Battery distribution unit

Abstract

Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein the strip-shaped busbar (138) has a first wide side (300) and a second wide side (302) extending along the length of the strip-shaped busbar (138) between a first end (304) and a second end (306), wherein the strip-shaped busbar (138) has an upper cross-terminal (140) and a lower cross-terminal (140) extending between the first end (304) and the second end (306), wherein the first and second cross-terminal (140) are attached at arbitrary points along the length either to the upper cross-terminal (140) or to the lower cross-terminal (140), and wherein the first and second cross-terminal (140) interact with both the first wide side (300) and the second wide side (302).

Description

[0001] The present subject matter generally relates to battery distribution units (BDUs) for battery systems. Batteries, such as those for electric or hybrid vehicles, typically contain multiple cells grouped together as a battery pack or battery set. The battery pack includes a battery distribution unit, which is responsible for managing the power capacity and functionality of the battery pack. Battery distribution units are typically installed inside a housing of the battery pack. The battery distribution unit includes numerous electrical devices, such as at least one power relay, at least one pre-charge relay, at least one pre-charge resistor, at least one Y-capacitor, at least one fuse, a current sensor, and other electrical devices.

[0002] US 2008 / 0180884A1 discloses a power distribution module comprising a housing with multiple channels and multiple busbars integrated within the housing for distributing power between multiple electrical components. Each busbar has multiple terminals that can be positioned within the respective channels based on a predetermined arrangement of the electrical components.

[0003] Conventional battery distribution units use bolted / nut connections, increasing the number of components inside the unit's housing and lengthening assembly time. The battery distribution unit is relatively large to accommodate these connections. The large number of parts further increases the unit's cost. Other battery distribution unit designs utilize custom-formed busbars, typically created by stamping and forming. In these designs, the busbar is horizontally oriented, and stamped contact blades are formed at a 90° angle, extending vertically to connect to the fixtures. Bolted / nut connections can be used with such busbars. Other systems employ box-type terminals that fit onto the contact blades.Conventional 12V fuse relay boxes with individual busbars typically use an arrangement of the busbars in multiple (e.g., four) different layers, which increases the overall cost and size of the 12V fuse relay box. These systems are complex and have many components. Such systems lack design flexibility to adapt to different orientations, available spaces, and shapes. They are also difficult to integrate with other connectors or devices. Furthermore, controlling tolerances regarding the blade position of the individually designed busbar is very difficult. Sometimes, it can be challenging to accommodate the blade orientation of the devices. Cost is a significant disadvantage of such systems.

[0004] The solution to the problem consists of a robust battery distribution unit, as disclosed herein, which is flexible in its design, has a small size for arrangement within the battery system, and is capable of accommodating the positioning of devices such as relays, fuses, resistors, and the like. A battery distribution unit (BDU) according to the invention is configured to hold a first electronic device with a first blade terminal extending away from it, and a second electronic device with a second blade terminal extending away from it. The battery distribution unit comprises a battery distribution unit housing, a strip-shaped busbar accommodated in the battery distribution unit housing, and a first and a second cross-shaped terminal, respectively, which are accommodated in the battery distribution unit housing.The first cross-connector receives the strip-shaped busbar at one end and is designed to receive the first knife connection at its other end. The second cross-connector receives the strip-shaped busbar at one end and is designed to receive the second knife connection at its other end.

[0005] In a first embodiment of a battery distribution unit according to the invention, the strip-shaped busbar has a first and a second broad side extending along its length between a first and a second end. The strip-shaped busbar has an upper edge and a lower edge extending between the first and second ends. The first and second cross terminals are located at arbitrary points along the length, either on the upper edge or on the lower edge, and the first and second cross terminals interact with both the first and the second broad side.

[0006] In a second embodiment of a battery distribution unit according to the invention, at least one of the first and the second cross-connection has a plurality of protrusions extending from the wall segments into a cruciform cavity formed by a plurality of L-shaped wall segments. The protrusions are designed to interact with the strip-shaped busbar when the strip-shaped busbar is inserted into the cruciform cavity.

[0007] In a third embodiment of a battery distribution unit according to the invention, the strip-shaped busbar has a rectangular cross-section along its entire length, formed by opposing wide sides extending between an upper edge and a lower edge, wherein the cross terminals for interacting with the two wide sides are attached either to the upper edge or to the lower edge.

[0008] In a fourth embodiment of a battery distribution unit according to the invention, the first and second cross-connections have L-shaped wall segments arranged in four quadrants, wherein the L-shaped wall segments form a cross-shaped cavity designed to receive the strip-shaped busbar.

[0009] In a fifth embodiment of a battery distribution unit according to the invention, the first and second cross-connections each have a cross-shaped cavity with a first cavity segment and a second cavity segment that is perpendicular to and intersects the first cavity segment. The first and second cross-connections are coupled to the strip-shaped busbar in different orthogonal orientations by inserting the strip-shaped busbar into the first cavity segment or into the second cavity segment of the respective first or second cross-connection.

[0010] The invention will now be described by way of an example with reference to the accompanying drawings; these show: Fig. 1 a battery system with a battery distribution unit (BDU) designed according to an exemplary embodiment; Fig. 2. An expanded view of a battery distribution unit of the battery system according to an exemplary embodiment; Fig. 3 a perspective view from below of a cross-connection of the battery distribution unit, designed according to an exemplary embodiment; Fig. 4 a perspective view of the in Fig. 3 shown cross connection; Fig. 5 a perspective view from below of an electronic device of the battery distribution unit; Fig. 6. A representation of electrical components of the battery distribution unit; Fig. 7 an enlarged view of an area of ​​the battery distribution unit; Fig. 8 a representation of an area of ​​the battery distribution unit; Fig. 9 a representation of an area of ​​the battery distribution unit; Fig. 10 A perspective view of the battery distribution unit from below.

[0011] Fig. Figure 1 illustrates a battery system 100 with a battery distribution unit (BDU) 106 configured according to an exemplary embodiment. The battery system 100 includes a battery pack or battery set 102, which is contained within an outer housing 104. The battery distribution unit (BDU) 106 is coupled to the battery pack 102. The battery pack 102 can be part of a high-voltage energy storage system. For example, the battery pack 102 can be used in a motor vehicle application, such as in an electric vehicle or a hybrid-electric vehicle.

[0012] The battery distribution unit 106 is used to manage the power capacity and functionality of the battery system 100, for example, by measuring the current and regulating the power distribution of the battery pack 102. The battery system 100 can have both a high-current power circuit and a low-current power circuit, both of which are electrically connected to the battery pack 102 via the battery distribution unit 106. The battery distribution unit 106 can monitor and / or control the operation of the components of the battery system 100. The battery distribution unit 106 can measure or react to the battery health of the battery pack 102. The battery distribution unit 106 can measure or react to the battery state of the battery pack 102. The battery distribution unit 106 can monitor for and / or react to overvoltage and / or undervoltage conditions in the battery pack 102.The battery distribution unit 106 can react to temperature changes in the battery pack 102. The battery distribution unit 106 can manage charging functions of the battery pack 102. The battery distribution unit 106 can have external connections and / or connectors, such as for attaching power terminals to the battery distribution unit 106 and / or the battery pack 102, for attaching sensors to the battery distribution unit 106, for data communication to / from the battery distribution unit 106, and the like.

[0013] In other embodiments, the battery distribution unit 106 can be enclosed within the outer housing 104. Alternatively, the battery distribution unit 106 can be attached directly to an outer surface of the outer housing 104. The battery distribution unit 106 comprises a battery distribution unit housing 108 and a cover 110, which is coupled to the battery distribution unit housing 108 to cover the components contained therein. In an exemplary embodiment, a positive battery terminal 112 and a negative battery terminal 114 can be accessible through the battery distribution unit housing 108 and / or the cover 110 for external connection to the battery distribution unit 106. In an exemplary embodiment, high-voltage wires 116 and / or low-voltage wires 118 can extend from the battery distribution unit 106.A sensor connector 120 is accessible through the battery distribution unit housing 108 and / or the cover 110 to establish an external connection with one or more sensors of the battery distribution unit 106.

[0014] In an exemplary embodiment, the battery system 100 may include a manual service disconnect switch (MSD) 122 for disconnecting the power circuit of the battery system 100, for example, for servicing purposes. The manual service disconnect switch 122 may be directly connected to the outer housing 104. Alternatively, the manual service disconnect switch may be directly connected to the battery distribution unit 106. The manual service disconnect switch 122 is used to interrupt or disconnect the power circuit of the battery system 100, for example, during service or maintenance operations. For example, a disconnect switch plug of the manual service disconnect switch 122 can be disconnected from and removed from a disconnect switch socket of the manual service disconnect switch 122.The manual service disconnect switch 122 may include a high voltage interlock circuit (HVIL circuit, where HVIL stands for High Voltage InterLock) for controlling the high current power circuit during the opening and closing of the manual service disconnect switch 122.

[0015] In one exemplary embodiment, the battery pack 102 comprises a plurality of battery cells 124 housed within the outer casing 104. The battery cells 124 can be of any type. For example, they can be pocket-sized or prismatic battery cells. Alternative embodiments may utilize other types of battery cells. Optionally, the battery cells 124 can be narrow plates arranged in a stacked configuration. The battery pack 102 can contain any number of battery cells 124. Each battery cell 124 can be electrically connected to the battery distribution unit 106 via a suitable electrical connection within the battery pack 102.

[0016] Fig. Figure 2 shows an exploded view of the battery distribution unit 106, which is designed according to an exemplary embodiment. In the exemplary embodiment, the battery distribution unit housing 108 is a two-part housing with an upper housing element 130 and a lower housing element 132. The upper housing element 130 is designed for coupling with the lower housing element 132. The cover 110 is designed for attachment to the upper housing element 130. The lower housing element 132 includes mounting flanges 134 for attaching the battery distribution unit 106 to the outer housing 104 (in Fig. (1 shown), such as on an inside or outside of the outer housing 104. The battery distribution unit 106 can be attached to the outer housing 104 such that the lower housing element 132 is attached to or arranged inside the outer housing 104, and the upper housing element 132 faces outwards from the outer housing 104. Alternatively, the battery distribution unit 106 can be attached to the outer housing 104 such that the upper housing element 130 is arranged inside the outer housing 104, and the bottom of the lower housing element 132 faces outwards from the outer housing 104.

[0017] In an exemplary embodiment, the upper and lower housing elements 130, 132 are made of a dielectric material, such as a plastic. The upper housing element 130 contains a plurality of electronic devices, generally shown at reference numeral 136. The lower housing element 132 holds a plurality of strip-shaped busbars 138 and cross-shaped terminals 140, which are used to electrically connect the electronic devices 136 to one another. When the upper housing element 130 is coupled to the lower housing element 132, the electronic devices 136 can be electrically connected to corresponding busbars 138 via corresponding cross-terminals 140. Optionally, the lower housing element 132 can hold one or more electronic devices 136.Optionally, the upper housing element 130 can hold one or more strip-shaped busbars 138 and / or cross terminals 140.

[0018] Depending on the specific requirements of the battery system 100 (in Fig. As shown in Figure 1, any type of electronic device 136 can be part of the battery distribution unit 106. In the illustrated embodiment, the battery distribution unit 106 includes a pair of power relays 142, 144, a pre-charge relay 146, a pre-charge resistor 148, a pair of fuses 150, 152, Y-capacitors 154, 156, a sensor 158, and the positive and negative battery terminals 112, 114. In alternative embodiments, other types of electronic devices 136 can be used. The positioning of the electronic devices 136 can be designed such that the footprint of the battery distribution unit 106 is minimized.

[0019] The strip-shaped busbars 138 form electrical paths between corresponding electronic devices 136. The strip-shaped busbar 138 can be easily installed inside the lower housing element 132 between the corresponding electronic devices 136. The strip-shaped busbars 138 and the cross-connectors 140 allow for convenient and simple connections between the strip-shaped busbars 138 and the electronic devices 136. The cross-connectors 140 allow for quick insertion of the electronic devices 136 into the battery distribution unit 106, as well as quick removal of the electronic devices 136 from the battery distribution unit 106. The cross-connectors 140 eliminate some or all of the wiring connections to the electronic devices 136, thus reducing the assembly time of the battery distribution unit 106.

[0020] In an exemplary embodiment, the lower housing element 132 comprises a top 160 and a bottom 162. The lower housing element 132 includes a plurality of channels 164 formed therein, which are open at the top 160 and / or the bottom 162. The strip-shaped busbars 138 are inserted into corresponding channels 164. The channels 164 serve to position and retain the strip-shaped busbars 138, as well as to provide electrical insulation and prevent unintentional contact with the strip-shaped busbars 138. The dielectric material of the housing element 132 prevents short circuits among the conductive elements in the battery distribution unit 106. The channels 164 generally extend vertically within the lower housing element 132 between the top 160 and the bottom 162.The strip-shaped busbars 138 are received in the channels 164 such that they generally extend vertically within the lower housing element 132 between the top 160 and / or the bottom 162. In an exemplary embodiment, the strip-shaped busbars 138 are arranged on the same horizontal plane and received at the same depth within the lower housing element 132. For example, the strip-shaped busbars 138 are arranged around each other but are not vertically stacked above or below one another. Arranging all the strip-shaped busbars 138 at the same depth allows the lower housing element 132, and thus the battery distribution unit 106, to have a low profile, thereby saving valuable space in and around the battery system 100 and / or enabling a more compact battery system 100.By not routing busbars above or below each other, the need to provide an adequate creepage distance between such busbars, which would otherwise require additional space for the lower housing element 132, is eliminated. This arrangement reduces costs and size.

[0021] The lower housing element 132 contains a plurality of chambers 166, which are open to corresponding channels 164. The chambers 166 are open at the top 160 and / or at the bottom 162. The chambers 166 accommodate corresponding cross connectors 140. Optionally, the chambers 166 can be dimensioned and designed such that they retain the cross connectors 140 within them, for example, by means of a friction fit or by using locking devices. The chambers 166 can be dimensioned and designed such that they align the cross connectors 140 relative to the lower housing element 132 and the strip-shaped busbars 138 for connection to them. For example, the cross connectors 140 can be inserted into the chambers 166 and, when inserted into the chambers 166, connected to the strip-shaped busbars 138.The cross terminals 140 are received in corresponding chambers 166 to establish a mechanical and electrical connection with the corresponding strip-shaped busbars 138. The chambers 166 ensure the fixation, retention, alignment, orientation, and fastening of the cross terminals 140. The chambers 166 provide insulation around the cross terminals 140, ensuring electrical isolation and protection against accidental contact.

[0022] Fig. Figure 3 shows a perspective view from below of one of the cross-shaped connections or cross connections 140 in a design according to an exemplary embodiment. Fig. 4 shows a perspective view of the in Fig. Figure 3 shows the cross connection 140. The cross connection 140 comprises a body 200 formed by stamping and forming, which is cross-shaped. The cross connection 140 includes a plurality of L-shaped wall segments 202, which are spaced apart from one another to form a cross-shaped cavity 204. In an exemplary embodiment, four wall segments 202 are provided and arranged in four different quadrants. The wall segments 202 face each other across the cross-shaped cavity 204.

[0023] In an exemplary embodiment, the cruciform cavity 204 is formed by a first cavity segment 206 and a second cavity segment 208, which is perpendicular to and intersects the first cavity segment 206. The strip-shaped busbar 138 (in Fig. The cross connection 104 (shown in Figure 2) is designed to be received in either the first cavity segment 206 or the second cavity segment 208. The cross connection 104 is designed to be coupled to the strip busbar 138 in various orthogonal orientations by inserting the strip busbar 138 into the first cavity segment 206 or the second cavity segment 308. The cross connection 104 can thus be oriented relative to the strip busbar 138 at a position of 0 degrees, 90 degrees, 180 degrees, or 270 degrees.

[0024] The cross-connection 140 includes a plurality of projections 210 extending from the wall segments 202 into the cross-shaped cavity 204. The projections 210 are designed to interact with the strip-shaped busbar 138 when the busbar 138 is inserted into the cross-shaped cavity 204. In the illustrated embodiment, the projections 210 are formed by semicircular protrusions extending from the wall segments 202 into the cross-shaped cavity 204; however, in alternative embodiments, the projections 210 can also have other shapes. The projections can be flexible tongues punched out of the wall segments 202.

[0025] The cross connection 140 includes open sides 212, 214, 216, 218 extending between a first end 220 and a second end 222 of the cross connection 140. In an exemplary embodiment, the open sides 212, 214, 216, 218 are open at least along a portion of the length of the cross connection 140 between the first and second ends 220, 222. Connecting segments 224 extend between corresponding wall segments 202 across the sides 212, 214, 216, 218. The sides 212, 214, 216, 218 may be closed at the position of the connecting segments 224. Optionally, the connecting segments 224 along sides 212, 216 can be arranged approximately centrally, so that sides 212, 216 are open at the first and second ends 220, 222. Optionally, and as shown in Fig. As shown in Figure 4, the connecting segments 224 can extend along the sides 214, 218 to the second end 222, so that the sides 214, 218 are only open near the first end 220 and are closed near the second end 222.

[0026] In one exemplary embodiment, the body 200 is formed by stamping and forming such that an overlapping segment 226 extends away from a wall segment 202, across the side 218, and along the opposite wall segment 202. The overlapping segment 226 holds the cross connection 140 together. Alternatively, instead of using the overlapping segment 226, one or more wall segments 202 can be attached to one or more other wall segment(s), for example, by welding the wall segments 202 together by laser welding.

[0027] In the illustrated embodiment, the cross connection 140 is open on all four sides 212, 214, 216, 218 at the first end 220, while at the second end 222 it is open only on two sides 212, 216 and closed on the other two sides 214, 218. Alternatively, the second end 222 of the cross connection 140 can be identical to the first end of the cross connection 140 and be open on all four sides 212, 214, 216, 218. In further alternative embodiments, the first end 220 can be closed on any of the sides 212, 214, 216, 218, for example on the sides 214, 218 in a similar way to the second end 222, while the second end 222 of the cross connection 140 can be identical to the first end 220 of the cross connection 140, which is open on all four sides 212, 214, 216, 218.In further alternative embodiments, the first end 220 of the cross connector 140 can be identical to the second end of the cross connector 140 and open on two sides 212, 216, so that both the first and the second end 220, 222 have two open sides and two closed sides. Depending on the specific application, the ends 220, 222 can have any number of open sides and closed sides. In further alternative embodiments, the first end 220 of the cross connector 140 can be closed on all four sides, for example, when at least one contact blade branches outwards from the vertical strip-shaped busbar 138, while the second end 222 of the cross connector 140 can have any number of open sides and closed sides.

[0028] In an alternative embodiment, the cross connector 140 can have additional wall segments and additional cavity segments (e.g., 3 or more cavity segments) that allow additional mounting orientations of the cross connector 140 relative to the strip-shaped busbar 138 and the electronic device 136 (e.g., parallel, perpendicular, and transverse / non-parallel and non-perpendicular). In such embodiments, the cross-shaped cavity would then no longer be perpendicularly cross-shaped, but would have many intersecting cavity segments.

[0029] Fig. Figure 5 shows a perspective view from below of one of the electronic devices 136. The electronic device 136 has a body 240 with a base 242. A plurality of blade connections 244 extend from the base 242. The blade connections 244 are configured to connect to corresponding cross connections 140 (in Fig. 3 and Fig. (shown in Figure 4) or to be connected to other types of socket terminals. The knife terminals 244 are planar and extend to a free end 246. The knife terminals 244 have opposite sides 248 that extend between opposite edges 250.

[0030] Fig. Figure 6 illustrates electrical components of the battery distribution unit 106 (in Fig. 2 shown), wherein the battery distribution unit housing 108 (in Fig. 2 shown) has been removed for clarity. Fig. Figure 6 illustrates the strip-shaped busbars 138, which electrically connect corresponding electronic devices 136 to each other according to a specific power scheme for the battery distribution unit 106. In an exemplary embodiment, each strip-shaped busbar 138 is formed from a metal strip cut to length and bent into a predetermined shape, and is laid between corresponding electronic devices 136 and electrically connected to them via the cross terminals 140. The strip-shaped busbar 138 can have a rectangular cross-section along its entire length.

[0031] The strip-shaped busbar 138 has a first and a second wide side 300, 302, which extend along the length of the strip-shaped busbar 138 between a first and a second end 304, 306. The strip-shaped busbars 138 can have different lengths between their first and second ends 304, 306. The strip-shaped busbar 138 has a top edge 308 and a bottom edge 310, which extend between the first and second ends 304, 306. The strip-shaped busbars 138 can have any number of bends 312 between the first and second ends 304, 306. Optionally, the bends 312 can be 90-degree bends. Alternatively, the bends 312 can have other angles, so that the segments on opposite sides of the bends 312 are not perpendicular to each other.

[0032] The strip-shaped busbars 138 are routed through the battery distribution unit 106 to connect various electronic devices 136 or other components of the battery distribution unit 106 or the battery system 100 (in Fig. (1 shown) to connect electrically to each other. The strip-shaped busbars 138 run vertically under corresponding knife terminals 244 of the electronic devices 136, so that the cross terminals 140 can electrically connect the strip-shaped busbars 138 to the corresponding knife terminals 244. Optionally, the strip-shaped busbars 138 can be parallel to the knife terminals 244 (e.g., with the wide sides 300, 302 running parallel to the sides 248), or alternatively, the strip-shaped busbars 138 can be oriented at right angles to the knife terminals 244 (e.g., with the wide sides 300, 302 arranged at right angles to the sides 248).

[0033] The cross-shaped cavities 204 of the cross connectors 140 allow the strip-shaped busbars 138 to pass through the cross connectors 140 in various orthogonal orientations (e.g., parallel or perpendicular) to the knife connectors 244. The second ends 222 of the cross connectors 140 are coupled to the corresponding knife connectors 244, while the first ends 220 of the cross connectors 140 accommodate corresponding strip-shaped busbars 138. Since the second ends 222 have two open sides 212, 216, the cross connectors 140 are configured for coupling with the knife connectors 244 either in a zero-degree position or in a 180-degree position, so that the knife connectors 244 are located in the first cavity segment 206 (in Fig. 3 shown). The edges 350 extend beyond the sides 212, 216 of the cross connections 140. With such an orientation relative to the knife connection 244, the four open sides 212, 214, 216, 218 (in Fig. 3 shown) the cross connections 140 the strip-shaped busbars 138 either in the first cavity segment 206 or in the second cavity segment 208 (in Fig. (3 shown). When the strip busbar 138 is parallel to the knife terminal 244, the strip busbar 138 is accommodated in the first cavity segment 206. When the strip busbar 138 is perpendicular to the knife terminal 244, the strip busbar 138 is accommodated in the second cavity segment 208. The open-sided design allows flexibility in the positioning of the strip busbars 138 and the electronic devices 136. The cross terminals 140 have a greater positional tolerance relative to the strip busbars 138 and / or the electronic devices 136 compared to cross terminals 140 that have four closed sides at their first or second end.The design and layout of the strip-shaped busbars 138 and the electronic devices 136 within the battery distribution unit 106 can be simplified by using open-sided cross connections 140.

[0034] In an alternative embodiment, the cross terminals 140 can be rotated by 180 degrees, so that the first ends 220 are coupled to the knife terminals 244 and the second ends are coupled to the strip busbars 138. Since the second ends 222 are open only along the two sides 214, 218, the cross terminal 140 can only be received in the first cavity segment 206; however, the first end 220 can receive the knife terminal 244 either in the first cavity segment 206 or in the second cavity segment 208, so that the knife terminal 244 can be either parallel to the strip busbar 138 or perpendicular to the strip busbar 138.

[0035] The cross terminals 140 electrically connect the strip-shaped busbars 138 and corresponding knife terminals 244. Optionally, the strip-shaped busbars 138 can be electrically connected to other components in addition to one or more electronic components 136. For example, the strip-shaped busbars 138 can be connected to the positive or negative battery terminals 112, 114, or the sensor connector of a shunt sensor, or they can pass through a Hall sensor 120, the Y-capacitors 154, 156, electrical taps 320, or other components. In an exemplary embodiment, first wires 322 extending from the Y-capacitors 154, 156 are directly connected to the corresponding strip-shaped busbars 138, for example, by soldering or welding the wires 322 to the strip-shaped busbars 138.Second wires extending away from the Y capacitors 154, 156 are directly connected to external wires (not shown), for example by soldering or welding the wires to the external wires.

[0036] Optionally, the first or second end 304, 306 of the strip-shaped busbars 138 can be folded over to form tabs 324. The tabs 324 can be directly connected to other electrical components, such as directly to battery cells 124 (in Fig. 1 shown), directly with the manual service disconnect switch 122, if the manual service disconnect switch is located near the lower housing element 132 (in Fig. 2) or with other components. The tabs 324 can extend beyond the battery distribution unit housing 108 for connection with such additional electrical components. Optionally, the tabs 324 can form the positive and negative battery terminals 112, 114, as opposed to a configuration with separate battery terminals welded to the strip-shaped busbars 138.

[0037] The electrical taps or connectors 320 can be connected to the strip-shaped busbars 138 along any segment thereof. For example, the electrical taps 320 can have open-end terminals attached to wires. The open-end terminals are connected to the strip-shaped busbars 138 either along the upper edge 308 or along the lower edge 310. The wires connected to the electrical taps 320 can extend to other electrical components inside or outside the battery distribution unit 106. The electrical tap 320 can conduct current or can be used for voltage measurement or other functions.

[0038] In an exemplary embodiment, knife contacts 330 are coupled to at least some of the knife terminals 244 of the electronic devices 136. The knife contacts 330 can be connected to wires 332 that are routed inside and / or outside the battery distribution unit 106. Optionally, the wires 332 can connect one or more of the high-voltage wires 116 (in Fig. 1 shown) or the low-voltage wires 118 (in Fig. 1 shown) form, which lead from the battery distribution unit 106 to other components of the battery system 100.

[0039] Fig. Figure 7 shows an enlarged view of an area of ​​the battery distribution unit 106. Fig. Figure 7 illustrates strip-shaped busbars 138 which connect the pre-charging relay 146 to the pre-charging resistor 148 using appropriate cross connections 140. Fig. Figure 7 also illustrates the pre-charging relay 146, which is connected to the power relay 144 using corresponding cross terminals 140. Blade contacts 330 and corresponding wires 332 are connected to corresponding blade terminals 244 of the pre-charging relay 146 and the power relay 144. Such wires 332 can also be connected to other electrical components of the battery distribution unit 106. Fig. Figure 7 illustrates parts of other electronic devices 136 and strip-shaped busbars 138. Fig. Figure 7 shows the pre-charging relay 146, in which one of the strip-shaped busbars 138 is aligned perpendicular to the corresponding knife terminal 244, and another strip-shaped busbar 138 is aligned parallel to the corresponding knife terminal 244. The second ends 222 of the cross terminals 140 accommodate the knife terminals 244, and the first ends 220 of the cross terminals 140 accommodate the strip-shaped busbars 138. The strip-shaped busbars 138 are flexible in their configuration, thus enabling various layout schemes within the battery distribution unit 106 to reduce the overall size or footprint of the battery distribution unit 106.

[0040] Fig. Figure 8 illustrates an area of ​​the battery distribution unit 106. Fig. Figure 8 shows the pre-charge resistor 148, which is electrically connected to fuses 150 and 152 via corresponding cross-connections 140. Fuse 150 is electrically connected to another strip-shaped busbar 138 via a corresponding cross-connection 140. Fuse 152 is connected to a corresponding blade contact 330, whereby the corresponding wire 332 can be electrically connected to another electrical component inside or outside the battery distribution unit 106. Fig. Figure 8 illustrates a power tap 320 coupled to the upper edge 308 of the strip-shaped busbar 138. The electrical tap 320 can be connected to another component, such as an accessory device, a DC / DC converter, a voltage sensor, or another electrical component inside or outside the battery distribution unit 106. As shown in Fig. As shown in Figure 1, for example the high-voltage wires 116 and / or the low-voltage wires 118 emerge from the side of the battery distribution unit housing 108.

[0041] In the illustrated embodiment, the cross terminals 140 are connected to the strip-shaped busbar 138 along the upper edge 108 of the strip-shaped busbar 138. The upper edge 308 is received in the cross-shaped cavity 204 of the cross terminals 140.

[0042] Fig. Figure 9 illustrates a section of the battery distribution unit 106, showing one of the strip-shaped busbars 138, which is electrically connected via the corresponding cross terminals 140 to the pre-charge resistor 148 and the fuses 150, 152. In the illustrated embodiment, the cross terminals 140 are connected to the lower edge 310 of the strip-shaped busbar 138. The fuses 150, 152 are positioned below the strip-shaped busbar 138. Optionally, the fuses 150, 152 can be located below the base 162 (in Fig. 2 shown) of the lower housing element 132 (in Fig. 2 shown) be positioned, for example for access from outside the battery distribution unit housing 108 (in Fig. 2 shown).

[0043] Fig. Figure 10 shows a perspective view from below of the battery distribution unit 106 according to an alternative embodiment, showing the base 162 of the battery distribution unit housing 108. In the Fig. In the illustrated embodiment 10, the manual service disconnect switch 122 is shown connected to the base 162 of the battery distribution unit housing 108. The fuses 150, 152 are located inside the manual service disconnect switch 122. The fuses may not require any additional associated wires leading from the battery distribution unit housing 108 to the outside. The fuses 150, 152 can be concealed by the connector of the manual service disconnect switch 122 when the connector of the manual service disconnect switch 122 is connected to the base of the manual service disconnect switch 122. When the connector is removed, the fuses 150, 152 are exposed for maintenance and replacement.

[0044] The battery distribution unit 106 includes external connectors 340 along the base 162 for electrical connection with other complementary connectors (not shown). Cross terminals 140 are positioned within the external connectors 340 to make connections with the complementary connectors. The cross terminals 140 are configured to connect to corresponding strip-shaped busbars 138 along the lower edges 310 (both shown in Fig. (as shown in Figure 7) are to be coupled to the strip-shaped busbars 138. The cross terminals 140 are arranged for connection with the complementary connectors on an outer side of the battery distribution unit 106.

[0045] It is understood that the present description is intended for illustrative purposes and is not to be understood as limiting. For example, the embodiments described above (and / or aspects thereof) can be used in combination with one another. Furthermore, numerous modifications can be made to adapt a specific situation or material to the teachings of the invention without departing from its scope. Dimensions, material types, orientations of the various components, as well as the number and positions of the various components described herein, are intended to define parameters of specific embodiments and are in no way to be understood as limiting, but merely constitute exemplary embodiments. Those skilled in the art will recognize, upon reading the foregoing description, numerous further embodiments and modifications that are within the spirit and scope of the claims.

Claims

[1] Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein the strip-shaped busbar (138) has a first wide side (300) and a second wide side (302) extending along the length of the strip-shaped busbar (138) between a first end (304) and a second end (306), wherein the strip-shaped busbar (138) has an upper cross-terminal (140) and a lower cross-terminal (140) extending between the first end (304) and the second end (306), wherein the first and second cross-terminal (140) are attached at arbitrary points along the length either to the upper cross-terminal (140) or to the lower cross-terminal (140), and wherein the first and second cross-terminal (140) interact with both the first wide side (300) and the second wide side (302). [2] Battery distribution unit (106) according to claim 1, wherein the strip-shaped busbar (138) has at least two bends (312) along its length. [3] Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein at least one of the first and the second cross connection (140) has a plurality of protrusions (210) extending from wall segments (202) into a cruciform cavity (204) formed by a plurality of L-shaped wall segments (202); wherein the protrusions (210) are designed to interact with the strip-shaped busbar (138) when the strip-shaped busbar (138) is inserted into the cruciform cavity (204). [4] Battery distribution unit (106) according to one of the preceding claims, wherein the strip-shaped busbar (138) is formed from a metal strip which is cut to length and bent into a predetermined shape to electrically connect the first and second blade terminals (244) via the first and second cross terminals (140). [5] Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein the strip-shaped busbar (138) has a rectangular cross-section along its entire length, formed by opposing broad sides (300, 302) extending between an upper cross terminal (140) and a lower cross terminal (140), the cross terminals (140) being attached to the upper cross terminal (140) or the lower cross terminal (140) for interaction with the two broad sides. [6] Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein the first and second cross connection (140) have L-shaped wall segments (202) arranged in four quadrants, the L-shaped wall segments (202) forming a cross-shaped cavity (204) designed to receive the strip-shaped busbar (138). [7] Battery distribution unit (BDU) (106) configured to hold a first electronic device (136) with a first blade connection (244) extending away from it and a second electronic device (136) with a second blade connection (244) extending away from it, wherein the battery distribution unit (106) comprises: a battery distribution unit housing (108); a strip-shaped busbar (138) which is incorporated in the battery distribution unit housing (108); and a first and a second cross-connection (140) which are accommodated in the battery distribution unit housing (108), wherein the first cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the first blade connection (244) at a second end (222) of the first cross-connection (140), wherein the second cross-connection (140) accommodates the strip-shaped busbar (138) at a first end (220) of the same and is configured to accommodate the second blade connection (244) at a second end (222) of the second cross-connection (140); wherein the first and the second cross connection (140) each have a cruciform cavity (204) with a first cavity segment (206) and a second cavity segment (208) which is perpendicular to and intersects the first cavity segment (206), wherein the first and the second cross connection (140) are coupled to the strip-shaped busbar (138) in different orthogonal orientations by the strip-shaped busbar (138) being inserted into the first cavity segment (206) or into the second cavity segment (208) of the corresponding first or second cross connection (140) is inserted. [8] Battery distribution unit (106) according to one of the preceding claims, wherein the first and second cross terminals (140) have open sides (212, 214, 216, 218) at both their first end (220) and their second end (222) so that the strip busbar (138) and the corresponding first and second blade terminals (244) can pass through the open sides (212, 214, 216, 218). [9] Battery distribution unit (106) according to one of the preceding claims, wherein the battery distribution unit housing (108) has a channel (164) and chambers (166) open to the channel (164), wherein the strip busbar (138) is received in the channel (164) and wherein the first and second cross terminals (140) are received in corresponding chambers (166) to establish a mechanical and electrical connection with the strip busbar (138). [10] Battery distribution unit (106) according to one of the preceding claims, further comprising a second strip-shaped busbar (138) and a third cross-connection (140), wherein the third cross-connection (140) receives the second strip-shaped busbar (138) at a first end (220) of the same and is configured to receive a third contact blade (244) extending away from the second electronic device (136), so that both the strip-shaped busbar (138) and the second strip-shaped busbar (138) are electrically connected to the second electronic device (136).

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