CN110395122A - 高压电池外壳中的低压汇流条 - Google Patents

高压电池外壳中的低压汇流条 Download PDF

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CN110395122A
CN110395122A CN201910293515.8A CN201910293515A CN110395122A CN 110395122 A CN110395122 A CN 110395122A CN 201910293515 A CN201910293515 A CN 201910293515A CN 110395122 A CN110395122 A CN 110395122A
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vehicle
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大卫·J·贝雷尔
道格拉斯·B·索恩伯格
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Abstract

本公开提供了“高压电池外壳中的低压汇流条”。一种电动推进车辆具有高压电驱动系统和低压电气附件系统。高压电池组以相对较高的电压为牵引马达提供电力。低压配电系统在所述车辆内布线，为所述附件系统承载相对较低的电压。模制电池外壳包含所述电池组并且在车身/车架中的预定位置之间延伸。所述低压配电系统包括保持在所述外壳中并与所述电池组电隔离的汇流条。所述汇流条具有在所述预定位置处可触及的暴露的端子端部。将所述低压汇流条结合到所述高压电池外壳中使得用于所述低压配电系统的包装空间减小，同时加固了所述外壳。

Description

高压电池外壳中的低压汇流条
技术领域
本发明总体涉及汽车配电系统，并且更具体地涉及一种电动马达驱动的车辆，其具有支撑低压配电系统的一部分的高压电池外壳。
背景技术
鉴于电子模块和特征的数量日益增加，汽车制造中的一个重要问题涉及车辆布线的包装。具体地，由于包装空间的可用性有限以及需要将长距离电缆与其他布线分开以便最小化EMI敏感度，因此难以包装具有大直径的配电电缆。
电动推进车辆(例如，电池电动和气电混合动力车辆)是车辆行业不断增长的部分。电动车辆通常具有两部式电气系统，其具有：1)高压(HV)部分，其具有HV电池组以及在HV电池组、逆变器和牵引马达之间的HV布线系统；以及2)低压(LV)部分，其具有LV电池以及将LV附件和模块互连的LV布线系统。通过将容纳在电池外壳(例如，电池托盘)中的多个电池单元互连来获得电池组的高压。HV电池组可能在车辆区域中占用显著的包装空间，所述区域还必须支撑LV布线配电系统。
发明内容
在本发明的一个方面，电动牵引车辆包括车身/车架。高压电池组以相对较高的电压为牵引马达提供电力。低压配电系统在车辆内布线，其承载相对较低的电压并且被配置为将多个低压附件互连。模制电池外壳包含电池组并且在车身/车架中的预定位置之间延伸。低压配电系统包括保持在外壳中并与电池组电隔离的汇流条。汇流条具有在预定位置处可触及的暴露的端子端部。将低压汇流条结合到高压电池外壳中使得用于低压配电系统的包装空间减小，同时加固了外壳。
附图说明
图1是电动推进车辆的侧视图，示出了用于包装HV电池组的一些常规位置。
图2是示出电动车辆的一个实施例的框图。
图3是车身/车架的分解图，示出了在本发明的一个实施例中具有集成的LV汇流条的电池组。
图4是在本发明的另一个实施例中具有集成的LV汇流条的电池外壳的分解透视图。
图5是图4的电池盖沿着线5-5截取的剖视图。
图6是在本发明的另一个实施例中具有集成的LV汇流条的电池外壳的透视图。
图7是电池组的另一个实施例的横向剖视图，其中LV汇流条集成在电池外壳内。
图8是更详细地示出了与集成的汇流条的端子连接的一个实施例的透视图。
图9是示出了具有与集成的汇流条的端子连接的电池外壳的另一实施例的电池外壳的透视图。
具体实施方式
为了在车辆内分配低压电力，本发明部署汇流条，所述汇流条与高压电池外壳集成并且具有适当的端部端子以与LV配电系统的不同段连接。例如，汇流条可以是模制到外壳中或以其他方式保持在外壳中的铝杆。对于电池组所占用的距离而言，集成的汇流条与传统电缆布线相比节省了质量和包装空间。
电池外壳(例如，托盘和盖)通常由热塑性或热固性玻璃纤维材料制成。本发明的某些实施例可以使用高压注塑模制、吹塑模制、利用加热的压模进行的片材模塑化合物(SMC)模制、或树脂传递模塑(RTM)模制，以便将汇流条嵌入在托盘或盖的壁内。可以使用这些或其他已知的工艺技术来对汇流条包覆模制，使得汇流条与HV电池或导体电隔离。这些包覆模制工艺允许材料在金属汇流条上方和周围流动，同时使汇流条的端部在连接端子处可触及(即，未覆盖)。连接端子具有可以被直接附接的附接点，诸如螺栓接头或片式端子。集成的汇流条可以具有中间连接端子，以便于沿着电池组的中点处的电连接。例如，端部和/或中间端子连接可以接合到LV配电系统的配电箱。
除了节省包装空间以及降低制造成本和零件计数的益处之外，将金属汇流条模制到电池组中还可以增加电池组外壳的刚度。这有助于维持HV电池的完整性，尤其是在碰撞事件期间。
现在参考图1，电气化车辆10具有电池组11，所述电池组经由逆变器(未示出)来为电动马达提供电力。电池组11附接到车辆10的车身底部。因此，电池组可以具有相对小的垂直高度，同时具有显著的前后长度和横向(side-to-side)宽度。因此，电池组11在车辆10内的各个预定位置之间延伸，所述预定位置以相当大的距离隔开并且在其间需要分配LV电力。后地板区域12是可以安装电池组的另一空间，并且该空间也可能需要由LV配电系统横贯。
车辆10在图2中更详细地示出为混合动力电动车辆。尽管示出了功率分流混合动力布局，但本发明也适用于任何类型的电动车辆(例如，HEV、PHEV或全电动车辆)。内燃发动机13和HV电池组11为推进车辆10供应能量。电池11经由HV逆变器15来驱动电力牵引马达14。马达14具有联接到变速齿轮16的输出，用于驱动车轮(未示出)。发动机13的机械输出经由分流装置17联接到齿轮16，用于提供动力传动系统的发动机驱动模式。分流装置17还将齿轮16联接到发电机18，使得在再生制动期间，来自车轮的可用机械动力可用于使发电机18旋转，其中使用回收的能量为电池11充电，如本领域中已知的。
车辆10还具有低压电气系统，所述低压电气系统包括LV电池20、LV配电系统21和LV附件/控件22。LV电池20可以经由从HV系统(例如，HV电池11)供电的DC/DC转换器23来再充电。LV电池20可以具有约12V的电压，而HV电池11可以具有约60V至800V的输出电压。LV配电系统21可包括布线电缆/线束、配电箱和各种连接器，如本领域中已知的。LV附件/控件包括利用低压电力的电子模块和电子部件。
图3示出了用于将LV汇流条与HV电池外壳集成的一种优选布置。车辆25具有包括底盘部分26和车身部分27的车身/车架。如本文所用，车身/车架可由一体式车身结构、附接到下部车架的上部车身或任何其他类型的车辆结构构成。在图3中，底盘部分26支撑具有盖或罩30的电池组28。嵌入在盖30内的是LV铝制汇流条31，所述LV铝制汇流条具有在相对端部可触及的端子连接器32和33。连接器32和33设置在车辆25内的预定位置处。在预定位置处还设置有电力电缆36和37的配合连接器34和35。电缆36和37的另一端处的连接器38和39分别连接到配电箱(PDB)40和41。
图4提供了关于本发明的电池组、模制外壳和汇流条的一个实施例的更多细节。下部托盘45具有模制的侧壁、底壁和内壁，这些壁限定接纳多个电池单元46的内部隔室。单元46经由HV汇流条(未示出)来互连。HV汇流条和外部HV连接器端子(未示出)与LV汇流条系统保持电隔离，所述LV汇流条系统也保持在模制外壳内。在这个实施例中，使用紧固件48来将上部盖47密封到下部托盘45。从盖47延伸出的突起49用于将电池组从车身/车架的面向下的表面悬挂，如美国专利9,722,223中所述，该专利通过引用并入本文中。
模制盖47承载嵌入的铝制汇流条50和51。汇流条50从盖47露出以提供片式端子52和53，并且汇流条51从盖47露出以提供片式端子54和55。由于嵌入在盖47内，汇流条50和51与任何HV元件绝缘。如图5所示，由于包覆模制工艺，汇流条50和51被电绝缘的热塑性材料包围。盖47可以包括上部聚合物片材和下部聚合物片材，所述上部聚合物片材和下部聚合物片材被压缩以例如围绕每个汇流条形成SMC主体。
图6示出了本发明的另一个实施例，其中模制外壳60具有用于将电池组安装在车辆后部载货区域中的配置。外壳60具有使上汇流条61嵌入的壁或盖。暴露的端子端部62和63在预定位置延伸，在所述预定位置处形成与车辆中的低压配电系统的连接。通过形成具有对应曲率的汇流条61，所述位置可以是沿着外壳60的周边的任何位置。在这个实施例中，端子62和63形成为带孔端子。
图7示出了本发明的又一个实施例，其中电池组65由电池单元总成66构成，所述电池单元总成保持在上部托盘67和下部罩68之间的外壳空腔中。通过使用夹具72将具有绝缘护套71的金属汇流条70附接到托盘67的壁的内侧来将所述金属汇流条保持在外壳腔中。由于汇流条70是单独的部件而不是嵌入在壁中，因此护套71提供与HV电池总成66的电隔离。通过托盘67和/或罩68提供适当的密封开口(未示出)，以在期望位置提供与汇流条70的端子连接。使用支撑带74将电池组65紧固到车身/车架的底表面73，如本领域中已知的。
图8更详细地示出了端子端部连接器的实施例。模制外壳壁75具有嵌入的汇流条76，所述汇流条从壁75伸入连接器77中。连接器77在包覆模制主体内具有带孔端子80，并且可经由开口轴环78触及。罩81被设置用于在与端子80未形成连接时密封开口轴环78。端子80可以优选地包括螺纹部分，以便接收螺纹外部连接器，如本领域中已知的。
图9示出了另一个电池外壳85，该电池外壳具有嵌入的汇流条86，其一端具有带孔端子。汇流条86的另一端具有由螺柱91和底座92形成的端子端部90。螺柱91具有螺纹，使得LV配电系统中的电缆93的带孔端子94可以通过六角螺母95来与螺柱91保持电气连接。
使用在中间放置的螺柱96来获得与汇流条86的中间连接。螺柱96从汇流条86延伸并从外壳85延伸出，以在LV配电系统中的对应位置处接收连接器(未示出)。
根据本发明，提供一种电动牵引车辆，所述电动牵引车辆具有：车身/车架；高压电池组，其以相对较高的电压为牵引马达提供电力；低压配电系统，其在所述车辆内布线，承载相对较低的电压并且被配置为将多个低压附件互连；以及模制电池外壳，其包含所述电池组并且在所述车身/车架中的预定位置之间延伸；其中所述低压配电系统包括保持在所述外壳中并与所述电池组电隔离的汇流条，并且其中所述汇流条具有在所述预定位置处可触及的暴露的端子端部。
根据一个实施例，所述汇流条由设置在所述外壳中的铝杆构成，其中在所述外壳的外部在所述铝杆的所述暴露的端子端部处具有端子连接。
根据一个实施例，至少一个端子连接由片式端子构成。
根据一个实施例，至少一个端子连接由带孔端子构成。
根据一个实施例，上述发明的特征还在于中间连接器，所述中间连接器在所述外壳的外部并且延伸到所述外壳中以与所述汇流条的中间段接合。
根据一个实施例，所述汇流条嵌入在所述外壳的壁内。
根据一个实施例，所述外壳是具有盖的箱形形状，并且其中所述汇流条嵌入在所述盖内。
根据一个实施例，通过将聚合物片材在所述汇流条上进行压缩模制而形成所述外壳。
根据一个实施例，通过将聚合物材料在所述汇流条上进行树脂传递模制而形成所述外壳。
根据一个实施例，所述汇流条的至少一部分设置在所述外壳的内部腔室中。
根据本发明，提供一种用于车辆中的牵引电池组的模制外壳，所述模制外壳具有：模制托盘，其具有被配置为容纳所述电池组的腔室；以及模制盖，其附接到所述托盘，密封所述腔室；其中所述盖包括保持在所述外壳中并与所述电池组电隔离的汇流条，所述汇流条在所述外壳的外部在相对端部处具有暴露的端子连接器，用于连接到低压配电系统。
根据一个实施例，所述汇流条由嵌入在所述盖中的铝杆构成。
根据一个实施例，至少一个端子连接器由片式端子构成。
根据一个实施例，至少一个端子连接器由带孔端子构成。
根据一个实施例，上述发明的特征还在于中间连接器，所述中间连接器在所述外壳的外部并且延伸到所述外壳中以与所述汇流条的中间段接合。
根据一个实施例，通过将聚合物片材在所述汇流条上进行压缩模制而形成所述盖。
根据一个实施例，通过将聚合物材料在所述汇流条上进行树脂传递模制而形成所述盖。

Claims (15)

1.一种电动牵引车辆，其包括：
车身/车架；
高压电池组，所述高压电池组以相对较高的电压为牵引马达提供电力；
低压配电系统，所述低压配电系统在所述车辆内布线，承载相对较低的电压并且被配置为将多个低压附件互连；以及
模制电池外壳，所述模制电池外壳包含所述电池组并且在所述车身/车架中的预定位置之间延伸；
其中所述低压配电系统包括保持在所述外壳中并与所述电池组电隔离的汇流条，并且其中所述汇流条具有在所述预定位置处可触及的暴露的端子端部。
2.如权利要求1所述的车辆，其中所述汇流条由设置在所述外壳中的铝杆构成，其中在所述外壳的外部在所述铝杆的所述暴露的端子端部处具有端子连接。
3.如权利要求2所述的车辆，其中至少一个端子连接由片式端子构成。
4.如权利要求2所述的车辆，其中至少一个端子连接由带孔端子构成。
5.如权利要求2所述的车辆，其还包括中间连接器，所述中间连接器在所述外壳的外部并且延伸到所述外壳中以与所述汇流条的中间段接合。
6.如权利要求1所述的车辆，其中所述汇流条嵌入在所述外壳的壁内。
7.如权利要求6所述的车辆，其中所述外壳是具有盖的箱形形状，并且其中所述汇流条嵌入在所述盖内。
8.如权利要求1所述的车辆，其中通过将聚合物片材在所述汇流条上进行压缩模制而形成所述外壳。
9.如权利要求1所述的车辆，其中通过将聚合物材料在所述汇流条上进行树脂传递模制而形成所述外壳。
10.如权利要求1所述的车辆，其中所述汇流条的至少一部分设置在所述外壳的内部腔室中。
11.一种用于车辆中的牵引电池组的模制外壳，其包括：
模制托盘，所述模制托盘具有被配置为容纳所述电池组的腔室；以及
模制盖，所述模制盖附接到所述托盘，密封所述腔室；
其中所述盖包括保持在所述外壳中并与所述电池组电隔离的汇流条，所述汇流条在所述外壳的外部在相对端部处具有暴露的端子连接器，用于连接到低压配电系统。
12.如权利要求11所述的外壳，其中所述汇流条由嵌入在所述盖中的铝杆构成。
13.如权利要求11所述的外壳，其中至少一个端子连接器由片式端子构成。
14.如权利要求11所述的外壳，其中至少一个端子连接器由带孔端子构成。
15.如权利要求11所述的外壳，其还包括中间连接器，所述中间连接器在所述外壳的外部并且延伸到所述外壳中以与所述汇流条的中间段接合。
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