High-low voltage integrated connector, BDU, and processing method therefor

Abstract

The present invention relates to the technical field of vehicle BDU connectors, and provides a high-low voltage integrated connector. The high-low voltage integrated connector comprises a PCB and an integrated component, wherein a first electrical component is fixedly provided on the PCB; and the integrated component comprises a plastic board and a plurality of spaced-apart conducting strips, the conducting strips being fixedly arranged in the plastic board, either end of each conducting strip extending out of the plastic board, and being fixedly arranged on a second electrical component or the PCB, and the end of the conduction strip being electrically connected to the second electrical component or being electrically connected to the first electrical component by means of the PCB. The present invention, by means of coordinating the relatively rigid PCB and the flexible integrated component, can not only ensure the firm fixation of the high-low voltage connector at positions prone to loosening, but also enhance the overall flexibility of the high-low voltage connector to absorb internal stress generated during the assembly or use of a BDU, thus ensuring the normal operation of the BDU.

Description

A high-low voltage integrated connector, BDU and processing method thereof Technical Field

[0001] The present invention relates to the technical field of automobile BDU connectors, and in particular to a high-low voltage integrated connector, a BDU and a processing method thereof. Background Art

[0002] BDU (battery disconnect unit) is an important component of new energy vehicles. It provides charge and discharge control and circuit overload protection for the high-voltage system of new energy vehicles. In order to achieve high-voltage sampling and low-voltage control of BDU, the internal part of BDU usually adopts wiring harness connection, PCB board connection or FPC connection to make electrical connections of high and low voltage signals.

[0003] Patent publication number CN112498267A discloses a high- and low-voltage integrated BDU, comprising a BDU body, which includes a housing, an upper end of which is provided with an opening, a top cover for sealing the opening, a main positive relay, a main negative relay, a pre-charging resistor, a pre-charging relay, a heating relay, and a PCB integrated module. The pre-charging relay and the pre-charging resistor are arranged in parallel with the main positive relay, and the main negative relay is arranged in series with the heating relay. The main positive relay, the main negative relay, the pre-charging relay, and the heating relay are electrically connected to the PCB integrated module, and one end of the PCB integrated module is provided with a battery positive electrode connecting plate and a battery negative electrode connecting plate, respectively, and the other end is provided with a motor positive electrode connecting plate and a motor negative electrode connecting plate. Beneficial effects include: separation of high and low voltage lines, integrated packaging, and high safety and reliability.

[0004] In the above technical solution, in order to improve the structural compactness of the BDU and avoid difficulties in arranging and fixing the wiring harness in the shell, a PCB integrated module is used to connect various electrical components. However, due to the hard texture and lack of toughness of the PCB board, it is not only difficult to absorb the internal stress generated during assembly, but also easily affected by the vibration of the BDU, causing the connection to become detached, affecting the normal operation of the BDU.

[0005] Summary of the Invention

[0006] In view of this, the present invention proposes a high- and low-voltage integrated connector, a BDU and a processing method thereof, which can improve the toughness of the high- and low-voltage connectors in the BDU while ensuring the firm fixation and ensuring the normal operation of the BDU.

[0007] The technical solution of the present invention is implemented as follows: On the one hand, the present invention provides a high-low voltage integrated connector, including a PCB board and an integrated component, wherein:

[0008] There are multiple PCB boards, and a first electrical component is fixedly mounted on each PCB board;

[0009] The integrated component includes a plastic plate and a plurality of conductive strips arranged at intervals. The conductive strips are fixedly arranged in the plastic plate, with both ends extending out of the plastic plate and fixedly arranged on the second electrical component or the PCB board. The ends of the conductive strips are electrically connected to the second electrical component or are electrically connected to the first electrical component through the PCB board.

[0010] On the basis of the above technical solution, preferably, the plastic plate is provided with a plurality of insulating holes;

[0011] The integrated component also includes a connecting plate and insulating glue, wherein,

[0012] A plurality of connecting plates are integrally formed between two adjacent conducting bars, and the plurality of connecting plates are all cut off by the insulating holes;

[0013] The plurality of insulating holes are filled with the insulating glue.

[0014] More preferably, at least one end of the conductive strip is fixed to and electrically connected to the PCB board, wherein:

[0015] If one end of the conductive strip is fixed to and electrically connected to the PCB board, and the other end is fixed to and electrically connected to the second electrical component, then the conductive strip includes a wire strip and a connecting piece, the wire strip is fixedly arranged in the plastic plate, and its two ends extend out of the plastic plate, the connecting piece is integrally formed at one end of the wire strip, the connecting piece is fixed to and electrically connected to the second electrical component, the end of the wire strip away from the connecting piece is fixed to and electrically connected to the PCB board, the connecting piece and the end of the wire strip away from the connecting piece are both provided with a Z-shaped bending portion by a pressing and bending method, and the side of the connecting piece close to the second electrical component is in contact with the second electrical component fixed to and electrically connected to it;

[0016] If the two ends of the conductive strip are respectively fixed to and electrically connected to the two PCB boards, the conductive strip comprises a wire strip, which is fixedly disposed in the plastic plate, with its two ends extending out of the plastic plate, both ends of the wire strip are fixed to and electrically connected to the PCB boards, and both ends of the wire strip are provided with a Z-shaped bend portion by a press-bending method;

[0017] The plurality of strips are flush with each other on a side away from the PCB board.

[0018] More preferably, if the two PCB boards are electrically connected to the same second electrical component through the conductive strip, the two wire strips in the two conductive strips are integrally formed with the same connecting piece, and two bending portions are provided on the connecting piece.

[0019] In a second aspect, the present invention provides a high-low voltage integrated BDU, comprising the above-mentioned connector, a first electrical component, a second electrical component and a housing, wherein:

[0020] At least two fixing holes are formed on the PCB board and the plastic board, and at least one fixing hole is formed on the connecting piece;

[0021] The second electrical component is fixedly arranged on the shell, and a plurality of thermal anchor rods are integrally formed on the second electrical component and the shell, the plurality of thermal anchor rods correspond one-to-one to the positions of the plurality of fixing holes, and the PCB board and the plastic board are anchored to the shell and the thermal anchor rods through the fixing holes, and the connecting piece and the second electrical component are anchored to the thermal anchor rods through the fixing holes.

[0022] On the basis of the above technical solution, preferably, it further comprises a plurality of high-voltage copper bars, wherein the high-voltage copper bars are fixedly arranged in the housing and located on a side of the second electrical component away from the PCB board;

[0023] The first electrical component includes a cable connector, a pre-charging resistor, and a pre-charging relay. Two PCB boards are provided, the cable connector is fixedly provided on one of the PCB boards, and the pre-charging resistor and the pre-charging relay are fixedly provided on the other PCB board; and the cable connector, the pre-charging resistor, and the pre-charging relay are electrically connected to the conductive strip via the PCB board;

[0024] The second electrical component includes a fuse, a main positive relay, a fast charging positive relay, a main negative relay, a Shunt shunt and a plurality of terminals, and the fuse, the main positive relay, the fast charging positive relay, the main negative relay and the Shunt shunt are all fixedly arranged on the housing;

[0025] The fuse, the main positive relay, and the power supply end of the fast-charging positive relay are sequentially connected in series through the high-voltage copper busbar to form a positive circuit; the pre-charging resistor and the power supply end of the pre-charging relay are sequentially connected in series through the PCB board and then connected in parallel with the main positive relay to form a pre-charging circuit; the Shunt shunt and the power supply end of the main negative relay are sequentially connected in series through the high-voltage copper busbar to form a negative circuit;

[0026] The high-voltage copper busbar connected in series with the main negative relay and the fast-charging positive relay is fixed with a terminal and electrically connected thereto, and one end of the terminal away from the high-voltage copper busbar is fixed with the connecting piece and electrically connected thereto;

[0027] The conductive strips include multiple high-voltage conductive strips and multiple low-voltage conductive strips. The current output end of the fuse, the current output end of the main positive relay, the current output end of the fast-charging positive relay, the current input end of the main negative relay and the current output end of the Shunt shunt are all electrically connected to the cable connector through the high-voltage conductive strips and the PCB board; the two control ends of the main positive relay, the two control ends of the fast-charging positive relay, the two control ends of the main negative relay and the two control ends of the pre-charging relay are all electrically connected to the cable connector through the low-voltage conductive strips and the PCB board.

[0028] Further preferably, the second electrical component also includes a fast-charging negative relay, which is fixedly arranged on the housing, and the power supply end of the fast-charging negative relay is connected in series with the negative pole circuit through the high-voltage copper busbar, and the current input end of the fast-charging negative relay is electrically connected to the cable connector through the high-voltage conductive strip and the PCB board, and the two control ends of the fast-charging negative relay are electrically connected to the cable connector through the low-voltage conductive strip and the PCB board.

[0029] More preferably, the plurality of high-voltage copper bars include at least one supporting copper bar, and the supporting copper bar includes two connecting parts, a supporting part and two reinforcing parts, wherein:

[0030] One end of the connecting portion is fixed to and electrically connected to the second electrical component, and the two connecting portions are arranged in parallel and spaced apart;

[0031] The supporting portion is located between the two connecting portions and is perpendicular thereto;

[0032] The two reinforcement parts are respectively located between the two connecting parts and the supporting part. The cross section of the reinforcement part is U-shaped, and the two ends thereof are respectively continuously arranged with the connecting part and the supporting part and are integrally formed.

[0033] A reinforcement groove is provided on the shell, the reinforcement portion is engaged with the reinforcement groove, and the support portion is in contact with the inner wall of the shell.

[0034] In a third aspect, the present invention provides a method for processing a high- and low-voltage integrated BDU, comprising the following steps:

[0035] S1, taking out a copper plate, and punching holes in the copper plate using a punching machine to produce a first semi-finished product consisting of the conductive strip, the connecting plate, and the reinforcing member;

[0036] S2, according to actual needs, using a stamping device to stamp the bent portion on the first semi-finished product to produce a second semi-finished product;

[0037] S3, using an injection molding machine to inject plastic onto the outer side of the second semi-finished product to produce a third semi-finished product;

[0038] S4, first punching the third semi-finished product using a punching machine to remove the intervening plates and plastic in the insulating holes, cutting the multiple intervening plates, removing the plastic at the reinforcement and in the fixing and lightening holes, and then injecting the insulating glue into the insulating holes to produce the integrated component;

[0039] S5, preparing a PCB board on which the cable connector is installed and a PCB board on which the pre-charging resistor and the pre-charging relay are installed;

[0040] S6, sequentially installing the high-voltage copper busbar and a plurality of the second electrical components in the housing, and connecting the second electrical components using the high-voltage copper busbar;

[0041] S7, installing the PCB and the integrated component on the housing, and engaging the fixing holes in the PCB and the heat anchor rods at corresponding positions thereof, heating and deforming the heat anchor rods using a heat anchor device, and using the deformed heat anchor rods to hold and fix the PCB and the integrated component;

[0042] S8, welding the end of the wire strip and the connecting piece to the corresponding PCB board or the second electrical component by laser welding.

[0043] Based on the above technical solution, preferably, in step S1, the reinforcement member includes a rectangular ring frame located at the periphery of the conductive strip and the involvement plate and integrally formed with the two through the involvement plate, or a filling plate located between a plurality of the conductive strips and integrally formed with the conductive strips through the involvement plate.

[0044] The high-low voltage integrated connector, BDU and processing method thereof of the present invention have the following beneficial effects compared with the prior art:

[0045] (1) By combining a hard PCB board with a tough integrated component, it is possible to ensure that the high and low voltage connectors are firmly fixed in locations prone to loosening, and to improve their overall toughness to absorb the internal stress generated during BDU assembly or use, thereby ensuring the normal operation of the BDU.

[0046] (2) By providing a connecting plate between the conductive strips, the conductive strips can be bonded at intervals after being punched on the copper plate, which not only facilitates the injection molding of the plastic plate, but also avoids the short circuit problem caused by the position change of the conductive strips during the injection molding of the plastic plate. By providing insulating holes and insulating glue, the conductive strips can be sealed and insulated, thereby ensuring the normal use of the connector;

[0047] (3) By providing a bend on one end of the line tape close to the PCB board and on the connecting piece, not only can the line tape and the connecting piece absorb the internal stress generated during the assembly or use of the BDU, but also, while ensuring that the lines are in the same plane, the connecting piece can be attached to the second electrical component at different heights, thereby making the connector suitable for different models of electrical components;

[0048] (4) By improving the electrical architecture and optimizing the layout of high-voltage acquisition or low-voltage control connectors, not only can better acquisition effects be achieved, but the internal structure of the BDU can also be simplified, improving the compactness of the internal structure of the BDU;

[0049] (5) By punching multiple conductive strips from the same copper plate, the connecting piece and the second electrical component are fixed by laser welding, thereby improving the production and assembly efficiency of the BDU;

[0050] (6) By providing fixing holes and heat anchors to replace the bolt fixing method, not only can the rapid assembly and positioning of the electrical connector with the housing and the electrical components be improved, but also the torque risk caused by tightening the bolts on the connector in the prior art can be avoided;

[0051] (7) By providing support copper bars and buffer copper bars, the connection strength of the internal structural parts of the BDU can be improved or the internal stress generated during operation can be absorbed, thereby increasing the service life of the BDU. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0053] FIG1 is a perspective view of a high-low voltage integrated connector according to the present invention;

[0054] FIG2 is a perspective view of an integrated component in a high-low voltage integrated connector of the present invention;

[0055] FIG3 is an exploded view of the X in FIG2 ;

[0056] FIG4 is a perspective view of a conductive strip in a high-low voltage integrated connector according to the present invention;

[0057] FIG5 is a perspective view of a wire belt and a connecting piece in a high-low voltage integrated connector of the present invention;

[0058] FIG6 is a perspective view of a high and low voltage integrated BDU according to the present invention;

[0059] FIG7 is an exploded view of position Y in FIG6 ;

[0060] FIG8 is a top view of the second electrical component 4 in a high-low voltage integrated BDU of the present invention;

[0061] FIG9 is a perspective view of a high-voltage copper busbar in a high- and low-voltage integrated BDU according to the present invention;

[0062] FIG10 is a perspective view of a supporting copper busbar in a high and low voltage integrated BDU according to the present invention;

[0063] FIG11 is a cross-sectional view of the installation position of the support copper busbar in a high and low voltage integrated BDU of the present invention;

[0064] FIG12 is a cross-sectional view of a buffer copper bus in a high-low voltage integrated BDU according to the present invention;

[0065] FIG13 is a top view of a first semi-finished product including a frame in a method for manufacturing a high-low voltage integrated BDU according to the present invention;

[0066] FIG14 is a top view of a first semi-finished product including a filler plate in a method for manufacturing a high-low voltage integrated BDU according to the present invention;

[0067] FIG15 is a right side view of a second semi-finished product in a method for processing a high-low voltage integrated BDU according to the present invention;

[0068] FIG16 is a top view of a conductive strip in a high-low voltage integrated connector according to the present invention;

[0069] FIG17 is an electrical schematic diagram of a high and low voltage integrated BDU of the present invention;

[0070] FIG18 is an electrical schematic diagram of a high-low voltage integrated BDU of the present invention with a fast-charging negative relay added.

[0071] Among them: 1. PCB board; 101. Fixing hole; 2. Integrated component; 21. Plastic board; 22. Conductive strip; 221. Wire tape; 222. Connecting piece; 23. Connecting plate; 24. Insulating glue; 25. Frame; 26. Filling plate; 201. Insulating hole; 202. Bending part; 203. Weight-reducing hole; 3. First electrical component; 31. Cable connector; 32. Pre-charging resistor; 33. Pre-charging relay; 4. Second electrical component; 41. Fuse; 42. Main positive relay; 43. Fast charging positive relay; 44. Main negative relay; 45. Shunt shunt; 46. Terminal; 5. Housing; 51. Thermal anchor rod; 501. Reinforcement groove; 6. High-voltage copper busbar; 61. Supporting copper busbar; 611. Connecting part; 612. Supporting part; 613. Reinforcement part. DETAILED DESCRIPTION

[0072] The following will be combined with the specific embodiments of the present invention to clearly and completely describe the technical solutions of the present invention. Obviously, the embodiments described are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0073] As shown in FIG1-16 , a high-low voltage integrated BDU of the present invention includes a connector, a first electrical component 3 , a second electrical component 4 , a shell 5 and a plurality of high-voltage copper busbars 6 .

[0074] The connector is used to connect the first electrical component 3 and the second electrical component 4 to achieve low-voltage control and high-voltage collection inside the BDU. The connector includes a PCB board 1 and an integrated component 2.

[0075] The PCB board 1 is used to carry the first electrical component 3. There are multiple PCB boards 1. The first electrical component 3 is fixedly mounted on the PCB board 1. By utilizing its hard texture, the first electrical component 3 can be firmly installed and fixed to prevent it from loosening during use.

[0076] The integrated component 2 is used to achieve conduction between the first electrical component 3 and the second electrical component 4. The integrated component 2 includes a plastic plate 21 and a plurality of conductive strips 22 arranged at intervals. The plastic plate 21 is made of a tough plastic material. The conductive strips 22 are fixedly arranged in the plastic plate 21, and their two ends extend out of the plastic plate 21 and are fixedly arranged on the second electrical component 4 or the PCB board 1. The end of the conductive strip 22 is electrically connected to the second electrical component 4 or electrically connected to the first electrical component 3 through the PCB board 1 (using the copper traces etched on the PCB board); because the plastic plate 21 has a certain toughness, when assembling the BDU or during the use of the BDU, the integrated component 2 can absorb the internal stress of the BDU, thereby avoiding the falling off of the connection ends of the integrated component 2 and the first electrical component 3 and the second electrical component 4, thereby improving the fixing firmness of the integrated component 2 and ensuring the normal operation of the BDU.

[0077] The integrated component 2 is composed of a plurality of conductive bars 22 and a plastic plate 21. When processing the integrated component 2, it is usually achieved by punching out the plurality of conductive bars 22 from the copper plate one by one, then positioning the plurality of mutually independent conductive bars 22, and finally performing injection molding on the outside of the conductive bars 22. This production process is relatively cumbersome (the positioning operation of the conductive bars 22 is complicated and not easy to fix), and the conductive bars 22 are compounded with high and low voltage signal connection lines. The intervals between the high and low voltage lines are small, and there is a risk of short circuit. In view of this, an impingement plate 23 can be set in the integrated component 2, so that a plurality of impingement plates 23 are integrally formed between two adjacent conductive bars 22, so that the plurality of conductive bars 22 can be punched out integrally on the same copper plate, and During this punching process, the shape, position and spacing of the conductive strips 22 are fixed by the engaging plate 23, eliminating the tedious processing steps such as placement and positioning, thereby improving the processing efficiency of the integrated component 2; since the engaging plate 23 will cause conduction between the conductive strips 22, it is necessary to cut the engaging plate 23 in the subsequent processing steps. Preferably, a plurality of insulating holes 201 are opened on the plastic plate 21 so that the plurality of engaging plates 23 are cut off by the insulating holes 201 to ensure the insulation of the conductive strips 22. Insulating glue 24 should also be provided in the integrated component 2, and the insulating glue 24 should be filled in the plurality of insulating holes 201. This can not only improve the insulation performance between the conductive strips 22, but also seal the engaging plate 23 to prevent it from corrosion.

[0078] The conducting strip 22 combines the low-voltage control line and the high-voltage acquisition line. Although the rules for connecting the electrical components are different, at least one end of the conducting strip 22 is fixed to the PCB board 1 and electrically connected. If one end of the conducting strip 22 is fixed to the PCB board 1 and electrically connected, and the other end is fixed to the second electrical component 4 and electrically connected, then the conducting strip 22 includes a strip 221 and a connecting piece 222. The strip 221 is fixedly arranged in the plastic plate 21, and its two ends extend out of the plastic plate 21. The connecting piece 222 is integrally formed at one end of the strip 221. The connecting piece 222 is connected to the second electrical component 4. The gas component 4 is fixed and electrically connected, and the end of the tape 221 away from the connecting piece 222 is fixed and electrically connected to the PCB board 1. As shown in Figure 4, several conductive strips 22 with connecting pieces 222 in the figure belong to this situation. The connecting piece 222 and the end of the tape 221 away from the connecting piece 222 are both provided with a Z-shaped bending portion 202 by bending. The side of the connecting piece 222 close to the second electrical component 4 is in contact with the second electrical component 4 fixed and electrically connected thereto; as another case, if the two ends of the conductive strip 22 are respectively fixed to the two PCB boards 1 and electrically connected The conductive strip 22 includes a wire strip 221, which is fixedly arranged in the plastic plate 21, and its two ends extend out of the plastic plate 21. Both ends of the wire strip 221 are fixed to the PCB board 1 and electrically connected. As shown in FIG4 , the conductive strip 22 without the connecting piece 222 has a Z-shaped bending portion 202 at both ends of the wire strip 221 by pressing and bending. With this structural method, not only can the soldering installation space occupied by the integrated component 2 on the PCB board 1 be reduced, but the contact area between the integrated component 2 and the second electrical component 4 can also be increased, thereby improving the fixing strength of the two. ; The setting of the bending portion 202 not only allows the conductive strip 22 to absorb the internal stress of its connection end, but also allows multiple wire strips 221 to be flush with one side away from the PCB board 1, that is, the middle positions of multiple wire strips 221 are in the same plane, which reduces the space occupied by the integrated component 2 and improves the compactness of the internal structure of the BDU. At the same time, by setting bending portions 202 of different heights on each connecting piece 222, different connecting pieces 222 can be installed at different heights in the BDU, thereby adapting to the different heights of each second electrical component 4.

[0079] Furthermore, as shown in FIG16 , if two PCB boards 1 are electrically connected to the same second electrical component 4 through a conductive bar 22 (the two conductive bars 22 connected by the first connecting piece 222 at the bottom and right in the figure), the two wire strips 221 in the two conductive bars 22 are integrally formed with the same connecting piece 222, and two bending portions 202 are provided on this connecting piece 222 to save materials and improve the compactness of the BDU structure.

[0080] The first electrical component 3 includes a cable connector 31, a pre-charging resistor 32 and a pre-charging relay 33. Under this working condition, two PCB boards 1 are provided, the cable connector 31 is fixedly arranged on one of the PCB boards 1, and the pre-charging resistor 32 and the pre-charging relay 33 are fixedly arranged on the other PCB board 1; and the cable connector 31, the pre-charging resistor 32 and the pre-charging relay 33 are electrically connected to the conductive strip 22 through the PCB board 1. Since the cable connector 31 is prone to shaking when plugging and unplugging with the external line, it is necessary to use the PCB board 1 to strengthen its fixing firmness. Compared with other electrical components, the pre-charging resistor 32 and the pre-charging relay 33 do not require too many line connections, and only need to be connected in series. Therefore, the PCB board 1 is also used to support and fix the two, thereby ensuring the cable connector 31, the pre-charging resistor 32 and the pre-charging relay 33. The firmness of the fixation during use is guaranteed to prevent them from shaking.

[0081] The second electrical component 4 includes a fuse 41 , a main positive relay 42 , a fast charge positive relay 43 , a main negative relay 44 , a Shunt shunt 45 and a plurality of terminals 46 .

[0082] The shell 5 is the main frame of the BDU, which is used to carry and protect other components. The connecting parts and the second electrical parts 4 are all fixedly arranged on the shell 5, that is, the PCB board 1, the integrated part 2, the fuse 41, the main positive relay 42, the fast charging positive relay 43, the main negative relay 44 and the Shunt shunt 45 are all fixedly arranged on the shell 5; specifically, in the prior art, the electrical parts and the PCB board 1 are usually fixed by bolts, and since the wire tape 221 and the connecting piece 222 are embedded in the plastic plate 21, the structural strength of the protruding position of the end thereof is relatively fragile. When the bolts are tightened, this torque will drive the integrated part 2 to rotate and cause damage to it. In order to solve this problem, it is preferred to open at least two fixing holes 101 on the PCB board 1 and the plastic plate 21, and At least one fixing hole 101 is provided on the sheet 222 (the larger the area, the more the number of fixing holes 101 is provided), and a plurality of heat anchor rods 51 are integrally formed on the second electrical component 4 and the shell 5, as shown in Figures 6 and 7, so that the positions of the plurality of heat anchor rods 51 correspond one-to-one to the positions of the plurality of fixing holes 101, so that the PCB board 1 and the plastic plate 21 are anchored to the shell 5 through the fixing holes 101 and the heat anchor rods 51, and the connecting sheet 222 and the second electrical component 4 are anchored to the heat anchor rods 51 through the fixing holes 101. The anchoring is specifically implemented by allowing the heat anchor rod 51 to pass through the fixing hole 101, and then causing the heat anchor rod 51 to deform due to heat, so that the deformed heat anchor rod 51 is used to support and fix the PCB board 1, the plastic plate 21 or the connecting sheet 222. The operation process does not generate torque, and thus there is no torque risk.

[0083] The high-voltage copper busbar 6 is used to achieve high-voltage electrical conduction inside the BDU. The high-voltage copper busbar 6 is fixedly arranged in the shell 5 and is located on the side of the second electrical component 4 away from the PCB board 1. As shown in Figures 6 and 9, by optimizing the internal structure of the BDU, the control end connector and the low-voltage information acquisition connector of the second electrical component 4 are on the same side of the second electrical component 4, and the high-voltage copper busbar 6 is on the other side of the second electrical component 4 to provide good protection for the inside of the BDU; as shown in Figures 9 and 17, the power supply ends of the fuse 41, the main positive relay 42 and the fast charging positive relay 43 are connected in series in sequence through the high-voltage copper busbar 6 to form a positive circuit; the power supply ends of the pre-charging resistor 32 and the pre-charging relay 33 are connected in series in sequence through the PCB board 1 Then it is connected in parallel with the main positive relay 42 to form a pre-charge circuit; the power supply end of the Shunt shunt 45 and the main negative relay 44 are connected in series in sequence through the high-voltage copper bus 6 to form a negative circuit; the high-voltage copper bus 6 connected in series with the main negative relay 44 and the fast-charging positive relay 43 are fixed with and electrically connected with a terminal 46, and the end of the terminal 46 away from the high-voltage copper bus 6 is fixed and electrically connected to the connecting piece 222, so that the conductive bar 22 located on both sides of the second electrical component 4 and the high-voltage copper bus 6 are connected, so that the conductive bar 22 can be connected to the high-voltage copper bus 6 on one side of the control end of the second electrical component 4, thereby realizing the collection of high-voltage information, avoiding the bending design of the line, simplifying the internal structure of the BDU, and improving its structural compactness.

[0084] The conductive strip 22 includes a plurality of high-voltage conductive strips and a plurality of low-voltage conductive strips, which are used for high-voltage collection and low-voltage control respectively. As shown in FIG17 , the current output end of the fuse 41, the current output end of the main positive relay 42, the current output end of the fast-charge positive relay 43, the current input end of the main negative relay 44 and the current output end of the Shunt shunt 45 are respectively provided with connection points A, C, D, G and R. The high-voltage signals at various positions in the high-voltage conductive circuit are collected by using the connection points A, C, D, G and R. The connection points A, C, D, G and R are electrically connected to the cable connector 31 through the high-voltage conductive strip and the PCB board 1 so as to collect the high-voltage signals therefrom through the cable connector 31. Correspondingly, the main positive relay 4 2, the two control ends (KM1+ and KM1-), the two control ends (KM4+ and KM4-) of the fast charging positive relay 43, the two control ends (KM3+ and KM3-) of the main negative relay 44, and the two control ends (KM2+ and KM2-) of the pre-charging relay 33 are all electrically connected to the cable connector 31 through the low-voltage conductive strip and the PCB board 1, so that low-voltage control can be performed on them through the cable connector 31. The connection points A, C, D, G, KM1+, KM1-, KM2+, KM2-, KM3+, KM3-, KM4+ and KM4- of the conductive strip 22 fully cover all the points in the BDU that require high-voltage signal acquisition and low-voltage control, thereby realizing comprehensive control of the BDU.

[0085] A fast charge negative relay can also be provided in the second electrical component 4. The fast charge negative relay is fixedly arranged on the housing 5. As shown in FIG. 18, the power supply terminal of the fast charge negative relay is connected in series with the negative electrode circuit through a high-voltage copper bar 6, that is, the power supply terminals of the Shunt shunt 45, the main negative relay 44, and the fast charge negative relay are connected in series in sequence through the high-voltage copper bar 6 to form a negative electrode circuit. To achieve high-voltage acquisition and low-voltage control of the fast charge negative relay, a connection point F is preferably provided at the current input terminal of the fast charge negative relay, and the connection point F is electrically connected to the cable connector 31 through a high-voltage conduction bar and the PCB board 1, so as to collect the high-voltage signal at the position of the fast charge negative relay through the cable connector 31. The two control terminals (KM5+ and KM5-) of the fast charge negative relay 47 are both electrically connected to the cable connector 31 through a low-voltage conduction bar and the PCB board 1, so as to perform low-voltage control on it through the cable connector 31.

[0086] There are a large number of second electrical components 4 in the BDU, and their shapes are different, resulting in differences in the installation positions and shapes of the high-voltage copper bars 6. The multiple high-voltage copper bars 6 will at least include one support copper bar 61, which plays an auxiliary support role. As shown in FIG. 9, the high-voltage copper bar 6 at the bottom of the fuse 41. The specification of the fuse 41 is relatively small compared with other electrical components, and its placement position is likely to be inclined. Therefore, it is necessary to make the high-voltage copper bar 6 below it play a certain support role and set it as the support copper bar 61. For the structure of the support copper bar 61, it is preferably set that the support copper bar 61 includes two connecting parts 611, a support part 612, and two strengthening parts 613. Among them, one end of the connecting part 611 is fixedly and electrically connected to the second electrical component 4, and the two connecting parts 611 are arranged in parallel and at intervals; the support part 612 is located between the two connecting parts 611 and is perpendicular to them, that is, the two connecting parts 611 and a support part 612 form an I-shaped or C-shaped; the two strengthening parts 613 are respectively located between the two connecting parts 611 and the support part 612. The cross-section of the strengthening part 613 is U-shaped, and its two ends are continuously arranged and integrally formed with the connecting part 611 and the support part 612 respectively. As shown in FIG. 10, the two U-shaped strengthening parts 613 are located on the right side of the support part 612, the two connecting parts 611 are located on the left side of the support part 612, and the strengthening part 613 corresponds to the connecting part 611 one by one, so that the support copper bar 61 as a whole forms an I-shaped, playing a certain anti-overturning effect, and thus can provide a better support effect for the electrical components above it.

[0087] In order to improve the supporting effect of the supporting copper busbar 61, it is preferred to provide a reinforcement groove 501 on the shell 5, so that the reinforcement part 613 is engaged with the reinforcement groove 501, so that the support part 612 is in contact with the inner wall of the shell 5. Of course, the supporting copper busbar 61 can also be directly injection molded into the shell 5, as shown in Figure 11. The upper and lower sides of the two reinforcement parts 613 are in contact with the reinforcement groove 501, and the right side of the support part 612 is in contact with the shell 5. When the supporting copper busbar 61 is installed between electrical components, it will not move. Due to its I-shaped shape and the support of the shell 5, deformation of the supporting copper busbar 61 can also be avoided. If the supporting copper busbar 61 is removable, as shown in Figure 11, it can only slide to the left when it is separated from the electrical component to facilitate installation and removal of the supporting copper busbar 61.

[0088] The structural strength of the supporting copper busbar 61 is relatively increased, which can provide a good supporting effect, but its effect of absorbing internal stress is not very ideal. Therefore, a buffer copper busbar can also be provided. Compared with the supporting copper busbar 61, the buffer copper busbar also includes two parallel connecting parts 611 and a supporting part 612, but does not have a reinforcing part 613. The three are combined to form a U-shaped structure. When used under working conditions with relatively high stress, the two buffer copper buses are relatively arranged and slidably connected. Specifically, one of the connecting parts 611 of a buffer copper busbar is allowed to slide and be electrically connected to the supporting part 612 of the other buffer copper busbar, while the other connecting part 611 of the buffer copper busbar is fixed and electrically connected to the electrical component. As shown in Figure 12, the two buffer copper buses are respectively fixed to the two electrical components. The internal stress can be absorbed by sliding the two buffer copper buses in opposite or opposite directions. Of course, in order to improve the safety of the two buffer copper buses, tape or other structural parts can be used for simple positioning between the two buffer copper buses.

[0089] A processing method of a high-low voltage integrated BDU of the present invention is as follows:

[0090] S1, take out the copper plate, use a punching machine to punch holes in the copper plate, and make a first semi-finished product consisting of a conductive strip 22, an impingement plate 23 and a reinforcement member, the reinforcement member includes a rectangular ring frame 25 located outside the conductive strip 22 and the impingement plate 23 and integrally formed with the two through the impingement plate 23, or a filling plate 26 located between the plurality of conductive strips 22 and integrally formed with the conductive strip 22 through the impingement plate 23, wherein, as shown in FIG13, if the reinforcement member is a frame 25, the frame 25 is located outside the plurality of conductive strips 22, and holes and grooves are opened on the frame 25, not only can the plurality of conductive strips 22 be connected, but also the plurality of conductive strips 22 can be connected. Combining them into a larger whole prevents multiple conductive bars 22 from scattering or deforming, and can also facilitate the positioning and installation of the first semi-finished product, making subsequent processing operations easier; as shown in Figure 14, if the reinforcement is a filling plate 26, the filling plate 26 is set at a position where the distance between two adjacent conductive bars 22 is large or the distribution density of the conductive bars 22 is high, which can also make multiple conductive bars 22 combined into a larger whole, preventing multiple conductive bars 22 from scattering or deforming. Compared with the frame 25, it has relatively less waste and can provide better anti-deformation properties.

[0091] S2. Based on actual needs, a stamping machine is used to stamp the bent portion 202 on the first semi-finished product to produce a second semi-finished product. As shown in FIG15 , the bent portion 202 of the ribbon 221 connected to one end of the PCB board 1 has the same size, while the bent portions 202 of the connecting pieces 222 at different locations have different sizes to accommodate the second electrical component 4 at the corresponding locations.

[0092] S3, using an injection molding machine to inject plastic onto the outer side of the second semi-finished product to produce a third semi-finished product, with the conductive strip 22 and the connecting plate 23 embedded in the plastic plate 21;

[0093] S4. First, use a punching machine to punch out the third semi-finished product, remove the intervening plate 23 and plastic in the insulating hole 201, cut off the multiple intervening plates 23, and remove the plastic at the reinforcement, fixing hole 101, and weight-reducing hole 203. During processing, the multiple conductive bars 22 are maintained at intervals by the action of the intervening plates 23. When the intervening plates 23 are cut off, adjacent conductive bars 22 are not electrically conductive, ensuring the safety of the high and low voltage signal connector. Then, inject insulating glue 24 into the insulating hole 201 to ensure that the two parts of the same intervening plate 23 cut off by the insulating hole 201 are insulated and sealed, thereby producing the integrated component 2.

[0094] S5, preparing a PCB board 1 installed with a cable connector 31 and a PCB board 1 installed with a pre-charge resistor 32 and a pre-charge relay 33;

[0095] S6, sequentially install the high-voltage copper busbar 6 and multiple second electrical components 4 in the housing 5, and connect the second electrical components 4 using the high-voltage copper busbar 6, and conduct the second electrical components 4 using the electrical principle shown in Figure 17;

[0096] S7, installing the PCB 1 and the integrated component 2 on the housing 5, and engaging the fixing holes 101 inside the PCB and the corresponding heat anchors 51. Using a heat anchor device, heat and deform the heat anchors 51, and use the deformed heat anchors 51 to hold and secure the PCB 1 and the integrated component 2.

[0097] S8, using laser welding to weld the end of the wire strip 221 and the connecting piece 222 to the corresponding PCB board 1 or the second electrical component 4, thereby completing the connection of the connectors in the BDU.

[0098] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A high and low voltage integrated connector, characterized in that: It comprises a PCB board (1) and an integrated component (2), wherein: The PCB boards (1) are provided in plurality, and a first electrical component (3) is fixedly provided on the PCB boards (1); The integrated component (2) comprises a plastic plate (21) and a plurality of conducting strips (22) arranged at intervals, wherein the conducting strips (22) are fixedly arranged in the plastic plate (21), and both ends thereof extend out of the plastic plate (21) and are fixedly arranged on a second electrical component (4) or the PCB board (1), and the ends of the conducting strips (22) are electrically connected to the second electrical component (4) or are electrically connected to the first electrical component (3) through the PCB board (1).

2. A high and low voltage integrated connector according to claim 1, characterized in that: The plastic plate (21) is provided with a plurality of insulating holes (201); The integrated component (2) further comprises a connecting plate (23) and an insulating adhesive (24), wherein: A plurality of connecting plates (23) are integrally formed between two adjacent conducting bars (22), and the plurality of connecting plates (23) are all cut off by the insulating holes (201); The plurality of insulating holes (201) are all filled with the insulating glue (24).

3. A high and low voltage integrated connector as claimed in claim 2, characterized in that: At least one end of the conductive strip (22) is fixed to and electrically connected to the PCB board (1), wherein: If one end of the conducting strip (22) is fixed to and electrically connected to the PCB board (1), and the other end is fixed to and electrically connected to the second electrical component (4), then the conducting strip (22) comprises a wire strip (221) and a connecting piece (222), wherein the wire strip (221) is fixedly arranged in the plastic plate (21), and its two ends extend out of the plastic plate (21); the connecting piece (222) is integrally formed at one end of the wire strip (221), and the connecting piece (222) is connected to the second electrical component (4). The second electrical component (4) is fixed and electrically connected, one end of the wire band (221) away from the connecting piece (222) is fixed and electrically connected to the PCB board (1), the connecting piece (222) and one end of the wire band (221) away from the connecting piece (222) are both provided with a Z-shaped bending portion (202) by means of bending, and a side of the connecting piece (222) close to the second electrical component (4) is in contact with the second electrical component (4) fixed and electrically connected thereto; If the two ends of the conductive strip (22) are respectively fixed to the two PCB boards (1) and electrically connected, The conductive strip (22) comprises a wire strip (221), the wire strip (221) is fixedly arranged in the plastic plate (21), and its two ends extend out of the plastic plate (21), both ends of the wire strip (221) are fixed to and electrically connected to the PCB board (1), and both ends of the wire strip (221) are provided with a Z-shaped bending portion (202) by means of a bending press; The plurality of line strips (221) are flush with one another on a side away from the PCB board (1).

4. A high and low voltage integrated connector as claimed in claim 3, characterized in that: If the two PCB boards (1) are electrically connected to the same second electrical component (4) via the conductive strip (22), the two wire strips (221) in the two conductive strips (22) are integrally formed with the same connecting piece (222), and the connecting piece (222) is provided with two bent portions (202).

5. A high and low voltage integrated BDU, characterized in that: The invention comprises the connecting member as claimed in claim 4, a first electrical member (3), a second electrical member (4) and a housing (5), wherein: At least two fixing holes (101) are provided on the PCB board (1) and the plastic board (21), and at least one fixing hole (101) is provided on the connecting piece (222); The second electrical component (4) is fixedly arranged on the housing (5), and a plurality of heat anchor rods (51) are integrally formed on the second electrical component (4) and the housing (5), the positions of the plurality of heat anchor rods (51) correspond one to one with the positions of the plurality of fixing holes (101), and the PCB board (1) and the plastic board (21) are both anchored to the housing (5) through the fixing holes (101) and the heat anchor rods (51), and the connecting piece (222) and the second electrical component (4) are anchored to the heat anchor rods (51) through the fixing holes (101).

6. A high and low voltage integrated BDU as claimed in claim 5, characterized in that: It also comprises a plurality of high-voltage copper bars (6), wherein the high-voltage copper bars (6) are fixedly arranged in the housing (5) and are located on a side of the second electrical component (4) away from the PCB board (1); The first electrical component (3) comprises a cable connector (31), a pre-charging resistor (32) and a pre-charging relay (33); two PCB boards (1) are provided, the cable connector (31) is fixedly arranged on one of the PCB boards (1), and the pre-charging resistor (32) and the pre-charging relay (33) are fixedly arranged on the other PCB board (1); and the cable connector (31), the pre-charging resistor (32) and the pre-charging relay (33) are electrically connected to the conductive strip (22) via the PCB board (1); The second electrical component (4) comprises a fuse (41), a main positive relay (42), a fast charging positive relay (43), a main negative relay (44), a Shunt shunt (45) and a plurality of terminals (46); the fuse (41), the main positive relay (42), the fast charging positive relay (43), the main negative relay (44) and the Shunt shunt (45) are all fixedly arranged on the housing (5); The power supply ends of the fuse (41), the main positive relay (42) and the fast charging positive relay (43) are sequentially connected in series through the high-voltage copper busbar (6) to form a positive circuit; the pre-charging resistor (32) and the power supply end of the pre-charging relay (33) are sequentially connected in series through the PCB board (1) and then connected in parallel with the main positive relay (42) to form a pre-charging circuit; the power supply end of the Shunt shunt (45) and the main negative relay (44) are sequentially connected in series through the high-voltage copper busbar (6) to form a negative circuit; A terminal (46) is fixed and electrically connected to the high-voltage copper busbar (6) connected in series with the main negative relay (44) and the fast-charging positive relay (43); an end of the terminal (46) away from the high-voltage copper busbar (6) is fixed and electrically connected to the connecting piece (222); The conduction strip (22) comprises a plurality of high-voltage conduction strips and a plurality of low-voltage conduction strips; the current output end of the fuse (41), the current output end of the main positive relay (42), the current output end of the fast-charging positive relay (43), the current input end of the main negative relay (44) and the current output end of the Shunt shunt (45) are all electrically connected to the cable connector (31) through the high-voltage conduction strip and the PCB board (1); the two control ends of the main positive relay (42), the two control ends of the fast-charging positive relay (43), the two control ends of the main negative relay (44) and the two control ends of the pre-charging relay (33) are all electrically connected to the cable connector (31) through the low-voltage conduction strip and the PCB board (1).

7. A high and low voltage integrated BDU as claimed in claim 6, characterized in that: The second electrical component (4) further comprises a fast charging negative relay, which is fixedly arranged on the housing (5), the power supply end of the fast charging negative relay is connected in series with the negative electrode circuit via the high-voltage copper busbar (6), the current input end of the fast charging negative relay is electrically connected to the cable connector (31) via the high-voltage conductive strip and the PCB board (1), and both control ends of the fast charging negative relay are electrically connected to the cable connector (31) via the low-voltage conductive strip and the PCB board (1).

8. A high and low voltage integrated BDU as claimed in claim 7, characterized in that: The plurality of high-voltage copper bars (6) include at least one supporting copper bar (61), wherein the supporting copper bar (61) includes two connecting parts (611), a supporting part (612) and two reinforcing parts (613), wherein: One end of the connecting portion (611) is fixed to and electrically connected to the second electrical component (4), and the two connecting portions (611) are arranged in parallel and at intervals; The supporting portion (612) is located between the two connecting portions (611) and is perpendicular thereto; The two reinforcing parts (613) are respectively located between the two connecting parts (611) and the supporting part (612); the cross section of the reinforcing part (613) is U-shaped, and the two ends thereof are respectively continuously arranged with the connecting part (611) and the supporting part (612) and are integrally formed; The shell (5) is provided with a reinforcement groove (501), the reinforcement portion (613) is snap-fitted with the reinforcement groove (501), and the support portion (612) is in contact with the inner wall of the shell (5).

9. A method for processing a high-low voltage integrated BDU as claimed in any one of claims 6 to 8, characterized in that: The following steps are involved: S1, taking out the copper plate, and punching holes in the copper plate using a punching machine to obtain a first semi-finished product consisting of the conductive strip (22), the connecting plate (23) and the reinforcing member; S2, according to actual needs, using a stamping device to stamp the bent portion (202) on the first semi-finished product to obtain a second semi-finished product; S3, using an injection molding machine to inject plastic on the outer side of the second semi-finished product to obtain a third semi-finished product; S4, first punching the third semi-finished product using a punching machine to remove the connecting plate (23) and the plastic in the insulating hole (201), cutting off the multiple connecting plates (23), removing the plastic in the reinforcing member and the fixing hole (101) and the weight-reducing hole (203), and then injecting the insulating glue (24) into the insulating hole (201) to obtain the integrated component (2); S5, preparing a PCB board (1) on which the cable connector (31) is installed and a PCB board (1) on which the pre-charging resistor (32) and the pre-charging relay (33) are installed; S6, installing the high-voltage copper busbar (6) and a plurality of the second electrical components (4) in sequence in the housing (5), and connecting the second electrical components (4) using the high-voltage copper busbar (6); S7, installing the PCB board (1) and the integrated component (2) on the housing (5), and engaging the fixing holes (101) inside the two with the heat anchor rods (51) at corresponding positions thereof, so that Using a heat anchor device to heat and deform the heat anchor rod (51), and using the deformed heat anchor rod (51) to hold and fix the PCB board (1) and the integrated component (2); S8, using laser welding to weld the end of the wire strip (221) and the connecting piece (222) to the corresponding PCB board (1) or the second electrical component (4).

10. A method for processing a high and low voltage integrated BDU as claimed in claim 9, characterized in that: In step S1, the reinforcing member comprises a rectangular ring frame (25) located at the periphery of the conducting strip (22) and the connecting plate (23) and integrally formed with the two through the connecting plate (23), or a filling plate (26) located between a plurality of the conducting strips (22) and integrally formed with the conducting strips (22) through the connecting plate (23).

Images