 52 and each relay. The pre-charge module 6 is located on the side of the slave board 52 facing the bottom wall.

[0071] In this embodiment, the guide vane assembly 2 is disposed on the bottom wall, the relay assembly 3 is housed in the receiving cavity 1111 and located on the side of the guide vane 21 away from the bottom wall, the main control circuit board 51 and the slave board 52 are both located on the side of the relay away from the bottom wall, and the pre-charge module 6 is disposed on the side of the slave board 52 facing the bottom wall. When assembling the battery pack distribution box 10, the guide vane assembly 2 can be disposed on the bottom wall of the receiving cavity 1111 first, then the relay assembly 3 can be disposed in the receiving cavity 1111, and the contact part 311 of the relay can be connected to the corresponding guide vane 21. Then the main control circuit board 51 and the slave board 52 can be placed in the corresponding positions in the receiving cavity 1111, and the slave board 52 can be connected to each relay through the corresponding conductive sheet 9. This effectively reduces the number of wiring harnesses in the distribution box, facilitates the automated production of the distribution box, and thus effectively improves production efficiency.

[0072] The relay assembly 3 includes multiple relays arranged along a first direction, including a main positive relay 31, a fast-charging positive relay 32, a main negative relay 34, and a fast-charging negative relay 35. Each relay's contact portion 311 is connected to a current-carrying busbar 21. When multiple relays are placed in the receiving cavity 1111, the main positive relay 31, fast-charging positive relay 32, main negative relay 34, and fast-charging negative relay 35 can be placed simultaneously within the receiving cavity 1111. Furthermore, the connections between the main positive relay 31, fast-charging positive relay 32, main negative relay 34, and fast-charging negative relay 35 and their corresponding current-carrying busbars 21 can be operated simultaneously, facilitating the installation of each relay and thus promoting automated production of the distribution box and improving production efficiency. Additionally, the distribution box can provide discharge control and fast-charging control functions for the battery pack, exhibiting a high degree of integration.

[0073] The battery pack distribution box 10 also includes a pre-charge module 6, which is located on the side of the plate 52 facing the bottom wall. This allows the battery pack distribution box 10 to integrate a pre-charge function, meaning that when charging the battery pack, it can first charge the battery pack to a preset voltage with a relatively small current. This effectively avoids damage to circuit components caused by huge currents during battery pack charging, such as blown fuses or stuck relays due to huge current surges. Furthermore, the location of the pre-charge module 6 on the side of the plate 52 facing the bottom wall allows it to be assembled into the receiving cavity 1111 simultaneously with the plate 52, facilitating automated assembly of the battery pack distribution box 10.

[0074] The connection between the relay contact 311 and the current-carrying bus 21 can be welded or screwed, and there is no limitation on this. Both methods can ensure good conductivity between the relay contact 311 and the current-carrying bus 21.

[0075] In addition, the pre-charge module 6 may include a pre-charge resistor and a pre-charge relay, so that when charging the battery pack, the battery pack can be charged with a small current through the pre-charge module 6, avoiding relay failure due to large current in the circuit.

[0076] Furthermore, along the first direction, the precharge module 6 is located between the main positive relay 31 and the fast-charging positive relay 32. This facilitates the arrangement of current guides, such as copper busbars, in the parallel connection between the precharge module 6 and the main positive relay 31, reducing the difficulty of electrical connection between the precharge module 6 and the main positive relay 31 and facilitating the automated assembly of the battery pack distribution box 10.

[0077] Optionally, such as Figures 1-6 As shown, the battery pack distribution box 10 also includes a first capacitor 4a, and the relay assembly 3 also includes a capacitor switch relay 33 electrically connected to the first capacitor 4a. The first capacitor 4a and the capacitor switch relay 33 are arranged along a first direction and located between the fast charging positive relay 32 and the main negative relay 34. For example, the first capacitor 4a and the capacitor switch relay 33 are arranged adjacent to each other and are electrically connected to the capacitor switch relay 33.

[0078] Therefore, the battery pack distribution box 10 can also integrate a first capacitor 4a and a capacitor switch relay 33, achieving a high degree of integration. Furthermore, during assembly of the battery pack distribution box 10, the first capacitor 4a and the capacitor switch relay 33 can be placed simultaneously in the receiving cavity 1111 along with relays such as the main positive relay 31, fast-charging positive relay 32, main negative relay 34, and fast-charging negative relay 35. The first capacitor 4a and the capacitor switch relay 33 can operate together with the connection between the main positive relay 31 and the corresponding current guide 21, thus facilitating automated production of the distribution box and improving production efficiency. Additionally, the first capacitor 4a and the capacitor switch relay 33 can also provide a certain filtering effect on the circuit, making the DC current in the circuit smoother.

[0079] The first capacitor 4a can be located between the fast charging positive relay 32 and the capacitor switch relay 33 along the first direction. Alternatively, the first capacitor 4a can be located between the capacitor switch relay 33 and the main negative relay 34 along the first direction. Both arrangements allow the first capacitor 4a and the capacitor switch relay 33 to occupy a small space along the direction perpendicular to the first direction.

[0080] Optionally, such as Figures 7-10 As shown, the battery pack distribution box 10 also includes a second capacitor 4b, and the relay assembly 3 also includes a boost relay 36. The second capacitor 4b is disposed on the slave board 52, and the boost relay 36 is connected to the slave board 52 through a conductive sheet 9.

[0081] Therefore, the battery pack distribution box 10 can also integrate a boost charging control function, so that the battery pack equipped with the battery pack distribution box 10 can be boost charged, so that charging can still be carried out when the voltage of the charging power supply is lower than the voltage of the battery pack. This allows vehicles equipped with the battery pack distribution box 10 to be charged at low-voltage charging stations. By increasing the charging voltage and reducing the charging current, transmission loss is reduced, and more electrical energy can be effectively used to charge the battery pack, thereby effectively improving charging efficiency.

[0082] The boost relay 36 can be located between the fast charging positive relay 32 and the first capacitor 4a along the first direction, which facilitates the connection between the boost relay 36 and the fast charging positive relay 32.

[0083] In addition, the battery pack distribution box 10 may also include a third capacitor 4c, and the relay assembly 3 may also include a step-down relay 37. The third capacitor 4c is disposed on the slave board 52, and the step-down relay 37 is connected to the slave board 52 through a conductive sheet 9.

[0084] Therefore, the battery pack distribution box 10 can also integrate a step-down charging control function, so that the battery pack equipped with the battery pack distribution box 10 can perform step-down charging. This allows charging to continue even when the voltage of the charging power supply is greater than the voltage of the battery pack. As a result, vehicles equipped with the battery pack distribution box 10 can be charged at high-voltage charging stations. That is, with a certain output power of the charging station, the charging current can be increased by reducing the voltage, thereby effectively increasing the charging power, shortening the charging time, and improving the charging efficiency.

[0085] Among them, the step-down relay 37 can be located between the capacitor switch relay 33 and the main negative relay 34 along the first direction, which reduces the space occupied by the relay assembly 3 in the direction perpendicular to the first direction.

[0086] It is understood that in some embodiments, the battery pack distribution box 10 may further include a second capacitor 4b, and the relay assembly 3 may further include a boost relay 36, so that the battery pack equipped with the battery pack distribution box 10 can perform boost charging; in other embodiments, the battery pack distribution box 10 may further include a third capacitor 4c, and the relay assembly 3 may further include a buck relay 37, so that the battery pack equipped with the battery pack distribution box 10 can perform buck charging; in still other embodiments, the battery pack distribution box 10 may further include the second capacitor 4b and the third capacitor 4c, and the relay assembly 3 may further include a boost relay 36 and a buck relay 37, so that the battery pack equipped with the battery pack distribution box 10 can perform boost charging, buck charging, and buck-boost charging, so that the battery pack distribution box 10 can also be compatible with boost charging control function and buck charging control function simultaneously.

[0087] In some embodiments, such as Figures 5-10 As shown, the contact portion 311 of at least one of the main positive relay 31, fast charging positive relay 32, main negative relay 34 and fast charging negative relay 35 is disposed facing the bottom wall; the contact portion 311 of the capacitor switch relay 33 is disposed facing the side wall of the accommodating cavity 1111.

[0088] Therefore, at least one of the main positive relay 31, fast charging positive relay 32, main negative relay 34 and fast charging negative relay 35 can be installed in the accommodating cavity 1111 in an inverted position, while the capacitor switch relay 33 is installed in the accommodating cavity 1111 in a horizontal position. This effectively prevents a large current from appearing in the circuit due to a short circuit of a relay caused by vibration, and avoids the situation where other relays stick together due to a large current appearing in the circuit caused by a short circuit of a relay.

[0089] In this embodiment, at least one of the main positive relay 31, fast charging positive relay 32, main negative relay 34, and fast charging negative relay 35 has its contact portion 311 facing the bottom wall. This can be one of the main positive relay 31, fast charging positive relay 32, main negative relay 34, and fast charging negative relay 35 having its contact portion 311 facing the bottom wall, two of them having their contact portions 311 facing the bottom wall, or all three or all of them having their contact portions 311 facing the bottom wall.

[0090] For example, when the contact portions 311 of the main positive relay 31, fast charging positive relay 32, main negative relay 34, and fast charging negative relay 35 are all arranged facing the bottom wall, the structure of the guide bus 21 can be simplified, and the connections between the main positive relay 31 and the corresponding guide bus 21, the fast charging positive relay 32 and the corresponding guide bus 21, the main negative relay 34 and the corresponding guide bus 21, and the fast charging negative relay 35 and the corresponding guide bus 21 are all located at the bottom wall, making them easy to operate and implement.

[0091] Furthermore, the boost relay 36 can be installed in the receiving cavity 1111 in an inverted position or in a horizontal position; this is not limited here. Similarly, the buck relay 37 can be installed in the receiving cavity 1111 in an inverted position or in a horizontal position; this is also not limited here.

[0092] Furthermore, the main positive relay 31 can be a relay core without a casing. The relay core includes a contact portion and a magnetic circuit portion, meaning the relay core is configured as an integral structure with the contact portion on top and the magnetic circuit portion on the bottom. This effectively reduces the space occupied by the main positive relay 31, facilitating the miniaturization of the BDU.

[0093] The main negative relay 34 can also be a relay core without a casing, reducing the space occupied by the main negative relay 34. Similarly, the fast charging positive relay 32, fast charging negative relay 35, capacitor switch relay 33, boost relay 36 and buck relay 37 can all be relay cores without casings, effectively reducing the space occupied by the relay assembly 3 and facilitating the miniaturization of the BDU.

[0094] The aforementioned flow guide assembly 2 is disposed on the bottom wall. It can be that multiple flow guides 21 are laid on the bottom wall, or that the bottom wall is provided with a groove and multiple flow guides 21 are embedded in the groove. There is no limitation here.

[0095] Optionally, when a groove is provided on the bottom wall and multiple guide channels 21 are embedded in the groove, such as Figure 2 and Figure 11As shown, the bottom shell 11 has an outer bottom surface 11121 that is opposite to the bottom wall in a direction perpendicular to the bottom wall. A heat sink 7 is attached to the outer bottom surface 11121. The side of the guide tube 21 that is opposite to the relay assembly 3 in a direction perpendicular to the bottom wall is exposed on the outer bottom surface 11121 and is attached to the heat sink 7.

[0096] Therefore, the heat sink 7 can dissipate heat from the current-carrying busbar 21, so that the current-carrying busbar 21 is not easily affected by excessive temperature, which can increase the current-carrying capacity of the current-carrying busbar 21. At the same time, when the current carried by the current-carrying busbar 21 is constant, the area of ​​the current-carrying busbar 21 can be set larger without considering heat dissipation, which helps to reduce the amount of current-carrying busbar 21 used and reduce costs.

[0097] The material of the flow guide 21 can be at least one of copper, copper alloy, aluminum, aluminum alloy, etc., and is not limited here.

[0098] The heat sink 7 can be a heat sink, a heat dissipation pad, or a semiconductor cooling chip, etc., and is not limited here.

[0099] In addition, when the battery pack distribution box 10 is located inside the battery box of the battery pack, the heat sink 7 can be the heat sink 7 inside the battery pack, which is beneficial for cost control.

[0100] Optionally, such as Figure 2 As shown, an insulating heat-conducting element 8 is provided between the heat sink 7 and the flow guide 21. This effectively prevents short circuits between the flow guide 21 and the heat sink 7.

[0101] The insulating and thermally conductive component 8 can be either insulating and thermally conductive adhesive or an insulating and thermally conductive pad; there is no limitation on this.

[0102] In some embodiments, such as Figure 12 and Figure 13 As shown, the contact portion 311 of the main positive relay 31 has a columnar structure, and the outer peripheral wall of the contact portion 311 of the main positive relay 31 is provided with a first ceramic shell 312. The end of the contact portion 311 of the main positive relay 31 extends out of the first ceramic shell 312 towards the guide bus 21. The guide bus 21 connected to the contact portion 311 of the main positive relay 31 is also welded to the first ceramic shell 312. And / or, the contact portion 311 of the main negative relay 34 has a columnar structure, and the outer peripheral wall of the contact portion 311 of the main negative relay 34 is provided with a second ceramic shell. The end of the contact portion 311 of the main negative relay 34 extends out of the second ceramic shell towards the guide bus 21. The guide bus 21 connected to the contact portion 311 of the main negative relay 34 is also welded to the second ceramic shell.

[0103] This increases the contact area between the main positive relay 31 and the corresponding guide bus 21, allowing the heat generated by the main positive relay 31 during operation to be transferred to the corresponding guide bus 21 through the first ceramic shell 312. This improves the heat dissipation effect through the guide bus 21, effectively preventing the main positive relay 31 from being damaged due to overheating and improving the stability of the main positive relay 31 in use.

[0104] Similarly, the contact area between the main negative relay 34 and the corresponding guide bus 21 is increased, so that the heat generated by the main negative relay 34 during operation can be transferred to the corresponding guide bus 21 through the second ceramic, so that the heat dissipation effect through the guide bus 21 is better, effectively preventing the main negative relay 34 from being damaged due to overheating and improving the stability of the main negative relay 34.

[0105] The welding between the flow guide 21 and the first ceramic can be brazing, such as active metal brazing or low-temperature brazing, or it can be direct copper-clad welding, that is, in a high-temperature oxygen-containing atmosphere, the copper and ceramic interface undergo a eutectic reaction. Of course, in other embodiments, the welding between the flow guide 21 and the first ceramic can also be implemented in other ways, which are not limited here.

[0106] The welding between the flow guide 21 and the second ceramic can be roughly the same as the welding between the flow guide 21 and the first ceramic, and will not be described in detail here.

[0107] In addition, the connection between the fast charging positive relay 32 and the corresponding guide bus 21, and the connection between the fast charging negative relay 35 and the corresponding guide bus 21, can be roughly the same as the connection between the main positive relay 31 and the corresponding guide bus 21, and will not be described in detail here.

[0108] The aforementioned current guide assembly 2 can be disposed on the bottom wall in various ways. In one possible implementation, multiple current guides 21 are integrally injection molded with the bottom shell 11, which can make the connection between the current guide 21 and the bottom shell 11 more robust, thereby making the connection between the current guide 21 and the contact part 311 of the relay more robust, which is conducive to the current flow between the relay and the current guide 21.

[0109] In another possible implementation, the bottom shell 11 may include a bottom plate 1112 and a surrounding plate 1113, with the bottom plate 1112 and the surrounding plate 1113 forming an accommodating cavity 1111, and a plurality of flow channels 21 being vacuum-formed with the bottom plate 1112.

[0110] This allows for a connection between the flow guide 21 and the base plate 1112 that is both efficient and cost-effective, which is beneficial for improving the production efficiency and reducing the cost of the battery pack distribution box 10.

[0111] The number of slave plates 52 mentioned above can be one, two, or more, and is not limited here. The following detailed explanation will be based on the example of multiple slave plates 52.

[0112] In other embodiments, such as Figure 2 , Figures 7-10 As shown, the slave board 52 includes a first slave board 521 and a second slave board 522. The first slave board 521 and the second slave board 522 are electrically connected, and either the first slave board 521 or the second slave board 522 is electrically connected to the main control circuit board 51. The bottom shell 11 includes a first bottom shell 111 and a second bottom shell 112. The first slave board 521, the main positive relay 31, and the fast charging positive relay 32 are all located inside the first bottom shell 111. A conductive sheet 9 is connected between the first slave board 521 and the main positive relay 31 and the fast charging positive relay 32. The pre-charge module 6 is disposed on the first slave board 521. The first bottom shell 111 and the second bottom shell 112 are arranged sequentially along the first direction. The second slave board 522, the main negative relay 34, and the fast charging negative relay 35 are all located inside the second bottom shell 112. A conductive sheet 9 is connected between the second slave board 522 and the main negative relay 34 and the fast charging negative relay 35.

[0113] This allows the dimensions of the first sub-base shell 111 and the second sub-base shell 112 along the first direction to be relatively small, which is beneficial to improving the structural strength of the first sub-base shell 111, the second sub-base shell 112 and the third sub-base shell 113.

[0114] By having the first slave board 521, the main positive relay 31, and the fast-charging positive relay 32 all located within the first sub-bottom shell 111, and with conductive plates 9 connecting the first slave board 521 to the main positive relay 31 and the fast-charging positive relay 32, the connection between the main positive relay 31, the fast-charging positive relay 32, and the first slave board 521 can be simplified. This also simplifies the printed circuitry on the first slave board 521, making it easier to manufacture and control costs. Similarly, the connection between the main negative relay 34, the fast-charging negative relay 35, and the second slave board 522 can be simplified, and the printed circuitry on the third slave board 523 can also be simplified, further facilitating cost control.

[0115] The first slave board 521 and the second slave board 522 can be electrically connected through at least one of the following: wire harness, flexible circuit board, terminal connector, etc., without limitation.

[0116] Furthermore, the first slave board 521 or the second slave board 522 is electrically connected to the main control circuit board 51. This connection can be either the first slave board 521 directly connected to the main control circuit board 51 or the second slave board 522 directly connected to the main control circuit board 51; no limitation is made here. The implementation of the electrical connection between the first slave board 521 or the second slave board 522 and the main control circuit board 51 is largely the same as the implementation of the electrical connection between the first slave board 521 and the second slave board 522, and will not be elaborated further here. For example, when current or communication signals flow from slave board 52 to the main control circuit board 51, they can first flow from the first slave board 521 to the second slave board 522, and then from the second slave board 522 to the main control circuit board 51; or, they can first flow from the second slave board 522 to the first slave board 521, and then from the first slave board 521 to the main control circuit board 51.

[0117] Optionally, a plurality of first partition plates may be provided inside the first sub-bottom shell 111 to divide and form a plurality of small accommodating spaces within the accommodating cavity 1111 of the first sub-bottom shell 111. The main positive relay 31 and the fast charging positive relay 32 may be respectively housed in the corresponding small accommodating spaces to position the assembly of the main positive relay 31 and the fast charging positive relay 32, thereby improving production efficiency.

[0118] Similarly, multiple first baffles can also be provided inside the second sub-bottom shell 112 to divide and form multiple small accommodating spaces within the accommodating cavity 1111 of the second sub-bottom shell 112. The main negative relay 34 and the fast-charging negative relay 35 can be respectively housed in the corresponding small accommodating spaces to position the assembly of the main positive relay 31 and the fast-charging positive relay 32, which is beneficial to improving production efficiency.

[0119] Optionally, the slave board 52 further includes a third slave board 523. The first slave board 521 and the second slave board 522 are respectively connected to the third slave board 523 via a flexible circuit board 53. The third slave board 523 is connected to the main control circuit board 51. The bottom shell 11 also includes a third bottom shell 113. Along the first direction, the third bottom shell 113 is located between the first bottom shell 111 and the second bottom shell 112. The third slave board 523, the first capacitor 4a, the capacitor switch relay 33 and the main control circuit board 51 are all located inside the third bottom shell 113. The capacitor switch relay 33 is connected to the main control circuit board 51 via a conductive sheet 9.

[0120] Therefore, the first slave board 521 and the second slave board 522 are respectively connected to the third slave board 523 through the flexible circuit board 53. Compared with the method of connecting the first slave board 521, the second slave board 522 and the third slave board 523 through wire harness, it is beneficial to the automated assembly of the battery pack distribution box 10.

[0121] Furthermore, along the first direction, the third sub-bottom shell 113 is located between the first sub-bottom shell 111 and the second sub-bottom shell 112, and the third sub-slave plate 523 is located inside the third sub-bottom shell 113. Along the first direction, the third sub-slave plate 523 can be located between the first sub-slave plate 521 and the second sub-slave plate 522, which facilitates the arrangement and connection of the flexible circuit board 53 and helps to improve production efficiency.

[0122] The capacitor switch relay 33 is connected to the main control circuit board 51 through the conductive sheet 9. Compared with the capacitor switch relay 33 being connected to the main control circuit board 51 through the wire harness, this greatly facilitates the connection between the capacitor switch relay 33 and the main control circuit board 51, and is more conducive to the automated assembly of the battery pack distribution box 10, effectively improving production efficiency.

[0123] Additionally, the slave board 52 may also include a fourth slave board 524. The fourth slave board 524 is electrically connected to the batteries in the battery pack via a wiring harness and is used to monitor parameters such as voltage and temperature of the batteries in the battery pack. The fourth slave board 524 is also electrically connected to the main control circuit board 51 to transmit the monitored data signals to the main control circuit board 51. A second partition plate extending along the first direction is also provided inside the bottom shell 11, and the fourth slave board 524 can be disposed on the second partition plate.

[0124] The number of fourth slave boards 524 can be multiple. Each of the first sub-bottom shell 111, the second sub-bottom shell 112 and the third sub-bottom shell 113 can be provided with a fourth slave board 524, so that the number of batteries monitored by each fourth slave board 524 can be reduced, thereby reducing the manufacturing difficulty of the fourth slave board 524.

[0125] Optionally, the housing assembly 1 may further include a first sub-top cover 12, a second sub-top cover 13, and a third sub-top cover 14. The first sub-top cover 12 is disposed on the first sub-bottom shell 111 to seal the accommodating cavity 1111 of the first sub-bottom shell 111; the second sub-top cover 13 is disposed on the second sub-bottom shell 112 to seal the accommodating cavity 1111 of the second sub-bottom shell 112; and the third sub-top cover 14 is disposed on the third sub-bottom shell 113 to seal the accommodating cavity 1111 of the third sub-bottom shell 113. Thus, circuit boards, relays, etc., located in the first sub-bottom shell 111, circuit boards, relays, etc., located in the second sub-bottom shell 112, and circuit boards, relays, etc., located in the third sub-bottom shell 113 can be protected.

[0126] As described above, when assembling the battery pack distribution box 10, taking the assembly of the first sub-bottom shell 111 with other components, and using the integral molding of the current guide 21 and the first sub-bottom shell 111 as an example, firstly, the corresponding current guide 21 and the first sub-bottom shell 111 are integrally injection molded. Then, the first sub-bottom shell 111 with the integrally molded current guide 21 is placed on the assembly table. Subsequently, the main positive relay 31 and the fast charging positive relay 32 can be placed inside the first sub-bottom shell 111. Then, the first sub-bottom shell 111 is flipped over, and the main positive relay 31, the fast charging positive relay 32, and the corresponding current guide are placed inside. 21 is welded; then, the first sub-bottom shell 111 is flipped over again so that the guide tube 21 faces downward, the first sub-slave plate 521 and the fourth sub-slave plate 524 are placed inside the first sub-bottom shell 111, and the first sub-slave plate 521 is connected to the main positive relay 31, the fast charging positive relay 32, and other components inside the first sub-bottom shell 111; finally, the first sub-top cover 12 is assembled with the first sub-bottom shell 111 to complete the assembly of the first sub-bottom shell 111, the first sub-top cover 12, the first sub-slave plate 521, the fourth sub-slave plate 524, the main positive relay 31, and the fast charging positive relay 32.

[0127] The assembly of the second sub-bottom shell 112, the second sub-top cover 13, the second sub-slave board 522, the fourth sub-slave board 524, the main negative relay 34, and the fast charging negative relay 35 can be roughly the same as the assembly of the first sub-bottom shell 111, the first sub-top cover 12, the first sub-slave board 521, the fourth sub-slave board 524, the main positive relay 31, and the fast charging positive relay 32 described above, and will not be repeated here.

[0128] When assembling the third sub-bottom shell 113, the third sub-top cover 14, the main control circuit board 51, the third sub-slave board 523, the fourth sub-slave board 524, the first capacitor 4a, and the capacitor switch relay 33, the third sub-bottom shell 113, which is integrally injection molded with the corresponding current guide 21, can be placed on the assembly table first. Then, the first capacitor 4a can be placed in the third sub-bottom shell 113. Subsequently, the third sub-bottom shell 113 can be flipped over, and the first capacitor 4a can be soldered to the corresponding current guide 21. Then, the third sub-bottom shell 113 can be assembled again. The third sub-bottom shell 113 is flipped so that the current guide 21 faces downwards, and the capacitor switch relay 33 is placed horizontally in the third sub-bottom shell 113. The capacitor switch relay 33 and the corresponding current guide 21 are locked together with nuts. Then, the corresponding fourth sub-slave board 524 is assembled into the third sub-bottom shell 113, and then the main control circuit board 51 and the third sub-slave board 523 are assembled into the third sub-bottom shell 113. Finally, the third sub-top cover 14 is assembled into the third sub-bottom shell 113 to complete the assembly. After the three assembled boxes pass inspection, they are assembled into the battery pack, and the connection between the first sub-slave board 521 and the third sub-slave board 523, as well as the connection between the second sub-slave board 522 and the third sub-slave board 523, are completed through the flexible circuit board 53.

[0129] In some embodiments, a pulse width modulation chip is also included, which is disposed on the slave board 52 and electrically connected to the main positive relay 31 and / or the main negative relay 34.

[0130] Therefore, the main positive relay 31 and the main negative relay 34 can be started by the pulse width modulation chip, avoiding the need to set the coils in the main positive relay 31 or the main negative relay 34 as double-layer coils, reducing the cost of the main positive relay 31 and the main negative relay 34, and facilitating cost control of the battery pack distribution box 10.

[0131] The main positive relay 31 and the main negative relay 34 can each be electrically connected to a pulse width modulation chip, so that the start-up control of the main positive relay 31 and the main negative relay 34 is easy to operate.

[0132] In addition, the fast charging positive relay 32, the fast charging negative relay 35 and other relays can also be electrically connected to a pulse width modulation chip, so that the cost of the relay assembly 3 can be reduced, which is more conducive to cost control of the battery pack distribution box 10.

[0133] This application also provides a battery pack, such as Figure 14 As shown, the device includes a battery housing 20, a battery pack 30, and a battery pack distribution box 10 as described in any of the above embodiments. The battery pack 30 is disposed inside the battery housing 20, and the battery pack distribution box 10 is disposed inside the battery housing 20 and electrically connected to the battery pack 30.

[0134] In this embodiment, the battery pack distribution box 10 in the battery pack 110 is any of the battery pack distribution boxes 10 in each embodiment. Therefore, the battery pack 110 can produce the same or similar beneficial effects as the battery pack distribution boxes 10 in the above embodiments, and will not be described again here.

[0135] This application also provides a vehicle, such as Figure 15 As shown, it includes the battery pack 110 described in the above embodiments.

[0136] In this embodiment, the battery pack 110 in the vehicle 100 is the battery pack 110 described in the above embodiments. Therefore, the vehicle 100 has the same or similar beneficial effects as the battery pack 110 in the above embodiments. The battery pack distribution box 10 in the battery pack 110 in the above embodiments is the battery pack distribution box 10 in any of the above embodiments. Therefore, the vehicle 100 can produce approximately the same beneficial effects as the battery pack distribution box 10 in the above embodiments. For details, please refer to the above description, which will not be repeated here.

[0137] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A battery pack distribution box, characterized in that, include: A housing assembly, the housing assembly including a bottom shell having a receiving cavity having a bottom wall; A flow guide assembly is disposed on the bottom wall, and the flow guide assembly includes a plurality of flow guides; A relay assembly is housed within the accommodating cavity and located on the side of the guide bus away from the bottom wall. The relay assembly includes a plurality of relays arranged along a first direction, including a main positive relay, a fast charging positive relay, a main negative relay, and a fast charging negative relay. The contact portion of each relay is connected to one of the guide buses. A circuit board assembly, comprising a main control circuit board and a slave board, wherein the main control circuit is electrically connected to the slave board, and both the main control circuit board and the slave board are located on the side of the relay away from the bottom wall. The slave board is correspondingly arranged with a plurality of the relays, and a conductive sheet is connected between the slave board and each of the relays. A pre-charge module is disposed on the side of the plate facing the bottom wall.

2. The battery pack distribution box according to claim 1, characterized in that, The battery pack distribution box further includes a second capacitor, and the relay assembly further includes a boost relay. The second capacitor is disposed on the slave board, and the boost relay is connected to the slave board via the conductive sheet; and / or The battery pack distribution box also includes a third capacitor, and the relay assembly also includes a step-down relay. The third capacitor is disposed on the slave board, and the step-down relay is connected to the slave board through the conductive sheet.

3. The battery pack distribution box according to claim 2, characterized in that, Along the first direction, the boost relay and the buck relay are arranged between the fast charging positive relay and the main negative relay.

4. The battery pack distribution box according to any one of claims 1-3, characterized in that, The bottom shell has an outer bottom surface that is opposite to the bottom wall in a direction perpendicular to the bottom wall. A heat sink is attached to the outer bottom surface. The side of the flow guide that is opposite to the relay assembly is exposed on the outer bottom surface in a direction perpendicular to the bottom wall and is attached to the heat sink.

5. The battery pack distribution box according to any one of claims 1-3, characterized in that, The contact portion of the main positive relay has a columnar structure, and the outer peripheral wall of the contact portion of the main positive relay is provided with a first ceramic shell. The end of the contact portion of the main positive relay facing the guide bus extends out of the first ceramic shell, and the guide bus connected to the contact portion of the main positive relay is also welded to the first ceramic shell; and / or, the contact portion of the main negative relay has a columnar structure, and the outer peripheral wall of the contact portion of the main negative relay is provided with a second ceramic shell. The end of the contact portion of the main negative relay facing the guide bus extends out of the second ceramic shell, and the guide bus connected to the contact portion of the main negative relay is also welded to the second ceramic shell.

6. The battery pack distribution box according to any one of claims 1-3, characterized in that, The plurality of flow guides are integrally injection molded with the bottom shell, or the bottom shell includes a bottom plate and a surrounding plate, the bottom plate and the surrounding plate forming the accommodating cavity, and the plurality of flow guides are vacuum formed with the bottom plate.

7. The battery pack distribution box according to any one of claims 1-3, characterized in that, The battery pack distribution box also includes a first capacitor, and the relay assembly also includes a capacitor switch relay electrically connected to the first capacitor. The first capacitor and the capacitor switch relay are arranged along the first direction and located between the fast charging positive relay and the main negative relay.

8. The battery pack distribution box according to claim 7, characterized in that, The slave board includes a first sub-slave board and a second sub-slave board, the first sub-slave board and the second sub-slave board are electrically connected, and the first sub-slave board or the second sub-slave board is electrically connected to the main control circuit board; The bottom shell includes: The first sub-bottom shell, the first sub-slave board, the main positive relay and the fast charging positive relay are all located inside the first sub-bottom shell. The conductive sheet is connected between the first sub-slave board and the main positive relay and the fast charging positive relay. The pre-charge module is disposed on the first sub-slave board. The second sub-bottom shell, the first sub-bottom shell and the second sub-bottom shell are arranged along the first direction, the second sub-slave plate, the main negative relay and the fast charging negative relay are all located inside the second sub-bottom shell, and the conductive sheet is connected between the second sub-slave plate and the main negative relay and the fast charging negative relay.

9. The battery pack distribution box according to claim 8, characterized in that, The slave board also includes a third slave board, wherein the first slave board and the second slave board are respectively connected to the third slave board via flexible circuit boards, and the third slave board is connected to the main control circuit board; The bottom shell also includes a third sub-bottom shell. Along the first direction, the third sub-bottom shell is located between the first sub-bottom shell and the second sub-bottom shell. The third sub-slave board, the first capacitor, the capacitor switch relay, and the main control circuit board are all located inside the third sub-bottom shell. The capacitor switch relay is connected to the main control circuit board through the conductive sheet.

10. The battery pack distribution box according to claim 7, characterized in that, The contact portion of at least one of the main positive relay, the fast charging positive relay, the main negative relay, and the fast charging negative relay is disposed facing the bottom wall; the contact portion of the capacitor switch relay is disposed facing the side wall of the accommodating cavity.

11. The battery pack distribution box according to any one of claims 1-3, characterized in that, It also includes a pulse width modulation chip, which is disposed on the slave board and electrically connected to the main positive relay and / or the main negative relay.

12. A battery pack, characterized in that, include: Battery housing; A battery pack, wherein the battery pack is disposed within the battery housing; The battery pack distribution box according to any one of claims 1-10 is disposed inside the battery box and electrically connected to the battery pack.

13. A vehicle, characterized in that, Includes the battery pack as described in claim 12.

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