Distribution box, battery pack, and vehicle

Abstract

The present application relates to the technical field of distribution-box accessories, and relates in particular to a distribution box, a battery pack, and a vehicle. The distribution box comprises a main body portion, a first heating element, and a second heating element. The amount of heat generated per unit time by the first heating element is greater than the amount of heat generated per unit time by the second heating element. The main body portion is provided with a first accommodating cavity and a second accommodating cavity. The first accommodating cavity accommodates the first heating element and the second accommodating cavity accommodates the second heating element. The first heating element is configured to be arranged between the second heating element and a cooling apparatus of the battery pack, such that heat from the first heating element, which has a greater heat generation amount, can be quickly conducted away, thereby improving the temperature uniformity of the distribution box and preventing overheating of the distribution box caused by the failure to promptly discharge heat from the first heating element.

Description

Distribution boxes, battery packs and vehicles

[0001] This application claims priority to Chinese Patent Application No. 202410947931.6, filed on July 15, 2024, entitled "Power Distribution Box, Battery Pack and Vehicle", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This application belongs to the field of electrical distribution box technology, and in particular relates to an electrical distribution box, a battery pack, and a vehicle. Background Technology

[0003] The battery pack is equipped with a power distribution box, which connects to an external power source or other charging interface to charge the batteries within the pack. The components in the power distribution box generate heat during operation, which can affect the box's performance.

[0004] Different components in a distribution box generate different amounts of heat. Components that generate a lot of heat cannot dissipate the heat quickly, which can cause the distribution box to overheat. Summary of the Invention

[0005] The technical problem to be solved by this application is: to address the issue that the heat generated by high-heat components in existing distribution boxes cannot be quickly dissipated, and to provide a distribution box, battery pack, and vehicle.

[0006] To solve the above-mentioned technical problems, on the one hand, embodiments of this application provide a distribution box, including a main body, a first heating element and a second heating element, wherein the heat generated by the first heating element per unit time is greater than the heat generated by the second heating element per unit time;

[0007] The main body has a first receiving cavity and a second receiving cavity. The first receiving cavity receives the first heating element, and the second receiving cavity receives the second heating element. The first heating element is adapted to be disposed between the second heating element and the cooling device of the battery pack.

[0008] Optionally, it further includes a conductive connector for electrically connecting the first heating element, the conductive connector including a connector body and a terminal, the terminal being disposed on the outside of the body;

[0009] The main body of the connector is disposed in the first receiving cavity or the second receiving cavity.

[0010] Optionally, it also includes a spacer disposed between the first heating element and the second heating element and separating the first receiving cavity and the second receiving cavity.

[0011] Optionally, the main body is an insulating and sealed structure, which is obtained by wrapping the first heating element and the second heating element with potting compound.

[0012] Optionally, the main body includes a first insulating sealing structure and a second insulating sealing structure, wherein the first receiving cavity is disposed within the first insulating sealing structure and the second receiving cavity is disposed within the second insulating sealing structure.

[0013] Optionally, the potting compound forming the first insulating sealing structure and the potting compound forming the second insulating sealing structure have different physical properties.

[0014] Optionally, it also includes a heat sink, which is adapted to connect the cooling device of the main body and the battery pack.

[0015] Optionally, the distance between the side wall of the first receiving cavity near the heat sink and the heat sink is 1 to 5 mm.

[0016] Optionally, the heat sink is provided with a plurality of connection holes for injecting potting compound to connect the heat sink and the main body when the potting compound solidifies.

[0017] Optionally, the connecting hole is a strip-shaped hole.

[0018] On the other hand, embodiments of this application provide a battery pack, including a battery module, a cooling device, and a distribution box as described above;

[0019] The battery module and the distribution box are mounted on the cooling device.

[0020] Optionally, the cooling device is a cold plate.

[0021] In another aspect, embodiments of this application provide a vehicle including the battery pack as described above.

[0022] The distribution box provided in this application embodiment is arranged in layers according to the heat output of the first heating element per unit time and the heat output of the second heating element per unit time. The first heating element with higher heat output is placed in the lower part of the distribution box, and the second heating element with lower heat output is placed in the upper part of the distribution box. In this way, during operation, the heat generated by the first heating element is preferentially conducted by the cooling device of the battery pack, and the heat generated by the second heating element is absorbed by the main body and transferred to the cooling device of the battery pack. The heat of the first heating element with higher heat output can be quickly conducted away, thereby improving the temperature uniformity of the distribution box and avoiding the situation where the heat of the first heating element cannot be dissipated in time, resulting in an overheated distribution box. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments of this application or the prior art will be briefly introduced below. Obviously, the drawings described below are only a part of the embodiments of this application. These drawings and text descriptions are not intended to limit the scope of the concept of this application in any way, but to illustrate the concept of this application to those skilled in the art by referring to specific embodiments. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 is a schematic diagram of a distribution box provided in an embodiment of this application;

[0025] Figure 2 is a schematic diagram of the arrangement of the first heating element and the second heating element provided in an embodiment of this application;

[0026] Figure 3 is a schematic diagram of a first heating element provided in an embodiment of this application;

[0027] Figure 4 is a schematic diagram of a heat sink provided in an embodiment of this application;

[0028] Figure 5 is a schematic diagram of the assembly of the distribution box and the cold plate provided in an embodiment of this application.

[0029] Explanation of reference numerals in the attached drawings: 1. Distribution box; 11. Main body; 111. First insulating and sealing structure; 112. Second insulating and sealing structure; 12. Heat sink; 121. Connection hole; 13. First heating element; 131. Relay; 132. Fuse; 133. Pre-charge resistor; 14. Second heating element; 15. Conductive connector; 151. Connector body; 152. Wiring port; 2. Battery module; 3. Cold plate. Detailed Implementation

[0030] To make the technical problems, technical solutions, and beneficial effects solved by this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0031] As shown in Figures 1 to 5, an embodiment of this application provides a distribution box 1, which includes a main body 11, a first heating element 13, and a second heating element 14. The heat generated by the first heating element 13 per unit time is greater than the heat generated by the second heating element 14 per unit time.

[0032] The main body 11 is connected to the cooling device of the battery pack. The main body 11 has a first receiving cavity and a second receiving cavity. The first receiving cavity houses a first heating element 13, and the second receiving cavity houses a second heating element 14. The first heating element 13 is adapted to be disposed between the cooling device of the battery pack and the second heating element 14, and the first heating element 13 is closer to the cooling device of the battery pack than the second heating element 14. Specifically, the first heating element 13 is disposed above the cooling device of the battery pack, and the second heating element 14 is disposed above the first heating element 13.

[0033] In this embodiment, the main body is positioned above the cooling device of the battery pack. Based on the heat output of the first heating element 13 per unit time and the heat output of the second heating element 14 per unit time, the components in the distribution box 1 are arranged in layers according to the magnitude of their heat output. The first heating element 13, which generates more heat, is positioned at the lower part of the distribution box 1, while the second heating element 14, which generates less heat, is positioned at the upper part of the distribution box 1. This ensures that during operation, the heat generated by the first heating element 13 is preferentially conducted to the cooling device of the battery pack, while the heat generated by the second heating element 14 is absorbed by the main body 11 and transferred to the cooling device of the battery pack. This allows the heat from the first heating element to be quickly conducted away, thereby improving the temperature uniformity of the distribution box 1 and preventing the distribution box 1 from overheating due to the inability of the heat from the first heating element 13 to be dissipated in time.

[0034] In one embodiment, as shown in Figures 2 and 3, the first heating element 13 includes accessories such as a relay 131, a fuse 132, and a pre-charge resistor 133. It generates a relatively large amount of heat, and the above-mentioned heating elements should be placed on the same plane as much as possible to facilitate the cooling device of the battery pack to conduct heat away and the distribution box 1 to maintain a small temperature difference.

[0035] The second heating element 14 is a circuit board, which generates relatively little heat.

[0036] In one embodiment, as shown in Figures 1 and 2, the distribution box 1 further includes a conductive connector 15, which can electrically connect the first heating element 13 and external components through the wire connector. The conductive connector 15 includes a connector body 151 and a wiring port 152. The wiring port 152 is disposed outside the body 11, and the connector body 151 is disposed in a first receiving cavity or a second receiving cavity.

[0037] The conductive connector 15 mainly serves as an electrical connection and generates heat during operation. The heat generated by the conductive connector 15 is relatively small. It can be installed at the lower part of the distribution box 1 or at the upper part of the distribution box 1.

[0038] In one embodiment, the conductive connector 15 is a copper busbar, and the number of copper busbars can be one, two or more, and the number is set according to the number of the first heating elements 13.

[0039] In one embodiment, the distribution box 1 further includes a spacer, which is disposed between the first heating element 13 and the second heating element 14 and separates the first receiving cavity and the second receiving cavity. By separating the first heating element 13 and the second heating element 14 by the spacer, damage to the second heating element 14 due to high temperature is prevented.

[0040] Preferably, the spacer is made of a low-density insulating material.

[0041] As an example, the main body 11 is an insulating and sealed structure. The insulating and sealed structure has good thermal conductivity and insulation, which can transfer heat and prevent electrolyte or external rainwater from entering the distribution box and causing short circuits and arcing of the high voltage positive and negative poles.

[0042] At this point, the first heating element 13, the second heating element 14, the connector body 151, and the spacer are all sealed and enclosed by the insulating sealing structure. The conductive connector 15 is in close contact with the main body 11. Because the insulating sealing structure can transfer heat, the heat dissipation effect of the copper busbar is greatly improved, and the size and gap of the copper busbar can be appropriately reduced.

[0043] In another alternative example, the main body 11 is a conventional distribution box housing, and the first heating element 13 and the second heating element 14 are arranged in layers inside the distribution box housing. The heat generated by the first heating element 13 is preferentially conducted by the cooling device of the battery pack, and the heat generated by the second heating element 14 can be conducted to the cooling device of the battery pack through the distribution box housing.

[0044] In one embodiment, as shown in FIG1, the main body 11 is an insulating and sealed structure, and the first heating element 13 and the second heating element 14 are wrapped with potting compound to obtain an insulating and sealed structure after the potting compound solidifies.

[0045] The specific operation involves assembling the first heating element 13, the second heating element 14, the conductive connector 15, and the spacer in the distribution box 1, fixing them using a mold, and then filling the mold with potting compound for encapsulation. The potting compound can fill the remaining gaps in the mold, such as the gap between the first heating element 13 and the mold, and the gap between the second heating element 14 and the mold. The space occupied by the first heating element 13 in the potting compound is the first receiving cavity, and the space occupied by the second heating element 14 in the potting compound is the second receiving cavity.

[0046] After the potting compound has cured, the mold is removed, and the wiring port 152 of the wire connector is removed from the external connection. All other components, such as the first heating element 13, the second heating element 14, the connector body 151 and the spacer, are tightly wrapped by the potting compound to form a whole. This whole can be directly assembled into the battery pack without the need for a separate outer shell.

[0047] In addition, during the assembly of the distribution box 1, the spacer between the first heating element 13 and the second heating element 14 is used to fill the gap, which can reduce the amount of potting compound used during the potting process and reduce the weight of the distribution box 1.

[0048] As an example, the distribution box 1 includes a main body 11, a heat sink 12, a first heating element 13 and a second heating element 14. The main body 11 is an insulating and sealed structure, which is installed on the cooling device of the battery pack. The insulating and sealed structure encloses the first heating element 13 and the second heating element 14. The first heating element 13 is located between the second heating element 14 and the cooling device of the battery pack.

[0049] The preferential heat dissipation of the first heating element 13 improves the temperature uniformity of the distribution box 1. By filling the mold with potting compound, an insulating and sealing structure encapsulates and seals the first heating element 13 and the second heating element 14. This insulating and sealing structure has good insulation and thermal conductivity, further enhancing the heat conduction of the distribution box 1. Simultaneously, the insulating and sealing structure prevents short circuits and arcing of the high-voltage components inside the distribution box 1, achieving a balance between preventing short circuits and arcing and ensuring uniform heat dissipation.

[0050] In an alternative example, the distribution box 1 includes a main body 11, a heat sink 12, a first heating element 13 and a second heating element 14. The main body 11 is the distribution box housing, which is filled with potting compound so that the first heating element 13 and the second heating element 14 can be sealed and wrapped by the potting compound. This allows the distribution box 1 to maintain temperature consistency and prevent short circuits and arcing of the high-voltage electrical components inside the distribution box 1.

[0051] In one embodiment, as shown in FIG1, the main body 11 includes a first insulating sealing structure 111 and a second insulating sealing structure 112. A first receiving cavity is disposed within the first insulating sealing structure 111, and a second receiving cavity is disposed within the second insulating sealing structure 112. A first heating element 13 is enclosed within the first insulating sealing structure 111, and a second heating element 14 is enclosed within the second insulating sealing structure 112. The first insulating sealing structure 111 is disposed below the second insulating sealing structure 112. The first insulating sealing structure 111 and the second insulating sealing structure 112 have good thermal conductivity and insulation.

[0052] In one embodiment, the potting compound forming the first insulating sealing structure 111 and the potting compound forming the second insulating sealing structure 112 have different physical properties.

[0053] Based on the characteristics of the different heating elements in the upper and lower layers of the distribution box 1, the potting compound material can be changed accordingly to highlight different characteristics. In this embodiment, the potting compound of the first insulating sealing structure 111 is made of a material with good thermal conductivity and insulation, while the potting compound of the second insulating sealing structure 112 is made of a material with low density and average thermal conductivity.

[0054] During the potting process, after the first heating element 13, the second heating element 14, the conductive connector 15 and the spacer of the distribution box 1 are assembled, they are fixed by a mold. First, the first heating element 13 is potted and cured. After curing, the first insulating sealing structure 111 wraps the first heating element 13. Then, the second heating element 14 is potted and cured. After curing, the second insulating sealing structure 112 wraps the second heating element 14. At the same time, the second insulating sealing structure 112 can be tightly connected to the first insulating sealing structure 111, and finally they are assembled into a whole.

[0055] In one embodiment, as shown in Figures 2 and 3, the distribution box further includes a heat sink 12, which is adapted to connect the cooling device of the main body 11 and the battery pack. The first heating element 13 is closer to the heat sink 12 than the second heating element 14, and the first heating element 13 is disposed above the heat sink 12, while the second heating element 14 is disposed above the first heating element 13.

[0056] During operation, the heat generated by the first heating element 13 is preferentially transferred to the cooling device of the battery pack by the heat sink 12. The heat generated by the second heating element 14 is absorbed by the main body 11 and transferred to the heat sink 12, and then transferred to the cooling device of the battery pack by the heat sink 12. The heat sink 12 can enhance the heat transfer between the main body 11 and the cooling device of the battery pack.

[0057] In this embodiment, by placing the heat sink 12 between the main body 11 and the cooling device of the battery pack, it is beneficial for the power distribution box 1 to quickly conduct its own heat to the cold plate 3, and then dissipate heat through the cooling device of the battery pack, thereby improving the heat dissipation efficiency of the power distribution box 1.

[0058] As an example, the distribution box includes a main body 11, a first heating element 13, a second heating element 14, a conductive connector 15, a spacer, and a heat sink 12. The heat sink 12 is connected between the main body 11 and the cooling device of the battery pack. The first heating element 13 is located at the lower part of the main body 11 and closer to the heat sink. The first heating element 13 is preferentially transferred to the cooling device of the battery pack through the heat sink 12.

[0059] After the above components are assembled, they are placed in the mold, and potting compound is poured into the mold to fill the gaps in the mold, such as the gap between the first heating element 13 and the mold, the gap between the second heating element 14 and the mold, and the gap between the heat sink 12 and the first heating element 13. After solidification, the insulating and sealing structure seals and wraps the first heating element 13, the second heating element 14, the spacer and the main body 151 of the connector, and the heat sink 12 is tightly connected to the insulating and sealing structure.

[0060] In one embodiment, the heat sink 12 is made of a material with good thermal conductivity and certain strength, such as aluminum alloy or copper alloy, and its thickness is in the range of 0.8 to 3 mm.

[0061] In one embodiment, the distance between the side wall of the first receiving cavity near the heat sink 12 and the heat sink 12 is 1 to 5 mm. When the distance between the side wall of the first receiving cavity near the heat sink 12 and the heat sink 12 is within this range, it is convenient to pot the encapsulant, and the thermal resistance between the first heating element 13 and the heat sink 12 is small, which facilitates heat dissipation.

[0062] When the distance between the side wall of the first receiving cavity near the heat sink 12 and the heat sink 12 is less than 1mm, the poor flowability of the liquid potting compound during the potting process makes the potting process difficult, easily resulting in pores or cavities. This increases the thermal resistance between the first heating element 13 and the heat sink 12, worsens the heat dissipation effect, and may even cause short circuits and arcing. When the distance between the side wall of the first receiving cavity near the heat sink 12 and the heat sink 12 is greater than 5mm, the excessive distance will increase the thermal resistance between the first heating element 13 and the heat sink 12, worsening the heat dissipation effect. It will also increase the amount of potting compound used, leading to an increase in the size and weight of the distribution box 1, reducing integration and increasing manufacturing costs.

[0063] In one embodiment, as shown in FIG4, the heat sink 12 is provided with a plurality of connection holes 121, which are used to inject potting compound to connect the heat sink 12 and the main body 11 when the potting compound solidifies.

[0064] By providing connection holes 121 on the heat sink 12, potting compound can flow into and fill the connection holes 121 during the potting process. After the potting compound solidifies, the heat sink 12 is fixed on the insulating and sealing structure, which can ensure the connection strength between the heat sink 12 and the main body 11 and can strengthen the structural strength of the distribution box 1.

[0065] In one embodiment, the connection hole 121 is a strip-shaped hole, and multiple connection holes 121 are regularly arranged on the heat sink 12.

[0066] The heat sink 12 is square, and multiple connection holes 121 are spaced apart along the length or width of the heat sink 12 to ensure the connection between the heat sink 12 and the main body 11.

[0067] On the other hand, as shown in Figure 5, this application embodiment provides a battery pack, including a battery module 2, a cooling device, and a distribution box 1 as described in the above embodiment. The battery module 2 and the distribution box 1 are mounted on the cooling device, and the distribution box 1 can conduct heat out through the heat sink 12 and then transfer it to the cooling device.

[0068] In one embodiment, the cooling device is a cold plate 3. The heat sink 12 is in close contact with the cold plate 3 by thermally conductive adhesive or bolts. The entire distribution box 1 does not use an active cooling device; it is simply mounted on the cold plate 3 of the battery pack. When the distribution box 1 is working, the heat it generates is transferred to the thermal management system of the battery pack through the cold plate 3. Since the large temperature rise of the distribution box 1 generally corresponds to the high current charging and discharging condition of the battery pack, the thermal management system is in the on state at this time. Therefore, there is no need to control the thermal management system separately. The heat of the distribution box 1 can be dissipated when the thermal management system of the entire pack is on. Even if the thermal management system of the entire pack is not on, the heat of the distribution box 1 can still be transferred to the cold plate 3 through the heat sink 12. Due to the good thermal conductivity of the cold plate 3 and the large heat capacity of the entire pack, the temperature rise rate of the distribution box 1 can be reduced, thus preventing the distribution box 1 from overheating.

[0069] In another aspect, embodiments of this application provide a vehicle including the battery pack described in the above embodiments.

[0070] The terms "upper" and "lower" are used to describe the relative positions of the various structures in the accompanying drawings. They are only for clarity of description and are not intended to limit the scope of implementation of this application. Any changes or adjustments to the relative positions without substantially altering the technical content shall also be considered within the scope of implementation of this application.

[0071] It should be noted that, in this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0072] Furthermore, in this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0073] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of this disclosure. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0074] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A power distribution box, comprising a main body (11), a first heat generating element (13) and a second heat generating element (14), wherein the first heat generating element (13) has a greater heat generation per unit time than the second heat generating element (14) ; the main body (11) has a first accommodating cavity and a second accommodating cavity, the first accommodating cavity accommodates the first heat generating element (13), and the second accommodating cavity accommodates the second heat generating element (14), and the first heat generating element (13) is adapted to be arranged between the second heat generating element (14) and a cooling device of a battery pack. 2.The power distribution box according to claim 1, further comprising an electrically conductive connecting piece (15) for electrically connecting the first heat generating element (13), wherein the electrically conductive connecting piece (15) comprises a connecting piece main body (151) and a wiring port (152), and the wiring port (152) is arranged outside the main body (11) ; the connecting piece main body (151) is arranged in the first accommodating cavity or the second accommodating cavity. 3.The power distribution box according to any one of claims 1-2, further comprising a spacer, wherein the spacer is arranged between the first heat generating element (13) and the second heat generating element (14) and separates the first accommodating cavity and the second accommodating cavity. 4.The power distribution box according to any one of claims 1-3, wherein the main body (11) is an insulating sealing structure, and the first heat generating element (13) and the second heat generating element (14) are wrapped by potting glue to obtain the insulating sealing structure. 5.The power distribution box according to claim 4, wherein the main body (11) comprises a first insulating sealing structure (111) and a second insulating sealing structure (112), the first accommodating cavity is arranged in the first insulating sealing structure (111), and the second accommodating cavity is arranged in the second insulating sealing structure (112). 6.The power distribution box according to claim 5, wherein the potting glue forming the first insulating sealing structure (111) and the potting glue forming the second insulating sealing structure (112) have different physical properties. 7.The power distribution box according to any one of claims 1-6, further comprising a heat dissipation plate (12), wherein the heat dissipation plate (12) is adapted to connect the main body (11) and a cooling device of a battery pack. 8.The power distribution box according to claim 7, wherein the first accommodating cavity is close to a side wall surface of the heat dissipation plate (12), and the distance between the heat dissipation plate (12) and the first accommodating cavity is 1-5 mm. 9.The power distribution box according to any one of claims 7-8, wherein a plurality of connecting holes (121) are arranged on the heat dissipation plate (12), and the connecting holes (121) are used for injecting potting glue to connect the heat dissipation plate (12) and the main body (11) when the potting glue solidifies. 10.The power distribution box according to claim 9, wherein the connecting holes (121) are strip-shaped holes. 11.A battery pack, comprising a battery module (2), a cooling device and the power distribution box according to any one of claims 1-10, wherein the battery module (2) and the power distribution box are mounted on the cooling device.

12. The battery pack according to claim 11, wherein the cooling device is a cold plate (3).

13. A vehicle comprising the battery pack according to any one of claims 11-12.

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