CN111137141A - 具有用于高电流接口的低断面母线的电动化车辆 - Google Patents

具有用于高电流接口的低断面母线的电动化车辆 Download PDF

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CN111137141A
CN111137141A CN201911035149.2A CN201911035149A CN111137141A CN 111137141 A CN111137141 A CN 111137141A CN 201911035149 A CN201911035149 A CN 201911035149A CN 111137141 A CN111137141 A CN 111137141A
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拉杰什·纳拉亚南
弗朗西斯科·费尔南德斯-加林多
达尔科·阿塞夫斯基
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Ford Global Technologies LLC
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Abstract

本公开提供了“具有用于高电流接口的低断面母线的电动化车辆”。本公开涉及一种用于电动化车辆的低断面母线及对应方法。在所述电动化车辆的特定实施例中，示例性母线电连接到两个电子部件，并且所述母线的横截面具有一定高度和为所述高度的至少20倍的宽度。这样，所述母线的所述宽度相对于所述高度被放大，从而使所述母线具有低断面并且使所述母线特别适合于在具有减小的包装高度要求的空间中布线。

Description

具有用于高电流接口的低断面母线的电动化车辆
技术领域
本公开涉及一种用于电动化车辆的低断面母线及对应方法。具体地，母线具有放大的宽度尺寸，在一个示例中，所述宽度尺寸为母线的高度的至少20倍。
背景技术
对降低汽车燃料消耗和排放的需要是众所周知的。因此，正在开发减少或完全消除对内燃发动机的依赖性的车辆。电动化车辆是当前为此目的而开发的一种类型的车辆。一般来讲，电动化车辆与常规机动车辆的不同之处在于它们由一个或多个电池供电的电机选择性地驱动，而常规机动车辆仅依赖于内燃发动机来驱动车辆。电动化车辆的各种电子部件通过具有圆形横截面的传统线材或母线连接在一起。
发明内容
一种根据本公开的示例性方面的电动化车辆尤其包括母线，所述母线电连接到两个电子部件，所述母线的横截面具有一定高度和为所述高度的至少20倍的宽度。
在前述电动化车辆的另一非限制性实施例中，所述母线的所述宽度在所述高度的20至50倍的范围内。
在任一前述电动化车辆的另一非限制性实施例中，所述母线的所述宽度为所述高度的约30倍。
在任一前述电动化车辆的另一非限制性实施例中，所述母线的横截面积在50至100平方毫米的范围内。
在任一前述电动化车辆的另一非限制性实施例中，所述母线的横截面积为约75平方毫米。
在任一前述电动化车辆的另一非限制性实施例中，所述横截面为基本上矩形。
在任一前述电动化车辆的另一非限制性实施例中，所述母线为多层母线。
在任一前述电动化车辆的另一非限制性实施例中，所述母线的端部连接到连接器，所述连接器被配置为连接到所述两个电子部件，并且所述连接器具有相对于所述母线的所述宽度减小的宽度尺寸。
在任一前述电动化车辆的另一非限制性实施例中，所述连接器包括锁定凸片。
在任一前述电动化车辆的另一非限制性实施例中，所述连接器包括被配置为接收凸部的孔。
在任一前述电动化车辆的另一非限制性实施例中，所述母线的端部被配置为连接到具有基本上圆形横截面的线材。
在任一前述电动化车辆的另一非限制性实施例中，所述两个电子部件中的一个为电池组，并且所述电子部件中的另一个为所述电池组外部的电子部件。
在任一前述电动化车辆的另一非限制性实施例中，所述电子部件中的所述另一个为充电端口。
在任一前述电动化车辆的另一非限制性实施例中，所述两个电子部件为电池单元阵列。
一种根据本公开的另一个示例性方面的方法尤其包括使用横截面具有一定高度和为所述高度的至少20倍的宽度的母线来电连接电动化车辆的两个电子部件。
在前述方法的另一非限制性实施例中，所述母线的所述宽度在所述高度的20至50倍的范围内。
在任一前述方法的另一非限制性实施例中，所述母线包括邻近其端部的连接器，所述连接器具有相对于所述母线的宽度减小的宽度尺寸，并且所述方法还包括将所述连接器连接到所述两个电子部件中的相应一个。
在任一前述方法的另一非限制性实施例中，所述母线包括基本上矩形的横截面，并且所述方法还包括将所述母线的端部连接到具有基本上圆形横截面的线材。
在任一前述方法的另一非限制性实施例中，所述电连接步骤包括使用所述母线来连接电池组和所述电池组外部的电子部件。
在任一前述方法的另一非限制性实施例中，所述电连接步骤包括使用所述母线来连接两个电池单元阵列。
附图说明
图1示意性地示出了电动化车辆的动力传动系统。
图2示出了包括示例性母线的电连接。
图3是沿着图2的线3-3截取的示例性母线的剖视图。
图4示出了邻近母线的端部的示例性连接器。在图4中，连接器包括第一示例性保持特征。
图5示出了具有第二示例性保持特征的另一个示例性连接器。
具体实施方式
本公开涉及一种用于电动化车辆的低断面母线及对应方法。在电动化车辆的特定实施例中，示例性母线电连接到两个电子部件，并且母线的横截面具有一定高度和为高度的至少20倍的宽度。这样，母线的宽度相对于高度被放大，从而使母线具有低断面并且使母线特别适合于在具有减小的包装高度要求的空间中布线。换句话讲，该母线特别适合于穿过竖直狭窄的空间来布线。该母线还被配置为连接高电压电子部件并承载相对较高的电流，诸如与DC快速充电(DCFC)相关联的电流。从以下详细描述中将了解这些和其他益处。
现在参考附图，图1示意性地示出了电动化车辆12的动力传动系统10，所述电动化车辆被示出为电池电动车辆(BEV)。最初，图1所示的动力传动系统10是高度示意性的，而无意限制本公开。可替代地或除此之外，动力传动系统10可在本公开的范围内采用各种另外的部件。此外，尽管电动化车辆12被描绘为BEV，但是应当理解，本文描述的概念不限于BEV，而是可以扩展到其他电动化车辆，包括但不限于插电式混合动力电动车辆(PHEV)。因此，尽管在此实施例中未示出，但是电动化车辆12可以配备有内燃发动机，所述内燃发动机可以单独使用或与其他能源组合使用以推进电动化车辆12。此外，本公开扩展至任何混合动力或电动车辆，包括全混合动力、并联混合动力、串联混合动力、轻度混合动力和微混合动力等等。
在非限制性实施例中，电动化车辆12是仅通过电力(诸如通过电机14)推进的纯电动车辆，而无需内燃发动机的任何辅助。电机14可作为电动马达、发电机或两者进行操作。电机14接收电力并提供旋转输出功率。电机14可连接到齿轮箱16，用于以预先确定的齿轮比调节电机14的输出扭矩和转速。齿轮箱16通过输出轴20连接到一组驱动轮18。高电压总线22通过逆变器26将电机14电连接到电池组24。电机14、齿轮箱16和逆变器26可统称为传动装置28。
电池组24是能量存储装置，并且在此示例中是示例性电动化车辆电池。就这一点而言，电池组24可被称为“电池”。电池组24可以是高电压牵引电池组，其包括能够输出电力以操作电机14和/或电动化车辆12的其他电负载的多个电池总成25(即，电池阵列或电池单元组)。其他类型的能量储存装置和/或输出装置也可用于为电动化车辆12提供电力。
电动化车辆12还可包括充电系统30，所述充电系统用于对电池组24的电池单元周期性地充电。充电系统30可以连接到外部电源，诸如输电网络，以用于接收电力和向电池单元分配电力。例如，在一个非限制性实施例中，充电系统30包括第一接口32，所述第一接口为充电端口、位于电动化车辆12上。第一接口32适于选择性地从外部电源接收电力，诸如从连接到外部电源的电力电缆接收电力，然后将电力分配给电池组24以为电池单元充电。一个示例性外部电源是电动化车辆充电站，诸如公共可用的电动化车辆充电站。在特定示例中，充电站可以是DC快速充电站。在再一个示例中，电动化车辆充电站是私有的，诸如家庭或企业的充电站。
充电系统30还可配备有电力电子器件，所述电力电子器件用于将从外部电源接收的AC电力转换为DC电力，以用于对电池组24的电池单元充电。充电系统30还可以适应来自外部电源的一个或多个常规电压源(例如，110伏、220伏等)。
图1所示的动力传动系统10是高度示意性的，而无意限制本公开。在本公开的范围内可替代地或另外地使用各种其他部件。
图2示出了电动化车辆12内的示例性电连接件40。电连接件40表示电动化车辆12的两个电子部件之间的电连接件。在图2的示例中，两个电子部件是充电系统30的第一接口32或充电端口，以及被配置为连接到电池组24的第二接口42。
在该示例中，从第一接口32开始，电连接件40包括多个线材44，所述多个线材可以是与第一接口32相关联的线束的一部分。在该示例中，线材44是传统线材，其横截面为基本上圆形。线材44从第一接口32伸出相对短的距离到达母线46，并且在一个示例中，通过焊接电连接到母线46。这里，电连接(即，电耦合)是指通过导电路径连接。在另一个示例中，电连接件40不包括线材44，而是母线46直接连接到第一接口32。
母线46横穿第一接口32与第二接口42之间的大部分距离，即使不是整个距离，在该示例中，所述第二接口电连接到电池组24。第二接口42通过线材48电连接到母线46，所述线材是传统线材，其横截面为基本上圆形。在一个示例中，线材48可焊接到母线46。线材48并非必须存在，并且应当理解，本公开扩展至其中母线46直接连接到第二接口42的布置。此外，虽然示出了线材44、48，但母线46可使用其他类型的电连接件连接到第一接口32和第二接口42。
图2的电连接件40是高度示意性的，并且表示使用母线46在电池组24与电池组24外部的电子部件(在该示例中为第一接口32)之间的电连接件。应当理解，本公开不限于电池组24与第一接口32之间的电连接件，并且还扩展至电池组24内部的电子部件之间的连接件，诸如两个电池总成25之间的电连接件。
为此，电连接件40(包括母线46)能够连接高电压电子部件并承载相对高的电流，诸如与DC快速充电(DCFC)相关联的电流。例如，图2的电连接件40可以是DCFC连接件，其中来自DCFC充电站的插头被插入第一接口32中，并且电连接件40允许相对高的电流流到电池组24以能够进行相对快速的充电。电连接件40可被配置为处理约400安培的电流电平，并且允许高达约400kW的功率传输。
具体地，母线46被配置为允许这种高电平的电流和功率在两个电子部件之间流动，同时还能够在电动化车辆12内进行布线。电动化车辆12的许多跨度，包括在第一接口32与第二接口42之间的跨度，具有减小的包装高度要求，这意味着母线46必须通过若干竖直狭窄的空间。因此，在本公开中，母线46具有放大的(即，扩大或增加的)宽度尺寸，这为母线46提供了独特的横截面形状。所述横截面形状允许母线46在竖直狭窄的空间内布线，同时仍然能够处理相对较高的电流。
如图3所示，该图是沿着图2中的线3-3截取的母线46的剖视图，母线46具有由高度H和宽度W限定的基本上矩形的横截面。在该示例中，宽度W是高度H的至少20倍，因此宽度W相对于高度H被放大。母线46的长度足以跨越本发明的电子部件之间的距离。取决于母线46的长度，沿着所述长度可能需要一个或多个局部附接点，以减少振动并增加稳定性。
在该示例中，母线46是具有多个材料层50A至50D的多层母线，所述材料层被堆叠和/或层压在一起以形成母线46。层50A至50D中的每一个单独地具有总体上与母线46相同的宽度W，并且层50A至50D的高度在堆叠时一起为母线46提供高度H。虽然在图3中示出了四个层50A至50D，但应当理解，本公开扩展至具有不同数量的层的母线。在其他示例中，母线46不是多层母线，而是包括具有高度H和宽度W的单件材料，如图3所示。
在该示例中，母线46由铜(Cu)或铝(Al)制成。当母线46是多层母线时，诸如层50A至50D的层也由铜和/或铝制成。
为了允许相对高的电流流过母线46，母线46必须具有相对较大的横截面积，在一个示例中，所述横截面积在50至100平方毫米的范围内。然而，母线46的尺寸也受到电动化车辆12的成本和包装约束的限制。因此，本发明提供的母线46的宽度W为高度H的至少20倍。在另一示例中，母线46的宽度W在高度H的20至50倍的范围内，并且可以是高度H的约30倍。在后面的示例中，上端的宽度W受到限制，使得母线46不会变得过分脆弱。上端的宽度W并非必须限于高度H的50倍，并且可以理解的是，该范围存在实际上限。
在另一示例中，母线46的高度H为1.65mm并且宽度W为约45mm，从而为母线46提供约75平方毫米的横截面积。在一些示例中，母线的高度H可低至约1.2mm。
同样，这些仅是示例。高度和宽度尺寸的其他组合也在本公开的范围内。不管具体尺寸如何，母线46都具有增加的横截面积，从而使母线46能够处理相对高的电流，同时还允许母线46通过竖直狭窄的空间来布线，诸如已知存在于第一接口32和第二接口42之间的空间。
由于宽度W放大，因此母线46可能不容易连接到电动化车辆12的所有各种电子部件。因此，在本公开的一方面，母线46的端部52连接到连接器54，如图4和图5所示。具体地，图4示出了母线46的一个端部52通过焊道56连接到连接器54。连接器54被配置为直接连接到电动化车辆12的电子部件，诸如第一接口32或第二接口42或电池总成25。连接器54还被配置为直接或通过连接器连接到传统线材。
连接器54具有相对于母线46的宽度W减小的宽度W’。连接器54还可包括一个或多个保持特征，所述一个或多个保持特征被配置为便于连接器54连接到相邻的电子部件。在图4中，保持特征为孔58，所述孔穿过连接器54并且被配置为接收来自对应电子部件的凸部。在图5中，保持特征为布置在连接器54的相对侧上的一对锁定凸片60。在该示例中，锁定凸片60包括倾斜的前缘62。连接器54可包括图4和图5所示的保持特征中的一个、两个或都不包括。在其他示例中，除了保持特征之外，连接器54可被焊接以形成必要的电连接件。
应理解，诸如“约”和“基本上”的术语并不旨在为无边界术语，并且应被解释为与本领域技术人员将解释这些术语的方式一致。
尽管不同示例具有在图示中示出的特定部件，但是本公开的实施例不限于那些特定组合。可以将来自示例中的一个的部件或特征中的一些与来自示例中的另一个的特征或部件组合地使用。
本领域的普通技术人员将理解，上述的实施例是示例性而非限制性的。也就是说，本公开的修改将落入权利要求的范围内。因此，应研习以下权利要求来确定其真实范围和内容。

Claims (14)

1.一种电动化车辆，其包括：
母线，所述母线电连接到两个电子部件，所述母线的横截面具有一定高度和为所述高度的至少20倍的宽度。
2.如权利要求1所述的电动化车辆，其中所述母线的所述宽度在所述高度的20至50倍的范围内，并且任选地其中所述母线的所述宽度为所述高度的约30倍。
3.如权利要求1或2所述的电动化车辆，其中所述母线的横截面积在50至100平方毫米的范围内，并且任选地其中所述母线的横截面积为约75平方毫米。
4.如权利要求1所述的电动化车辆，其中所述横截面为基本上矩形。
5.如权利要求1所述的电动化车辆，其中所述母线为多层母线。
6.如权利要求1所述的电动化车辆，其中：
所述母线的端部连接到连接器，
所述连接器被配置为连接到所述两个电子部件，
所述连接器具有相对于所述母线的所述宽度减小的宽度尺寸，并且
任选地，所述连接器包括锁定凸片或被配置为接收凸部的孔。
7.如权利要求1所述的电动化车辆，其中所述两个电子部件中的一个为电池组，并且其中所述电子部件中的另一个为所述电池组外部的电子部件，并且其中任选地所述电子部件中的所述另一个为充电端口。
8.如权利要求1所述的电动化车辆，其中所述两个电子部件为电池单元阵列。
9.一种方法，其包括：
使用横截面具有一定高度和为所述高度的至少20倍的宽度的母线来电连接电动化车辆的两个电子部件。
10.如权利要求9所述的方法，其中所述母线的所述宽度在所述高度的20至50倍的范围内。
11.如权利要求9所述的方法，其中所述母线包括邻近其端部的连接器，所述连接器具有相对于所述母线的所述宽度减小的宽度尺寸，并且所述方法还包括将所述连接器连接到所述两个电子部件中的相应一个。
12.如权利要求9所述的方法，其中所述母线包括基本上矩形的横截面，并且所述方法还包括将所述母线的端部连接到具有基本上圆形横截面的线材。
13.如权利要求9所述的方法，其中所述电连接步骤包括使用所述母线来连接电池组和所述电池组外部的电子部件。
14.如权利要求9所述的方法，其中所述电连接步骤包括使用所述母线来连接两个电池单元阵列。
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