Distribution box and battery device
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- BYD CO LTD
- Filing Date
- 2025-11-05
- Publication Date
- 2026-05-15
Smart Images
Figure CN2025132734_15052026_PF_FP_ABST
Abstract
Description
A power distribution box and battery device
[0001] This disclosure claims priority to Chinese Patent Application No. 202422711322.9, filed on November 6, 2024, entitled “A Power Distribution Box and Battery Device”, the entire contents of which are incorporated herein by reference. Technical Field
[0002] This disclosure belongs to the field of battery technology, specifically relating to a power distribution box and a battery device. Background Technology
[0003] Battery devices, such as lithium-ion and sodium-ion batteries, are widely used in portable electronic devices, electric vehicles, energy storage devices, and other fields due to their advantages such as high energy density and good cycle performance. Battery devices typically contain high-voltage components such as relays and connectors. To prevent these high-voltage components from being scattered inside the battery device and causing leakage, they are usually installed in a distribution box.
[0004] Connectors in a distribution box typically include various types, such as high-voltage connectors and fast-charging connectors. Installing these connectors usually requires mounting multiple connector mounting brackets on the distribution box, and then securing the connectors within these brackets. However, this installation method necessitates the installation of multiple connector mounting brackets, making the distribution box structurally complex and costly. Summary of the Invention
[0005] The present disclosure aims to provide a power distribution box and battery device to solve the problems of complex structure and high cost of existing power distribution boxes.
[0006] To solve the above-mentioned technical problems, this disclosure is implemented as follows:
[0007] In a first aspect, a power distribution box is disclosed for use in a battery device, the power distribution box comprising:
[0008] Mounting base, the mounting base having a receiving cavity;
[0009] A connector assembly, comprising a fast charging connector and a main connector, wherein the fast charging connector and the main connector are integrally formed with the mounting base, and the fast charging connector and the main connector are at least partially exposed outside the receiving cavity;
[0010] The component group includes a main relay group and a fast charging relay group, which are located in the receiving cavity and at least partially exposed outside the receiving cavity; wherein the main relay group is electrically connected to the main connector and the fast charging relay group is electrically connected to the fast charging connector.
[0011] Optionally, the main relay group includes a main positive relay and a main negative relay, the fast charging relay group includes a fast charging positive relay and a fast charging negative relay, and the receiving cavity includes a first receiving cavity, a second receiving cavity, a third receiving cavity, and a fourth receiving cavity arranged at intervals. The main positive relay is disposed in the first receiving cavity, the fast charging positive relay is disposed in the second receiving cavity, the fast charging negative relay is disposed in the third receiving cavity, and the main negative relay is disposed in the fourth receiving cavity.
[0012] Optionally, the main positive relay is arranged adjacent to the fast charging positive relay, and the main negative relay is arranged adjacent to the fast charging negative relay.
[0013] Optionally, the component group further includes a shunt and a current sensor. The mounting base is also provided with an adjacent first mounting slot and a second mounting slot. The shunt is disposed in the first mounting slot, the current sensor is disposed in the second mounting slot, and the shunt is disposed adjacent to the main negative relay. The shunt is electrically connected to the main negative relay and the fast charging negative relay respectively, and the current sensor is electrically connected to the shunt.
[0014] Optionally, the component group further includes a first fuse and a second fuse. The mounting base is also provided with an adjacent third mounting slot and a fourth mounting slot. The first fuse is disposed in the third mounting slot, the second fuse is disposed in the fourth mounting slot, and the second fuse is disposed adjacent to the main positive relay. The second fuse is electrically connected to the main positive relay and the fast charging positive relay respectively, and the first fuse is electrically connected to the second fuse.
[0015] Optionally, the component group further includes a pre-charge resistor and a pre-charge relay. The mounting base is also provided with an adjacent fifth mounting slot and a sixth mounting slot. The pre-charge resistor is disposed in the fifth mounting slot, and the pre-charge relay is disposed in the sixth mounting slot. The pre-charge relay is disposed adjacent to the second fuse and is electrically connected to the second fuse. The pre-charge relay is also electrically connected to the pre-charge resistor.
[0016] Optionally, the distribution box further includes a self-made circuit board, which is connected to the mounting base;
[0017] The self-made circuit board has multiple connection ports, and multiple connectors are fixedly connected to the component group. The connectors are plugged into the connection ports to electrically connect the self-made circuit board to the component group.
[0018] Optionally, the connector assembly further includes a low-voltage connector integrally formed with the mounting base, and the low-voltage connector, the main connector, and the fast-charging connector are spaced apart on the same side of the mounting base.
[0019] Optionally, the connector assembly includes a fast charging connector housing, a main connector housing, and a low-voltage connector housing, all of which are integrally formed with the mounting base.
[0020] Optionally, the connector assembly further includes a plurality of electrical connectors, which are respectively embedded in the fast charging connector housing, the main connector housing, and the low-voltage connector housing, and are electrically connected to the component assembly.
[0021] Secondly, a battery device is also disclosed, the battery device comprising: the power distribution box described in any of the preceding claims.
[0022] In this embodiment of the disclosure, since the power distribution box includes a mounting base, a fast charging connector, and a main connector, by integrally molding the main connector, the fast charging connector, and the mounting base, it is possible to avoid installing additional components on the power distribution box, making the structure of the power distribution box simpler and reducing costs.
[0023] The above description is merely an overview of the technical solution disclosed herein. In order to better understand the technical means of this disclosure and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of this disclosure more apparent and understandable, specific embodiments of this disclosure are described below. Attached Figure Description
[0024] To more clearly illustrate the technical solutions in the embodiments of this disclosure or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this disclosure. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0025] Figure 1 is an exploded view of the structure of a power distribution box provided in an embodiment of this disclosure;
[0026] Figure 2 is one of the structural schematic diagrams of a power distribution box provided in an embodiment of this disclosure;
[0027] Figure 3 is a second structural schematic diagram of a power distribution box provided in an embodiment of this disclosure;
[0028] Figure 4 is one of the structural schematic diagrams of a mounting base for a power distribution box provided in an embodiment of this disclosure;
[0029] Figure 5 is a second schematic diagram of the structure of a mounting base for a power distribution box provided in an embodiment of this disclosure;
[0030] Figure 6 is a third structural schematic diagram of a mounting base for a power distribution box provided in an embodiment of this disclosure;
[0031] Figure 7 is a circuit diagram of a power distribution box provided in an embodiment of this disclosure.
[0032] Reference numerals: 1. Mounting base; 10. Receiving cavity; 101. First receiving cavity; 102. Second receiving cavity; 103. Third receiving cavity; 104. Fourth receiving cavity; 11. First mounting slot; 12. Second mounting slot; 13. Third mounting slot; 14. Fourth mounting slot; 15. Fifth mounting slot; 16. Sixth mounting slot; 17. Positive lead-out piece; 18. Negative lead-out piece; 20. Fast charging connector; 200. Fast charging connector housing; 2001. Fast charging connector negative housing; 2002. Fast charging connector positive housing; 21. Main connector; 210. Main connector housing; 2101. Main connector negative housing; 2102. Main connector positive housing; 22. Low-voltage connector; 220. Low-voltage connector housing; 23. Electrical connector; 30. Plug-in connector; 31. Main relay group; 311. Main positive relay; 312. Main negative relay; 32. Fast charging relay group; 321. Fast charging positive relay; 322. Fast charging negative relay; 33. Shunt; 34. Current sensor; 35. First fuse; 36. Second fuse; 37. Pre-charge resistor; 38. Pre-charge relay; 39. Self-made circuit board; 390. Connection port; 4. Protective cover; 41. Connector group; 42. Component group; 43. Battery module; 5. Distribution box. Specific Implementation
[0033] Embodiments of this disclosure will now be described in detail, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this disclosure, and should not be construed as limiting this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without inventive effort are within the scope of protection of this disclosure.
[0034] The terms "first" and "second" in this disclosure may explicitly or implicitly include one or more of the features. In the description of this disclosure, unless otherwise stated, "a plurality of" means two or more. Furthermore, in the specification and claims, "and / or" indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.
[0035] In the description of this disclosure, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this disclosure and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.
[0036] In the description of this disclosure, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linkage" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure based on the specific circumstances.
[0037] This disclosure provides a power distribution box 5, which is applied to a battery device. The power distribution box 5 of this disclosure will be described in detail below with reference to the accompanying drawings.
[0038] Referring to Figures 1-6, this embodiment of the present disclosure provides a power distribution box 5, which includes: a mounting base 1 having a receiving cavity 10; a connector group 41 including a fast charging connector 20 and a main connector 21, the fast charging connector 20 and the main connector 21 being integrally formed with the mounting base 1, and the fast charging connector 20 and the main connector 21 being at least partially exposed in the receiving cavity 10; and a component group 42 including a main relay group 31 and a fast charging relay group 32, the main relay group 31 and the fast charging relay group 32 being disposed in the receiving cavity 10 and at least partially exposed in the receiving cavity 10; wherein, the main relay group 31 is electrically connected to the main connector 21, and the fast charging relay group 32 is electrically connected to the fast charging connector 20.
[0039] Specifically, the main connector 21 and the main relay group 31 are electrically connected. The main connector 21 is a high-voltage connector used to connect to external devices to enable the discharge function of the power distribution box 5. The fast-charging connector 20 is electrically connected to the fast-charging relay group 32. The fast-charging connector 20 is used to connect to external devices to enable the fast-charging function of the power distribution box 5. Thus, the power distribution box 5 has both discharge and fast-charging functions, improving its applicability to high-voltage platforms and high-current operating conditions.
[0040] In this embodiment, by integrally molding the fast charging connector 20 and the main connector 21 with the mounting base 1, compared with the prior art which requires additional mounting components to be installed in the power distribution box 5 to install the fast charging connector 20 and the main connector 21, the installation of additional mounting components on the power distribution box 5 can be avoided, and the fast charging connector 20 and the main connector 21 can be integrally molded, making the structure of the power distribution box 5 simpler and reducing costs.
[0041] As shown in Figures 2-5, in some optional embodiments, the main relay group 31 includes a main positive relay 311 and a main negative relay 312, the fast charging relay group 32 includes a fast charging positive relay 321 and a fast charging negative relay 322, and the receiving cavity 10 includes a first receiving cavity 101, a second receiving cavity 102, a third receiving cavity 103, and a fourth receiving cavity 104 arranged at intervals. The main positive relay 311 is disposed in the first receiving cavity 101, the fast charging positive relay 321 is disposed in the second receiving cavity 102, the fast charging negative relay 322 is disposed in the third receiving cavity 103, and the main negative relay 312 is disposed in the fourth receiving cavity 104.
[0042] Specifically, the mounting base 1 forms a receiving cavity 10, which includes a first receiving cavity 101, a second receiving cavity 102, a third receiving cavity 103, and a fourth receiving cavity 104. The outer shells of the main positive relay 311, the main negative relay 312, the fast charging positive relay 321, and the fast charging negative relay 322 are removed. The core of the main positive relay 311 is fixed in the first receiving cavity 101 by potting glue. The core of the main negative relay 312 is set in the fourth receiving cavity 104 by potting glue. The core of the fast charging negative relay 322 is fixed in the third receiving cavity 103 by potting glue. The core of the fast charging positive relay 321 is fixed in the second receiving cavity 102 by potting glue.
[0043] In practical applications, on the one hand, by setting the receiving cavity 10 into a first receiving cavity 101, a second receiving cavity 102, a third receiving cavity 103, and a fourth receiving cavity 104, each relay can be located in a different receiving cavity, effectively avoiding mutual interference between relays and ensuring a more independent and stable working environment for each relay. On the other hand, there is no need to install a plastic shell outside the core of each relay; the walls of each receiving cavity can directly protect and seal the core of each relay, further simplifying the structure of the distribution box 5 and reducing its cost. Furthermore, by fixing the cores of each relay with potting compound, each relay core is integrated with the mounting base 1, reducing the installation space occupied by each relay mounting component on the mounting base 1, achieving the simplest structure of the distribution box 5 and maximizing the utilization of the space on the mounting base 1. Moreover, the potting compound can improve the heat dissipation capacity of each relay core, thereby extending the lifespan of the distribution box 5.
[0044] As shown in Figures 2-5, optionally, the main positive relay 311 and the fast charging positive relay 321 are arranged adjacent to each other, and the main negative relay 312 and the fast charging negative relay 322 are arranged adjacent to each other.
[0045] Specifically, as shown in Figure 4, on the mounting base 1, four relays can be arranged in the order of main negative relay 312, fast charging negative relay 322, fast charging positive relay 321, and main positive relay 311. This makes the main positive relay 311 and fast charging positive relay 321 adjacent to each other, and the main negative relay 312 and fast charging negative relay 322 adjacent to each other. In practical applications, since the positive and negative circuits are usually separate, arranging the main positive relay 311 and fast charging positive relay 321 adjacent to each other, and the main negative relay 312 and fast charging negative relay 322 adjacent to each other, helps to better isolate circuits of different polarities and facilitates the connection of other devices in the positive and negative circuits with the corresponding relays.
[0046] Optionally, the component group 42 further includes a shunt 33 and a current sensor 34. The mounting base 1 is also provided with an adjacent first mounting slot 11 and a second mounting slot 12. The shunt 33 is disposed in the first mounting slot 11, and the current sensor 34 is disposed in the second mounting slot 12. The shunt 33 is disposed adjacent to the main negative relay 312. The shunt 33 is electrically connected to the main negative relay 312 and the fast charging negative relay 322 respectively. The current sensor 34 is electrically connected to the shunt 33.
[0047] As shown in Figure 2, specifically, the shunt 33 is fixedly connected to the first mounting slot 11, the shape of which matches the shape of the shunt 33. The current sensor 34 is fixed in the second mounting slot 12, the shape of which matches the shape of the current sensor 34. The shunt 33 is arranged adjacent to the main negative relay 312. Thus, the current passing through the main negative relay 312 and the fast-charging negative relay 322 can be detected by the current sensor 34 and the shunt 33. In this embodiment, the current is detected by the shunt 33 and the current sensor 34, providing double protection for the detected current, thereby enhancing circuit protection. By placing the shunt 33 and the current sensor 34 in their respective mounting slots, the shunt 33 and the current sensor 34 can be protected, improving the reliability and service life of the distribution box 5.
[0048] Furthermore, a negative lead-out piece 18 is provided at the end of the mounting base 1 near the current sensor 34. One end of the shunt 33's lead-out piece is bolted to the negative lead-out piece 18, and the current sensor 34 is bolted to the lead-out piece of the shunt 33, thus achieving electrical connection between the shunt 33 and the current sensor 34. The other end of the shunt 33's lead-out piece is bolted to the terminals of the main negative relay 312 and the fast-charging negative relay 322, thus achieving electrical connection between the shunt 33 and the main negative relay 312 and the fast-charging negative relay 322. In practical applications, by arranging the current sensor 34 and the shunt 33 adjacently, the shunt 33 adjacently to the main negative relay 312, and the main negative relay 312 adjacently to the fast-charging negative relay 322, the length of the lead-out pieces can be reduced, further simplifying the structural design of the distribution box 5, and reducing the amount of lead-out pieces used, thereby lowering the cost of the distribution box 5. The lead-out pieces can be copper busbars.
[0049] Optionally, the component group 42 further includes a first fuse 35 and a second fuse 36. The mounting base 1 is also provided with an adjacent third mounting slot 13 and a fourth mounting slot 14. The first fuse 35 is disposed in the third mounting slot 13, and the second fuse 36 is disposed in the fourth mounting slot 14. The second fuse 36 is disposed adjacent to the main positive relay 311. The second fuse 36 is electrically connected to the main positive relay 311 and the fast charging positive relay 321 respectively. The first fuse 35 is electrically connected to the second fuse 36.
[0050] As shown in Figures 2-6, the first fuse 35 is placed in the third mounting slot 13, and the second fuse 36 is placed in the fourth mounting slot 14. The shape of the third mounting slot 13 matches the shape of the first fuse 35, and the shape of the fourth mounting slot 14 matches the shape of the second fuse 36. The first fuse 35 and the second fuse 36 are electrically connected. The second fuse 36 is arranged adjacent to the main positive relay 311 and is connected to both the main positive relay 311 and the main negative relay 312. This electrical connection between the second fuse 36 and the main positive relay 311 and the fast-charging positive relay 321 allows for rapid circuit disconnection in the event of overcurrent or short-circuit faults, protecting the entire system. The electrical connection between the first fuse 35 and the second fuse 36 further enhances the system's protection levels, ensuring more reliable system operation under multi-level protection. By placing the first fuse 35 and the second fuse 36 in their respective mounting slots, the first fuse 35 and the second fuse 36 can be protected, thereby improving the reliability and service life of the distribution box 5.
[0051] Furthermore, a positive lead-out piece 17 is provided on the side of the mounting base 1 near the first fuse 35. One end of the lead-out piece of the first fuse 35 is bolted to the positive lead-out piece 17, and the other end of the lead-out piece is bolted to the second fuse 36, thus achieving electrical connection between the first fuse 35 and the second fuse 36. One end of the lead-out piece of the second fuse 36 is bolted to the terminals of the main positive relay 311 and the fast-charging positive relay 321, thus achieving electrical connection between the second fuse 36 and the main positive relay 311 and the fast-charging positive relay 321. In practical applications, by arranging the first fuse 35 and the second fuse 36 adjacent to each other, and the main positive relay 311 and the fast-charging positive relay 321 adjacent to each other, the length of the lead-out pieces can be further reduced, the structural design of the distribution box 5 can be further simplified, and the number of lead-out pieces used can be reduced, thereby reducing the cost of the distribution box 5. The lead-out piece can be a copper busbar.
[0052] As shown in Figures 2-6, optionally, the component group 42 further includes a pre-charge resistor 37 and a pre-charge relay 38. The mounting base 1 is also provided with adjacent fifth mounting slots 15 and sixth mounting slots 16. The pre-charge resistor 37 is disposed in the fifth mounting slot 15, and the pre-charge relay 38 is disposed in the sixth mounting slot 16. The pre-charge relay 38 is disposed adjacent to the second fuse 36 and is electrically connected to the second fuse 36. The pre-charge relay 38 is also electrically connected to the pre-charge resistor 37.
[0053] Specifically, as shown in Figure 4, the fifth mounting slot 15 is located below the third mounting slot 13, the sixth mounting slot 16 is located below the fourth mounting slot 14, the pre-charge resistor 37 is located in the fifth mounting slot 15, and the pre-charge relay 38 is located in the sixth mounting slot 16. This arrangement ensures that the pre-charge relay 38 and the second fuse 36 are adjacent, facilitating the electrical connection between them and reducing the length of the connecting parts, thus further simplifying the structural design of the distribution box 5. By placing the pre-charge resistor 37 and the pre-charge relay 38 in their respective mounting slots, both are protected, improving the reliability and service life of the distribution box 5.
[0054] Furthermore, both the fifth mounting slot 15 and the sixth mounting slot 16 are provided with multiple clips. The pre-charge resistor 37 is placed in the fifth mounting slot 15 and the pre-charge relay 38 is placed in the sixth mounting slot 16. The pre-charge resistor 37 can be fixed in the fifth mounting slot 15 by engaging with the clips, and the pre-charge relay 38 can be fixed in the sixth mounting slot 16 by engaging with the clips. This can improve the installation stability of the pre-charge resistor 37 and the pre-charge relay 38 in the mounting base 1.
[0055] Optionally, the power distribution box 5 further includes a self-made circuit board 39, which is connected to the mounting base 1. The self-made circuit board 39 is provided with multiple connection ports 390, and multiple plug-in pieces 30 are fixedly connected to the component group 42. The plug-in pieces 30 are plugged into the connection ports 390 to electrically connect the self-made circuit board 39 to the component group 42.
[0056] Specifically, the mounting base 1 is provided with multiple fasteners, and the self-made circuit board 39 is fixedly connected to the mounting base 1 through the fasteners. The fasteners can be fixed posts or the like, which can be used to fix the position of the self-made circuit board 39. The present disclosure does not specifically limit the structure of the fasteners.
[0057] Specifically, each component in component group 42 is equipped with a connector 30, and the self-made circuit board 39 is equipped with an interface corresponding to the position of each connector 30. The interface connects to the connector 30, so that the self-made circuit board 39 is electrically connected to the components in the component group. In this embodiment, the battery management controller and high-voltage monitoring acquisition device are integrated on the self-made circuit board 39, which has functions such as calculating energy, power, etc., and battery protection based on current data. The self-made circuit board 39 can dynamically adjust charging current, voltage parameters, etc., to ensure the safety and reliability of the electrical circuit in the power distribution box 5. The self-made circuit board 39 and the various devices on the mounting base 1 form a pre-charge circuit, a high-voltage detection circuit, and a low-voltage communication circuit. The various circuits are connected to each other through connectors 30, eliminating the need for separate connecting copper busbars or wire harnesses from the self-made circuit board 39 to the main positive relay 311 core, the main negative relay 312 core, the pre-charge relay 38, and the current sensor 34, further reducing the cost of the power distribution box 5. The connector 30 can be a plug or a pin.
[0058] Specifically, as shown in Figure 1, a positive lead-out piece 17 is provided on the side of the mounting base 1 near the first fuse 35, and a negative lead-out piece 18 is provided on the end near the current sensor 34. The self-made circuit board 39 includes a pre-charge circuit connection circuit, comprising a high-voltage electrical connection circuit from the pre-charge resistor 37 to the pre-charge relay 38, and a high-voltage electrical connection circuit between the pre-charge relay 38 and the high-voltage positive lead-out piece 17 on the mounting base 1. The connectors 30 on the pre-charge resistor 37 and the pre-charge relay 38 are connected to the connectors on the self-made circuit board 39, and the pre-charge circuit is activated through the high-voltage electrical connection circuit from the pre-charge circuit to the pre-charge relay 38.
[0059] The high-voltage detection circuit consists of multiple high-voltage detection points, such as the high-voltage lead-out connector 30 on the first fuse 35, the high-voltage connector 30 on the second fuse 36, the high-voltage positive lead-out piece 17 on the mounting base 1, and the high-voltage negative lead-out piece 18 on the mounting base 1, which are directly connected to the self-made circuit board 39 through connectors 30, thus realizing the high-voltage sampling function of the self-made circuit board 39.
[0060] The low-voltage communication circuit is formed by directly connecting the low-voltage lead-out connectors 30 of the main positive relay 311 core, the main negative relay 312 core, the pre-charge relay 38, and the current sensor 34 to the self-made circuit board 39 through the connectors 30, thereby realizing the low-voltage communication function of the self-made circuit board 39.
[0061] Optionally, the connector group 41 further includes a low-voltage connector 22, which is integrally formed with the mounting base 1 and is spaced apart from the main connector 21 and the fast charging connector 20 on the same side of the mounting base 1.
[0062] Specifically, the low-voltage connector 22, the main connector 21, and the fast-charging connector 20 are located on the same side of the mounting base 1 and are integrally formed with the mounting base 1. The low-voltage connector 22 is used to connect with external devices to achieve low-voltage communication. In practical applications, by placing the low-voltage connector 22, the main connector 21, and the fast-charging connector 20 on the same side of the mounting base 1, the available space of the mounting base 1 can be fully utilized, thereby improving the integration of the mounting base 1.
[0063] Optionally, the connector assembly 41 includes a fast charging connector housing 200, a main connector housing 210, and a low-voltage connector housing 220, all of which are integrally formed with the mounting base 1.
[0064] Specifically, the mounting base 1 is a plastic mounting base 1. Through an integrated injection molding process, the fast-charging connector housing 200, the main connector housing 210, and the low-voltage connector housing 220 are integrally molded with the mounting base 1. In practical applications, this integral molding not only makes the installation of each connector housing on the mounting base 1 more stable and reliable, but also reduces the difficulty of installing each connector housing on the mounting base 1, eliminating the need for separate installation steps. This improves the integration of the distribution box 5 and increases its production efficiency. The integrated injection molding process provides better electrical insulation performance and reduces mold and process costs during production. With fewer high-voltage assembly components, the number of failure points is reduced, improving system stability. The integrated design helps optimize the thermal management of the distribution box 5, improving the overall performance and lifespan of the equipment. During processing, the mold for the plastic housing itself serves as the connector mold, significantly reducing resources such as equipment, jigs, and molds required for product manufacturing, resulting in optimal product cost. Furthermore, the fast-charging connector 20, main connector 21, and low-voltage connector 22 are themselves product components, featuring built-in waterproofing and leak-proof functionality. This simplifies the connector structure to the minimum, eliminating the need for auxiliary sealing rings, adhesives, or other auxiliary structures, further reducing the size of the power distribution box 5.
[0065] Furthermore, the fast charging connector housing 200 and the main connector housing 210 can be connected as shown in Figure 3, or they can be spaced apart. The choice can be made flexibly according to the actual situation.
[0066] Furthermore, the low-voltage connector housing 220 is positioned diagonally below the main connector housing 210 and the fast-charging connector housing 200. This ensures the stability of the fit between the main connector housing 210 and the low-voltage connector housing 220 and their corresponding external components, while also ensuring their independence from each other and preventing interference when they fit with their corresponding external components.
[0067] Furthermore, the connector assembly 41 also includes a plurality of electrical connectors 23, which are respectively embedded in the fast charging connector housing 200, the main connector housing 210 and the low-voltage connector housing 220, and the electrical connectors 23 are electrically connected to the component assembly 42.
[0068] Specifically, the main connector housing 210 includes a main connector negative housing 2101 and a main connector positive housing 2102. The electrical connector 23 embedded in the main connector negative housing 2101 is a high-voltage negative connector, and the electrical connector 23 embedded in the main connector positive housing 2102 is a high-voltage positive connector. The high-voltage negative connector is connected to the main negative relay 312, and the high-voltage positive connector is connected to the main positive relay 311. The fast charging connector housing 200 includes a fast charging connector negative housing 2001 and a fast charging connector positive housing 2002. The electrical connector 23 embedded in the fast charging connector negative housing 2001 is a fast charging negative connector, and the electrical connector 23 embedded in the fast charging connector positive housing 2002 is a fast charging positive connector. The fast charging negative connector is connected to the fast charging negative relay 322, and the fast charging positive connector is connected to the fast charging positive relay 321. The electrical connector 23 embedded in the low-voltage housing is a low-voltage electrical connector 23, which is used for low-voltage communication.
[0069] In practical applications, by injection molding the high-voltage positive and negative electrical connectors on the main connector 21, the positive and negative electrical connectors on the fast-charging connector 20, and the low-voltage electrical connectors in the low-voltage connector 22 into inserts positioned in the plastic mold of the mounting base 1, the mounting base 1, the main connector housing 210, the fast-charging connector housing 200, and the low-voltage connector housing 220, along with the electrical connectors 23 disposed within their respective housings, are integrally injection molded. This allows the mounting base 1 to function as a connector through its irregular structure, thereby improving the integration of the power distribution box 5. By placing each electrical connector 23 within its corresponding housing, the main connector 21, the low-voltage connector 22, and the fast-charging connector 20 can be formed, thus fully utilizing the available space on the mounting base 1. The electrical connectors 23 can be metal connecting pieces, which can be stamped. Since the material utilization rate of stamping structures can reach over 92%, material and processing costs are minimized, thereby reducing the cost of the power distribution box 5.
[0070] As shown in Figure 1, a positive lead-out piece 17 is provided on the side of the mounting base 1 near the first fuse 35, and a negative lead-out piece 18 is provided on the side near the current sensor 34. The positive lead-out piece 17 is used to electrically connect to the positive terminal of the battery module 43 in the battery device, and the negative lead-out piece 18 is used to electrically connect to the negative terminal of the battery module 43 in the battery device. The terminals of the main positive relay 311, main negative relay 312, fast charging positive relay 321, and fast charging negative relay 322 are respectively fixed to the positive lead-out piece 17 and the negative lead-out piece 18 by bolts. The terminals of the main positive relay 311 and the main negative relay 312 are directly connected to the positive and negative electrical connectors of the main connector 21 by bolts, and the terminals of the fast charging positive relay 321 and the fast charging negative relay 322 are connected to the positive and negative electrical connectors of the fast charging connector 20 by bolts.
[0071] Referring to Figure 7, the electrical circuit formed by the various components 42 in the power distribution box 5 of this embodiment, and the constituent components may include:
[0072] The components constituting the positive circuit include the first fuse 35, the second fuse 36, the core of the main positive relay 311, and the high-voltage positive lead-out piece 17 on the mounting base 1.
[0073] The components constituting the negative circuit include a current sensor 34, a shunt 33, a main negative relay 312 core, and a high-voltage negative lead-out piece 18 on the mounting base 1.
[0074] The components constituting the precharge circuit include a first fuse 35, a second fuse 36, a precharge resistor 37, a precharge relay 38, a self-made circuit board 39, and a high-voltage positive lead-out piece 17 on the mounting base 1.
[0075] The components constituting the fast charging positive circuit include a first fuse 35, a second fuse 36, a fast charging positive relay core, and a high-voltage positive lead-out piece 17 on the mounting base 1.
[0076] The components constituting the fast charging negative circuit include a current sensor 34, a shunt 33, a fast charging negative relay core, and a high-voltage negative lead-out piece 18 on the mounting base 1.
[0077] The high-voltage detection circuit 1 consists of a high-voltage lead-out piece at the main positive relay 311 and a self-made circuit board 39.
[0078] The high-voltage detection circuit 2 consists of a pre-charge resistor 37, a high-voltage lead-out piece, and a self-made circuit board 39.
[0079] The high-voltage detection circuit 3 consists of a fast-charging connector 20, a positive high-voltage lead-out piece, and a self-made circuit board 39.
[0080] The high-voltage detection circuit 4 consists of a fast-charging connector 20, a negative high-voltage lead-out piece, and a self-made circuit board 39.
[0081] The high-voltage detection circuit 5 consists of a high-voltage connector negative lead-out piece 18 on the mounting base 1 and a self-made circuit board 39.
[0082] The high-voltage detection circuit 6 consists of a high-voltage lead-out piece at the 35th end of the first fuse and a self-made circuit board 39.
[0083] The high-voltage detection circuit 7 includes a battery module 43 and a self-made circuit board 39.
[0084] The low-voltage communication circuit comprises the low-voltage lead-out piece of the main positive relay 311, the low-voltage lead-out piece of the main negative relay 312, the low-voltage lead-out piece of the fast-charging positive relay 321, the low-voltage lead-out piece of the fast-charging negative relay 322, the low-voltage lead-out piece of the pre-charge relay 38, and a self-made circuit board 39.
[0085] It should be noted that the descriptions of the above circuits are merely examples, and the components in each circuit can be flexibly configured according to the actual situation.
[0086] Optionally, the power distribution box 5 includes a protective cover 4, which is placed on the mounting base 1. Specifically, it can be connected to the mounting base 1 by snap-fit or bolts to protect the various devices installed on the mounting base 1.
[0087] Secondly, this disclosure also provides a battery device, which includes the power distribution box 5 described in any of the above embodiments; the battery device also includes a battery module 43, and the power distribution box 5 is connected to the battery module 43.
[0088] Specifically, the battery device can be a power battery pack or an energy storage cabinet. In practical applications, the mounting structure of the mounting base in the power distribution box 5 can be modified to match the installation position of the specific battery device, depending on its structure. The components in the power distribution box 5 are directly electrically connected to the battery module 43, and the power distribution box 5 is used to charge and discharge the battery module 43. The specific specifications of the corresponding components in the power distribution box 5 can be adjusted according to the charging and discharging parameters of the specific battery device.
[0089] It should be noted that in this embodiment, the structure of the power distribution box 5 is the same as that of the power distribution box 5 described in any of the above embodiments, and its beneficial effects are also similar, so it will not be described in detail here.
[0090] 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.
[0091] Numerous specific details are set forth in the specification provided herein. However, it will be understood that embodiments of this disclosure may be practiced without these specific details. In some instances, well-known methods, structures, and techniques have not been shown in detail so as not to obscure the understanding of this specification.
[0092] In the claims, any reference signs placed between parentheses should not be construed as limiting the claims. The word "comprising" does not exclude the presence of elements or steps not listed in the claims. The word "a" or "an" preceding an element does not exclude the presence of a plurality of such elements. The use of the words first, second, and third, etc., does not indicate any order. These words may be interpreted as names.
[0093] Although embodiments of this disclosure have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of this disclosure, the scope of which is defined by the claims and their equivalents.
Claims
1. A power distribution box (5) for use in a battery device, wherein, The distribution box (5) includes: Mounting base (1), the mounting base (1) having a receiving cavity (10); A connector assembly (41) includes a fast charging connector (20) and a main connector (21), wherein the fast charging connector (20) and the main connector (21) are integrally formed with the mounting base (1), and the fast charging connector (20) and the main connector (21) are at least partially exposed in the receiving cavity (10); And a component group (42), the component group (42) including a main relay group (31) and a fast charging relay group (32), the main relay group (31) and the fast charging relay group (32) are disposed in the receiving cavity (10) and at least partially exposed outside the receiving cavity (10); wherein, the main relay group (31) is electrically connected to the main connector (21) and the fast charging relay group (32) is electrically connected to the fast charging connector (20).
2. The distribution box (5) according to claim 1, wherein, The main relay group (31) includes a main positive relay (311) and a main negative relay (312), the fast charging relay group (32) includes a fast charging positive relay (321) and a fast charging negative relay (322), the receiving cavity (10) includes a first receiving cavity (10), a second receiving cavity (10), a third receiving cavity (10) and a fourth receiving cavity (10) arranged at intervals, the main positive relay (311) is disposed in the first receiving cavity (10), the fast charging positive relay (321) is disposed in the second receiving cavity (10), the fast charging negative relay (322) is disposed in the third receiving cavity (10), and the main negative relay (312) is disposed in the fourth receiving cavity (10).
3. The distribution box (5) according to claim 2, wherein, The main positive relay (311) is arranged adjacent to the fast charging positive relay (321), and the main negative relay (312) is arranged adjacent to the fast charging negative relay (322).
4. The distribution box (5) according to claim 3, wherein, The component group (42) also includes a shunt (33) and a current sensor (34). The mounting base (1) is also provided with an adjacent first mounting slot (11) and a second mounting slot (12). The shunt (33) is disposed in the first mounting slot (11), and the current sensor (34) is disposed in the second mounting slot (12). The shunt (33) is disposed adjacent to the main negative relay (312). The shunt (33) is electrically connected to the main negative relay (312) and the fast charging negative relay (322) respectively. The current sensor (34) is electrically connected to the shunt (33).
5. The distribution box (5) according to claim 3, wherein, The component group (42) also includes a first fuse (35) and a second fuse (36). The mounting base (1) is also provided with an adjacent third mounting slot (13) and a fourth mounting slot (14). The first fuse (35) is disposed in the third mounting slot (13), and the second fuse (36) is disposed in the fourth mounting slot (14). The second fuse (36) is disposed adjacent to the main positive relay (311). The second fuse (36) is electrically connected to the main positive relay (311) and the fast charging positive relay (321) respectively. The first fuse (35) is electrically connected to the second fuse (36).
6. The distribution box (5) according to claim 5, wherein, The component group (42) further includes a pre-charge resistor (37) and a pre-charge relay (38). The mounting base (1) is also provided with an adjacent fifth mounting slot (15) and a sixth mounting slot (16). The pre-charge resistor (37) is disposed in the fifth mounting slot (15), and the pre-charge relay (38) is disposed in the sixth mounting slot (16). The pre-charge relay (38) is disposed adjacent to the second fuse (36). The pre-charge relay (38) is electrically connected to the second fuse (36), and the pre-charge relay (38) is electrically connected to the pre-charge resistor (37).
7. The distribution box (5) according to any one of claims 1-6, wherein, The power distribution box (5) also includes a self-made circuit board (39), which is connected to the mounting base (1); The self-made circuit board (39) is provided with multiple connection ports (390), and multiple plugs (30) are fixedly connected to the component group (42). The plugs (30) are plugged into the connection ports (390) to electrically connect the self-made circuit board (39) and the component group (42).
8. The distribution box (5) according to claims 1-7, wherein, The connector group (41) further includes a low-voltage connector (22), which is integrally formed with the mounting base (1). The low-voltage connector (22), the main connector (21), and the fast-charging connector (20) are spaced apart on the same side of the mounting base (1).
9. The distribution box (5) according to claim 8, wherein, The connector assembly (41) includes a fast charging connector housing (200), a main connector housing (210), and a low-voltage connector housing (220), all of which are integrally formed with the mounting base (1).
10. The distribution box (5) according to claim 8 or 9, wherein, The connector group (41) further includes a plurality of electrical connectors (23), which are respectively embedded in the fast charging connector housing (200), the main connector housing (210) and the low voltage connector housing (220), and the electrical connectors (23) are electrically connected to the component group (42).
11. A battery device, wherein, The battery device includes: the power distribution box (5) as described in any one of claims 1-10.