CN117877928A - A battery pack disconnect unit with vertically mounted relay - Google Patents

Abstract

The present invention discloses a battery pack circuit breaker unit with a vertically mounted relay, wherein the main relay is a relay core without a housing; the relay core is an integral structure assembled by a contact part and a magnetic circuit part in a distribution manner in which the contact part is on the upper side and the magnetic circuit part is on the lower side; the main relay is installed in the housing in an inverted manner; a 2-core high-voltage plug-in is also integrated on the side of the housing to connect the positive and negative poles in the housing; the high-voltage sampling circuit and the low-voltage control circuit both use a small copper bar, which is integrated on the housing. The present invention has a simple structure and low cost. By installing the relay inverted, the battery pack circuit breaker unit is prevented from causing condensation on the upper housing to drip onto the conductive end of the relay in an environment with a large temperature difference, thereby causing the relay to fail. The transfer copper bar and locking bolts between the battery pack circuit breaker unit and the 2-core high-voltage plug-in are eliminated, which can reduce costs and reduce the temperature rise pressure of the battery pack circuit breaker unit.

Description

A battery pack disconnect unit with vertically mounted relay

Technical Field

The present invention relates to the technical field of relays, and in particular to a battery pack disconnecting unit with a vertically mounted relay.

Background technique

BDU (Battery Disconnect Unit) is a battery pack disconnect unit designed for the inside of the battery pack and is also a type of distribution box. As a battery module for protecting the battery box of an electric vehicle, BDU is a safety solution for lithium batteries in electric vehicles. It is an important protection module for the high-voltage circuit system of electric vehicles and an important part of the vehicle control system of electric vehicles. Its role is to coordinate the function conversion and energy distribution of high-voltage accessories such as the drive motor control system, battery management system, charging management system, DC/DC, electric air conditioning, electric power steering, and braking system. In the existing battery pack disconnect unit, the relay is usually set with a shell. Installing it in the battery pack disconnect unit is not only large in size and space, but also requires glue dispensing technology and has high manufacturing costs. The existing structure of the shell-free relay set in the battery pack disconnect unit is complex and costly, and the contact part is set upward. When the battery pack disconnect unit is in an environment with a large temperature difference, condensation on the upper shell will drip onto the conductive end of the relay, causing the relay to fail. In addition, the 2-core high-voltage plug-in is usually installed on the aluminum shell plate of the battery pack, and a transfer copper busbar is required to connect the BDU. At this time, the transfer copper busbar and locking bolts between the BDU and the 2-core high-voltage plug-in will increase the cost, and the transfer copper busbar and locking point will increase the internal resistance of the loop. When the BDU is working, the heat generated at this position is high, thereby increasing the temperature rise pressure of the BDU and the battery pack.

Summary of the invention

The object of the present invention is to overcome the deficiencies of the prior art and to provide a battery pack circuit breaker unit with a vertically mounted relay, which has a simple structure and low cost. The relay is installed upside down to prevent condensation from dripping from the upper shell of the battery pack circuit breaker unit to the conductive end of the relay in an environment with a large temperature difference, thereby causing the relay to fail. In addition, the transfer copper busbar and locking bolts between the battery pack circuit breaker unit and the 2-core high-voltage plug-in are eliminated, which can reduce costs and reduce the temperature rise pressure of the battery pack circuit breaker unit.

The technical solution adopted by the present invention to solve its technical problems is: a battery pack circuit breaker unit with a vertically installed relay, comprising a shell, electronic devices installed in the shell, and a high-voltage sampling circuit and a low-voltage control circuit connected to the corresponding electronic devices, the electronic devices comprising a main relay; the main relay is a relay core without a shell; the relay core is an integral structure assembled together by a contact part and a magnetic circuit part in a distribution manner in which the contact part is on the top and the magnetic circuit part is on the bottom; the main relay is installed in the shell in an inverted manner; a 2-core high-voltage plug-in is also integrated on the side of the shell to connect the positive and negative poles in the shell; the high-voltage sampling circuit and the low-voltage control circuit both use small copper bars, and the small copper bars are integrated on the shell.

The shell includes an upper cover and a box body, the upper cover is provided with a receiving groove opening downward; the bottom of the relay core is adapted in the receiving groove of the upper cover and is fixed to the upper cover; the contact part of the head of the relay core is provided with two static contact terminals protruding outward, and the static contact terminals are fixedly connected to the copper busbar by bolts to realize the connection between the relay and the high-voltage circuit; the bolts connected to the main relay also fix the box body together, thereby realizing the phase fixation between the upper cover, the relay core and the box body.

An elastic buffer pad made of rubber, silicone or elastic plastic is also padded between the inner side of the top surface of the upper cover and the bottom of the relay core; mutually adaptable buckles are also provided between the side walls of the upper cover and the side surfaces of the relay core, and the relay and the upper cover are fixed, and the elastic buffer pad is pressed tightly between the upper cover and the bottom of the relay core through interference fit of the buckles.

The small copper bars of the high-voltage sampling circuit and the low-voltage control circuit are integrated in the upper cover by injection molding. A plug-in terminal is also provided at the connection point of the high-voltage sampling circuit and the low-voltage control circuit. The plug-in terminal is connected to the corresponding small copper bar. The upper cover has an integrally formed connector box and constitutes a sampling output connector and a low-voltage output connector with the corresponding small copper bar.

The electronic device also includes a pre-charge relay, a pre-charge resistor, a fuse and a shunt; the pre-charge relay, the pre-charge resistor, the fuse and the shunt are respectively installed in the box body in an inverted manner; the main circuit copper busbar used to connect the electronic devices is distributed on the bottom inner side of the box body.

The main relay comprises a main positive relay and a main negative relay. A copper busbar connected to one contact of each of the main positive relay and the main negative relay is bent upward from the bottom of the box body and connected to a 2-core high-voltage plug-in on the side.

The 2-core high-voltage plug-in is fixed on the side of the upper cover.

The main circuit copper bar is integrated at the bottom of the box body by injection molding.

The main circuit copper busbar is also partially exposed from the bottom surface of the box body, an insulating film is also pasted on the position of the exposed copper busbar of the box body, and a thermal conductive pad for contacting the battery pack water cooling plate is also pasted under the insulating film to reduce the temperature rise of the product.

A heat-conducting ceramic sheet for heat dissipation is also provided at the bottom of the box body, and the heat-conducting ceramic sheet is sandwiched between two heat-conducting pads.

Compared with the prior art, the beneficial effects of the present invention are:

1. The present invention adopts the main relay as a relay core without a housing; the relay core is an integral structure assembled by the contact part and the magnetic circuit part in a distribution manner in which the contact part is on the top and the magnetic circuit part is on the bottom; the main relay is installed in the housing in an inverted manner; the side of the housing is also integrated with a 2-core high-voltage plug-in to connect the positive and negative poles in the housing; the high-voltage sampling circuit and the low-voltage control circuit both use small copper bars, which are integrated on the housing. This structure of the present invention removes the housing of the relay, reduces the use of parts, reduces the weight and cost of the relay, and can help the relay dissipate heat better. The relay is installed inverted so that the conductive end of the relay is located at the bottom of the housing, which can prevent the battery pack circuit breaker unit from being in an environment with a large temperature difference. The condensation on the upper housing drips onto the conductive end of the relay, causing the relay to fail. The present invention also eliminates the copper busbar and locking bolts between the battery pack disconnect unit and the 2-core high-voltage plug-in, further reducing costs. Due to the reduction of the copper busbar and locking points, the internal resistance of the circuit becomes smaller. When the battery pack disconnect unit is working, the heat generated at this position will be reduced, thereby reducing the temperature rise pressure of the battery pack disconnect unit and the battery pack. At the same time, the wireless bundle design can realize automatic assembly and improve production efficiency.

2. The present invention adopts an elastic buffer pad made of rubber, silicone or elastic plastic between the inner side of the top surface of the upper cover and the bottom of the relay core; a mutually adapted buckle is provided between the side wall of the upper cover and the side of the relay core, and the relay and the upper cover are fixed, and the elastic buffer pad is pressed tightly between the upper cover and the bottom of the relay core through the interference fit of the buckle. This structure of the present invention, through the structural design of the injection molded part, realizes the fixing and clamping of the shell-less relay at the lowest cost, and uses an elastic gasket between the upper cover and the relay core, which can not only press the shell-less relay, but also absorb a certain amount of vibration impact energy to protect the relay core.

3. The present invention uses the small copper bars of the high-voltage sampling circuit and the low-voltage control circuit to be integrated into the upper cover by injection molding. A plug-in terminal is also provided at the connection point of the high-voltage sampling circuit and the low-voltage control circuit. The plug-in terminal is connected to the corresponding small copper bar. The upper cover is integrally formed with a connector box and forms a sampling output connector and a low-voltage output connector with the corresponding small copper bar. This structure of the present invention realizes a wire harness-free design, making the overall assembly of the battery pack circuit breaker unit simpler, thereby realizing automated assembly and making production efficiency higher.

4. The present invention partially exposes the bottom surface of the box body due to the main circuit copper busbar, and an insulating film is pasted at the position of the exposed copper busbar of the box body, and a thermal pad for contacting the battery pack water cooling plate is pasted under the insulating film to achieve the effect of reducing the temperature rise of the product. A thermally conductive ceramic sheet for heat dissipation is also provided at the bottom of the box body, and the thermally conductive ceramic sheet is sandwiched between two thermally conductive pads. This structure of the present invention directly conducts the heat on the main circuit copper busbar to the outside of the battery pack circuit breaker unit, helping the battery pack circuit breaker unit to dissipate heat, and the thermally conductive ceramic sheet has insulating properties, which can prevent the current on the main circuit copper busbar from escaping to the outside of the battery pack circuit breaker unit, causing the risk of electric shock to personnel.

The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments; however, the battery pack disconnecting unit with a vertically mounted relay of the present invention is not limited to the embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is an exploded schematic diagram of the present invention;

Fig. 2 is a front view of the present invention;

Fig. 3 is a cross-sectional view of the present invention;

FIG4 is a cross-sectional view of the upper cover of the present invention;

FIG5 is an enlarged schematic diagram of point A in FIG4 ;

FIG6 is an enlarged schematic diagram of point B in FIG4 ;

FIG. 7 is a top view of the high-voltage sampling circuit and the low-voltage control circuit of the present invention.

Detailed ways

Example

Referring to FIGS. 1 to 7 , a battery pack disconnecting unit with a relay installed vertically of the present invention comprises a housing 4, electronic devices installed in the housing 4, and a high-voltage sampling circuit 6 and a low-voltage control circuit 7 connected to the corresponding electronic devices, wherein the electronic devices comprise a main relay; the main relay is a relay core without a housing; the relay core is an integral structure assembled together by a contact part and a magnetic circuit part in a distribution manner in which the contact part is on top and the magnetic circuit part is on the bottom; the main relay is installed in the housing in an inverted manner, specifically, the main relay comprises a main positive relay 2 and a main negative relay 3, the main positive relay 2 and the main negative relay 3 are respectively relay cores without a housing, the main positive relay 2 is assembled together by a contact part 21 and a magnetic circuit part 22, and the main negative relay 3 is assembled together by a contact part 31 and a magnetic circuit part 32; a 2-core high-voltage plug-in 1 is also integrated on the side of the housing 4 to connect the positive and negative poles in the housing 4; the high-voltage sampling circuit 6 and the low-voltage control circuit 7 both use small copper bars, which are integrated on the housing 4.

In this embodiment, the housing 4 includes an upper cover 41 and a box body 42, the upper cover 41 is provided with a receiving groove 411 opening downward; the bottom of the relay core body is adapted in the receiving groove 411 of the upper cover 41 and fixed to the upper cover 41; the contact part of the head of the relay core body is provided with two static contact terminals protruding outward, and the static contact terminals are fixedly connected to the copper bar 5 by bolts 8 to achieve the connection between the relay and the high-voltage circuit; the bolts 8 connected to the main relay also fix the box body 42 together, thereby achieving the fixation between the upper cover 41, the relay core body and the box body 42. Specifically, the contact part 21 of the main positive relay 2 is provided with two static contact terminals 211 protruding outward, and the contact part 31 of the main negative relay 3 is provided with two static contact terminals 311 protruding outward, and the static contact terminals 211, 311 are fixedly connected to the copper bar 5 by bolts 8 to achieve the connection between the relay and the high-voltage circuit.

In this embodiment, an elastic buffer pad 15 made of rubber, silicone or elastic plastic is also padded between the inner side of the top surface of the upper cover 41 and the bottom of the relay core; a mutually adapted buckle 412 is also provided between the side wall of the upper cover 41 and the side surface of the relay core, and the relay and the upper cover 41 are fixed, and the elastic buffer pad 15 is pressed tightly between the upper cover 41 and the bottom of the relay core through the interference fit of the buckle 412.

In this embodiment, the small copper busbars of the high-voltage sampling circuit 6 and the low-voltage control circuit 7 are integrated into the upper cover 41 by injection molding. A plug-in terminal 16 is also provided at the connection point of the high-voltage sampling circuit 6 and the low-voltage control circuit 7. The plug-in terminal 16 is connected to the corresponding small copper busbar. The upper cover 41 has an integrally formed connector box and constitutes a sampling output connector 61 and a low-voltage output connector 71 with the corresponding small copper busbar.

In this embodiment, the electronic device also includes a pre-charging relay 9, a pre-charging resistor 10, a fuse 11 and a shunt 12; the pre-charging relay 9, the pre-charging resistor 10, the fuse 11 and the shunt 12 are respectively installed in the box body 42 in an inverted manner; the main circuit copper bus 5 used to connect the electronic devices is distributed on the inner side of the bottom of the box body 42.

In this embodiment, the copper bar 5 connected to each contact of the main positive relay 2 and the main negative relay 3 is bent upward from the bottom of the box body 42 and connected to the 2-core high-voltage plug-in 1 on the side. The 2-core high-voltage plug-in 1 is fixed to the side of the upper cover 41.

In this embodiment, the main circuit copper bar 5 is integrated at the bottom of the box body 42 by injection molding. Later, cooling components such as a water cooling plate can be placed at the bottom of the battery pack circuit breaker unit to effectively reduce the temperature of the battery pack circuit breaker unit and ensure the safety of the battery pack circuit breaker unit.

In this embodiment, the main circuit copper bar 5 is partially exposed on the bottom surface of the box body 42, and an insulating film is pasted at the position of the exposed copper bar of the box body 42, and a thermal pad for contacting the battery pack water cooling plate is pasted under the insulating film to reduce the temperature rise of the product. A thermally conductive ceramic sheet for heat dissipation is also provided at the bottom of the box body 42, and the thermally conductive ceramic sheet is sandwiched between two thermally conductive pads.

In this embodiment, an insulating sealing gasket 17 is respectively connected to the two static contact terminals 211 of the main positive relay 2 and the two static contact terminals 311 of the main negative relay 3 to increase the electrical gap between the two static contact terminals.

In this embodiment, a card slot 413 is provided on the upper cover 41, and a card protrusion 421 is provided on the box body 42. The card slot 413 of the upper cover 41 and the card protrusion 421 of the box body 42 are snap-connected to strengthen the fixation between the upper cover 41, the relay core and the box body 42.

A battery pack circuit breaker unit with a vertically installed relay of the present invention is configured such that a main relay and a portion of a copper busbar 5 are installed with an upper cover 41 first, and then a pre-charge relay 9, a pre-charge resistor 10, a fuse 11, a shunt 12 and a box body 42 are installed. Finally, the two parts are assembled together, and the static contact terminal of the main relay is locked with the box body 42 using bolts 8, so that the upper cover 41, the main relay and the box body 42 are firmly fastened together.

A battery pack circuit breaker unit with a vertically mounted relay of the present invention adopts the main relay as a relay core without a housing; the relay core is an integral structure assembled by a contact part and a magnetic circuit part in a distribution manner in which the contact part is on the top and the magnetic circuit part is on the bottom; the main relay is installed in the housing 4 in an inverted manner; the side of the housing 4 is also integrated with a 2-core high-voltage plug-in 1 to connect the positive and negative poles in the housing 4; the high-voltage sampling circuit 6 and the low-voltage control circuit 7 both use small copper bars, which are integrated on the housing 4. This structure of the present invention removes the housing of the relay, reduces the use of parts, reduces the weight and cost of the relay, and can help the relay to dissipate heat better, and the relay is installed inverted so that the conductive end of the relay is located at the bottom of the housing, which can prevent the battery pack circuit breaker unit from being in an environment with a large temperature difference. The condensation on the upper housing drips onto the conductive end of the relay, causing the relay to fail. The present invention also eliminates the copper busbar and locking bolts between the battery pack disconnect unit and the 2-core high-voltage plug-in, further reducing costs. Due to the reduction of the copper busbar and locking points, the internal resistance of the circuit becomes smaller. When the battery pack disconnect unit is working, the heat generated at this position will be reduced, thereby reducing the temperature rise pressure of the battery pack disconnect unit and the battery pack. At the same time, the wireless bundle design can realize automatic assembly and improve production efficiency.

A battery pack disconnect unit for vertically mounted relays of the present invention adopts an elastic buffer pad 15 made of rubber, silicone or elastic plastic between the inner side of the top surface of the upper cover 41 and the bottom of the relay core; a mutually adapted buckle 412 is also provided between the side wall of the upper cover 41 and the side of the relay core, and the relay and the upper cover are fixed, and the elastic buffer pad 15 is pressed tightly between the upper cover 41 and the bottom of the relay core through the interference fit of the buckle 412. This structure of the present invention, through the structural design of the injection molded part, realizes the fixing and clamping of the shell-less relay at the lowest cost, and uses an elastic gasket between the upper cover and the relay core, which can not only press the shell-less relay, but also absorb a certain amount of vibration impact energy to protect the relay core.

A battery pack circuit breaker unit with a vertical relay installation of the present invention adopts the small copper bars of the high-voltage sampling circuit 6 and the low-voltage control circuit 7 to be integrated in the upper cover 41 by injection molding, and a plug-in terminal 16 is also provided at the connection point of the high-voltage sampling circuit 6 and the low-voltage control circuit 7, and the plug-in terminal 16 is connected to the corresponding small copper bar. The upper cover 41 is integrally formed with a connector box and constitutes a sampling output connector 61 and a low-voltage output connector 71 with the corresponding small copper bar. This structure of the present invention realizes a wire harness-free design, making the overall assembly of the battery pack circuit breaker unit simpler, thereby realizing automated assembly and making production efficiency higher.

A battery pack circuit breaker unit with a vertically mounted relay of the present invention adopts the main circuit copper busbar 5 to partially expose the bottom surface of the box body 42, and an insulating film is also pasted at the position of the exposed copper busbar of the box body 42, and a thermal pad for contacting the battery pack water cooling plate is also pasted under the insulating film to achieve the effect of reducing the temperature rise of the product. A thermally conductive ceramic sheet for heat dissipation is also provided at the bottom of the box body 42, and the thermally conductive ceramic sheet is sandwiched between two thermally conductive pads. This structure of the present invention directly conducts the heat on the main circuit copper busbar to the outside of the battery pack circuit breaker unit, helping the battery pack circuit breaker unit to dissipate heat, and the thermally conductive ceramic sheet has insulating properties, which can prevent the current on the main circuit copper busbar from escaping to the outside of the battery pack circuit breaker unit, causing the risk of electric shock to personnel.

The above is only a preferred embodiment of the present invention, and does not limit the present invention in any form. Although the present invention has been disclosed as above in the preferred embodiment, it is not used to limit the present invention. Any technician familiar with the art can make many possible changes and modifications to the technical solution of the present invention by using the technical content disclosed above, or modify it into an equivalent equivalent embodiment without departing from the scope of the technical solution of the present invention. Therefore, any simple modification, equivalent change and modification made to the above embodiments according to the technical essence of the present invention without departing from the content of the technical solution of the present invention should fall within the scope of protection of the technical solution of the present invention.

Claims (10)

1. A battery pack circuit breaker unit with a vertically mounted relay, comprising a shell, electronic devices installed in the shell, and a high-voltage sampling circuit and a low-voltage control circuit connected to the corresponding electronic devices, wherein the electronic devices include a main relay; characterized in that: the main relay is a relay core without a shell; the relay core is an integral structure assembled together by a contact part and a magnetic circuit part in a distribution manner in which the contact part is on the top and the magnetic circuit part is on the bottom; the main relay is installed in the shell in an inverted manner; a 2-core high-voltage plug-in is also integrated on the side of the shell to connect the positive and negative poles in the shell; the high-voltage sampling circuit and the low-voltage control circuit both use small copper bars, and the small copper bars are integrated on the shell. 2. The battery pack circuit breaker unit with a vertically mounted relay according to claim 1 is characterized in that: the shell includes an upper cover and a box body, the upper cover is provided with a downwardly opening receiving groove; the bottom of the relay core is adapted in the receiving groove of the upper cover and is fixed to the upper cover; the contact part of the head of the relay core is provided with two static contact terminals protruding outward, and the static contact terminals are fixed to the copper busbar by bolts to realize the connection between the relay and the high-voltage circuit; the bolts connected to the main relay also fix the box body together, thereby realizing the phase fixation between the upper cover, the relay core and the box body. 3. The battery pack circuit breaker unit with a vertically mounted relay according to claim 2 is characterized in that: an elastic buffer pad made of rubber, silicone or elastic plastic is also padded between the inner side of the top surface of the upper cover and the bottom of the relay core; and mutually adaptable buckles are also provided between the side walls of the upper cover and the side surfaces of the relay core, and the relay and the upper cover are fixed, and the elastic buffer pad is pressed tightly between the upper cover and the bottom of the relay core through interference fit of the buckles. 4. The battery pack circuit breaker unit with a vertically mounted relay according to claim 2 is characterized in that the small copper bars of the high-voltage sampling circuit and the low-voltage control circuit are integrated into the upper cover by injection molding, and plug-in terminals are also provided at the connection points of the high-voltage sampling circuit and the low-voltage control circuit, and the plug-in terminals are connected to the corresponding small copper bars. The upper cover has an integrally formed connector box and constitutes a sampling output connector and a low-voltage output connector with the corresponding small copper bars. 5. According to the vertically mounted relay battery pack disconnecting unit of claim 2, it is characterized in that: the electronic components further include a pre-charge relay, a pre-charge resistor, a fuse and a shunt; the pre-charge relay, the pre-charge resistor, the fuse and the shunt are respectively installed in the box body in an inverted manner; the main circuit copper busbar used to connect the electronic components is distributed on the bottom inner side of the box body. 6. The battery pack circuit breaker unit with vertically mounted relays according to claim 5 is characterized in that: the main relay comprises a main positive relay and a main negative relay, and the copper busbar connected to one contact of each of the main positive relay and the main negative relay is bent upward from the bottom of the box body and connected to the 2-core high-voltage plug-in on the side. 7. The battery pack circuit breaker unit with a vertically mounted relay according to claim 6, characterized in that the 2-core high-voltage plug-in is fixed on the side of the upper cover. 8. The battery pack circuit breaker unit with a vertically mounted relay according to claim 7, wherein the main circuit copper busbar is integrated at the bottom of the box body by injection molding. 9. The battery pack circuit breaker unit with a vertically mounted relay according to claim 8 is characterized in that: the main circuit copper busbar is partially exposed on the bottom surface of the box body, an insulating film is pasted on the position of the exposed copper busbar of the box body, and a thermal pad for contacting the battery pack water cooling plate is pasted under the insulating film to reduce the temperature rise of the product. 10. The battery pack disconnecting unit with a vertically mounted relay according to claim 9, characterized in that: a thermally conductive ceramic sheet for heat dissipation is also provided at the bottom of the box body, and the thermally conductive ceramic sheet is sandwiched between two thermally conductive pads.