High-voltage distribution box and power battery system

Abstract

The utility model provides a kind of high-voltage distribution box and power battery system, wherein the high-voltage distribution box includes: box body, the side of the box body is equipped with through hole;Manual maintenance switch, including fixed seat, the fixed seat passes through the through hole, and the fixed seat is installed in the side of the box body by fastener;Insulating part, it is equipped with the opening compatible with the shape of the fixed seat, the insulating part is arranged in the inner side wall of the box body, and the opening contains the fixed seat;Busbar, it is equipped with mounting hole;The fixed seat is provided with locking piece, the locking piece is threaded the mounting hole, to install the busbar in the fixed seat, and the edge of the busbar is pressed in the corresponding position of the insulating part.The utility model can increase the electrical clearance between the end of fastener and the mounting hole position of busbar, creepage distance, ensure electrical safety.

Description

Technical Field

[0001] This utility model relates to the field of power battery technology, and in particular to a high-voltage distribution box and a power battery system. Background Technology

[0002] The power distribution unit (PDU) is a key component of the high-voltage electrical system of an electric vehicle. It is responsible for the safe and reliable distribution of the high-voltage electrical energy generated by the battery to various high-voltage subsystems of the vehicle, such as the electric motor, air conditioning compressor, and charging interface. Simultaneously, the PDU also features overload protection, short-circuit protection, voltage monitoring, and isolating switches to ensure the stable operation of the electric vehicle's electrical system and provide safety assurance for maintenance and repair.

[0003] However, the existing high-voltage distribution boxes do not have additional insulation protection structures, resulting in small electrical clearances and creepage distances between the copper busbars inside the high-voltage distribution box and the bolts on the base of the Manual Service Disconnect (MSD). This makes them prone to arcing and poses a significant safety hazard. In severe cases, it can even lead to equipment damage, fire, or electric shock accidents.

[0004] Therefore, it is necessary to provide a high-voltage distribution box and a power battery system to solve the above-mentioned problems existing in the prior art. Utility Model Content

[0005] In view of the shortcomings of the prior art described above, the purpose of this utility model is to provide a high-voltage distribution box and a power battery system to solve the technical problem of small electrical clearance and creepage distance between the copper busbar inside the high-voltage distribution box and the bolts of the manual maintenance switch base in the prior art.

[0006] To solve the above-mentioned technical problems, this utility model provides a high-voltage distribution box, comprising:

[0007] The box body has a through hole on its side;

[0008] A manual maintenance switch includes a mounting base that passes through the through hole and is mounted on the side of the housing by fasteners.

[0009] An insulating part has an opening that matches the shape of the fixing seat. The insulating part is disposed on the inner side wall of the box body, and the opening accommodates the fixing seat.

[0010] The busbar has a mounting hole; the mounting base is provided with a locking member, which passes through the mounting hole to install the busbar on the mounting base, and the edge of the busbar is pressed against the corresponding position of the insulating part.

[0011] The high-voltage distribution box provided by this utility model has the following beneficial effects:

[0012] The mounting base, with a through hole on the side of the box, is installed onto the box using fasteners. This means the manual maintenance switch is fixed to the side of the box. An insulating part with an opening matching the shape of the mounting base is placed on the inner wall of the box, accommodating the mounting base. Simultaneously, a locking element on the mounting base passes through the busbar's mounting hole, securing the busbar to the mounting base. At this point, the edge of the busbar presses against the corresponding position of the insulating part, thus fixing the insulating part. Because the voltage level in high-voltage distribution boxes is high, this invention adds an extra insulating part between the fastener and the busbar, increasing the electrical clearance and creepage distance between the fastener end and the busbar's mounting hole, preventing arc discharge, effectively reducing the risk of electrical faults, and ensuring electrical safety.

[0013] Furthermore, it also includes a protective sleeve, which is fitted onto the fastener.

[0014] Furthermore, the manual maintenance switch also includes a socket housing, which is connected to the mounting base; the socket housing has mounting holes evenly distributed along its circumference, and the fastener passes through the mounting holes to fix the mounting base to the side of the box.

[0015] Furthermore, the manual maintenance switch also includes a plug that is connected to the socket housing.

[0016] Furthermore, it also includes a battery pack high-voltage interface, which is located on one side of the housing and electrically connected to the busbar.

[0017] Furthermore, it also includes a low-voltage communication interface, which is located on one side of the housing.

[0018] Furthermore, it also includes a low-voltage connector, which is disposed on one side of the housing and is located on the same side as the low-voltage communication interface.

[0019] Furthermore, it also includes two handles, which are located on opposite sides of the box body.

[0020] Furthermore, the box body includes a bottom plate, a side plate, and a top cover. One end of the side plate is erected on the bottom plate along the circumference of the bottom plate, and the top cover is disposed on the other end of the side plate and is disposed opposite to the bottom plate.

[0021] To solve the above-mentioned technical problems, this utility model also provides a power battery system, including: the high-voltage distribution box as described above.

[0022] The beneficial effects of the power battery system provided by this utility model are the same as those of the high-voltage distribution box described above. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the high-voltage distribution box according to an embodiment of the present utility model;

[0024] Figure 2 This is a schematic diagram of the high-voltage distribution box after removing the top cover according to an embodiment of the present utility model;

[0025] Figure 3 This is a schematic diagram of the high-voltage distribution box without the box body according to an embodiment of the present utility model;

[0026] Figure 4 for Figure 3 A partially enlarged schematic diagram;

[0027] Figure 5 This is a partial structural schematic diagram of the high-voltage distribution box according to an embodiment of the present utility model.

[0028] Component designation explanation

[0029] 1. Box body; 11. Base plate; 12. Side plate; 13. Top cover; 2. Manual maintenance switch; 21. Mounting base; 211. Locking element; 22. Fastener; 23. Socket housing; 231. Mounting hole; 24. Plug; 3. Insulation part; 31. Opening; 4. Busbar; 41. Mounting hole; 5. Protective cover; 6. Battery pack high-voltage interface; 7. Low-voltage communication interface; 8. Low-voltage connector; 9. Handle. Detailed Implementation

[0030] The following specific embodiments illustrate the implementation of this utility model. Those skilled in the art can easily understand other advantages and effects of this utility model from the content disclosed in this specification.

[0031] It should be understood that the structures, proportions, sizes, etc., illustrated in the accompanying drawings are merely for illustrative purposes to aid those skilled in the art and are not intended to limit the implementation of this utility model. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in proportions, or adjustments to size, without affecting the effectiveness and purpose of this utility model, should still fall within the scope of the technical content disclosed in this utility model. The following detailed description should not be considered restrictive, and the scope of the embodiments of this application is limited only by the claims of the published patents. The terminology used herein is for describing specific embodiments only and is not intended to limit this application. Spatial terms such as "upper," "lower," "left," "right," "below," "below," "lower part," "above," "upper part," etc., may be used in the text to illustrate the relationship between one element or feature shown in the figures and another element or feature.

[0032] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," "fixing," and "holding" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] Furthermore, as used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context indicates otherwise. It should be further understood that the terms “comprising,” “including,” indicate the presence of the stated feature, operation, element, component, item, kind, and / or group, but do not preclude the presence, occurrence, or addition of one or more other features, operations, elements, components, items, kinds, and / or groups. The terms “or” and “and / or” as used herein are interpreted as inclusive, or mean any one or any combination thereof. Thus, “A, B, or C” or “A, B, and / or C” means “any one of: A; B; C; A and B; A and C; B and C; A, B, and C.” Exceptions to this definition arise only when combinations of elements, functions, or operations are inherently mutually exclusive in some manner.

[0034] like Figures 1-5As shown, an embodiment of this utility model provides a high-voltage distribution box, including: a box body 1, a manual service disconnect 2, an insulation part 3, and a busbar 4. The box body 1 is used to carry and accommodate various electrical components such as the manual service disconnect 2, the insulation part 3, and the busbar 4. It should be understood that the manual service disconnect 2 (Manual Service Disconnect, MSD) is a high-voltage, high-current mechanical switch connected in series inside the entire power battery system. By connecting and disconnecting the high-voltage circuit, it protects the safety of technicians repairing electric vehicles in high-voltage environments or responds to sudden events. It can quickly disconnect the high-voltage circuit, making maintenance and other work in a relatively safe state.

[0035] A through hole is provided on the side of the housing 1. The manual maintenance switch 2 includes a mounting base 21. The mounting base 21 passes through the through hole and is installed on the side of the housing 1 by fasteners 22. The insulating part 3 has an opening 31 that matches the shape of the mounting base 21. The insulating part 3 is located on the inner side wall of the housing 1, and the opening 31 accommodates the mounting base 21. The busbar 4 has a mounting hole 41. A locking member 211 is provided on the mounting base 21. The locking member 211 passes through the mounting hole 41 to install the busbar 4 on the mounting base 21, and the edge of the busbar 4 is pressed against the corresponding position of the insulating part 3.

[0036] The mounting base 21, which has a through hole on the side of the box 1, is installed on the box 1 by fastener 22. That is, the manual maintenance switch 2 is installed and fixed on the side of the box 1. When the insulating part 3, which has an opening 31 that matches the shape of the mounting base 21, is set on the inner side wall of the box 1, the opening 31 accommodates the mounting base 21, that is, the mounting base 21 is placed in the opening 31. At the same time, the locking member 211 provided on the mounting base 21 passes through the mounting hole 41 of the busbar 4 and fixes the busbar 4 to the mounting base 21. At this time, the edge of the busbar 4 is pressed against the corresponding position of the insulating part 3, thereby fixing the insulating part 3. Since the voltage level in the high-voltage distribution box is high, this utility model increases the electrical clearance and creepage distance between the end of the fastener 22 and the mounting hole 41 of the busbar 4 by adding an additional insulating part 3 between the fastener 22 and the busbar 4, preventing arc discharge, effectively reducing the risk of electrical faults, and ensuring electrical safety and stable operation of equipment.

[0037] It should be understood that electrical clearance refers to the shortest straight-line distance between two conductive parts. In high-voltage electrical equipment, ensuring a certain electrical clearance is one of the important parameters for the safe operation of the equipment. Creepage distance refers to the shortest distance along the insulating surface between two conductive parts. By ensuring sufficient creepage distance, the safety of high-voltage electrical equipment is improved.

[0038] Specifically, two manual maintenance switches 2 are installed on the side of the housing 1, thereby providing double safety protection for the high-voltage system and effectively preventing misoperation, thus improving the safety of the high-voltage system.

[0039] For example, the locking element 211 is a stud, one end of which is embedded in the fixing base 21, and the other end of which passes through the mounting hole 41 of the busbar 4 and is locked by a nut, thereby fixing the busbar 4 to the fixing base 21. The material of the busbar 4 is, for example, copper or aluminum.

[0040] like Figure 2 and Figure 3 As shown, in some embodiments of this utility model, the high-voltage distribution box further includes a protective sleeve 5. The protective sleeve 5 is fitted onto the fastener 22. By fitting the protective sleeve 5 onto the end of the fastener 22, the electrical clearance and creepage distance between the end of the fastener 22 and the mounting hole 41 of the busbar 4 are further increased, ensuring electrical safety. Exemplarily, the protective sleeve 5 is made of rubber insulation, which has good insulation performance and wear resistance, and provides insulation between the end of the fastener 22 and the mounting hole 41 of the busbar 4, improving electrical safety performance.

[0041] like Figure 3 and Figure 4 As shown, in some embodiments of this utility model, the manual maintenance switch 2 further includes a socket housing 23. The socket housing 23 is connected to the fixing base 21. The socket housing 23 has evenly distributed fixing holes 231 along its circumference. Fasteners 22 pass through the fixing holes 231 to fix the fixing base 21 to the side of the housing 1. By providing evenly distributed fixing holes 231 on the circumference of the socket housing 23, and fasteners 22 passing through the fixing holes 231, the fixing base 21 is fixedly installed to the side of the housing 1, that is, the manual maintenance switch 2 is installed and fixed to the side of the housing 1. The fasteners 22 are, for example, bolts, and are locked with nuts. One end of the bolt passes through the fixing hole 231, and the other end of the bolt is tightened with a nut, thereby fixing the fixing base 21 to the side of the housing 1. After tightening with bolts and nuts, a protective sleeve 5 is placed on the end of the bolt to isolate the end of the bolt from the mounting hole 41 of the busbar 4, ensuring electrical safety. For example, the number of fixing holes 231 corresponding to a manual maintenance switch 2 is four, and the number of fasteners 22 and protective sleeves 5 is also four. Furthermore, the four fixing holes 231 are evenly arranged around the outside of the fixing base 21.

[0042] Furthermore, since the insulating part 3 must allow the fixing seat 21 and the four fasteners 22 fitted with protective sleeves 5 to pass through simultaneously, the opening 31 of the insulating part 3 is adapted to the shape of the fixing seat 22 and the four fasteners 22. This ensures that when the insulating part 3 is located on the side of the box body 1, it can simultaneously avoid the fixing seat 21 and the four fasteners 22. For example, the insulating part 3 is a plastic insulating sheet, which can better fit on the inner wall of the box body 1 and block the end of the fastener 22 from the position corresponding to the mounting hole 41 of the busbar 4, ensuring insulation and electrical safety.

[0043] like Figure 3 and Figure 4 As shown, in some embodiments of this utility model, the manual maintenance switch 2 further includes a plug 24. The plug 24 is connected to the socket housing 23. Specifically, the plug 24 is provided with a manual maintenance switch handle for opening or closing the switch, thereby controlling the connection and disconnection of the circuit.

[0044] For example, the installation steps between the housing 1, the manual maintenance switch 2, the insulation part 3, and the busbar 4 are as follows: First, the mounting base 21 is inserted through the through hole of the housing 1 from the outside to the inside. At this time, the socket housing 23 is attached to the outer or inner side wall of the housing 1. Then, four fasteners 22 are respectively inserted into the corresponding fixing holes 231 of the socket housing 23, thereby fixing the manual maintenance switch 2 to the side of the housing 1. At this time, the mounting base 21 is located inside the housing 1. Then, four protective sleeves 5 are respectively fitted onto the ends of the corresponding fasteners 22. Next, attach the insulating part 3 to the inner wall of the box body 1, with the opening of the insulating part 3 avoiding the fixing seat 21 and the four fasteners 22; then align the mounting hole 41 of the corresponding busbar 4 with the locking member 211 so that the locking member 211 passes through the mounting hole 41 to lock it, thereby fixing the busbar 4 to the fixing seat 21. At this time, the edge of the busbar 4 presses against the corresponding position of the insulating part 3, thereby fixing the insulating part 3 to the inner wall of the box body 1 and placing it between the end of the fastener 22 and the position of the mounting hole 41 of the busbar 4. It should be noted that, in order to ensure that the edge of the busbar 4 can press against the insulating part 3 when it is attached to the inner wall of the box body 1, the thickness of the insulating part 3 should be matched with the thickness of the fixing seat 21, or a mounting plate can be provided on the inner wall of the box body 1 to increase the thickness. The insulating part 3 is attached to the mounting plate, so that the surface of the insulating part 3 facing the inside of the box body 1 is pressed against the busbar 4 to fix the insulating part 3 and ensure that the insulating part 3 does not fall off during the operation of the vehicle.

[0045] like Figure 1 , Figure 2 and Figure 3As shown, in some embodiments of this utility model, the high-voltage distribution box further includes a battery pack high-voltage interface 6. The battery pack high-voltage interface 6 is disposed on one side of the box body 1 and electrically connected to the busbar 4. Exemplarily, the battery pack high-voltage interface 6 and the busbar 4 are connected by bolts and nuts. In this embodiment, the battery pack and the high-voltage distribution box are connected through the battery pack high-voltage interface 6, and specifically, the battery pack high-voltage interface 6 is connected through the busbar 4 to electrically connect the battery pack to the manual maintenance switch 2, that is, one end of the busbar 4 is connected to the battery pack high-voltage interface 6, and the other end is connected to the manual maintenance switch 2. Further, when the manual maintenance switch 2 is in the closed state, the positive terminal of the battery pack high-voltage interface 6 is connected to the positive terminal of the manual maintenance switch 2 to transmit high-voltage positive electricity, so that current flows out of the battery pack; the negative terminal of the battery pack high-voltage interface 6 is connected to the negative terminal of the manual maintenance switch 2 to provide a path for the current to return to the battery pack, forming a complete circuit loop. When the manual maintenance switch 2 is turned on, the connection between the positive and negative terminals of the manual maintenance switch 2 is cut off, thereby disconnecting the voltage between the battery system output terminals, which plays a protective role and prevents the operator from being electrocuted in the event of vehicle maintenance, repair or malfunction.

[0046] like Figure 2 and Figure 3 As shown, in some embodiments of this utility model, the high-voltage distribution box further includes a low-voltage communication interface 7. The low-voltage communication interface 7 is located on one side of the box body 1. Specifically, the low-voltage communication interface 7 and the manual maintenance switch 2 are located on the same side of the box body 1. In this embodiment, communication is established with the vehicle's high-voltage control system through the low-voltage communication interface 7 to calculate and detect the insulation resistance of the high-voltage system circuit. When the insulation resistance of the entire high-voltage system is lower than a set threshold, the high-voltage circuit is automatically disconnected, further enhancing safety.

[0047] like Figure 2 and Figure 3 As shown, in some embodiments of this utility model, the high-voltage distribution box further includes a low-voltage connector 8. The low-voltage connector 8 is disposed on one side of the box body 1 and is located on the same side as the low-voltage communication interface 7. In this embodiment, the low-voltage connector 8 is electrically connected to the power-consuming device via a cable, and is used to supply power to the communication module, sampling module, and management module of the power-consuming device to ensure the safety and reliability of the battery.

[0048] like Figure 1 and Figure 2 As shown, in some embodiments of this utility model, the high-voltage distribution box further includes two handles 9. The two handles 9 are disposed on opposite sides of the box body 1. By providing a handle 9 on each opposite side of the box body 1, it is convenient for operators to lift the high-voltage distribution box for installation and disassembly.

[0049] like Figure 1 and Figure 5As shown, in some embodiments of this utility model, the box body 1 includes a base plate 11, side plates 12, and a top cover 13. One end of the side plate 12 is erected on the base plate 11 along its circumference, and the top cover 13 covers the other end of the side plate 12 and is disposed opposite to the base plate 11. Exemplarily, the shape of the box body 1 is a cuboid. Specifically, two handles 9 are disposed on the two relatively shorter side plates 12, and two manual maintenance switches 2, a low-voltage communication interface 7, and a low-voltage connector 8 are disposed on the relatively longer side plate 12. The layout design is reasonable and improves space utilization.

[0050] In some embodiments of this utility model, a DCCH interface is also provided on the side plate 12, which is equipped with two manual maintenance switches 2, a low-voltage communication interface 7, and a low-voltage connector 8. It should be understood that the DCCH (Dedicated Control Channel) interface is a point-to-point bidirectional control channel used to transmit necessary control information between the mobile station and the base station during call setup and communication. Other electrical components in the high-voltage distribution box are implemented with reference to existing technology and will not be described further here.

[0051] An embodiment of this utility model also provides a power battery system, including the aforementioned high-voltage distribution box. Furthermore, the power battery system also includes a battery pack. Specifically, the manual maintenance switch 2 of the high-voltage distribution box is connected to the battery pack via a busbar 4 and the high-voltage interface 6 of the battery pack, realizing the connection and disconnection of the circuit.

[0052] In summary, addressing the technical problem of insufficient electrical clearance and creepage distance between the copper busbars inside the high-voltage distribution box and the bolts of the manual maintenance switch base due to the lack of additional insulation protection structure in existing technologies, this utility model provides a high-voltage distribution box and power battery system. A fixing seat with a through hole on the side of the box is installed in the box using fasteners, thus fixing the manual maintenance switch to the side of the box. An insulating part with an opening matching the shape of the fixing seat is provided on the inner wall of the box, accommodating the fixing seat; the fixing seat is placed within the opening. Simultaneously, a locking member on the fixing seat passes through the busbar mounting hole, securing the busbar to the fixing seat. When the busbar is pressed against the corresponding position of the insulation part, the insulation part is fixed. Since the voltage level in the high-voltage distribution box is high, and compared to existing technologies which lack additional insulation protection structures, this invention increases the electrical clearance and creepage distance between the fastener end and the busbar mounting hole by adding an additional insulation part between the fastener and the busbar. Furthermore, a protective sleeve is fitted onto the fastener end. Through the dual protection of the insulation part and the protective sleeve, the electrical clearance and creepage distance between the fastener end and the busbar mounting hole are guaranteed, preventing arc discharge and effectively reducing the risk of electrical faults, ensuring electrical safety and stable equipment operation. Therefore, this invention effectively overcomes the various shortcomings of existing technologies and has high industrial application value.

[0053] The above embodiments are merely illustrative of the principles and effects of this utility model and are not intended to limit the scope of this utility model. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of this utility model. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in this utility model should still be covered by the claims of this utility model.

Claims

1. A high-voltage distribution box, characterized in that, include: The box body has a through hole on its side; A manual maintenance switch includes a mounting base that passes through the through hole and is mounted on the side of the housing by fasteners. An insulating part has an opening that matches the shape of the fixing seat. The insulating part is disposed on the inner side wall of the box body, and the opening accommodates the fixing seat. The busbar has a mounting hole; the mounting base is provided with a locking member, which passes through the mounting hole to install the busbar on the mounting base, and the edge of the busbar is pressed against the corresponding position of the insulating part.

2. The high-voltage distribution box according to claim 1, characterized in that, It also includes a protective sleeve, which is fitted onto the fastener.

3. The high-voltage distribution box according to claim 1, characterized in that, The manual maintenance switch also includes a socket housing, which is connected to the mounting base. The socket housing has mounting holes evenly spaced along its circumference, and the fasteners pass through the mounting holes to fix the mounting base to the side of the box.

4. The high-voltage distribution box according to claim 3, characterized in that, The manual maintenance switch also includes a plug that is connected to the socket housing.

5. The high-voltage distribution box according to claim 1, characterized in that, It also includes a battery pack high-voltage interface, which is located on one side of the housing and electrically connected to the busbar.

6. The high-voltage distribution box according to claim 1, characterized in that, It also includes a low-voltage communication interface, which is located on one side of the housing.

7. The high-voltage distribution box according to claim 6, characterized in that, It also includes a low-voltage connector, which is located on one side of the housing and on the same side as the low-voltage communication interface.

8. The high-voltage distribution box according to claim 1, characterized in that, It also includes two handles, which are located on opposite sides of the box body.

9. The high-voltage distribution box according to claim 1, characterized in that, The box body includes a bottom plate, a side plate, and a top cover. One end of the side plate is erected on the bottom plate along the circumference of the bottom plate, and the top cover is placed on the other end of the side plate and is disposed opposite to the bottom plate.

10. A power battery system, characterized in that, include: The high-voltage distribution box as described in any one of claims 1 to 9.

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