Lightweight high-voltage distribution box frame

Abstract

The utility model provides a kind of lightweight high-voltage distribution box frame, comprising: main body frame, battery frame and bottom frame, battery frame is detached and installed on the upper surface of main body frame, the both sides of main body frame are respectively connected with U type suspension arm, first connecting hole and second connecting hole are respectively equipped on the surface of two U type suspension arms, second connecting hole is attached with connecting plate, connecting bolt is threadedly connected in connecting plate. By skin PPGF material replaces heavy truck existing steel material or aluminum alloy material skin, utilizes PPGF low density characteristics to reduce skin weight, can avoid the problem that heavy truck skin is difficult to realize lightweight due to material density is big;By inner edge support auxiliary skin leveling, avoid flat plate material installation deformation, and skin PPGF material is easy to shape without high cost modeling mold, can avoid the problem that frame has no skin leveling capacity, flat plate is easy to deform or modeling needs high cost mold.

Description

Technical Field

[0001] This utility model relates to the field of high-voltage distribution box technology, specifically to a lightweight high-voltage distribution box frame. Background Technology

[0002] With the rapid development of the new energy vehicle industry, the demand for weight reduction and range improvement of vehicles is becoming increasingly urgent. As a core component of the high-voltage power distribution system of new energy vehicles, the weight optimization of the high-voltage power distribution box directly affects the energy consumption and range performance of the vehicle. Therefore, the lightweight design of the high-voltage power distribution box frame has become an important direction for industry research and development.

[0003] For example, the national authorized patent announcement number CN219959888U discloses a lightweight high-voltage distribution cabinet, including a main cabinet, an air inlet chamber, partitions, and a fixing frame. The main cabinet has partitions evenly spaced inside, and the main cabinet and partitions are fixedly connected. An empty compartment is located at the bottom of the main cabinet, and rotary motors are installed on both sides of the top of the empty compartment. A threaded rod is installed on the output shaft of each rotary motor. By incorporating the air inlet chamber and empty compartment within the main cabinet, the overall weight of the main cabinet can be effectively reduced. Simultaneously, when the rotary motors on both sides of the top of the empty compartment are activated, they drive the threaded rod to rotate inside a threaded cylinder, causing the threaded cylinder to push the moving wheels at the bottom of the movable plate out from inside the bottom of the main cabinet, allowing for rapid movement of the main cabinet.

[0004] However, current lightweight high-voltage switchgear still has the following drawbacks:

[0005] Commonly found in new energy commercial vehicles (such as heavy trucks) or passenger cars, most heavy trucks on the market use steel or aluminum alloy skins, which have high material density and are difficult to lighten. At the same time, the frame lacks the ability to level the skin, and using flat materials can easily lead to installation deformation. Making shapes to enhance rigidity requires the use of molds, which is costly. Utility Model Content

[0006] The present invention aims to solve the problems mentioned in the background art by providing a lightweight high-voltage distribution box frame.

[0007] The specific technical solution is as follows:

[0008] A lightweight high-voltage distribution box frame includes: a main frame, a battery frame, and a bottom frame. The battery frame is detachably installed on the upper surface of the main frame. U-shaped booms are connected to both sides of the main frame. The surfaces of the two U-shaped booms are respectively provided with a first connecting hole and a second connecting hole. A connecting plate is fitted into the second connecting hole. A connecting bolt is threaded into the connecting plate. The other end of the connecting plate is fixedly connected to the high-voltage distribution box body. The surface of the bottom frame is provided with a fastening hole. The first connecting holes of the two U-shaped booms are respectively connected to a first connecting bracket and a second connecting bracket by bolts. The other ends of the first connecting bracket and the second connecting bracket are connected to the fastening hole provided in the bottom frame by another bolt. Each of the two adjacent vertical rods of the bottom frame is provided with a connecting lug. The connecting lug is connected to a lightweight component by screws. A door panel is provided at one end of the bottom frame.

[0009] As a preferred embodiment of the present invention, the lightweight component includes an inner edge bracket, both ends of which are respectively detachably connected to one end of a connecting ear by bolts, and a skin is attached to one side of the inner edge bracket, and multiple skins are respectively attached to the surface of the bottom frame.

[0010] As a preferred embodiment of this utility model, the skin and the bottom frame surface are provided with coaxial threaded holes, and the threaded holes are internally threaded with connecting bolts. The skin is used to beautify the appearance and prevent wire harnesses from being exposed. The skin is made of PPGF material.

[0011] As a preferred embodiment of this utility model, positioning plates are respectively installed on both sides of the inner wall of the bottom frame, and the positioning plates are used to position and support the high-voltage distribution box.

[0012] As a preferred embodiment of this utility model, a reinforcing rod is installed in the center of the battery frame. The reinforcing rod is X-shaped, and each end of the reinforcing rod is connected to the inner wall of the center of the battery frame. A docking plate is installed at each of the four corners of the lower surface of the battery frame. The four docking plates are aligned with the corresponding sides of the two U-shaped booms and tightened with bolts.

[0013] As a preferred embodiment of this utility model, an interface connector is provided on one side of the battery frame, which is used to connect the battery frame with external high-voltage wiring harnesses and signal wiring harnesses. Connecting cylinders are respectively installed at both ends of the upper surface of the battery frame.

[0014] As a preferred embodiment of this utility model, one end of the door panel is connected to a door hinge by a pull rivet, the other end of the door hinge is connected to one side of the skin, a latch is provided on one side of the door panel, the latch cooperates with the skin to lock the door panel, an inner frame is provided on the inner side of the door panel, and a fastening rivet is inserted into one side of the door panel surface, the fastening rivet is used to rivet and fix the door panel to the inner frame.

[0015] As a preferred embodiment of this utility model, a reinforcing rib is installed on one side of the first connecting bracket, and a reinforcing rib is installed on one side of the second connecting bracket.

[0016] As a preferred embodiment of this utility model, the surface of the skin away from the bottom frame is integrally formed with an anti-slip texture. The anti-slip texture is in the form of a continuous grid or a 45° diagonal pattern, and the depth of the anti-slip texture is 0.3-0.8mm. This is used to improve the anti-slip performance and scratch resistance of the skin surface, while also enhancing the visual layering of the skin's appearance.

[0017] As a preferred embodiment of this utility model, a buffer pad is attached to the side of the positioning plate facing the high-voltage distribution box with environmentally friendly adhesive. The buffer pad has a thickness of 1-2mm and is made of aging-resistant rubber or high-elasticity polyurethane. The side of the buffer pad away from the positioning plate is in close contact with the bottom of the high-voltage distribution box to buffer the vibration generated when the high-voltage distribution box is working, and to avoid surface wear or vibration transmission caused by rigid contact between the positioning plate and the high-voltage distribution box.

[0018] This utility model has the following beneficial effects:

[0019] 1. The lightweight high-voltage distribution box frame provided by this utility model integrates components such as the high-voltage distribution box body and battery frame based on the main frame, reducing redundant structures. The skin of the lightweight components uses PPGF material to replace traditional steel or aluminum alloy materials, reducing density and achieving lightweighting. The inner edge bracket assists in leveling the skin, avoiding deformation of the flat material during installation. Moreover, the PPGF skin is easy to shape without the need for additional high-cost molding molds, solving the problems of high density and difficulty in lightweighting of the skin material of heavy truck high-voltage distribution box frames, as well as the lack of leveling ability of the frame, easy deformation of the flat plate, or the need for high-cost molding molds. At the same time, the inner edge bracket transmits the pressure and vibration borne by the skin, the X-shaped reinforcing rod enhances the torsional resistance of the battery frame, and the positioning plate improves the overall stability, ensuring structural reliability.

[0020] 2. The lightweight high-voltage distribution box frame provided by this utility model achieves stable opening and closing and locking of the door panel through door hinges and latches. Fastening rivets connect the door panel and the inner frame of the door to enhance the strength of the door panel and avoid deformation after long-term use. The reinforcing ribs of the first connecting bracket and the reinforcing ribs of the second connecting bracket improve the bending resistance and prevent load-bearing deformation, which solves the problems of easy deformation and unstable connection of frame components and ensures the reliability of the overall structure for long-term use. Attached Figure Description

[0021] Figure 1 A schematic diagram of the main frame structure of the lightweight high-voltage distribution box frame provided in this embodiment of the utility model;

[0022] Figure 2A schematic diagram of the lightweight component structure of the lightweight high-voltage distribution box frame provided in an embodiment of this utility model;

[0023] Figure 3 A schematic diagram of the skin structure of the lightweight high-voltage distribution box frame provided in an embodiment of this utility model;

[0024] Figure 4 A schematic diagram of the frame assembly structure of the lightweight high-voltage distribution box frame provided in this embodiment of the utility model;

[0025] Figure 5 A schematic diagram of the connecting bracket structure of the lightweight high-voltage distribution box frame provided in this embodiment of the utility model;

[0026] Figure 6 A schematic diagram of the skin texture structure of the lightweight high-voltage distribution box frame provided in this embodiment of the utility model;

[0027] Figure 7 A schematic diagram of the charging port door structure of the lightweight high-voltage distribution box frame provided in this embodiment of the utility model.

[0028] In the attached image:

[0029] 1. Main frame; 101. First connecting hole; 102. Second connecting hole; 103. U-shaped boom;

[0030] 2. High-voltage distribution box; 201. Connecting plate; 202. Connecting bolts;

[0031] 3. First connecting bracket; 31. Reinforcing rib; 301. Second connecting bracket; 3011. Reinforcing rib;

[0032] 4. Lightweight components; 401. Inner edge support; 402. Skin; 403. Connecting bolts;

[0033] 5. Bottom frame; 501. Connecting hole; 502. Positioning plate; 503. Connecting lug;

[0034] 6. Door panel; 601. Door hinge; 602. Lock; 603. Fastening rivets; 604. Inner door frame;

[0035] 7. Battery frame; 701. Reinforcing rod; 702. Connecting plate; 703. Interface connector; 704. Connecting cylinder. Detailed Implementation

[0036] The technical solution of this utility model will be further described below with reference to the accompanying drawings and specific embodiments.

[0037] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of this utility model, some components in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0038] In the accompanying drawings of this utility model, the same or similar reference numerals correspond to the same or similar components. In the description of this utility model, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting this patent. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0039] In the description of this utility model, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating the connection relationship between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0040] Example 1

[0041] The lightweight high-voltage distribution box frame provided in this embodiment, such as Figures 1-7As shown, it includes: a main frame 1, a battery frame 7, and a bottom frame 5. The battery frame 7 is detachably installed on the upper surface of the main frame 1. U-shaped booms 103 are connected to both sides of the main frame 1. The surfaces of the two U-shaped booms 103 are respectively provided with a first connecting hole 101 and a second connecting hole 102. A connecting plate 201 is attached to the second connecting hole 102. A connecting bolt 202 is connected to the internal thread of the connecting plate 201. A high-voltage distribution box 2 is fixedly connected to the other end of the connecting plate 201. A connecting hole 501 is provided on the surface of the bottom frame 5. The first connecting holes 101 of the two U-shaped booms 103 are respectively connected to a first connecting bracket 3 and a second connecting bracket 301 by bolts. The other ends of the first connecting bracket 3 and the second connecting bracket 301 are connected to the connecting hole 501 provided in the bottom frame 5 by another bolt. A connecting ear 503 is provided on each of the two adjacent vertical bars of the bottom frame 5. A lightweight component 4 is connected to the connecting ear 503 by screws. A door panel 6 is provided on one end of the bottom frame 5. The lightweight component 4 includes an inner edge bracket 401, with both ends of the inner edge bracket 401 detachably connected to one end of a connecting ear 503 via bolts. A skin 402 is attached to one side of the inner edge bracket 401, and multiple skins 402 are attached to the surface of the bottom frame 5. The skin 402 and the surface of the bottom frame 5 have coaxial threaded holes, with connecting bolts 403 threaded into the threaded holes. The skin 402 is used to improve the appearance and prevent wire harness exposure, and is made of PPGF material. Positioning plates 502 are installed on both sides of the inner wall of the bottom frame 5, and the positioning plates 502 are used to position and support the high-voltage distribution box 2. A reinforcing rod 701 is installed in the center of the battery frame 7. The reinforcing rod 701 is X-shaped, and each end of the reinforcing rod 701 is connected to the inner wall of the center of the battery frame 7. A mating plate 702 is installed at each of the four corners of the lower surface of the battery frame 7. The four mating plates 702 are aligned with the corresponding sides of the two U-shaped booms 103 and tightened with bolts. The battery frame 7 has an interface connector 703 on one side. The interface connector 703 is used to connect the battery frame 7 with external high-voltage wire harnesses and signal wire harnesses. Connecting cylinders 704 are installed at both ends of the upper surface of the battery frame 7.

[0042] Through the design of the battery frame 7, U-shaped boom 103, high-voltage distribution box 2, and lightweight components 4, the main frame 1 serves as the foundation. The high-voltage distribution box 2 is fixed to the U-shaped boom 103 by connecting bolts 202 inserted into the connecting plates 201 installed on both sides, completing the assembly of the high-voltage distribution box 2 and the main frame 1. Then, the first connecting bracket 3 and the second connecting bracket 301 are connected to the first connecting hole 101 by bolts. Then, the other end of the first connecting bracket 3 and the second connecting bracket 301 is connected to the connecting hole 501 of the bottom frame 5, realizing the connection between the main frame 1 and the bottom frame 5. Finally, the mating plate 702 on the lower surface of the battery frame 7 is aligned with the first connecting hole 101 on the other side of the U-shaped boom 103 and tightened by bolts. The battery frame 7 is fixed to the main frame 1. Then, the inner edge bracket 401 is connected to the connecting ear 503 of the bottom frame 5 with screws. After the skin 402 is attached, it is fixed with the connecting bolt 403 through the threaded hole. The pressure and vibration external force borne by the skin 402 will be transmitted to the rigid base of the bottom frame 5 through the inner edge bracket 401, avoiding stress concentration in the skin 402 and causing deformation. The positioning plate 502 is attached to the bottom of the high voltage distribution box 2 to complete the positioning, thereby improving the overall structural stability. The skin 402 is made of PPGF material, which can reduce the weight of the frame, while covering the wire harness to avoid exposure and beautify the appearance. The X-shaped reinforcing rod 701 inside the battery frame 7 enhances its torsional resistance. The interface connector 703 improves the convenience of external wire harness docking.

[0043] Example 2

[0044] The lightweight high-voltage distribution box frame provided in this embodiment, such as Figures 1-7 As shown, the device includes: a door panel 6 with one end connected to a door hinge 601 via a pull rivet; the other end of the door hinge 601 connected to one side of a skin 402; a latch 602 on one side of the door panel 6, which engages with the skin 402 to lock the door panel 6; an inner frame 604 on the inner side of the door panel 6; and fastening rivets 603 inserted into one side of the surface of the door panel 6 to rivet and fix the door panel 6 to the inner frame 604. A reinforcing rib 31 is installed on one side of the first connecting bracket 3, and a reinforcing rib 3011 is installed on one side of the second connecting bracket 301.

[0045] Through the design of door hinge 601, fastening rivet 603, and first connecting bracket 3, door hinge 601 is fixed to one end of door panel 6 by pull rivet, and the other end of door hinge 601 is connected to skin 402, which realizes the opening and closing function of door panel 6. Then, the latch 602 cooperates with skin 402 to lock door panel 6 after it is closed, preventing door panel 6 from loosening. Then, fastening rivet 603 is passed through door panel 6 and inner frame 604 to realize the riveting and fixing of the two, thereby enhancing the structural strength of door panel 6 and preventing deformation of door panel 6 after long-term use. The first connecting bracket 3 has a reinforcing rib 31 installed on one side, and the second connecting bracket 301 has a reinforcing rib 3011 installed on one side, which can improve the bending resistance of the two connecting brackets, prevent the brackets from deforming when bearing load, and ensure the connection stability between the main frame 1 and the bottom frame 5.

[0046] Specifically, in this embodiment, the surface of the skin 402 away from the bottom frame 5 is integrally formed with an anti-slip texture. The anti-slip texture is in the form of a continuous grid or a 45° diagonal pattern, and the depth of the anti-slip texture is 0.3-0.8mm. It is used to improve the anti-slip performance and scratch resistance of the skin 402 surface, while enhancing the visual layering of the skin 402 appearance.

[0047] Specifically, in this embodiment, a buffer pad is attached to the side of the positioning plate 502 facing the high-voltage distribution box 2 with environmentally friendly adhesive. The buffer pad is 1-2mm thick and is made of aging-resistant rubber or high-elasticity polyurethane. The side of the buffer pad away from the positioning plate 502 is tightly attached to the bottom of the high-voltage distribution box 2 to buffer the vibration generated when the high-voltage distribution box 2 is working, and to avoid surface wear or vibration transmission caused by rigid contact between the positioning plate 502 and the high-voltage distribution box 2.

[0048] It is worth noting that the charging port door is made of PP material, which requires the door body to be molded. In order to avoid the investment in molds, reduce costs and achieve further weight reduction, the charging port door assembly is formed by connecting the inner frame 604, door panel 6, latch 602 and door hinge 601 with core-pulling rivets. This can avoid the investment in new molds and also take into account the aesthetics.

[0049] In summary, the lightweight high-voltage distribution box frame provided in this embodiment has the following advantages: by replacing the existing steel or aluminum alloy materials of heavy truck skin with 402PPGF material, the weight of the skin is reduced by utilizing the low density characteristics of PPGF, which avoids the problem that it is difficult to achieve lightweighting of heavy truck skin due to the high material density; the inner edge bracket 401 assists in leveling the skin 402, avoiding deformation of the flat plate material during installation, and the 402PPGF material of the skin is easy to shape without the need for high-cost molding molds, which avoids the problems of the frame lacking the leveling ability of the skin 402, the easy deformation of the flat plate, or the need for high-cost molds for shaping reinforcement.

[0050] In use, the main frame 1 serves as the core foundation. The high-voltage distribution box 2 is fixed to the U-shaped boom 103 via connecting plate 201 and connecting bolt 202. The battery frame 7 is aligned with one side of the U-shaped boom 103 via docking plate 702 and fastened to the top of the main frame 1 with bolts. The bottom frame 5 is connected to the main frame 1 via the first connecting bracket 3 and the second connecting bracket 301 to form the main load-bearing structure. The lightweight component 4 provides the mounting base for the skin 402 via the inner edge bracket 401, so that the external force on the skin 402 is transferred to the rigid base of the bottom frame 5 to avoid stress concentration. The X-shaped reinforcing rod 701 inside the battery frame 7 enhances the torsional resistance. The reinforcing rib 31 and reinforcing bar 3011 of the first connecting bracket 3 improve the bending resistance. The PPGF material skin 402 achieves lightweighting. The door panel 6 achieves the opening and closing function via door hinge 601 and latch 602.

[0051] The above are merely preferred embodiments of the present utility model and are not intended to limit the implementation methods and protection scope of the present utility model. Those skilled in the art should realize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A lightweight high voltage distribution box frame, characterized by, include: The main frame (1), battery frame (7), and bottom frame (5) are provided. The battery frame (7) is detachably installed on the upper surface of the main frame (1). U-shaped booms (103) are connected to both sides of the main frame (1). The surfaces of the two U-shaped booms (103) are respectively provided with a first connecting hole (101) and a second connecting hole (102). A connecting plate (201) is attached to the second connecting hole (102). A connecting bolt (202) is threaded into the connecting plate (201). A high-voltage distribution box (2) is fixedly connected to the other end of the connecting plate (201). The bottom frame (5) 5) The surface is provided with a connecting hole (501). The first connecting hole (101) of the two U-shaped booms (103) is respectively connected to the first connecting bracket (3) and the second connecting bracket (301) by bolts. The other end of the first connecting bracket (3) and the second connecting bracket (301) is connected to the connecting hole (501) provided in the bottom frame (5) by another bolt. The bottom frame (5) has a connecting ear (503) on each of the two adjacent vertical rods. The connecting ear (503) is connected to a lightweight component (4) by screws. The bottom frame (5) has a door panel (6) on one end.

2. The lightweight high-voltage distribution box frame of claim 1, wherein, The lightweight component (4) includes an inner edge bracket (401), both ends of which are detachably connected to one end of a connecting ear (503) by bolts. A skin (402) is attached to one side of the inner edge bracket (401), and multiple skins (402) are attached to the surface of the bottom frame (5).

3. The lightweight high-voltage distribution box frame of claim 2, wherein, The skin (402) and the bottom frame (5) are provided with coaxial threaded holes, and the threaded holes are connected with connecting bolts (403). The skin (402) is used to beautify the appearance and prevent wire harnesses from being exposed. The skin (402) is made of PPGF material.

4. The lightweight high-voltage distribution box frame of claim 1, wherein, Positioning plates (502) are installed on both sides of the inner wall of the bottom frame (5), and the positioning plates (502) are used to position and support the high voltage distribution box (2).

5. The lightweight high-voltage distribution box frame of claim 1, wherein, A reinforcing rod (701) is installed in the center of the battery frame (7). The reinforcing rod (701) is X-shaped. Each end of the reinforcing rod (701) is connected to the inner wall of the center of the battery frame (7). A docking plate (702) is installed at each of the four corners of the lower surface of the battery frame (7). The four docking plates (702) are aligned with the corresponding sides of the two U-shaped booms (103) and tightened with bolts.

6. The lightweight high-voltage distribution box frame of claim 5, wherein, The battery frame (7) is provided with an interface connector (703) on one side. The interface connector (703) is used to connect the battery frame (7) with external high-voltage wire harnesses and signal wire harnesses. Connecting cylinders (704) are respectively installed at both ends of the upper surface of the battery frame (7).

7. The lightweight high-voltage distribution box frame of claim 1, wherein, One end of the door panel (6) is connected to a door hinge (601) by a pull rivet, and the other end of the door hinge (601) is connected to one side of the skin (402). A latch (602) is provided on one side of the door panel (6). The latch (602) cooperates with the skin (402) to lock the door panel (6). An inner frame (604) is provided on the inner side of the door panel (6). A fastening rivet (603) is inserted into one side of the surface of the door panel (6). The fastening rivet (603) is used to rivet and fix the door panel (6) to the inner frame (604).

8. The lightweight high-voltage distribution box frame of claim 1, wherein, The first connecting bracket (3) has a reinforcing rib (31) installed on one side, and the second connecting bracket (301) has a reinforcing rib (3011) installed on one side.

9. The lightweight high-voltage distribution box frame of claim 3, wherein, The skin (402) has an integrally formed anti-slip texture on the side away from the bottom frame (5). The anti-slip texture is a continuous grid or a 45° diagonal pattern. The depth of the anti-slip texture is 0.3-0.8mm. It is used to improve the anti-slip performance and scratch resistance of the skin (402) surface, and at the same time enhance the visual layering of the skin (402) appearance.

10. The lightweight high-voltage distribution box frame of claim 4, wherein, The side of the positioning plate (502) facing the high-voltage distribution box (2) is covered with a buffer pad by environmentally friendly adhesive. The buffer pad is 1-2mm thick and is made of aging-resistant rubber or high-elasticity polyurethane. The side of the buffer pad away from the positioning plate (502) is in close contact with the bottom of the high-voltage distribution box (2) to buffer the vibration generated when the high-voltage distribution box (2) is working, and to avoid surface wear or vibration transmission caused by rigid contact between the positioning plate (502) and the high-voltage distribution box (2).

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