BDU box and BDU system

Abstract

Provided in the present application are a BDU box and a BDU system. The BDU box in the BDU system comprises a box lid (120) and a box body (110), wherein the box body (110) is provided with an accommodating cavity (111), which is configured to accommodate a relay (200), the accommodating cavity (111) being provided with an opening; the relay (200) can be placed into the accommodating cavity (111) via the opening; the box lid (120) is connected to the box body (110) and seals the opening; and a snap-fitting member (112) is provided on the cavity wall of the accommodating cavity (111) opposite the opening, the snap-fitting member (112) is integrally formed with the box body (110), and the snap-fitting member (112) can be snap-fitted and fixed into a penetrating hole (210) in the relay (200).

Description

BDU box and BDU system

[0001] This application claims priority to the Chinese patent application filed with the China Patent Office on July 5, 2024, with application number 202421598715.7. The entire contents of the above application are incorporated by reference into this application.

[0002] Technical Field

[0003] The present application relates to the field of vehicle battery technology, and in particular to a BDU box and a BDU system.

[0004] Background Art

[0005] The BDU, or Battery Disconnect Unit, is a crucial component in new energy vehicle battery systems. It's primarily used to quickly disconnect the battery from the vehicle's electrical circuits in emergency situations like collisions and short circuits, preventing accidents. A BDU typically includes a BDU housing, relays, pre-charge resistors, Hall effect devices, and busbars.

[0006] Technical issues

[0007] In the prior art, the relay is secured to the BDU housing by threaded fastening. During the injection molding process of the BDU housing, a nut is embedded in the mold, securing the nut within the molded BDU housing. The relay is then placed within the BDU housing, and a screwdriver is used to thread a bolt through the relay's holes and secure it to the nut within the BDU housing. This fastening method is not only complex and difficult to operate, but also inefficient and cannot meet actual production needs.

[0008] Technical Solutions

[0009] In a first aspect, an embodiment of the present application provides a BDU box, comprising:

[0010] lid; and

[0011] A box body, the box body having a housing cavity configured to accommodate the relay, the housing cavity having an opening, the relay being placed in the housing cavity along the opening, and the box cover being connected and fixed to the box body and sealing the opening;

[0012] A clamping piece is provided on the cavity wall of the accommodating cavity opposite to the opening, and the clamping piece is clamped and fixed to the through hole on the relay.

[0013] In a second aspect, an embodiment of the present application provides a BDU system, comprising a Hall device, a pre-charge resistor, a collection harness, a bus, a relay, and the BDU box as described above, wherein the Hall device, the pre-charge resistor, and the relay are all accommodated and fixed in the BDU box, and the collection harness is configured to connect the Hall device, the pre-charge resistor, the relay, and the bus.

[0014] Beneficial effects

[0015] The BDU box provided in the present application is configured to accommodate a relay by providing a accommodating cavity configured to accommodate the relay in the box body, and opening an opening in the accommodating cavity. The relay can be placed in the accommodating cavity along the opening, and a box cover is provided to be connected to the box body and close the opening, thereby realizing the accommodation of the relay in the BDU box. By providing a clamping piece on the cavity wall opposite to the opening in the accommodating cavity, the clamping piece is clamped and fixed to the through hole on the relay, thereby ensuring the relative fixation of the relay and the accommodating cavity. The structure is simple, the operation is convenient, the fixing effect of the relay and the box body is good, the installation efficiency of the relay and the box body is high, and actual installation requirements are met.

[0016] The present application also provides a BDU system. By applying the above-mentioned BDU box, the relay is accommodated and fixed in the BDU box, which not only ensures the stable installation of the relay and the BDU box, but also improves the assembly efficiency of the relay and the BDU box.

[0017] BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG1 is a schematic structural diagram of a BDU system provided in an embodiment of the present application;

[0019] FIG2 is an exploded schematic diagram of a BDU system provided in an embodiment of the present application;

[0020] FIG3 is a cross-sectional schematic diagram of a BDU system provided in an embodiment of the present application;

[0021] FIG4 is a partial enlarged schematic diagram of point A in FIG3 ;

[0022] FIG5 is a schematic structural diagram of a clamping member provided in an embodiment of the present application;

[0023] FIG6 is a top view of the box body provided in an embodiment of the present application;

[0024] FIG7 is a schematic structural diagram of a protection structure provided in an embodiment of the present application;

[0025] FIG8 is a cross-sectional schematic diagram of a box cover and a protective structure provided in an embodiment of the present application;

[0026] FIG9 is a circuit diagram of a BDU system according to an embodiment of the present application.

[0027] In the picture:

[0028] 100, BDU box; 110, box body; 111, accommodating chamber; 1111, first accommodating area; 1112, second accommodating area; 1113, third accommodating area; 112, clamping member; 113, isolation structure; 1131, first isolation member; 1132, second isolation member; 1133, third isolation member; 1134, fourth isolation member; 1135, fifth isolation member; 114, first limiting protrusion;

[0029] 120, box cover; 121, protective structure; 1211, pressing portion; 12111, second limiting protrusion; 122, U-shaped buckle; 123, installation notch;

[0030] 200. Relay; 210. Penetration hole.

[0031] Modes for Carrying Out the Invention

[0032] As shown in Figure 1, this embodiment provides a BDU system, which includes a Hall device, a pre-charge resistor, a collection harness, a bus, a relay 200 and the above-mentioned BDU box 100. The bus serves as the output pole of the relay 200. The Hall device, the pre-charge resistor and the relay 200 are all accommodated and fixed in the BDU box 100. The collection harness is configured to connect the Hall device, the pre-charge resistor, the relay 200 and the bus.

[0033] In the prior art, the relay 200 is secured to the BDU housing 100 by threading. During the injection molding process of the BDU housing 100, a nut is embedded in the mold, securing the nut within the molded BDU housing 100. The relay 200 is then placed within the BDU housing 100, and a screwdriver is used to thread a bolt through the hole 210 in the relay 200, securing it to the nut within the BDU housing 100. This fixing method is not only complex and difficult to operate, but also inefficient, failing to meet actual production requirements.

[0034] As shown in Figures 1 to 4, this embodiment provides a BDU box 100. The BDU box 100 includes a box body 110 and a box cover 120. The box body 110 has a receiving cavity 111 configured to accommodate a relay 200. The receiving cavity 111 has an opening, and the relay 200 can be placed into the receiving cavity 111 along the opening. The box cover 120 is connected to the box body 110 and closes the opening. A clamping member 112 is provided on the cavity wall of the receiving cavity 111 opposite the opening. The clamping member 112 can be clamped and fixed with a through hole 210 on the relay 200. The BDU box 100 is provided with a accommodating cavity 111 configured to accommodate the relay 200 in the box body 110, and an opening is opened in the accommodating cavity 111, so that the relay 200 can be placed in the accommodating cavity 111 along the opening, and a box cover 120 is provided to be connected with the box body 110 and close the opening, thereby realizing the accommodation of the relay 200 in the BDU box 100. By providing a clamping member 112 on the cavity wall opposite to the opening in the accommodating cavity 111, the clamping member 112 is clamped and fixed to the through hole 210 on the relay 200, which can ensure the relative fixation of the relay 200 and the accommodating cavity 111. The structure is simple, the operation is convenient, the fixing effect of the relay 200 and the box body 110 is good, the installation efficiency of the relay 200 and the box body 110 is high, and the actual installation requirements are met.

[0035] The clip 112 is integrally formed with the housing 110. This integral molding of the clip 112 and housing 110 significantly improves production efficiency and reduces manufacturing difficulty compared to the related art method of pre-embedded nuts. Furthermore, the integral molding of the clip 112 and housing 110 makes subsequent installation of the relay 200 simple: simply insert the relay 200 into the opening of the housing 110, aligning the through-hole 210 with the clip 112.

[0036] In this embodiment, the box body 110 and the box cover 120 are each separately formed by injection molding. Injection molding offers high production efficiency and produces products with high precision and consistent specifications. In other embodiments, the box body 110 and the box cover 120 may also be formed by stamping or other integral molding methods, which is not limited in this embodiment.

[0037] When the relay 200 needs to be accommodated and fixed in the BDU box 100, first open the box cover 120 to open the opening of the accommodating cavity 111, then place the relay 200 into the accommodating cavity 111 along the opening, and snap-fit ​​the through hole 210 on the relay 200 to the cavity wall of the accommodating cavity 111 at the end opposite to the opening, completing the accommodation and fixation of the relay 200 and the box body 110. Finally, reconnect the box cover 120 to the box body 110 and close the opening, completing the accommodation and fixation of the relay 200 and the BDU box 100.

[0038] In addition, in this embodiment, the Hall device and the box body 110 can be accommodated and fixed, and the pre-charging resistor and the box body 110 can be accommodated and fixed by using a clamping member 112 and the mounting hole on the Hall device, and the clamping member 112 and the mounting hole on the pre-charging resistor can be accommodated and fixed, and this embodiment does not limit this.

[0039] Since the through hole 210 in the relay 200 is a circular hole, the clamping member 112 is a circumferential buckle to ensure the clamping effect between the clamping member 112 and the through hole 210. By setting the clamping member 112 as a circumferential buckle, the structural characteristics of the circumferential buckle can be utilized to ensure the clamping and fixing effect between the circumferential buckle and the circular through hole 210.

[0040] In addition, as shown in FIG5 , the introduction angle α of the clip 112 is 15°≤α≤55°, and the disassembly angle β of the clip 112 is 45°≤β≤90°. By limiting the introduction angle α of the clip 112 to 15° to 55°, the clip 112 can be quickly and effortlessly inserted into the through-hole 210. By limiting the disassembly angle β of the clip 112 to 45° to 90°, the clip 112 can be removed from the through-hole 210 with a greater force, thereby ensuring the effective engagement between the clip 112 and the through-hole 210. In this embodiment, the introduction angle α of the clip 112 is 30°, and the disassembly angle β of the clip 112 is 50°. In other embodiments, the value of the introduction angle α of the clamp 112 can be arbitrarily adjusted within the range of 15° to 55°, and the value of the disassembly angle β of the clamp 112 can be arbitrarily adjusted within the range of 45° to 90°, which is not limited in this embodiment.

[0041] In one embodiment, as shown in FIG6 , the housing body 110 is further provided with an isolation structure 113. The isolation structure 113 is configured to separate the accommodating cavity 111 into at least two accommodating areas, each of which corresponds to a relay 200. A clamping member 112 is provided on the cavity wall of each accommodating area opposite the opening. By using the isolation structure 113 to separate the accommodating cavity 111 into at least two accommodating areas, each of which corresponds to a relay 200, and providing a clamping member 112 on the cavity wall of each accommodating area opposite the opening, multiple relays 200 can be individually clamped and fixed to the housing body 110.

[0042] In this embodiment, there are three relays 200 in total, namely a positive pole relay, a negative pole relay and a fast charging relay. The isolation structure 113 includes a first isolation member 1131, a second isolation member 1132, a third isolation member 1133, a fourth isolation member 1134 and a fifth isolation member 1135, which are arranged at intervals. The first isolation member 1131 and the second isolation member 1132 jointly divide the first accommodating area 1111 from the accommodating cavity 111. The second isolation member 1132 and the third isolation member 1133 jointly divide the accommodating cavity 111 into a second accommodating area 1112. The third isolation member 1133, the fourth isolation member 1134 and the fifth isolation member 1135 jointly divide the third accommodating area 1113 from the accommodating cavity 111. The negative pole relay is accommodated in the first accommodating area 1111, the fast charging relay is accommodated in the second accommodating area 1112, and the positive pole relay is accommodated in the third accommodating area 1113. In other embodiments, the number of relays 200 may be adjusted according to actual needs, and the number of isolation elements in the isolation structure 113 may be adjusted according to actual needs, which is not limited in this embodiment.

[0043] In order to improve the fixing effect of the positive relay, the negative relay and the fast charging relay, in this embodiment, at least two clips 112 are provided in the first accommodating area 1111, the second accommodating area 1112 and the third accommodating area 1113. The at least two clips 112 in the first accommodating area 1111, the second accommodating area 1112 and the third accommodating area 1113 are respectively arranged at intervals along the outer contours of the positive relay, the negative relay and the fast charging relay. At least two through holes 210 are arranged at intervals on the outer peripheral walls of the positive relay, the negative relay and the fast charging relay. Each clip 112 is clipped and fixed to a through hole 210, thereby achieving the effect of at least two clips 112 being clipped and fixed to the positive relay, the negative relay and the fast charging relay at the same time, so as to improve the fixing effect of the positive relay, the negative relay and the fast charging relay.

[0044] In this embodiment, the outer contours of the positive relay, the negative relay, and the fast-charging relay are all rectangular, and two clips 112 are provided in the first accommodating area 1111, the second accommodating area 1112, and the third accommodating area 1113. The two clips 112 are respectively arranged relative to each other along the diagonal direction of the rectangular contour, so as to maximize the fixing effect of the clips 112 on the positive relay, the negative relay, and the fast-charging relay on the basis of reducing the number of clips 112. In other embodiments, three, four, or more clips 112 can be arranged at intervals along the outer contours of the positive relay, the negative relay, and the fast-charging relay according to actual needs. It is only necessary to provide corresponding through holes 210 on the outer peripheral walls of the positive relay, the negative relay, and the fast-charging relay to ensure that each clip 112 is clipped and fixed to a through hole 210. This embodiment does not limit this.

[0045] In one embodiment, as shown in Figures 1 and 2, a U-shaped fastener 122 is provided on the outer peripheral wall of the box cover 120 near one end of the box body 110. The U-shaped fastener 122 extends toward the box body 110 and protrudes from the box cover 120. A first limiting protrusion 114 is provided on the outer peripheral wall of the box body 110, and the U-shaped fastener 122 is fixedly engaged with the first limiting protrusion 114. By providing the U-shaped fastener 122 on the outer peripheral wall of the box cover 120 near the main body, so that the U-shaped fastener 122 extends toward the box body 110 and protrudes from the box cover 120, and providing the first limiting protrusion 114 on the outer peripheral wall of the box body 110, the U-shaped fastener 122 is fixedly engaged with the first limiting protrusion 114, thereby achieving a connection and fixation between the box cover 120 and the box body 110, resulting in a simple structure and ingenious design. When the box cover 120 needs to be connected and fixed to the box body 110, the box cover 120 is first moved to the top of the box body 110, and then the box cover 120 is driven downward until the first limiting protrusion 114 on the box body 110 is engaged and fixed in the U-shaped groove of the U-shaped fastener 122. At this time, the lower end surface of the box cover 120 is exactly in contact with the upper end surface of the box body 110, so as to complete the buckling and fixation of the box body 110 and the box cover 120.

[0046] To improve the fastening and fixing effect between the box body 110 and the box cover 120, the box cover 120 is provided with at least two U-shaped fasteners 122. The at least two U-shaped fasteners 122 are arranged at intervals along the circumference of the box cover 120 on the outer peripheral wall of the box cover 120. At least two first limiting protrusions 114 are arranged at intervals circumferentially on the outer peripheral wall of the box body 110, and each U-shaped fastener 122 is fastened and fixed with one of the first limiting protrusions 114. By providing at least two first limiting protrusions 114 at intervals on the outer peripheral wall of the box body 110 and at least two U-shaped fasteners 122 at intervals circumferentially on the outer peripheral wall of the box cover 120, each U-shaped fastener 122 is fastened and fixed with one of the first limiting protrusions 114. The box body 110 and the box cover 120 are fastened and fixed together by the at least two U-shaped fasteners 122 and the at least two first limiting protrusions 114. In this embodiment, four first position-limiting protrusions 114 are circumferentially spaced apart on the outer circumferential wall of the box body 110, and four U-shaped fasteners 122 are circumferentially spaced apart on the outer circumferential wall of the box cover 120. In other embodiments, the number of U-shaped fasteners 122 and first position-limiting protrusions 114 can be adjusted according to actual needs, as long as each U-shaped fastener 122 is corresponding to a first position-limiting protrusion 114. This embodiment is not limited thereto.

[0047] In one embodiment, as shown in Figures 1, 7, and 8, a protective structure 121 is provided on the box cover 120. The protective structure 121 is detachably connected to the box cover 120 and covers the exterior of the output pole of the relay 200. By detachably attaching the protective structure 121 to the box cover 120, the protective structure 121 covers the periphery of the output pole of the relay 200, thereby improving the protection of the output pole of the relay 200.

[0048] In this embodiment, the box cover 120 is provided with a mounting notch 123, the outer wall of the protective structure 121 is provided with a pressing portion 1211, and the outer end surface of the pressing portion 1211 is provided with a second limiting protrusion 12111, which is engaged and fixed with the mounting notch 123. By providing the mounting notch 123 on the box cover 120, providing the pressing portion 1211 on the outer wall of the protective structure 121, and providing the second limiting protrusion 12111 on the outer end surface of the pressing portion 1211, and utilizing the second limiting protrusion 12111 to engage and fix with the mounting notch 123, the box cover 120 and the protective structure 121 can be removably fixed.

[0049] When the protective structure 121 needs to be fixed to the box cover 120, the protective structure 121 is first aligned with the mounting notch 123 in the up and down directions. Then, while driving the protective structure 121 to move downward, a force is applied to the pressing portion 1211 in the direction away from the side wall of the mounting notch 123 opposite to it, so that the second limiting protrusion 12111 on the outer end surface of the pressing portion 1211 can move from the upper end of the mounting notch 123 to the lower end of the mounting notch 123. Then, the pressing portion 1211 is released, and the pressing portion 1211 moves and resets, and the upper end surface of the second limiting protrusion 12111 abuts against the lower end surface of the box cover 120, thereby realizing the clamping and fixing of the protective structure 121 and the box cover 120. When it is necessary to disassemble the protective structure 121 and the box cover 120 that are fixed together, first apply force to the pressing portion 1211 in a direction away from the side wall of the installation notch 123 set opposite to it, and then drive the protective structure 121 to move upward so that the second limiting protrusion 12111 on the outer end surface of the pressing portion 1211 can smoothly move from the lower end of the installation notch 123 to the upper end of the installation notch 123, completing the disassembly of the protective structure 121 and the box cover 120.

[0050] In this embodiment, the protective structure 121 is manufactured using injection molding. Injection molding offers high production efficiency and produces products with high precision and consistent specifications. In other embodiments, the protective structure 121 may also be formed using stamping or other integral molding methods, which are not limited in this embodiment.

[0051] In one embodiment, in order to minimize the size specifications of the output pole of the relay 200 while meeting the functional requirements of the output pole of the relay 200, the box cover 120 is provided with multiple protective structures 121 and multiple installation notches 123 at intervals along its circumference. Each installation notch 123 is arranged corresponding to a protective structure 121, so that the output pole of the relay 200 can extend toward the outside of the BDU box 100 along the shortest distance, thereby achieving the effect of reducing the size specifications of the output pole of the relay 200.

[0052] In this embodiment, as shown in Figures 1 and 9, the output pole of the relay 200 includes a battery positive pole, a battery negative pole, a fast charging positive pole, a fast charging negative pole, a slow charging positive pole, a slow charging negative pole, a discharge positive pole and a discharge negative pole, and the box cover 120 is provided with four protective structures 121 and four mounting notches 123 at intervals along its circumference, wherein the battery positive pole and the slow charging positive pole are a group, the two are opposite to one mounting notch 123 and are jointly protected by a protective structure 121; the fast charging positive pole and the discharge positive pole are a group, the two are opposite to one mounting notch 123 and are jointly protected by a protective structure 121; the slow charging negative pole, the discharge negative pole and the fast charging negative pole are a group, the three are opposite to one mounting notch 123 and are jointly protected by a protective structure 121; the battery negative pole is a separate group, and the battery negative pole is alone opposite to one mounting notch 123 and is protected by a protective structure 121.

[0053] In one embodiment, the walls of the BDU housing 100's accommodating cavity 111 are further provided with routing clips configured to clamp and secure the collection wiring harness. By providing routing clips on the walls of the BDU housing 100's accommodating cavity 111 and using them to clamp and secure the collection wiring harness, the collection wiring harness within the BDU housing 100 can be effectively organized and stored, facilitating subsequent inspection and maintenance.

Claims

1. A battery disconnect device (BDU) housing, comprising: Box cover (120); as well as A box body (110), the box body (110) having a receiving cavity (111) configured to receive a relay (200), the receiving cavity (111) having an opening, the relay (200) being placed into the receiving cavity (111) along the opening, and the box cover (120) being connected to the box body (110) and closing the opening; A clamping piece (112) is provided on a cavity wall of the accommodating cavity (111) opposite to the opening, and the clamping piece (112) is clamped and fixed to a through hole (210) on the relay (200).

2. The BDU box according to claim 1, wherein: An isolation structure (113) is also provided on the box body (110), and the isolation structure (113) is configured to split and isolate the accommodating cavity (111) into at least two accommodating areas, each of which corresponds to one of the relays (200), and a clamping member (112) is provided on the cavity wall of each of the accommodating areas opposite to the opening.

3. The BDU box according to claim 2, wherein: At least two of the clamping members (112) are provided in each of the accommodating areas. The at least two of the clamping members (112) are spaced apart along the outer contour of the relay (200). At least two of the through holes (210) are spaced apart on the outer peripheral wall of the relay (200). Each of the clamping members (112) is fixedly connected to one of the through holes (210).

4. The BDU box according to any one of claims 1 to 3, wherein: A U-shaped fastener (122) is provided on the outer peripheral wall of the box cover (120) close to one end of the box body (110), and the U-shaped fastener (122) extends in a direction close to the box body (110) and extends out of the box cover (120). A first limiting protrusion (114) is provided on the outer peripheral wall of the box body (110), and the U-shaped fastener (122) is fixedly engaged with the first limiting protrusion (114).

5. The BDU box according to claim 4, wherein: At least two U-shaped fasteners (122) are provided on the box cover (120), and at least two U-shaped fasteners (122) are provided on the outer peripheral wall of the box cover (120) at intervals along the circumference of the box cover (120). At least two first limiting protrusions (114) are provided on the outer peripheral wall of the box body (110) at intervals along the circumference, and each U-shaped fastener (122) is fixedly engaged with one of the first limiting protrusions (114).

6. The BDU box according to any one of claims 1 to 3, wherein: A protective structure (121) is provided on the box cover (120), the protective structure (121) is detachably connected to the box cover (120), and the protective structure (121) is provided outside the output pole of the relay (200).

7. The BDU box according to claim 6, wherein: The box cover (120) is provided with a mounting notch (123), the outer wall of the protective structure (121) is provided with a pressing portion (1211), the outer end surface of the pressing portion (1211) is provided with a second limiting protrusion (12111), and the second limiting protrusion (12111) is fixedly engaged with the mounting notch (123).

8. The BDU box according to any one of claims 1 to 3, wherein: The introduction angle of the clamping member (112) is α, 15°≤α≤55°; The disassembly angle of the clamping member (112) is β, 45°≤β≤90°.

9. The BDU box according to any one of claims 1 to 3, wherein: The clamping member (112) and the box body (110) are integrally formed.

10. A BDU system, comprising a Hall device, a pre-charge resistor, a collection harness, a bus, a relay (200), and a BDU box according to any one of claims 1 to 9, wherein the Hall device, the pre-charge resistor, and the relay (200) are all accommodated and fixed in the BDU box, and the collection harness is configured to connect the Hall device, the pre-charge resistor, the relay (200), and the bus.

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