An integrated battery distribution box

Abstract

The utility model discloses an integrated battery distribution box, including upper casing, lower casing and PTC fuse, the PTC fuse is installed to the upper casing, the PTC fuse is connected with the BDU output pole copper bar on the lower casing through PTC adapter copper bar, and the limit mechanism is equipped on the upper casing and is located the outside of PTC fuse. The application integrates the PTC fuse to the upper casing, and is connected with the BDU output pole copper bar on the lower casing through PTC adapter copper bar, and the design can simplify the BDU design, and the miniaturization, light weight of battery distribution box assembly, install it to the upper casing, and it is convenient for after-sales quick maintenance, and if adding PTC fuse again subsequently, it can be directly installed to the upper casing, need not to remove the upper casing and the lower casing, and it is convenient for quick installation.

Description

Technical Field

[0001] This utility model relates to the field of power battery technology, specifically to an integrated battery distribution box. Background Technology

[0002] The battery distribution unit (BDU) is the power distribution unit of the power battery pack. Its function is to ensure that the battery pack transmits power to the vehicle, and it acts as a bridge for power and signal transmission between the battery pack and the high-voltage equipment of the vehicle. It also receives instructions from the battery management system (BMS) to promptly enable and disable the battery pack's power-on and power-off functions. Due to the energy density requirements of the battery pack, more battery cells need to be arranged inside to achieve a longer driving range, leaving very little space for the battery distribution unit assembly. Vehicle requirements often include branch circuits (such as the vehicle heating PTC circuit), and branch fuses are often included as optional features in these circuits.

[0003] The current common approach is to place the PTC fuse inside the lower housing of the battery distribution box (BDU). However, this approach occupies a large amount of space, places high demands on the battery pack's space, and cannot effectively utilize vertical space to save internal space within the BDU. Both larger and smaller electrical components are integrated into the lower housing, with smaller and larger parts competing for limited space, which is detrimental to the miniaturization and lightweight design of the battery distribution box assembly. Furthermore, because the branch circuit fuses are integrated inside the BDU, after-sales maintenance is inconvenient, leading to increased after-sales costs.

[0004] Alternatively, this can also be achieved using an external PTC fuse box, but a separate fuse box requires establishing new part numbers and developing separate molds, which increases the battery pack BOM cost, part storage and management costs, and mold costs. Utility Model Content

[0005] The technical problem to be solved by this utility model is: how to solve the problem of the large space occupied by the lower shell of the current battery distribution box.

[0006] To solve the above-mentioned technical problems, this utility model provides the following technical solution:

[0007] An integrated battery distribution box includes an upper housing, a lower housing, and a PTC fuse. The PTC fuse is installed in the upper housing and is connected to the BDU output copper busbar in the lower housing via a PTC adapter copper busbar.

[0008] This application integrates the PTC fuse into the upper housing and connects it to the BDU output copper busbar on the lower housing via a PTC adapter copper busbar. This design simplifies the BDU design, enabling the battery distribution box assembly to be miniaturized and lightweight. Installing it on the upper housing facilitates quick after-sales maintenance, and any subsequent additions of PTC fuses can be directly installed on the upper housing without removing the upper and lower housings, facilitating rapid installation.

[0009] As a further embodiment of this utility model, a limiting mechanism is provided on the upper housing and located outside the PTC fuse.

[0010] As a further embodiment of this utility model: the limiting mechanism includes a limiting push plate and a stop block fixed on the upper housing, the PTC fuse is installed between the limiting push plate and the stop block, and the inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

[0011] As a further embodiment of this utility model: the limiting mechanism includes a stop block and a limiting push plate that slides on the upper housing, the PTC fuse is installed between the limiting push plate and the stop block, and the inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

[0012] As a further embodiment of this utility model: the limiting mechanism includes a stop block and a limiting push plate that can be detachably installed on the upper housing, the PTC fuse is installed between the limiting push plate and the stop block, and the inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

[0013] As a further embodiment of this utility model: a fuse connecting post for fixing the PTC fuse is provided on the upper housing and between the limiting push plate and the stop block.

[0014] As a further embodiment of this utility model: one end of the PTC adapter copper busbar is provided with a first connection end that is sleeved with the fuse connection post, and the other end of the PTC adapter copper busbar is provided with a second connection end that is connected with the BDU output electrode copper busbar.

[0015] As a further embodiment of this utility model, a protective cover is provided on the outside of the connection between the BDU output copper busbar and the second connection terminal.

[0016] As a further embodiment of this utility model: a battery management system is detachably installed on the upper housing and on one side of the PTC fuse, and the top horizontal plane of the battery management system is higher than the top horizontal plane of the PTC fuse.

[0017] As a further embodiment of this utility model, a PTC protective cover is provided on the outside of the PTC fuse.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] This application integrates the PTC fuse into the upper housing and connects it to the BDU output copper busbar on the lower housing via a PTC adapter copper busbar. This design simplifies the BDU design, enabling the battery distribution box assembly to be miniaturized and lightweight. Installing it on the upper housing facilitates quick after-sales maintenance, and any subsequent additions of PTC fuses can be directly installed on the upper housing without removing the upper and lower housings, facilitating rapid installation.

[0020] This application adds a separate PTC protective cover to the outside of the PTC fuse, which can protect it and also facilitate quick after-sales repair.

[0021] The battery management system (BMS) is fixed in the upper casing of the BDU in this application, and the PTC fuse is installed in the space between the height difference between the BMS and the BDU, which effectively utilizes the space between the height difference between the BMS and the BDU without taking up additional space.

[0022] This application provides a limiting push plate and a stop on the outside of the PTC fuse to limit its movement, and a battery connection post between the two to further limit the PTC fuse, so as to ensure the stability of the PTC fuse; and the limiting push plate can be slidably installed or detachably installed, which is conducive to increasing the number of PTC fuses in the future. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the integrated battery distribution box according to an embodiment of the present invention;

[0024] Figure 2 This is a partial structural schematic diagram of the integrated battery distribution box according to an embodiment of the present utility model;

[0025] Figure 3 This is an exploded view of the upper shell and its upper structure according to an embodiment of the present invention;

[0026] Figure 4 This is a schematic diagram of the limiting push plate and the stop block in an embodiment of the present utility model;

[0027] Figure 5 A schematic diagram showing the addition of a protective cover to the PTC adapter copper busbar connection in an embodiment of this utility model;

[0028] Figure 6 This is a schematic diagram of the PTC adapter copper busbar connection in an embodiment of this utility model;

[0029] Explanation of reference numerals in the attached figures:

[0030] 1. Upper shell;

[0031] 2. Lower casing;

[0032] 3. Battery Management System;

[0033] 4. PTC protective cover;

[0034] 5. PTC adapter copper busbar; 51. First connection terminal; 52. Second connection terminal;

[0035] 6. Limiting push plate; 61. Push block;

[0036] 7. Stop;

[0037] 8. PTC fuse; 81. Connection port;

[0038] 9. Battery connection post; 10. Clip; 11. Fuse connection post; 12. Locking block; 13. Protective cover; 14. BDU output copper busbar. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below in conjunction with the embodiments of this utility model. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0040] Example 1

[0041] Reference Figure 1 , Figure 2 , Figure 3 and Figure 5 An integrated battery distribution box includes an upper housing 1, a lower housing 2, a battery management system 3, a PTC protection cover 4, a PTC adapter copper busbar 5, a limit push plate 6, a stop block 7, a PTC fuse 8, a battery connecting post 9, a buckle 10, a fuse connecting post 11, a locking block 12, and a protective cover 13.

[0042] The upper housing 1 is located on the lower housing 2, and the two are detachably connected by a snap-fit ​​and bolt structure. Specifically, the upper housing 1 is provided with a snap-fit ​​10 on its side, and the lower housing 2 is provided with a corresponding snap-fit ​​block on its side. The snap-fit ​​10 and the snap-fit ​​block are aligned. The upper housing 1 is provided with a bolt group on its side and / or top, and the lower housing 2 is provided with bolt holes on its side and / or top. The bolt group and the bolt holes are aligned, and the snap-fit ​​10 is used to engage with the snap-fit. The bolt group and the bolt holes are threaded together, thereby realizing the connection between the upper housing 1 and the lower housing 2.

[0043] For ease of understanding and description, the orientations of the sides and top mentioned above are... Figure 1The center is used as the reference, and the other directions are deduced from this reference. It should be understood that this orientation setting is only for the convenience of description and understanding, and should not be construed as a limitation of this application.

[0044] Reference Figure 2 The top side of the upper housing 1 is provided with a battery connecting post 9. The battery connecting post 9 can be a screw. The corresponding position of the battery management system 3 is provided with a mounting hole corresponding to the position of the battery connecting post 9. Therefore, after the battery connecting post 9 passes through the mounting hole, the battery management system 3 can be installed by using a nut.

[0045] Reference Figure 2 A PTC fuse 8 is installed on the top of the upper housing 1 and on one side of the battery connection post 9. The top horizontal plane of the PTC fuse 8 is lower than the top horizontal plane of the battery management system 3. The PTC fuse 8 is installed within the height difference range between the battery management system 3 and the upper housing, which effectively utilizes the height difference space between the battery management system 3 (BMS) and the battery distribution box (BDU) and saves space.

[0046] Reference Figure 1 and Figure 3 A limiting push plate 6 and a stop block 7 are provided on the top of the upper housing 1 and on the outside of the PTC fuse 8 for limiting the PTC fuse 8. The limiting push plate 6 and the stop block 7 are fixed on the top of the upper housing 1, and a push block 61 that can contact the PTC fuse 8 is provided on the inner side of the limiting push plate 6. The PTC fuse 8 can be clamped and fixed from both sides by the push block 61 and the stop block 7.

[0047] Two sets of fuse connecting posts 11 are provided at the top of the upper housing 1 and between the limiting push plate 6 and the stop block 7. The two ends of the PTC fuse 8 are provided with connection ports 81. The two sets of fuse connecting posts 11 can pass through the two connection ports 81 of the PTC fuse 8, thereby realizing the limiting of the PTC fuse 8 itself, and fixing the PTC fuse 8 in conjunction with the limiting push plate 6 and the stop block 7. The first connection end 51 of the PTC adapter copper bus 5 can also pass through one of the fuse connecting posts 11, so as to connect with the PTC fuse 8 and fix the PTC adapter copper bus 5 at the same time. After installation, the fuse connecting posts 11 can be locked by the locking block 12.

[0048] Reference Figure 1 and Figure 3 The PTC fuse 8 is provided with a PTC protective cover 4 on the outside. The PTC protective cover 4 is located inside the limiting push plate 6 and is used to protect the PTC fuse 8.

[0049] Reference Figure 3 and Figure 5One end of the PTC adapter copper busbar 5 is provided with a first connection end 51, and the other end of the PTC adapter copper busbar 5 is provided with a second connection end 52. The first connection end 51 passes through the battery connection post 9 and is connected to the connection port 81 of the PTC fuse 8. The second connection end 52 is connected to the BDU output electrode copper busbar 14 provided on the lower housing 2. After the connection is completed, the connection between the second connection end 52 and the BDU output electrode copper busbar 14 is protected by the protective cover 13.

[0050] This application simplifies the design of the battery distribution box (BDU), enabling the battery distribution box assembly to be miniaturized and lightweight; the separate protective cover design facilitates quick after-sales maintenance.

[0051] Example 2

[0052] Unlike Embodiment 1, in this embodiment, the limiting push plate 6 is slidably installed on the top of the upper housing 1, and the PTC fuse 8 is installed between the limiting push plate 6 and the stop block 7. Since the limiting push plate 6 is slidably installed, if the number of PTC fuses 8 can be increased or other electrical components need to be added later, they can be directly installed on the upper housing 1 without disassembling the upper housing 1 and the lower housing 2, or modifying the upper housing 1 and the lower housing 2, thus saving costs. Furthermore, the limiting push plate 6 can be slidably installed by opening corresponding sliding grooves on the upper housing 1. After sliding to the desired position, the position of the limiting push plate 6 can be locked using a locking block.

[0053] Example 3

[0054] Unlike Embodiment 1, in this embodiment, the limiting push plate 6 is detachably installed on the top of the upper housing 1 by bolts or pins, and several screw holes are equally spaced on the top of the upper housing 1. Due to the detachable installation of the limiting push plate 6, if the number of PTC fuses 8 can be increased or other electrical components need to be added later, it can be directly installed on the upper housing 1 by adjusting the installation position of the bolts or pins, without disassembling the upper housing 1 and the lower housing 2, or modifying the upper housing 1 and the lower housing 2, thus saving costs.

[0055] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. An integrated battery distribution box, comprising an upper housing, a lower housing, and a PTC fuse, characterized in that, The PTC fuse is installed on the upper housing, and the PTC fuse is connected to the BDU output copper busbar on the lower housing via a PTC adapter copper busbar.

2. The integrated battery distribution box according to claim 1, characterized in that: A limiting mechanism is provided on the upper housing and outside the PTC fuse.

3. An integrated battery distribution box according to claim 2, characterized in that: The limiting mechanism includes a limiting push plate and a stop block fixed on the upper housing. The PTC fuse is installed between the limiting push plate and the stop block. The inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

4. An integrated battery distribution box according to claim 2, characterized in that: The limiting mechanism includes a stop block and a limiting push plate that slides on the upper housing. The PTC fuse is installed between the limiting push plate and the stop block. The inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

5. An integrated battery distribution box according to claim 2, characterized in that: The limiting mechanism includes a stop block and a limiting push plate that can be detachably installed on the upper housing. The PTC fuse is installed between the limiting push plate and the stop block. The inner side of the limiting push plate is provided with a push block that contacts the PTC fuse.

6. An integrated battery distribution box according to claim 3, 4, or 5, characterized in that: The upper housing is provided with a fuse connecting post for fixing the PTC fuse, located between the limiting push plate and the stop block.

7. An integrated battery distribution box according to claim 6, characterized in that: One end of the PTC adapter copper busbar is provided with a first connection end that is sleeved with the fuse connection post, and the other end of the PTC adapter copper busbar is provided with a second connection end that is connected with the BDU output electrode copper busbar.

8. An integrated battery distribution box according to claim 7, characterized in that: The external part of the connection between the BDU output copper busbar and the second connection terminal is provided with a protective cover.

9. An integrated battery distribution box according to claim 1, characterized in that: A battery management system is detachably installed on the upper housing and on one side of the PTC fuse, and the top horizontal plane of the battery management system is higher than the top horizontal plane of the PTC fuse.

10. An integrated battery distribution box according to claim 1, characterized in that: The PTC fuse is covered with a PTC protective cover.

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