CN116638968A - Small-volume high-voltage distribution box structure and manufacturing method thereof - Google Patents

Abstract

The embodiment of the invention discloses a small-volume high-voltage distribution box and a manufacturing method thereof, and the small-volume high-voltage distribution box comprises a substrate, wherein an electric device layer and a conductive layer are arranged in the substrate, at least one electric device is arranged in the electric device layer, both the positive end and the negative end of the electric device are connected with the conductive layer, a plurality of conductors respectively connected with the positive electrode and the negative electrode of the electric device are arranged in the conductive layer, and the conductors are sheet conductors. According to the small-volume high-voltage distribution box, all electric devices are tiled to form an electric device layer, all electric conductors are tiled to form an electric conduction layer, a clear-cut structure is formed between the electric devices and the electric conductors, the thickness of the electric conductors can be conveniently controlled, and the small-volume high-voltage distribution box is minimum. The technology reasonably distributes the electric interface, the electric conductor and the electric device, compactly distributes the electric conductor and the electric device together by an injection molding integrated technology, and reduces the whole volume of the high-voltage distribution box by keeping the excellent electric performance condition of the high-voltage distribution box.

Description

Small-volume high-voltage distribution box structure and manufacturing method thereof

Technical Field

The embodiment of the invention relates to the technical field of new energy battery accessories, in particular to a small-size high-voltage distribution box and a manufacturing method thereof.

Background

With the increasing maturity of new energy automobile technology, the energy supply measures are more and more perfect, the duration is longer and longer, the acceptance of people to electric automobiles is also more and more accepted, and with the increasing of electric automobiles, the duration ratio of electric automobiles is more and more vigorous. Under the condition that the vehicle type of the electric vehicle and the size of the battery pack cannot be increased, if long endurance is required, on one hand, the energy density of the battery cells needs to be improved, and on the other hand, more battery cells need to be put down in the battery pack so as to achieve the purpose of increasing the endurance.

However, when the number of the electric cores is increased, the space reserved for the high-voltage distribution box in the battery pack is reduced, fig. 1 is an assembly diagram of the existing high-voltage distribution box, fig. 1 is a base body, fig. 1 is an electric device such as a relay and a current sensor, and fig. 2 is a copper bar used for playing a role of a wire, as shown in fig. 1, the electric device is a standard part, the copper bar needs to be bent and needs to be stacked in a staggered manner, more space is required to be used for placing the copper bar in an intangible manner, in addition, the volume of the relay is large, most of space is occupied, if the volume of the high-voltage distribution box is reduced, the electric device in the layout is stacked conventionally, the safe electric gap is reduced, the heat dissipation space is insufficient, the safety performance such as insulation voltage resistance is reduced, and the heat is excessively concentrated, so that a distribution combustion phenomenon is generated, and therefore, the high-voltage distribution box with reasonable layout is required, and the proper gaps are formed between the electric devices and the copper bar.

Disclosure of Invention

Therefore, the embodiment of the invention provides a small-size high-voltage distribution box and a manufacturing method thereof, which are used for solving the problem of large occupied space of copper bars caused by unreasonable layout of electric devices and the copper bars in the prior art.

In order to achieve the above object, the embodiment of the present invention provides the following technical solutions:

the utility model provides a small-size high voltage distribution box structure, includes the base member, be equipped with electric device layer and conducting layer in the base member, be equipped with at least one electric device in the electric device layer, the conducting layer is all connected at the positive and negative both ends of electric device, be equipped with a plurality of electric conductors of connecting electric device positive pole and negative pole respectively in the conducting layer, the electric conductor is sheet-like electric conductor.

Further, the thickness of the conductor ranges from 2 mm to 5mm.

Further, the width of the outer conductive structure is in the range of 16-30mm.

Further, the conductor is provided with a collection point.

Further, the collection points are arranged on the conductor and located between the two sides of the conductor and the connection positions of the electrical devices.

Further, the base body is provided with a connecting column for fixing the electric conductor.

Further, a limiting structure for forming an electric device embedded groove is arranged on the base body, and a through hole for a conductor to penetrate is formed in the limiting structure.

Further, a partition structure for isolating adjacent conductors is provided on the base.

Further, a through hole for the power supply device to penetrate is formed in the base body.

The manufacturing method of the small-size high-voltage distribution box comprises the following steps of:

and S1, setting an electric interface by combining the arrangement of the electric cores in the battery pack and the trend of the electric conductor of the high-voltage distribution box.

And S2, pressing and riveting the pressing and riveting bolt on the position of the collecting point of the conductor, and integrally forming the conductor, the pressing and riveting bolt and the matrix through injection molding.

S3, inversely placing the electric device at the installation position of the electric device on the inner side of the upper cover of the base body, turning over the assembly of the electric device and the upper cover of the base body, buckling the upper cover of the base body and the base body base, enabling the electric device to be inserted into the limiting structure, and locking the electric device and the electric conductor inside the base body together by using the flat head bolt according to the specified torque.

And S4, fixing the high-voltage acquisition wire harness on an acquisition point of the conductor.

The embodiment of the invention has the following advantages:

according to the small-volume high-voltage distribution box, all electric devices are tiled to form an electric device layer, all electric conductors are tiled to form an electric conduction layer, a clear-cut structure is formed between the electric devices and the electric conductors, the thickness of the electric conductors can be conveniently controlled, and the small-volume high-voltage distribution box is minimum. The technology reasonably distributes the electric interface, the electric conductor and the electric device, has simple manufacturing method and lower cost, compactly distributes the electric conductor and the electric device together by injection molding integrated technology, and reduces the whole volume of the high-voltage distribution box by keeping the excellent electric performance condition of the high-voltage distribution box.

Because the thickness of all conductors in this technique is the same, only need change cutting die during the production and processing, just can process out multiple conductor that satisfies the circuit demand, it is simpler to generate processing. And the distance between the conductors in the technology is short compared with the conventional conductors, and the manufacturing cost is lower.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below. It will be apparent to those skilled in the art from this disclosure that the drawings described below are merely exemplary and that other embodiments may be derived from the drawings provided without undue effort.

The structures, proportions, sizes, etc. shown in the present specification are shown only for the purposes of illustration and description, and are not intended to limit the scope of the invention, which is defined by the claims, so that any structural modifications, changes in proportions, or adjustments of sizes, which do not affect the efficacy or the achievement of the present invention, should fall within the ambit of the technical disclosure.

Fig. 1 is a product structure diagram of a high voltage distribution box in the prior art;

fig. 2 is an overall structure diagram of a small-sized high-voltage distribution box according to an embodiment of the present invention;

FIG. 3 is a top view of FIG. 2, with thick black lines being high voltage acquisition circuitry;

fig. 4 is a top view of the removed electrical device of fig. 3.

Fig. 5 is a circuit diagram of a small-sized high-voltage distribution box according to an embodiment of the present invention;

fig. 6 is a flow chart of a method for manufacturing a small-volume high-voltage distribution box according to an embodiment of the present invention.

In the figure:

1. a base; 2. an electrical device; 3. a copper bar; 4. an electric conductor; 5. a limit structure; 6. an acquisition point; 7. a connecting column; 8. a partition structure.

Detailed Description

Other advantages and advantages of the present invention will become apparent to those skilled in the art from the following detailed description, which, by way of illustration, is to be read in connection with certain specific embodiments, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

Example 1

As shown in fig. 2, a small-volume high-voltage distribution box includes a base 1, where the base 1 is divided into a base (the base shown in fig. 2 is a base) and a base upper cover (not shown in the figure), and an electric device layer and a conductive layer are disposed in the base 1, and the positional relationship between the electric device layer and the conductive layer is not limited, and may be an upper-lower relationship, such as that the electric device layer is further upper, the conductive layer is further lower, or that the conductive layer is further upper, and that the electric device layer is further lower, or that the electric device layer is further left-right, such as that the electric device layer is left, or that the electric device layer is right, and that the conductive layer is left, so long as the two adjacent relationships fall within the protection scope of the present invention. The implementation principle and beneficial effects of each structure are further described below by taking the example that an electric device layer is arranged on an upper conductive layer and then the conductive layer is arranged on a lower conductive layer:

1. electric device layer

The invention is characterized in that at least one electric device 2 is arranged in the electric device layer, the electric device 2 such as a relay, a fuse, a current sensor, an electric interface and the like is connected with the electric device 2, namely, positive connection ends and negative connection ends of all the electric devices 2 are connected with the electric layer, and the positive connection ends and the negative connection ends of all the electric devices 2 in the electric device layer are preferably positioned in the same plane. If the connection ends between the electric devices 2 are not in the same plane due to the self-cause of the electric devices 2, the local thickness of the conductive layer is increased to make up the connection gap between the conductive layer and the electric device layers, so that the conductive layer and all the electric devices 2 are in connection relation.

The base body 1 is provided with a limit structure 5 for forming an embedded groove of the electric device 2, the limit structure 5 is used for isolating each electric device 2, and on one hand, the limit structure is used for electric isolation and thermal isolation, so that the safety is improved; on the other hand is used for limiting the electric device 2, in order to achieve the technical effect, as the limiting structure 5 at least surrounds 3 sides of the electric device 2, the limiting structure 5 is easy to cover the distribution route of the conductive layer, and therefore, the limiting structure 5 is provided with a first through hole for the electric conductor 4 to penetrate, so that the electric conductor 4 can conveniently penetrate.

The base body 1 is provided with a through hole through which the power supply device 2 penetrates, so that the electric device 2 with larger volume extends out of the base body 1, the volume of the base body 1 is convenient to reduce, the base body 1 which wraps the extending part of the electric device 2 can be fixedly connected with the base body 1, the electric device 2 is prevented from being infringed by external impact and the like, and the base body 1 is only used for wrapping a conductive layer and a part of the structure of the electric device 2 which is connected with the conductive layer, so that the base body 1 is miniaturized under the condition of ensuring a reasonable gap between the electric device 2 and the electric conductor 4.

2. Conductive layer

As shown in fig. 3, a plurality of conductors 4 respectively connected with the positive electrode and the negative electrode of the electric device 2 are arranged in the conductive layer, that is, the conductor 4 connected with the positive electrode of the electric device 2 in the conductive layer is the positive conductor 4, and the conductor 4 connected with the negative electrode of the electric device 2 in the conductive layer is the negative conductor 4. The conductor 4 is a sheet-shaped conductor 4, such as a plate-shaped copper bar 3, and preferably the thicknesses of the positive conductor 4 and the negative conductor 4 are the same, so that the uniformity of the thickness of the conductive layer can be ensured, the resistance of the conductor 4 is the same as the resistance of the conventional conductor 4 according to the width of the widened conductor 4, the technical effect of an ultrathin conductive layer is realized, and the smoothness of the conductive layer is beneficial to the appearance design of the substrate 1 and the electric device 2, and the production cost is reduced.

The thickness range of the conductor is 2-5mm; the width of the outer conductive structure is 16-30mm, a copper bar with the length of 80mm is taken as an example, the resistance range of the conductor obtained by the specification is 9uΩ -40.9 uΩ, and the conductors with various specifications in the following table are exemplified:

	thickness of conductor (mm)	Width of conductor (mm)	Conductor resistance (uΩ)
				1	2	16	40.9
2	2	30	22.5
				3	3	25	17.8
4	4	20	16.6
				5	5	16	16.4
6	5	30	9

According to the conductor data of a plurality of specifications in the table, the conductor of the specification can meet the resistance requirement of the conductive component in the high-voltage distribution box.

The electric conductor 4 is provided with a collection point 6, and the collection point 6 is used for being connected with a high-voltage collection circuit and can collect electrical data such as voltage, current and the like of a circuit where the electric conductor 4 is located. The collection points 6 are preferably arranged between the connection positions of the electrical devices 2 at the two ends on the electrical conductor 4, so that a high-voltage collection line is arranged between the two electrical devices 2, gaps between the electrical devices 2 can be fully utilized, the overall size of the high-voltage distribution box is reduced, and the press riveting bolts are press-riveted at the collection points 6 of the conductive layer by using a press riveting process during installation.

The base body 1 is provided with connecting posts 7 for fixing the electrical conductor 4. The connecting column 7 penetrates through the conductor 4, and can be fixed through screw threads and nuts, or the connecting column 7 penetrates through the conductor 4 and then is in interference connection with the conductor 4, the interference connection is superior to the screw threads, the cost is low, the used parts are few, and the small-size connecting column is more in line with the beneficial effects of the technology.

The base body 1 is provided with a partition structure 8 for isolating the adjacent conductors 4, and if the limiting structure 5 exists, the partition structure 8 is used for supplementing the area of the limiting structure 5, which is not isolated from the adjacent conductors 4, so that isolation is realized between all the adjacent conductors 4 in the technology.

Example 2

The manufacturing method of the high-voltage distribution box disclosed by the embodiment 2 of the invention comprises the following steps:

as shown in fig. 6, the position of the electrical interface is first set in the base, the positional relationship between the high-voltage distribution box and the battery pack is first determined, then the setting position of the electrical interface on the base is determined by combining the arrangement of the electrical core in the battery pack and the trend of the electrical conductor 4 of the high-voltage distribution box, so as to ensure that the distance between the electrical conductor 4 is shortest, and the electrical conductors 4 are all located in the same plane. As shown in fig. 3-5, in fig. 3, the battery + "and the battery-" are respectively arranged at two sides of the high-voltage distribution box, so that two electrical interfaces of the highest voltage circuit are separated, and then the electrical interfaces with the functions of output + "," fast charge- "," output- ", etc. are sequentially arranged at one side, so that the wiring connection of external circuits is facilitated. The method for setting the electric conductors is that the trend of the electric conductors is set according to the circuit diagram of fig. 5, the battery plus ends of the two relays on the left side in fig. 5 are provided with crossing points, the battery minus ends of the two relays on the right side are provided with crossing points, as shown in fig. 4, the electric conductors of a plurality of electric devices are simultaneously connected according to the crossing point design in fig. 5, and meanwhile, the electric conductors are respectively arranged on two sides of a high-voltage distribution box according to the battery plus and the battery minus, so that the output ends of the two electric conductors are respectively arranged on two sides of the high-voltage distribution box; 4 conductors respectively connected with the other ends of the 4 relays are also arranged, meanwhile, according to the following steps of 'output plus', 'quick charge-' the electrical interfaces with the functions of output, and the like are sequentially arranged on one side, the output ends of the 4 conductors are arranged on one side by side, so that all conductors are in the same plane, and a conductive layer is formed.

Then the collecting point 6 is fixed on the conductor 4 through a bolt press riveting technology, and then the conductor 4, the press riveting bolt and the matrix 1 are integrally formed through injection molding, wherein the matrix 1 is made of PBT material with excellent insulating property, so that an interval insulating effect can be achieved, and safety and redundancy of an electric gap are ensured. Specifically, the press-riveting bolt is press-riveted on the position of the collecting point 6 of the conductor 4 to form a conductor 4 assembly; then placing the conductor 4 assembly at a corresponding position in the matrix 1 die, and placing the conductor 4 in the matrix base or the matrix upper cover die according to the design position requirement; starting the injection molding machine, filling plastic particles into a cavity of a matrix 1 die after melting, molding for a period of time, and integrally molding into a matrix component.

Then the electric device 2 (such as a relay) is reversely placed at the installation position of the electric device in the upper cover of the base body, then the electric device 2 is fixed on the base body 1 through the horizontal quick clamp, the electric device 2 is limited to move in any degree of freedom, the electric device is prevented from shaking, and the electric device 2 installed on the upper cover of the base body in the embodiment is 4 relays. Then, starting a turnover motion, synchronously turning over the electric device 2 and the base body 1 by 180 degrees, inserting the 4 turned-over electric devices 2 into the limiting structure 5, finally locking the electric device 2 inserted into the limiting structure 5 and the electric conductor 4 inside the base body 1 together by using flat head bolts according to a specified torque, enabling the positive pole and the negative pole of the electric device 2 to be respectively in close contact with the corresponding electric conductor 4, starting the turnover tool again, turning over the components, and returning to a normal upward state.

Finally, the high-voltage acquisition harness is fixed on the acquisition point 6 of the conductor 4. Specifically, a ring terminal of the high-voltage acquisition wire harness is sleeved on the press-riveting bolt, and then the ring terminal is locked on the press-riveting bolt through a flange nut according to a specified torque.

While the invention has been described in detail with respect to the general description and specific embodiments thereof, it will be apparent to those skilled in the art that modifications and improvements may be made thereto, such as electrical interface position adjustment, electrical interface addition, and electrical device specification and model adjustment. Accordingly, such modifications or improvements may be made without departing from the spirit of the invention and are intended to be within the scope of the invention as claimed.

Claims (10)

1. The utility model provides a small-size high voltage distribution box structure, includes base member, its characterized in that: the electric device comprises a substrate, and is characterized in that an electric device layer and a conductive layer are arranged in the substrate, at least one electric device is arranged in the electric device layer, both the positive end and the negative end of the electric device are connected with the conductive layer, a plurality of conductors respectively connected with the positive electrode and the negative electrode of the electric device are arranged in the conductive layer, and the conductors are sheet conductors.

2. A low-volume high-voltage distribution box structure according to claim 1, characterized in that: the thickness of the conductor ranges from 2 mm to 5mm.

3. A low-volume high-voltage distribution box structure according to claim 1, characterized in that: the width of the outer conductive structure ranges from 16 mm to 30mm.

4. A low-volume high-voltage distribution box structure according to claim 1, characterized in that: and the conductor is provided with a collection point.

5. A low-volume high-voltage distribution box according to claim 4, characterized in that: the collection points are arranged on the conductor and located between the two sides of the conductor and the connection positions of the electric devices.

6. A low-volume high-voltage distribution box according to claim 1, characterized in that: the base body is provided with a connecting column for fixing the electric conductor.

7. A low-volume high-voltage distribution box according to claim 1, characterized in that: the base body is provided with a limiting structure for forming an electric device embedded groove, and the limiting structure is provided with a through hole for a conductor to penetrate.

8. A low-volume high-voltage distribution box according to claim 1, characterized in that: and a partition structure for isolating adjacent conductors is arranged on the substrate.

9. A low-volume high-voltage distribution box according to claim 1, characterized in that: and a through hole for the power supply device to penetrate is formed in the base body.

10. The manufacturing method of the small-size high-voltage distribution box is characterized by comprising the following steps of:

step S1, setting an electrical interface by combining the arrangement of the electric cores in the battery pack and the trend of the electric conductors of the high-voltage distribution box;

s2, pressing and riveting the pressing and riveting bolt on the position of the collecting point of the conductor, and integrally forming the conductor, the pressing and riveting bolt and the matrix through injection molding;

s3, inversely placing the electric device at the installation position of the electric device on the inner side of the upper cover of the base body, turning over the assembly of the electric device and the upper cover of the base body, buckling the upper cover of the base body and the base body base, enabling the electric device to be inserted into the limiting structure, and locking the electric device and the electric conductor in the base body together by using the flat head bolt according to the specified torque;

and S4, fixing the high-voltage acquisition wire harness on an acquisition point of the conductor.