WO2015097534A1

WO2015097534A1 - Power distribution box and power distributor assembly

Info

Publication number: WO2015097534A1
Application number: PCT/IB2014/002865
Authority: WO
Inventors: Xiao Zhou; Lingcong GUO
Original assignee: Tyco Electronics (Shanghai) Co., Ltd.; Tyco Electronics Uk Ltd
Priority date: 2013-12-23
Filing date: 2014-12-23
Publication date: 2015-07-02

Abstract

The present invention relates to a power distribution box (10300, 20200) and a power distributor assembly. According to a first aspect of the invention, the height of a back wall plate (10301) of the power distribution box is less than the height of a front wall plate (10302) of the power distribution box. Such a configuration can facilitate the manufacture of the power distribution box or the assembly of components into the power distribution box. According to a second aspect of the invention, more power distribution components can be accommodated in the power distribution box by arranging a mounting plate (20500) in the accommodating cavity of the power distribution box to stereoscopically divide the space inside the power distribution box.

Description

POWER DISTRIBUTION BOX AND POWER DISTRIBUTOR ASSEMBLY

FIELD OF THE INVENTION

The present invention relates to a power distribution box and a power distributor assembly, in particular to a power distribution box and a power distributor assembly for an electric vehicle.

BACKGROUND OF THE INVENTION

Power distribution boxes and power distributor assemblies are applicable to a variety of fields and can safely distribute power from a power supply to multiple electrical appliances for use in a controlled way. For example, with the enrichment of functions of the electric vehicle, a power battery is required to be capable of safely supplying power to a variety of electrical appliances in a controlled way. Thus, it is required to distribute a high-voltage bus into multiple circuits for supplying power to the various electrical appliances. A power supply circuit can be distributed into multiple branch circuits through a power distributor and each branch circuit is used for supplying power to one or more of the electrical appliances.

I.

A high-voltage power distributor is required to have good sealing property and electromagnetic shielding performance. Fig. 1-1 shows a high-voltage power distributor, which comprises a box body 10200 and a box cover 10300. The box body 10200 comprises a bottom cover 10201 and a box body wall 10202 which is integrally arranged on the four sides. The box body wall 10202 is fixedly arranged on the bottom cover 10201. The bottom cover 10201 and the box body wall 10202 jointly form an accommodating cavity (not shown in the figure). The accommodating cavity is used for accommodating power distribution components. The box cover 10300 is mounted on the box body wall 10202 for sealing the accommodating cavity. In this case, an input interface 10401 and a plurality of output interfaces, which comprise a first output interface 10701, six second output interfaces 10702, a third output interface 10703 and a fourth output interface 10704, are arranged on one side of the box body wall 10202. A power cord is electrically connected with a power distribution device arranged in the accommodating cavity through the input interface 10401. The power distribution device can distribute electric energy to multiple supply lines, output the electric energy through the plurality of output interfaces and transmit the electric energy to the various electrical appliances through corresponding conductors. As shown in Fig. 1-1 , a cable 107021 is arranged on one of the second output interfaces 10702. The fourth output interface 10704 is electrically connected with an electric connection wire 10 705.

In order to facilitate overhaul, resist electromagnetic interference and prevent from water and moisture, the box cover 10300 is hermetically mounted on the box body wall 10202. Furthermore, in order to reduce the damage, the box cover 10300 should be detached as little as possible.

As shown in Fig. 1-1, taking into account of the arrangement of wiring in the accommodating cavity, the input interface 10401 and the plurality of output interfaces in the power distributor are arranged on one side of the box body wall 10202. As the area of the box body wall 10202 is limited, the number of the input interface 10401 and the output interfaces is limited.

With higher requirements of people for the electric vehicles, the functions of the electric vehicles are increasingly richer, and more electrical appliances are needed. Thus, the power supply is required to be capable of supplying power for more electrical appliances. This will inevitably cause the need of increasing the number of the output interfaces of the high- voltage power distributor and even increasing the number of the input interfaces. The input interfaces and the output interfaces are simultaneously arranged on one side of the box body wall or the same plate. As the area is limited, it is difficult to increase the number of the input interfaces and the output interfaces. Furthermore, the wire outlet direction of the electrical interfaces is relatively single and thus difficult to adapt to actual wiring requirements. The box body wall 10202 is a casting and the four sides thereof have the same height. When the box body wall 10202 is relatively high, the machining of the internal structure and the assembly treatment of parts are relatively difficult. Or the overall strength is not high, the vibration resistance grade is low and the sealing effect is not good in the case of using a metal plate as a housing;

For the existing electric vehicle, the size of the high- voltage power distributor has been determined and is not easy to change. For a newly designed vehicle, taking compact structure into account, the size of the power distributor needs to be as small as possible. Thus, it is very difficult to realize a method for conveniently increasing the number of the input interfaces and the output interfaces by increasing the size of the high- voltage power distributor.

II.

Among them, an electric vehicle requires not only high-voltage power distribution, but also low-voltage power distribution devices. As the internal structure of a power distribution box is single and only an accommodating cavity is arranged, it is difficult to arrange more power distribution devices. Thus, the high-voltage power distribution devices and the low-voltage power distribution devices are respectively arranged in two power distribution boxes. Such arrangement not only occupies more space of a vehicle, but also increases production cost, thereby being unfavorable for centralized uniform management.

SUMMARY OF THE INVENTION

The present invention provides a power distribution box and a power distributor assembly as follows:

Part I: First Aspect of the Invention

A first objective of the invention is to overcome the shortcomings of the prior art and provide a power distribution box, the internal structure of which can be conveniently processed.

In order to realize the objective, the invention is implemented by adopting the following technical solution:

A power distribution box comprises a box body and a box cover, wherein the box cover is arranged at the upper end of the box body;

The box body comprises a front wall plate, two side wall plates and a bottom plate; the front wall plate and the side wall plates are arranged on the bottom plate and protrude out of the bottom plate to define an accommodating cavity; and the box cover is movably mounted at the upper end of the box body;

The power distribution box is characterized in that the side wall plates are trapezoidal or triangular.

Preferably, the power distribution box further comprises a back wall plate, and the back wall plate and the front wall plate are oppositely arranged on the bottom plate; the height that the back wall plate protrudes out of the bottom plate is less than the height that the front wall plate protrudes out of the bottom plate; and the side wall plates are trapezoidal.

Preferably, the side wall plates are right-angled trapezoidal.

Preferably, the two end portions of the side wall plates are respectively connected with the back wall plate and the front wall plate, the back end portion of each side wall plate is the same as the height of the back wall plate and the front end portion of each side wall plate is the same as the front wall plate in height.

Preferably, the box cover comprises a back plate, a top plate and two side plates; and the back plate and the two side plates are arranged on the top plate and protrude out of the lower surface of the top plate.

Preferably, the side plates are triangular or trapezoidal.

Preferably, the front wall plate is provided with a plurality of mounting holes for arranging electrical interfaces; and the mounting holes are communicated with the accommodating cavity.

Preferably, the front wall plate is provided with a protective cover; and the protective cover covers the mounting holes.

Preferably, the front wall plate is provided with a recessed structure; and the mounting holes are formed in the recessed structure.

Preferably, the upper wall of the recessed structure is an inclined plate; a part of the mounting holes are formed in the inclined plate; and the mounting holes formed in the inclined plate are vertical to the inclined plate.

Preferably, a circle of mounting plate is arranged at the lower end of the box cover; the width of the mounting plate is adapted to the width at the upper end of the box body; and the mounting plate is rested at the upper end of the box body.

Preferably, the box body is a metal casting box body; and the box cover is a metal plate box cover.

A second objective of the invention is to overcome the shortcomings of the prior art and provide a power distributor assembly, the internal structure of which can be conveniently processed. In order to realize the objective, the invention is implemented by adopting the following technical solution:

A power distributor assembly is characterized by comprising the aforementioned power distribution box and electrical interfaces; mounting holes are formed in the front wall plate; the electrical interfaces are arranged in the mounting holes; and electrical components are arranged in the accommodating cavity.

Preferably, the electrical interfaces comprise a manual service disconnect.

According to the power distribution box and the power distributor assembly in the invention, the height that the back wall plate protrudes out of the bottom plate is less than the height that the front wall plate protrudes out of the bottom plate, which indicates the back wall plate is shorter, thereby facilitating machining or assembly of the structure in the accommodating cavity. The mounting holes for mounting the electrical interfaces are formed in the front wall plate, thereby being capable of ensuring the sufficient area to arrange the plurality of electrical interfaces. The box body is manufactured by adopting a casting and the box cover is manufactured by adopting a metal plate, so that the production is convenient, the firmness of the box body can be ensured and the overall weight of the power distribution box is also reduced. The front wall plate is provided with the recessed structure and the mounting holes are formed in the wall plates of the recessed structure, thereby being capable of protecting the electrical interfaces. The recessed structure can be used for arranging the electrical interfaces with the downward outgoing lines in the inclined plate and arranging the electrical interfaces with the horizontal outgoing lines in the vertical plate, thereby enriching the outgoing lines directions of the electrical interfaces and enhancing the applicability thereof. The protective cover is arranged on the box body for protecting the electrical interfaces, thereby being capable of protecting the plug-in connectors on the electrical interfaces from damage due to the strong impact of a certain external force when in mounting, maintenance and even accidents.

Part II: Second Aspect of the Invention

A third objective of the present invention is to overcome the shortcomings of the prior art and provide a power distribution box capable of integrating more power distribution devices. In order to realize the objective above, the present invention is implemented by adopting the following technical solution:

The power distribution box comprises a box body and a box cover, wherein the box body comprises a side wall and a bottom plate; the side wall is arranged on the bottom plate; the box cover is arranged at the upper end of the side wall; and the box body and the box cover define an accommodating cavity;

The power distribution box is characterized in that a mounting plate is arranged in the accommodating cavity; the mounting plate comprises an upper surface and a lower surface; and the mounting plate is arranged between the bottom plate and the box cover and is spaced apart from the bottom plate and the box cover.

Preferably, the mounting plate is detachably mounted in the accommodating cavity.

Preferably, a through hole is formed in the mounting plate; and the through hole runs through the mounting plate from the upper surface to the lower surface.

Preferably, a reinforcing rib is arranged on the lower surface of the mounting plate; and the reinforcing rib protrudes out of the lower surface of the mounting plate and is arranged around the through hole.

Preferably, a baffle plate is arranged on the upper surface of the mounting plate; the baffle plate protrudes out of the upper surface of the mounting plate.

Preferably, the power distribution box further comprises a support structure, the support structure is arranged on the bottom plate and the mounting plate is arranged on the support structure.

A fourth objective of the invention is to overcome the shortcomings of the prior art and provide a power distributor assembly capable of integrating more power distribution devices.

The power distributor assembly is characterized by comprising the above-mentioned power distribution box, wherein a plurality of high-voltage power distribution devices and a plurality of low- voltage power distribution devices are arranged in the accommodating cavity; and at least a part of the plurality of high-voltage power distribution devices and the plurality of low-voltage power distribution devices are arranged on the mounting plate. Preferably, a through hole is formed in the mounting plate; the through hole runs through the mounting plate from the upper surface to the lower surface; the high-voltage power distribution devices are arranged on the upper surface of the mounting plate; and part of the high-voltage power distribution devices arranged on the upper surface of the mounting plate span the through hole.

Preferably, one or more of the plurality of high- voltage power distribution devices and the plurality of low-voltage power distribution devices are arranged on the bottom plate; and part of the high-voltage power distribution devices or the low-voltage power distribution devices arranged on the bottom plate are arranged facing the through hole.

Preferably, the high-voltage power distribution devices and the low-voltage power distribution devices are arranged on the upper surface of the mounting plate; the high-voltage power distribution devices comprise high- voltage fuses; and the low-voltage power distribution devices comprise low-voltage fuses.

Preferably, a baffle plate is arranged on the upper surface of the mounting plate; the baffle plate protrudes out of the upper surface of the mounting plate; and the high-voltage power distribution devices are arranged on one side of the baffle plate and the low-voltage power distribution devices are arranged on the other side of the baffle plate.

Preferably, a plurality of circuit boards are arranged in the accommodating cavity; and the plurality of circuit boards are arranged in parallel with one another.

Preferably, the high-voltage power distribution devices and the low-voltage power distribution devices are arranged on the upper surface of the mounting plate; and the plurality of circuit boards comprise a low-voltage connection circuit board, the low- voltage connection circuit board is fixedly arranged on the mounting plate and electrically connected with the low-voltage power distribution devices on the mounting plate.

Preferably, the plurality of circuit boards comprise a low-voltage control circuit board and one or more control chips are arranged on the low-voltage control circuit board. Preferably, the low-voltage control circuit board at least comprises part of a vehicle control unit.

Preferably, the low-voltage control circuit board is connected with the vehicle control unit through a controller area network.

Preferably, a plurality of electrical interfaces are arranged on the side wall, one end of each electrical interface is respectively electrically connected with one of the high-voltage power distribution devices and the low-voltage power distribution devices and the other end of each electrical interface is directly connected to an electrical component.

Preferably, the plurality of electrical interfaces comprise a low-voltage control interface.

Preferably, the box cover comprises a box cover main body and an auxiliary cover; a penetration hole is formed in the box cover main body; the auxiliary cover is mounted on the outer surface of the box cover main body, sealing the penetration hole; and the penetration hole on the cover faces the through hole in the mounting plate in a longitudinal direction.

According to the power distribution box and the power distributor assembly in the invention, more power distribution devices can be arranged by arranging the mounting plate in the accommodating cavity to stereoscopically divide the space of the accommodating cavity. The invention can fully utilize the internal space of the power distribution box and save the using space. The high-voltage power distribution devices and the low-voltage power distribution devices are arranged in the same power distribution box, thereby not only saving the space and the production cost, but also facilitating management. The reinforcing rib is arranged on the lower surface of the mounting plate, thereby being capable of increasing the strength of the mounting plate. The reinforcing rib can eliminate the influence of reducing the strength of the mounting plate due to the arrangement of the through hole. The through hole is arranged in the mounting plate and the power distribution devices below the mounting plate can be detached and mounted by passing through the through hole, thereby being convenient to use and maintain.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1- 1 is a schematic diagram of the structure of a high- voltage power distributor assembly. Fig. 1 -2 is a schematic diagram of the structure of Embodiment 1, in which a protective cover is not shown.

Fig. 1-3 is a schematic diagram of the structure of Embodiment 1 observed from another angle.

Fig. 1-4 is a side view of Embodiment 1 , in which the protective cover is not shown.

Fig. 1 -5 is a schematic diagram of the structure of the box body of Embodiment 1 , in which mounting holes and the protective cover are not shown.

Fig. 1-6 is a sectional schematic diagram of the box body of Embodiment I , in which the protective cover is not shown.

Fig. 1 -7 is a schematic diagram of the structure of a box cover.

Fig. 1-8 is a side view of the box cover.

Fig. 1-9 is a schematic diagram of the structure of Embodiment 1, in which the protective cover is shown.

Fig. 1-10 is a schematic diagram of the structure of Embodiment 2, in which the protective cover is not shown.

Fig. 1 -11 is a schematic diagram of the structure of Embodiment 2, in which the protective cover is shown.

Fig. 2-1 is a schematic diagram of an external structure of a power distributor assembly in the present invention.

Fig. 2-2 is a diagram of an internal structure of the power distributor assembly as shown in Fig. 2-1.

Fig. 2-3 is a perspective sectional view of the internal structure of the power distributor assembly.

Fig. 2-4 is a perspective view of the internal structure of the power distributor assembly by sectioning from another angle.

Fig. 2-5 is a sectional front view of the internal structure of the power distributor assembly as shown in Fig. 2-4.

Fig. 2-6 is a schematic diagram of an internal structure of a power distribution box.

Fig. 2-7 is a schematic diagram of a structure of an upper surface of a mounting plate in the present invention. Fig. 2-8 is a schematic diagram of a structure of a lower surface of the mounting plate in the present invention.

Fig. 2-9 is a schematic diagram of the structure of the upper surface of the mounting plate provided with power distribution devices and a circuit board.

Fig. 2-10 is a schematic diagram of the structure of the lower surface of the mounting plate as shown in Fig. 2-9.

Fig. 2-11 is a perspective view of the internal structure of the power distributor assembly after removal of the mounting plate as shown in Fig. 2-9.

Fig. 2-12 is a principle diagram of a state when in maintenance and use of the power distributor assembly of the present invention.

Figs. 2-13-2-15 are principle diagrams of the states when in maintenance and use of another power distributor assembly of the present invention.

Fig. 2-13 is a schematic diagram of the state of the power distributor assembly in the present invention when an auxiliary cover is detached.

Fig. 2-14 is a schematic diagram of the state after detaching part of high-voltage fuses on the basis of Fig. 2-13.

Fig. 2-15 is a schematic diagram of the state after detaching a high-voltage contactor on the basis of Fig. 2-14.

DETAILED DESCRIPTION OF THE EMBODIMENTS

The invention will be described below in detail in conjunction with accompanying drawings and embodiments.

First Aspect of the Invention

Embodiment 1 of the First Aspect

As shown in Fig. 1-2 through Fig. 1-6 and Fig. 1-9, a power distribution box in the invention comprises a box body 10300 and a box cover 10400. The box cover 10400 is detachably mounted to the upper end of the box body 10300. The box body 10300 comprises a back wall plate 10301 , a front wall plate 10302, two side wall plates 10303 and a bottom plate 10304. The back wall plate 10301, the front wall plate 10302 and the side wall plates 10303 are arranged on the bottom plate 10304 and protrude out of the bottom plate 10304, thereby defining an accommodating cavity 10305. The height h that the back wall plate 10301 protrudes out of the bottom plate 10304 is less than the height H that the front wall plate 10302 protrudes out of the bottom plate 10304. The side wall plates 10303 are right-angled trapezoidal. One end portion of each side wall plate 10303 is connected with the back wall plate 10301 and has the same height as the back wall plate 10301 ; and the other end portion of each side wall plate 10303 is connected with the front wall plate 10302 and has the same height as the front wall plate 10302.

Preferably, the box body 10300 adopts a casting structure to ensure the firmness of the box body 10300 and the whole power distribution box. In the example described above, due to the specific shapes of the back wall plate 10301 and the two side wall plates 10303 of the box body 10300, the areas of the back wall plate 10301 and the two side wall plates 10303 of the casting box body 10300 are reduced and thereby the overall weight of the box body 10300 and the whole power distribution box is further reduced.

In a preferred embodiment, the front wall plate 10302 is provided with a recessed structure 10308. The recessed structure 10308 is an open groove and is provided with an opening in the front wall plate 10302. The recessed structure 10308 comprises a vertical plate 10309 and an inclined plate 10310. The inclined plate 10310 is the top wall of the recessed structure. The front wall plate 10302 is provided with a plurality of mounting holes 10312 for arranging electrical interfaces. The shapes and the number of the mounting holes 10312 can be determined according to the electrical interfaces which need to be mounted. The mounting holes 10312 are communicated with the accommodating cavity 10305. A art of the mounting holes 10312 are formed in the recessed structure 10308. The other part of the mounting holes 10312 are formed in the front wall plate 10302. The mounting holes 10312 formed in the recessed structure 10308 can be formed in the vertical plate 10309 and can also be formed in the inclined plate 10310. The mounting holes 10312 formed in the inclined plate 10310 are vertical to the inclined plate 10310.

The front wall plate 10302 is provided with a protective cover 10311. The protective cover 10311 covers the mounting holes 10312 formed in the front wall plate 10302 and in the recessed structure 10308. As shown in Fig. 1 -7 and Fig. 1-8, the box cover 10400 comprises a back plate 10401 , a top plate 10402 and two side plates 10403. The back plate 10401 and the two side plates 10403 are arranged on the top plate 10402 and protrude out of the lower surface of the top plate 10402. The side plates 10403 are triangular. Preferably, the box cover 10400 adopts a metal plate for manufacturing so as to reduce the weight of the box cover 10400, facilitate mounting and detaching operations and reduce the overall weight of the power distribution box. In the example described above, as the box cover 10400 comprises the back plate 10401 and the two side plates 10403, the areas of the back wall plate 10301 and the two side wall plates 10303 of the casting box body 10300 can be further reduced and thus the overall weight of the power distribution box is further reduced.

A circle of mounting plate 10408 is mounted at the lower end of the box cover 10400. The width of the mounting plate 10408 is adapted to the width at the upper end of the box body 10300. The mounting plate 10408 is rested at the upper end of the box body 10300. Screws penetrate the mounting plate 10408 and are screwed into the box body 10300. The box cover 10400 is detachably connected with the box body 10300 through the screws.

In the preferred embodiment of the invention, the power distribution box described above is the power distribution box for an electric vehicle.

Embodiment 2 of the First Aspect

As shown in Fig. 1 -10 and Fig. 1-11, a power distributor assembly in the invention comprises the power distribution box in Embodiment 1. Electrical components are arranged in the accommodating cavity 10305 (not shown in the figures). The electrical components can be selected according to actual needs. A plurality of electrical interfaces 10315 are arranged in the positions of the mounting holes 10312. The electrical interfaces 10315 are various available electrical interfaces. External electrical devices are electrically connected with the electrical components through the electrical interfaces 10315. For example, the electrical interfaces 10315 in the power distributor assembly can comprise a manual service disconnect (MSD) 10316.

In the preferred embodiment of the invention, the power distributor assembly described above is the power distributor assembly for an electric vehicle. According to the power distribution box and the power distributor assembly in the invention, the height that the back wall plate protrudes out of the bottom plate is less than the height that the front wall plate protrudes out of the bottom plate, which indicates the back wall plate is shorter, thereby facilitating machining or assembly of the structure in the accommodating cavity. The mounting holes for mounting the electrical interfaces are formed in the front wall plate, thereby ensuring sufficient area to arrange the plurality of electrical interfaces. The box body adopts a casting and the box cover adopts a metal plate for manufacturing, so that the production is convenient, the firmness of the box body can be ensured and the overall weight of the power distribution box is also reduced. The front wall plate is provided with the recessed structure and the mounting holes are formed in the wall plates of the recessed structure, thereby protecting the electrical interfaces. In the recessed structure, the electrical interfaces with downward outgoing lines can be arranged in the inclined plate and the electrical interfaces with the horizontal outgoing lines can be arranged on the vertical plate, thereby enriching the outgoing line directions of the electrical interfaces and enhancing the applicability.

The protective cover arranged on the box body is used for protecting the electrical interfaces, thereby being capable of protecting the plug-in connectors on the electrical interfaces from damage due to the strong impact of a certain external force when in mounting, maintenance and even accidents.

The embodiments in the invention are only used for illustrating the invention and are not intended to limit the scope of the claims. Any other substantially equivalent substitutions that those skilled in the art can conceive are within the protection scope of the invention.

Second Aspect of the Invention

As shown in Fig. 2-1 through Fig. 2-6, a power distributor assembly 20100 in the invention comprises a power distribution box 20200, a plurality of power distribution devices mounted in the power distribution box 20200, and electrical interfaces which are arranged on the power distribution box 20200 and used for connecting various external electrical components. The power distribution box 20200 comprises a box body 20300 and a box cover 20400. The box cover 20400 is detachably mounted at the upper end of the box body 20300 and hermetically connected with the box body 20300. The box body 20300 comprises a side wall plate 20301 and a bottom plate 20302. The side wall plate 20301 is arranged on the bottom plate 20302 and protrudes out of the bottom plate 20302, thereby defining an accommodating cavity 20305. The box cover 20400 is arranged at the upper end of the side wall plate 20301. The box cover 20400 can be detachably arranged on the side wall plate 20301 and can also be pivotally arranged. In an example as shown in Fig. 2-1, the box cover 20400 comprises a box cover main body 20401 and an auxiliary cover 20402, wherein the box cover main body 20401 is hermetically connected with the box body 20300. A penetration hole 20403 is formed in the box cover main body 20401 (as shown in Fig. 2-13 through Fig. 2-15). The auxiliary cover 20402 can be detachably mounted on the outer surface of the box cover main body 20401 and cover the penetration hole 20403. According to a preferred embodiment of the invention described below, the penetration hole 20403 and a through hole 20504 in a mounting plate 20500 face each other in a longitudinal direction.

A plurality of electrical interfaces can be arranged on the power distribution box 20200 for connecting the various power distribution devices in the power distribution box 20200 to the various external electrical components. For example, the plurality of electrical interfaces can be selectively arranged on the box body 20300 and the box cover 20400. In the example as shown in the figure, the plurality of electrical interfaces are arranged on the side wall plate 20301 of the box body 20300. The number and form of the electrical interfaces can be determined according to actual needs. As a preferred embodiment, the electrical interfaces adopt plug-in type interfaces, such as various electrical connectors. In the example as shown in the figures, the electrical interfaces are cylinder-penetrating type connectors and can be in plug-in connection with mating connectors. As shown in the figures, the electrical interfaces can comprise a power supply input interface 20210, power distribution interfaces 20220, a charging interface 20230 and other safety device (such as a manual service disconnect (MSD)) interfaces 20240. In the present invention, the power distribution interfaces 20220 comprise not only high-voltage power distribution interfaces, but also low-voltage power distribution interfaces. The electrical interfaces are used for connecting a power supply and conveying the power which is distributed by the power distribution devices to the electrical components. As shown in the figures, the electrical interfaces can be electrically connected with the various external electrical components. For example, the power supply input interface 20210 can be connected with a power supply input end (not shown). Also, the safety device interface 20240 can be connected with the manual service disconnect (MSD). According to a preferred embodiment of the invention, the power which is distributed by the power distribution devices is directly convey to the electrical components by the electrical interfaces without passing through other power distribution units. For example, the power distribution interfaces 20220 comprise the low-voltage power distribution interfaces 20222 and the low-voltage power distribution interfaces 20222 can be directly electrically connected with various vehicle electrical devices by harness devices without low-voltage power distribution.

As shown in Fig. 2-2 through Fig. 2-6, a support structure is arranged in the accommodating cavity 305 of the power distribution box 20200 for supporting the mounting plate 20500 and various circuit boards. The support structure can be selected and determined according to actual needs. The support structure can be a support plate, a support table, a support rod or a support column. In the example as shown in the figures, the support structure can be one or more support columns 20320. A plurality of support columns 20320 are mounted on the bottom plate 20302 at intervals.

The mounting plate 20500 is arranged in the power distribution box 20200. In the example as shown in the figures, the mounting plate 20500 is detachably mounted at the upper ends of the support columns 20320. In conjunction with Figs. 2-7-2-10, the mounting plate 20500 comprises an upper surface 20501 and a lower surface 20502. In a preferred embodiment according to the invention, a baffle plate 20503 is arranged on the upper surface 20501. The upper surface 20501 is divided into two regions by the baffle plate 20503 to facilitate the arrangement of different power distribution devices. In the example as shown in the figures, one baffle plate 20503 is provided. The upper surface 20502 is divided into two regions, such as a high-voltage region and a low-voltage region, by the baffle plate 20503 for respectively mounting the high-voltage power distribution devices and the low-voltage power distribution devices. According to a preferred embodiment of the invention, a through hole 20504 is formed in the mounting plate 20500. The through hole 20504 runs through the mounting plate 20500 from the upper surface 20501 to the lower surface 20502. After the mounting plate 20500 is fixed in the box body 20300, an operator can mount and detach the power distribution devices on the bottom plate 20302 via the through hole 20504 without firstly detaching the mounting plate 20500 from the box body 20300. A reinforcing rib 20506 is arranged on the lower surface 20502 of the mounting plate 20500. The reinforcing rib 20506 protrudes out of the lower surface 20502 and is arranged around the through hole 20504. The reinforcing rib 20506 is plate-like.

As shown in Fig. 2-2 through Fig. 2-5 and Fig. 2-9, the plurality of high- voltage power distribution devices and the plurality of low-voltage power distribution devices are arranged on the upper surface 20501 of the mounting plate 20500. The high-voltage power distribution devices can be determined according to actual needs. In the example as shown in the figures, for example, the high-voltage power distribution devices are a plurality of high-voltage fuses 20611. The low- voltage power distribution devices can be determined according to actual needs. In the example as shown in the figures, the low-voltage power distribution devices comprise a plurality of low- voltage relays 20621 , a plurality of low- voltage fuses 20622 and a plurality of low-voltage connectors 20623. According to a preferred embodiment of the invention, the high-voltage power distribution devices and the low-voltage power distribution devices are respectively arranged on the two sides of the baffle plate 20503. The baffle plate 20503 separates the high- voltage power distribution devices and the low-voltage power distribution devices, thereby being capable of preventing mutual interference and facilitating management. According to another preferred embodiment of the invention, the power distribution devices are mounted on the upper surface 20501 of the mounting plate 20500 and span the through hole 20504 in the mounting plate 20500.

According to a preferred embodiment, the high-voltage power distribution devices and the low-voltage power distribution devices can also be respectively arranged on the bottom plate 20302 of the box body 20300. In the example as shown in Fig. 2-11 , a plurality of high- voltage contactors 20612 are arranged on the bottom plate 20302 of the box body 20300. By using the mounting plate 20500, the high-voltage power distribution devices and the low-voltage power distribution devices are arranged in the accommodating cavity 20305 of the power distribution box 20200 in layers, thereby more reasonably and more fully using the accommodating cavity 20305 in the power distribution box 20200 to achieve the purpose of saving space. According to another preferred embodiment of the invention, the power distribution devices can penetrate the through hole 20504 in the mounting plate 20500, is arranged facing the through hole 20504 and is mounted on the mounting plate 20500. When the power distribution devices need to be maintained, the operator can detach and mount the power distribution devices, which are arranged facing the through hole 20504, through the through hole 20504 in the mounting plate 20500 without detaching the mounting plate 20500, thereby facilitating and simplifying the operation.

The various power distribution devices arranged in the power distribution box 200 can be respectively electrically connected with their mating electrical interfaces. As shown in Fig. 2-2 through Fig. 2-5, Fig. 2-11 and Fig. 2-12, the high- voltage power distribution devices are respectively electrically connected with their mating high-voltage power distribution interfaces. The electrical connection form can be determined according to the actual needs. In the example as shown in the figures, the high-voltage power distribution devices are electrically connected with the high-voltage power distribution interfaces through conducting wires. Similarly, the low-voltage power distribution devices are electrically connected with their mating low-voltage power distribution interfaces 20222, and the connection form can be determined according to actual needs. In the example as shown in the figures, the plurality of low-voltage power distribution devices are arranged on a low-voltage connection circuit board 20510. Through the low-voltage connection circuit board 20510, the low- voltage power distribution devices are electrically connected with the low-voltage power distribution interfaces 20222.

A plurality of circuit boards are further arranged in the accommodating cavity 20305 of the power distribution box 20200 of the present invention, including the low-voltage connection circuit board 20510 in the above example. In the example as shown in Fig. 2-3 through Fig. 2-5 and Fig. 2-10, the low- voltage connection circuit board 20510 is fixedly arranged below the mounting plate 20500 and electrically connected with the low-voltage power distribution devices on the mounting plate 20500. As shown in Fig. 2-9 and Fig. 2-10, the low- voltage connection circuit board 20510 which is fixedly arranged below the mounting plate 20500 and the various power distribution devices which are fixedly arranged on the mounting plate 20500 form a module structure.

According to a preferred embodiment of the invention, the plurality of circuit boards can be arranged in layers and in parallel to facilitate the reasonable use of space. As shown in Fig. 2-3 through Fig. 2-5, the plurality of circuit boards can be mounted in the accommodating cavity 20305 of the power distribution box 20200 in a conventional fixation way. In the example as shown in the figures, a plurality of support columns 20320 are arranged in the accommodating cavity 20305. A first circuit board 20520 is arranged at the upper ends of the support columns 20320. A second circuit board 20530 is arranged on the plurality of support columns 20320 near the bottom plate 20302. The first circuit board 20520 is arranged above the second circuit board 20530. The first circuit board 20520 is arranged below the mounting plate 20500 and arranged spacing apart from the mounting plate 20500. According to a preferred embodiment of the invention, the first circuit board 20520 is arranged below the low- voltage connection circuit board 20510.

The functions of the first circuit board 20520 and the second circuit board 20530 can be determined according to actual needs. The first circuit board 20520 and the second circuit board 20540 can be used for controlling the low-voltage power distribution devices to work and can also be used for communicating with external electrical devices. In the example as shown in the figures, the first circuit board 20520 is a low-voltage control circuit board and one or more control chips are arranged on the first circuit board 20520. According to a preferred embodiment of the invention, the low-voltage control circuit board 20520 can communicate with a vehicle control unit (VCU). For example, the low-voltage control circuit board 20520 can communicate with the vehicle control unit through a controller area network (CAN) or other types of buses. According to another preferred embodiment of the invention, the low-voltage control circuit board comprises at least part of the vehicle control unit. For example, the control chips on the low-voltage control circuit board 20520 can implement part of functions of the vehicle control unit, thereby simplifying the structure and the functions of the vehicle control unit and reducing the burden of the vehicle control unit. Fig. 2-12 shows a principle diagram of detaching and mounting the power distribution devices positioned on the mounting plate 20500 and the bottom plate 20302 in the box body 20300. When the high-voltage fuses 20611 need to be replaced, the operator can firstly open the box cover 20400 from the upper part of the box body 20300 and then replace the high-voltage fuses 20611 on the mounting plate 20500. If the power distribution devices on the bottom plate 20302 need to be replaced, the high-voltage fuses 20611 positioned at the through hole 20504 of the mounting plate 20500 can be firstly detached. Then, the operator can stretch his hand to a position below the mounting plate 20500 from the through hole 20504 and further detach or mount the power distribution devices, such as the high-voltage contactors 20612, positioned on the bottom plate 20302. In the invention, when the power distribution devices below the mounting plate 20500 are detached and mounted, the mounting plate 20500 does not need to be detached, thereby facilitating maintenance and repair during use.

Another power distributor assembly 20100 is shown in Fig. 2-13 through Fig. 2-15, wherein the auxiliary cover 20402 is arranged on the box cover 20400 of the power distribution box 20200 (see Fig. 2-1). When the power distribution devices in the box body 20300 need to be maintained, only the auxiliary cover 20402 needs to be removed from the power distribution box 20200 and then the high- voltage fuses 20611 on the mounting plate 20500 can be exposed (see Fig. 2-13). At this time, the operator can conveniently mount and detach the high- voltage fuses 20611. After the high- voltage fuses 20611 are detached, the power distribution devices, such as the high- voltage contactors 20612, on the bottom plate 20302 can be exposed from the through hole 20504 in the mounting plate 20500 (see Fig. 2-14). At this time, the operator can conveniently replace the power distribution devices on the bottom plate 20302 through the through hole 20504 in the mounting plate 20500 (see Fig. 2-15). According to a preferred embodiment of the invention, when the power distribution devices in the power distribution box 20200 need to be maintained, the box cover 20400 does not need to be opened, and only the auxiliary cover 20402 needs to be removed from the box cover 20400 to implement the operation.

According to the power distribution box and the power distributor assembly in the invention, more power distribution devices can be arranged by arranging the mounting plate in the accommodating cavity to stereoscopically divide the space of the accommodating cavity. The invention can fully utilize the internal space of the power distribution box, integrate the high-voltage power distribution devices and the low-voltage power distribution devices into a whole ahd thus save the mounting space. The high-voltage power distribution devices and the low-voltage power distribution devices are arranged in the same power distribution box, thereby not only saving the space and the production cost, but also facilitating management. The reinforcing rib is arranged on the lower surface of the mounting plate, thereby being capable of increasing the strength of the mounting plate. The reinforcing rib can eliminate the influence of reducing the strength of the mounting plate due to the arrangement of the through hole. The through hole is arranged in the mounting plate and the power distribution devices below the mounting plate can be detached and mounted by passing through the through hole.

The embodiments in the invention are merely used for describing the invention and are not intended to limit the scope of the claims. Those skilled in the art can conceive other substantially equivalent substitutions which are within the protection scope of the invention.

Claims

2 ! 1 24 CLAIMS

1. A power distribution box, comprising a box body and a box cover,

wherein the box body comprises a front wall plate, a back wall plate, two side wall plates and a bottom plate; the front wall plate, the back wall plate, and the side wall plates extending from the bottom plate to define an accommodating cavity; and

wherein the box cover is movably mounted at an upper end of the box body;

characterized in that the side wall plates are trapezoidal or triangular.

2. The power distribution box according to claim 1, characterized in that the back wall plate protrudes out of the bottom plate for a height that is smaller than a height of the front wall plate protruding out of the bottom plate.

3. The power distribution box according to claim 1, characterized in that the side wall plates are right-angled trapezoidal.

4. The power distribution bo according to claim 1, characterized in that the front wall plate is provided with a plurality of mounting holes for arranging electrical interfaces; and the mounting holes are communicated with the accommodating cavity.

5. The power distribution box according to claim 1 , characterized in that the front wall plate is provided with a recessed structure; and the mounting holes are partly formed in the recessed structure.

6. The power distribution box according to claim 5, characterized in that the recessed structure has an upper wall in the form of an inclined plate; a part of the mounting holes are formed in the inclined plate; and the mounting holes formed in the inclined plate are vertical to the inclined plate.

7. A power distribution box, comprising a box body and a box cover, wherein the box body comprises a side wall and a bottom plate; the side wall is arranged on the bottom plate; the box cover is arranged at an upper end of the side wall; the box body and the box cover define an accommodating cavity;

characterized in that a mounting plate is detachably mounted in the accommodating cavity; the mounting plate comprises an upper surface and a lower surface; and the mounting plate is arranged between and spaced apart from the bottom plate and the box cover.

8. The power distribution box according to claim 7, characterized in that the mounting plate is formed with a through hole; and the through hole runs through the mounting plate from the upper surface to the lower surface.

9. A power distributor assembly, characterized by comprising the power distribution box according to claim 7, wherein a plurality of high-voltage power distribution devices and a plurality of low- voltage power distribution devices are arranged in the accommodating cavity; and at least a part of the plurality of high-voltage power distribution devices and of the plurality of low- voltage power distribution devices are arranged on the mounting plate.

10. The power distributor assembly according to claim 9, characterized in that the mounting plate is formed with a through hole; the through hole runs through the mounting plate from the upper surface to the lower surface; and a part of the high-voltage power distribution devices are arranged on the upper surface of the mounting plate, some of which are arranged spanning the through hole.

11. The power distributor assembly according to claim 10 characterized in that one or more of the plurality of high-voltage power distribution devices and of the plurality of low-voltage power distribution devices are arranged on the bottom plate; and the part of the high-voltage power distribution devices or of the low-voltage power distribution devices arranged on the bottom plate are aligned with the through hole.

12. The power distributor assembly according to claim 9, characterized in that a baffle plate is formed on an upper surface of the mounting plate; wherein the high-voltage power distribution devices are arranged on one side of the baffle plate and the low-voltage power distribution devices are arranged on the other side of the baffle plate.

13. The power distributor assembly according to claim 9, characterized in that a plurality of circuit boards are arranged in the accommodating cavity; the plurality of circuit boards comprise a low-voltage connection circuit board; and the low-voltage connection circuit board is fixedly arranged on the mounting plate and electrically connected with the low-voltage power distribution devices on the mounting plate.

14. The power distributor assembly according to claim 9, characterized in that a plurality of circuit boards are arranged in the accommodating cavity; the plurality of circuit boards comprise a low-voltage control circuit board with one or more control chips; and the low-voltage control circuit board is connected with a vehicle control unit through a controller area network.

15. The power distributor assembly according to claim 14, characterized in that the low-voltage control circuit board comprises at least part of a vehicle control unit.