A high-voltage distribution unit compatible with multiple wire diameters, high protection and high integration

Abstract

The utility model discloses a kind of compatible multi-line diameter high-protection high integration's high-voltage power distribution unit, solve the problem of the conventional power distribution unit in prior art, generally bulky, not conducive to installation.The utility model includes base subassembly, base subassembly is equipped with the wiring harness subassembly that can realize one-to-many, PCBA subassembly and the inner cover for encapsulating PCBA subassembly are equipped in base subassembly and cooperate with wiring harness subassembly, base is equipped with upper cover subassembly, the lower portion of base subassembly is equipped with high-voltage drive connector.The high-voltage power distribution unit formed by the PCBA subassembly and wiring harness subassembly integrated in the base subassembly of the utility model is small in size, light in weight, low in cost, and adopts combined mounting mode to be convenient for disassembling, while shielding effect is good and not prone to produce a large amount of heat and the like characteristics, and suitable for complex installation environment.

Description

Technical Field

[0001] This utility model relates to the field of electrical equipment technology for new energy vehicles, and in particular to a high-voltage power distribution unit. Background Technology

[0002] In the field of new energy electric vehicles, as the market share of new energy vehicles increases year by year, the number and types of vehicle electrical appliances have surged, leading to increased vehicle circuit power, which in turn results in higher space utilization. Furthermore, the integration of vehicle load circuits is relatively high, which further leads to a gradual increase in the number of circuits required in vehicles. At the same time, the platform voltage of the entire vehicle has increased from 400V to 800V and then to 1000V.

[0003] Existing technology, such as the Chinese patent with publication number CN120149128A, discloses a vehicle-mounted miniature quick-replacement type I high-voltage dual fuse box. This box includes an upper cover assembly, within which a high-voltage fuse and an upper shielding layer cooperating with the high-voltage fuse are detachably connected. A lower cover assembly is detachably connected to the lower part of the upper cover assembly, containing a lower shielding layer. The high-voltage fuse is located within the shielding cavity formed by the upper and lower shielding layers. The lower cover assembly also contains terminals cooperating with the high-voltage fuse, with the terminals connected to wires extending from the lower cover assembly. Although this patent uses the upper and lower shielding layers to form an electromagnetic shielding scheme, completely enclosing the high-voltage fuse and terminals, thus solving the problem of poor shielding in existing fuse boxes, it still suffers from difficulties in fuse replacement and inconvenient installation.

[0004] Existing wiring harnesses are insufficient for 1000V platforms. Traditional connections involve connectors to the electric drive and the power distribution unit, which are connected via a copper wire with connectors at both ends. Existing automotive high-voltage power distribution units and traditional high-voltage splitters are typically bulky, occupying significant space within the vehicle and increasing costs. Therefore, there is an urgent need to develop a simple, compact high-voltage power distribution unit that can meet the requirements of a 1000V platform. Utility Model Content

[0005] To address the shortcomings in the aforementioned background technology, this utility model proposes a high-voltage power distribution unit that is compatible with multiple wire diameters, has high protection, and is highly integrated, thus solving the problem that traditional power distribution units in the prior art are usually large in size and inconvenient to install.

[0006] The technical solution of this utility model is as follows: a high-voltage power distribution unit compatible with multiple wire diameters, high protection and high integration, including a base sub-assembly, a wire harness assembly capable of splitting one wire into multiple wires on the base sub-assembly, a PCBA assembly that mates with the wire harness assembly and an inner cover for encapsulating the PCBA assembly inside the base sub-assembly, an upper cover sub-assembly on the base, and a high-voltage drive connector installed at the lower part of the base sub-assembly.

[0007] More preferably, the PCBA assembly includes a PCB board, on which at least one high-voltage fuse and a conductive sheet group corresponding to the high-voltage fuse are provided.

[0008] More preferably, the conductive sheet group includes at least one conductive sheet three and at least two conductive sheets two, both of which are L-shaped structures, and both conductive sheets three and conductive sheets two are mounted on the PCB board and electrically connected to the corresponding high-voltage fuse.

[0009] More preferably, the base sub-assembly includes an aluminum housing, and an insulating bracket is provided inside the aluminum housing to be installed and fitted with the PCBA assembly.

[0010] Further preferably, the upper part of the aluminum housing is provided with a groove, and the groove contains silicone for sealing connection with the upper cover sub-assembly. The lower part of the aluminum housing is provided with a sheet metal bracket.

[0011] More preferably, the wiring harness assembly includes solder terminals and through-hole terminals that mate with the PCBA assembly. Both the solder terminals and through-hole terminals are mounted on an insulating bracket and mate with corresponding conductive sheets.

[0012] More preferably, both the welding terminal and the hole terminal are connected to a wire harness, and the wire harness is provided with an inner metal hoop, a shielding ring, a sealing ring and a tail clip in sequence, with the tail clip connected to the aluminum shell.

[0013] More preferably, the upper cover assembly includes a cover body and a flip cover. The flip cover is connected to a rotating shaft rotatably connected to the cover body. The flip cover is set on the observation hole of the cover body and fixedly connected to the cover body by bolts. The cover body is provided with a groove, and a high-pressure head marking is pasted in the groove.

[0014] More preferably, the cover is provided with a plurality of threaded holes corresponding to the aluminum shell, and the cover is connected to the aluminum shell by a bolt group.

[0015] The beneficial effects of this utility model are as follows: The high-voltage power distribution unit formed by integrating the PCBA assembly and wire harness assembly within the base assembly of this utility model is small in size, light in weight, and low in cost. It also features convenient disassembly via a modular installation method, good shielding effect, and low heat generation, making it suitable for complex installation environments. This utility model directly integrates the power distribution unit with the connector, and the shielding device can be replaced by a metal shell. The integration of the power distribution unit with the electric drive connector saves costs, facilitates maintenance, reduces current transmission losses, reduces heat generation during vehicle operation, and adapts to complex installation environments. The shielding effect is achieved through the tight bonding between the aluminum shell of the power distribution unit and the shell of the connector, eliminating the need for a separate shielding device on the connector and meeting lightweight requirements. Attached Figure Description

[0016] To more clearly illustrate the embodiments of this utility model, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the structure of this utility model; Figure 2 This is an exploded view of the upper cover sub-assembly of this utility model; Figure 3 This is an exploded view of the base sub-assembly of this utility model; Figure 4 This is an exploded view of the PCBA assembly of this utility model; Figure 5 This is a schematic diagram of the high-voltage drive connector. In the diagram: 1. M5 bolt one; 2. Top cover sub-assembly; 3. Base sub-assembly; 4. High-voltage drive connector; 201. High-voltage marking; 202. M5 bolt two; 203. Flip cover; 204. Rotating shaft; 205. Cover body; 206. Observation hole; 207. Groove; 301. M6 bolt one; 302. M5 bolt three; 303. Inner cover; 304. PCBA assembly; 305. M5 shaped nut; 306. Conductive sheet one; 307. Insulating bracket; 3 08. Aluminum housing; 309. Sheet metal bracket; 310. M6 bolt one; 311. Tail clip; 312. Sealing ring; 313. Inner metal clamp; 314. Shielding ring; 315. Hole terminal; 316. 50 flat tail clip; 317. 50 flat sealing ring; 318. 50 flat inner metal clamp; 319. 50 flat shielding ring; 320. Welded terminal; 3041. High voltage fuse; 3042. Conductive sheet two; 3043. PCB board; 3044. Conductive sheet three. Detailed Implementation

[0018] 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.

[0019] like Figure 1As shown in Embodiment 1, a high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration includes a base sub-assembly 3. The base sub-assembly 3 has a wire harness assembly capable of splitting one wire into multiple wires. Inside the base sub-assembly 3 is a PCBA assembly 304 that mates with the wire harness assembly and an inner cover 303 for encapsulating the PCBA assembly 304. An upper cover sub-assembly 2 is located on the base. A high-voltage drive connector 4 is installed at the lower part of the base sub-assembly 3. In this device, the base sub-assembly 3 and the corresponding high-voltage drive connector 4 are integrated together, and each connector requires electromagnetic shielding. This eliminates the wire harness between the electric drive and the power distribution unit, saving costs—specifically, saving three connectors and one copper wire. Maintenance is convenient, current transmission losses are reduced, heat generation during vehicle operation is reduced, and it is suitable for complex installation environments. It improves the convenience of automotive power distribution and enhances vehicle safety. The protection level is IP68. This high-voltage power distribution unit is small in size, lightweight, low in cost, and easy to disassemble using a modular installation method. It also features good shielding and low heat generation, making it suitable for complex installation environments.

[0020] like Figure 2 As shown in Embodiment 2, a high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration differs from the technical solution of Embodiment 1 in that the PCBA assembly 304 includes a PCB board 3043, on which at least one high-voltage fuse 3041 and a corresponding conductive sheet group are provided. The PCBA assembly 304 contains two fuses and is fixed to an insulating bracket 307 by bolts. The conductive sheet group includes at least one conductive sheet 3044 and at least two conductive sheets 3042. Both conductive sheets 3044 and 3042 have an L-shaped structure and are mounted on the PCB board 3043 and electrically connected to the corresponding high-voltage fuse 3041.

[0021] All other structures are the same as in Example 1.

[0022] like Figure 3 and Figure 5As shown in Embodiment 3, a high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration differs from the technical solution of Embodiment 1 in that the base sub-assembly 3 can accommodate two-to-six wires and also serves as line protection. The base sub-assembly 3 includes an aluminum housing 308, within which an insulating bracket 307 is installed to mate with the PCBA assembly 304. The upper part of the aluminum housing 308 has a groove 207, within which a silicone ring is provided for sealing connection with the upper cover sub-assembly 2. Shielding is achieved through the tight connection between the power distribution unit's aluminum housing 308 and the connector's outer shell, eliminating the need for a separate connector shielding device and meeting lightweight requirements. The aluminum housing 308 integrates an IPT through-hole connector; one end of the connector can accommodate 2.5mm², 4mm², and 6mm² copper wires, while the other end accommodates 50mm² wires. The fuse is soldered onto the PCB board 3043 and onto the conductive sheet and corresponding connection terminal on the PCB board 3043.

[0023] In this embodiment, a sheet metal bracket 309 is provided at the lower part of the aluminum housing 308. The aluminum housing 308 is directly connected to the high-voltage drive connector, and the sheet metal bracket 309 connects the aluminum housing 308 to the external installation environment. The base sub-assembly 3 and the high-voltage drive connector 4 are connected by M6 bolts, distributing the electric drive power to the MCU and the air conditioner. The aluminum housing 308 is connected to the high-voltage drive connector 4 by bolts via the sheet metal bracket 309, which facilitates disassembly and maintenance.

[0024] In this embodiment, the wire harness assembly includes solder terminals 320 and through-hole terminals 315 that mate with the PCBA assembly 304. Both the solder terminals 320 and through-hole terminals 315 are mounted on an insulating bracket 307 and mate with corresponding conductive sheets 306. Both the insulating bracket 307 and the aluminum housing 308 have through-holes that mate with the solder terminals 320 and through-hole terminals 315. Wire harnesses are connected to both the solder terminals 320 and through-hole terminals 315. The wire harnesses are sequentially provided with an inner metal clamp 313, a shielding ring 314, a sealing ring 312, and a tail clip 311. The tail clip 311 is connected to the aluminum housing 308; specifically, the tail clip is connected to the aluminum housing through an elastic structure.

[0025] All other structures are the same as in Example 1.

[0026] like Figure 4As shown in Embodiment 4, a high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration differs from the technical solution of Embodiment 1 in that the upper cover assembly 2 includes a cover body 205 and a flip cover 203. The flip cover 203 is connected to a rotating shaft 204 rotatably connected to the cover body 205. The flip cover 203 is set on the observation hole 206 of the cover body 205 and is fixedly connected to the cover body 205 by bolts. The cover body 205 has a groove 207, in which a high-voltage marking 201 is pasted. The groove 207 is the bonding point for the high-voltage marking 201. Both the upper cover and the flip cover 203 contain through holes. The rotating shaft 204 is knurled to prevent slippage. The upper cover and the flip cover 203 are connected by the rotating shaft 204. The base assembly 3 is connected to the high-voltage drive connector 4 by M6 bolts. The cover body 205 has several threaded holes corresponding to the aluminum housing 308, and the cover body 205 is connected to the aluminum housing 308 by bolts. The silicone seal between the cover 205 and the aluminum shell 308 provides an IP69 protection rating.

[0027] All other structures are the same as in Example 1.

[0028] like Figures 1-5 As shown in Example 5, a high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration is mainly used in the high-voltage electrical system of new energy vehicles. This high-voltage power distribution unit is an innovation of common automotive power distribution units, solving the problem that traditional power distribution units are usually large in size and not conducive to installation. At the same time, it has a modular method, which makes disassembly and maintenance convenient. This high-voltage power distribution unit has excellent electromagnetic shielding effect, protection level IP69, and is suitable for 1000V platforms, while improving the safety of the entire vehicle.

[0029] like Figure 1 The diagram shows an exploded view of a high-voltage power distribution unit compatible with multiple wire diameters, high protection level, and high integration. This unit is designed for installation in new energy vehicles, located within the vehicle's wiring system, and provides protection for the wiring. It is a single-circuit splitter suitable for high-voltage, high-protection, and multi-wire diameter specifications, with a small size and minimal space occupation within the vehicle. The fuse box achieves an IP68 protection rating. The high-voltage power distribution unit includes: bolts, a top cover sub-assembly, a base sub-assembly, and a high-voltage drive connector. The top cover sub-assembly and the base sub-assembly are fixed together with M5 bolts. The base sub-assembly contains grooves with a silicone ring around the grooves, improving the overall vehicle protection level and enhancing the safety of normal electrical operation.

[0030] like Figure 2 As shown, the top cover assembly includes a high-pressure indicator 201, an M5 bolt 202, a flip cover 203, a pivot 204, and a top cover 205. The top cover 202 has a groove with a ring of silicone adhesive bonded to it. Furthermore, the top cover is die-cast and machined, resulting in a high degree of flatness and ensuring airtightness.

[0031] like Figure 3 As shown, the main sub-assembly includes M6 bolts 301, M5 bolts 302, inner cover 303, PCBA assembly 304, M5 special-shaped nut 305, conductive sheet 306, insulating bracket 307, aluminum shell 308, sheet metal bracket 309, M6 bolts 310, tail clip 311, sealing ring 312, inner metal clamp 313, shielding ring 314, hole terminal 315, 50 flat tail clip 316, 50 flat sealing ring 317, 50 flat inner metal clamp 318, 50 flat shielding ring 319, and welding terminal 320. First, the insulating bracket 307 is bolted to the shell 308. Then, the PCBA assembly 302 is also mounted on the insulating bracket 307. The hole terminal 315 and welding terminal 320 are bolted to the PCBA assembly 302 and the insulating bracket 307. Due to the use of a wire-spinning exit method, and considering airtightness and electromagnetic shielding, the wiring harness assembly includes a tail clip 311, a sealing ring 312, an inner cobalt metal 313, a shielding ring 314, a hole-type terminal 315, a 50mm flat tail clip 316, a 50mm flat sealing ring 317, a 50mm flat inner metal clamp 318, a 50mm flat shielding ring 319, and a welding terminal 320, ensuring the safe operation of new energy vehicles in complex environments.

[0032] like Figure 4 As shown, the PCBA assembly includes a high-voltage fuse 3041, a second conductive sheet 3042, a PCB board 3043, a third conductive sheet 3044, and two high-voltage fuses soldered onto the PCB board 3043. The second conductive sheet 3042 and the third conductive sheet 3044 are connected to the PCB board 3043 by soldering. The PCB board 3043 is copper-plated to ensure that the conductive sheets and the high-voltage fuses are connected in series.

[0033] like Figure 5 The diagram shows a high-voltage drive connector for a high-voltage power distribution unit that is compatible with multiple wire diameters, has a high protection level, and is highly integrated. The terminals of the high-voltage drive connector are directly connected to the electric drive. A slot is cut into the high-voltage drive connector, and the base sub-assembly is bolted to this slot. The perimeter of the slot is machined to ensure a high degree of flatness and airtightness.

[0034] Working Process: This high-voltage power distribution unit is compatible with multiple wire diameters, has a high protection level, and is highly integrated. It can accommodate 2.5mm², 4mm², and 6mm² wire diameters. The line is equipped with a high-voltage fuse; in the event of an accident and the fuse blows, only the PCBA sub-assembly needs to be replaced. Through its integrated structural design, this high-voltage power distribution unit solves the problems of traditional power distribution units being large in size and occupying significant space, making installation difficult. It also addresses the issue of existing high-voltage power distribution units being unable to adapt to 1000V platform voltages. Furthermore, this high-voltage power distribution unit boasts excellent electromagnetic shielding and a high protection level, thus improving the overall safety of the vehicle.

[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A high-voltage power distribution unit compatible with multiple wire diameters, high protection, and high integration, characterized in that, The base sub-assembly (3) includes a wire harness assembly capable of splitting into multiple parts. The base sub-assembly (3) contains a PCBA assembly (304) that mates with the wire harness assembly and an inner cover (303) for encapsulating the PCBA assembly (304). The base is equipped with an upper cover sub-assembly (2). A high-voltage drive connector (4) is installed at the lower part of the base sub-assembly (3).

2. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 1, characterized in that, The PCBA assembly (304) includes a PCB board (3043), on which at least one high-voltage fuse (3041) and a conductive sheet group corresponding to the high-voltage fuse (3041) are provided.

3. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 2, is characterized in that, The conductive sheet group includes at least one conductive sheet three (3044) and at least two conductive sheets two (3042). Both the conductive sheet and the conductive sheet two (3042) are L-shaped structures, and both the conductive sheet three (3044) and the conductive sheet two (3042) are mounted on the PCB board (3043) and electrically connected to the corresponding high-voltage fuse (3041).

4. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 2 or 3, characterized in that, The base sub-assembly (3) includes an aluminum housing (308), an insulating bracket (307) that is installed and cooperates with the PCBA assembly (304) is provided inside the aluminum housing (308), and a conductive sheet (306) that cooperates with the PCBA assembly (304) is provided inside the insulating bracket (307).

5. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 4, characterized in that, The upper part of the aluminum shell (308) is provided with a groove, and the groove is provided with silicone for sealing connection with the upper cover sub-assembly (2).

6. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 5, is characterized in that, The lower part of the aluminum housing (308) is provided with a sheet metal bracket (309).

7. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration as described in claim 5 or 6, characterized in that, The wiring harness assembly includes solder terminals (320) and hole terminals (315) that mate with the PCBA assembly (304). Both the solder terminals (320) and the hole terminals (315) are mounted on an insulating bracket (307) and mate with the corresponding conductive sheet (306).

8. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration according to claim 7, characterized in that, Both the welding terminal (320) and the hole terminal (315) are connected to wire harnesses. The wire harnesses are provided with an inner metal hoop (313), a shielding ring (314), a sealing ring (312) and a tail clip (311) in sequence. The tail clip (311) is connected to the aluminum shell (308).

9. The high-voltage distribution unit with compatible multi-wire diameter, high protection, and high integration according to any one of claims 1 to 3, 5, 6, and 8, characterized in that, The upper cover assembly (2) includes a cover body (205) and a flip cover (203). The flip cover (203) is connected to a rotating shaft (204) rotatably connected to the cover body (205). The flip cover (203) is set on the observation hole (206) of the cover body (205) and fixedly connected to the cover body (205) by bolts. The cover body (205) is provided with a groove (207), and a high-pressure head mark (201) is pasted in the groove (207).

10. The high-voltage power distribution unit with compatible multi-wire diameter, high protection, and high integration according to claim 9, characterized in that, The cover (205) is provided with a number of threaded holes corresponding to the aluminum shell (308), and the cover (205) is connected to the aluminum shell (308) by bolts.

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