Sealed power distribution unit for an electrical power distribution system

A power distribution unit for a vehicle including an enclosure and power distributing means for distributing electrical power between a battery and a load application, the enclosure including an external casing and an internal casing having a faceplate and a mounting plate, the mounting plate having upper dielectric partitions protruding upward from a top face of the mounting plate, and the power distributing means being mounted on the mounting plate, wherein the upper dielectric partitions are configured to both maintain a separation between different voltage groups and define an insulating barrier between components of the power distributing means, the internal cartridge is configured to be inserted into the external casing, and the enclosure is configured to be sealed from an external environment.

BACKGROUND OF THE INVENTION

The present disclosure is directed to a power distribution unit, and in particular to a power distribution unit for an electrical power distribution system for example for vehicle applications.

Conventionally, power distribution units, also known as PDUs, include internal components that require some form of protection from the environment and restricts access to the high voltages contained within. Power distribution units for use in mobility systems, specifically vehicles, are typically designed where the vehicle provides most, if not all, of the protection for the internal components. However, in many of these mobility systems, the power distribution unit is developed in parallel with the application that they serve and result in power distribution units being positioned in relatively inaccessible area of vehicles. This results in unique challenges with respect to serviceability and leads to increased maintenance time.

The present disclosure provides a power distribution unit that, with a simple configuration, merges the functions of the application interface, component layout, mechanical fixation and environmental sealing. The retention of the components is accomplished by mounting functional elements together on a single component and fastening said single component at a single surface to minimize time and effort necessary to gain access to the functional elements.

Additionally, the modular design of the power distribution unit allows the power distribution unit to be mounted remotely from their battery sources, which creates easier servicing and maintenance on the electrical power distribution system without creating direct exposure to the high voltage of the battery sources.

SUMMARY OF THE INVENTION

According to an aspect of an example embodiment, a power distribution unit may include an enclosure; and power distributing means for distributing electrical power between a battery and a load application, wherein the enclosure may include: an external casing having a closed end, an open end, a top surface, a bottom surface and opposing side surfaces, each of the opposing side surfaces having a support slot, and the bottom surface having one or more alignment guide; and an internal casing having a faceplate and a mounting plate, the mounting plate extending rearward from the faceplate, opposing sides of the mounting plate being configured to be slidably disposed within the support slots, the mounting plate having upper dielectric partitions protruding upwardly from a top face of the mounting plate and lower dielectric partitions protruding downwardly from a bottom face of the mounting plate, wherein the internal cartridge is configured to be inserted into the external casing through the open end, wherein the faceplate has a plurality of external interfaces adapted for connecting to the battery and the load application, wherein the power distributing means is mounted on the mounting plate, wherein the enclosure is configured to be sealed from an external environment, and wherein the upper and lower dielectric partitions are configured to both maintain a separation between different voltage groups and define an insulating barrier between components of the power distributing means.

Further, the internal cartridge may be configured to slide on the one or more alignment guide such that the mounting plate is engaged with the support slots.

Further, the external casing may include a sealing surface disposed around a rim of the open end. The sealing surface may be configured to create a seal between the external casing and the internal cartridge.

The rim and the faceplate may include a plurality of corresponding holes for fastening the internal cartridge to the external casing.

Further, the enclosure may include a gasket for creating a seal between the external casing and the internal cartridge.

The power distributing means may include one or more selected from the group consisting of a contactor, a pre-charge circuit, a fuse, a plurality of sensors.

In an example embodiment, the external casing and the internal cartridge may be made from plastic.

According to an example embodiment, the internal cartridge may further include a lower mounting plate that extends rearward from a rear end of a lower dielectric partition.

Further, each of the opposing side surfaces may further comprise a lower support slot, opposing sides of the lower mounting plate being configured to be slidably disposed within the lower support slots.

The power distributing means may include a plurality of electrical components, and some of the electrical components may be mounted to the mounting plate and some of the electrical components may be mounted to the lower mounting plate.

According to an example embodiment, the one or more alignment guide may protrude upwardly from the bottom surface of the external casing and taper towards the open end. The lower mounting plate may be configured to slide on the one or more alignment guide.

The lower mounting plate may include protrusions configured to provide support for the power distributing means.

The power distribution unit may further include a battery management unit (BMU) configured to monitor status of the battery, the BMU may be mounted to the mounting plate, and the faceplate may have a connector for connecting to the BMU.

According to an example embodiment, the power distributing means may include a positive contactor, a negative contactor, a pre-charge resistor, a pre-charge contactor, a first fuse corresponding to the positive contactor, a second fuse corresponding to the negative contactor, a current sensor, and a battery management unit (BMU).

Also, a vehicle of the present disclosure may include the power distribution unit having any one of the above-described configurations.

DETAILED DESCRIPTION OF THE INVENTION

Detailed embodiments of the claimed structures are disclosed herein; however, it can be understood that the disclosed embodiments are merely illustrative of the claimed structures that may be embodied in various forms. Aspects of this disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth herein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of this disclosure to those skilled in the art. In the description, details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the presented embodiments.

Referring to the figures, the invention relates to a power distribution unit configured to simplify assembly and maintenance of the power distribution unit for use in a vehicle, and provide environmental protection for electrical components disposed within.

As shown inFIG.1andFIG.2, the power distribution unit10includes an enclosure100and means for distributing electrical power between a battery to a load application200(hereinafter “power distributing means”). The enclosure100, including an external casing110and an internal cartridge120, provides protection for the power distributing means200and restricts external access to the high voltages within. For example, the enclosure100can provide protection from shock, vibration, extreme temperatures, water spray, and the like.

The enclosure100may be made of any suitable materials, but are preferably made of materials that provide adequate electrical insulation and environmental protection. In an example embodiment, the enclosure100is made up of plastic, which provides adequate insulation and environmental protection while also being low in cost and weight.

FIG.3shows a perspective view of the external casing110. The external casing110includes a closed end111, an open end112, a top surface113, a bottom surface114and opposing side surfaces115. The external casing further includes a rim112A around the open end112, which serves as a surface for fixing the internal cartridge120in the external casing110and sealing the enclosure100from external environments. In an example embodiment, as shown inFIG.3, the rim may include a plurality of screw holes for fastening the internal cartridge120to the external casing110for sealing the enclosure.

The opposing side surfaces115of the external casing110each has a support slot117for receiving the internal cartridge120. The bottom surface114of the casing110may also have a support slot117. The support slots117are configured to provide support for the internal cartridge120within the external casing110and restrict excessive movement of the internal cartridge120inside of the external casing110. Although this is merely an example, the support slots117inFIG.3extend a full length from the open end112to the closed end111. However, the length and position of the support slots117are not limited thereto.

The external casing110may further include lower support slots118. As shown inFIG.3, the lower support slots118may be positioned below the support slots117on the opposing side surfaces115. The lower support slots118may provide additional alignment for the internal cartridge120as it is inserted into the external casing110and additional support for the internal cartridge120when it is fixed within the external cartridge110.

The bottom surface114of the external casing110has one or more alignment guides119for guiding the internal cartridge120during insertion into the external casing110. The one or more alignment guide119may be inclined such that the height is increased toward the closed end111of the external casing110and tapers at the open end112of the external casing110. Although the external casing110is shown inFIG.3as having two alignment guides119spaced equally on the bottom surface114, the quantity and arrangement of the one or more alignment guide119is not limited thereto.

FIG.4shows a perspective view of the internal cartridge120. The internal cartridge120includes a faceplate121and a mounting plate122on which the power distributing means200are mounted. The mounting plate122of the internal cartridge120extends rearward from the faceplate121and is configured such that opposing sides of the mounting plate122can be slidably disposed within the support slots117of the external casing110.

The faceplate121includes a plurality of external interfaces126adapted for connecting to the battery and to the load application. The plurality of external interfaces may include interface holes for electrical connectors, or the like. Additionally, the faceplate121may also include a plurality of fastening holes127for fastening the internal cartridge120to the external casing110.

The mounting plate122includes upper dielectric partitions123extending upward from a top face122A and lower dielectric partitions124extending downward from a bottom face122B. The upper dielectric partitions123and the lower dielectric partitions124provide barriers across the mounting plate122for isolating the power distributing means200. The upper dielectric partitions and the lower dielectric partitions create distance between positively charged electrical components and negatively charged electrical components of the power distributing means200and create insulating barriers between the positively charged electrical components and the negatively charged electrical components In addition, as shown inFIG.5, the mounting plate may include a plurality of support protrusions123A for supporting the electrical components of the power distributing means200on the mounting plate122.

In an example embodiment, the internal cartridge120may further include a lower mounting plate125that extends rearward from the lower dielectric partitions124and in which opposing sides of the lower mounting plate125can be slidably disposed within the lower support slots118of the external casing110. Additionally, as shown inFIGS.4and5, the lower mounting plate125may also have protrusions125A for supporting the power distributing means200.

The power distributing means200may include a plurality of electrical components configured to manage the interconnection of an electrical supply, such as a battery, battery pack or module, or the like, and a load application. The plurality of electrical components are connected to the electrical supply and the output device by way of the plurality of external interfaces on the faceplate121of the internal cartridge120.

The plurality of electrical components may include, for example, one or more of a high voltage contactor, a pre-charge circuit, including pre-charge resistors and pre-charge contactors, a high voltage fuse, one or more sensor, and control electronics. For example, the control electronics may include a battery management unit (BMU) for monitoring the status of the battery. The plurality of electrical components may also include connection components such as connectors and wires.

In an example embodiment, as shown inFIGS.6and7, the plurality of electrical components includes a positive contactor210, a negative contactor210, a pre-charge resistor212, a pre-charge contactor213, a first fuse214corresponding to the positive contactor210, a second fuse215corresponding to the negative contactor211, a current sensor216, a circuit board217, and a BMU (not shown). The positive contactor210, the negative contactor211, the pre-charge resistor212, and the pre-charge contactor213may be mounted to the lower mounting plate125, and the first fuse214, the second fuse215, and the current sensor may be mounted on the bottom surface122B of the mounting plate122.

The plurality of electrical components can be mounted to the mounting plate122with the positively charged electrical components and the negatively charged electrical components isolated from each other. In an example embodiment, as shown inFIGS.5and6, the positive contactor210and the negative contactor211are mounted on opposite sides of the internal cartridge120with the upper dielectric partitions123positioned in between the positively and negatively charged electrical components.

The power distributing means200are mounted to the mounting plate122of the internal cartridge120. Additionally, in an embodiment including the lower mounting plate125as shown inFIGS.5and6, the power distributing means200can be mounted to both the mounting plate122and the lower mounting plate125. In this configuration, the power distributing means200can be compiled at a single location and the overall assembly of the power distributing means200onto the internal cartridge121can be simplified.

The power distribution unit10is assembled by inserting the internal cartridge120through the open end112of the external casing110. As the internal cartridge120is inserted into the external casing110, the mounting plate122slides along the one or more alignment guide119and the opposing sides of the mounting plate122engage with the support slots117. In an example embodiment, when the internal cartridge120with the lower mounting plate125is inserted into the external casing110with the lower support slot118, the lower mounting plate125makes contact with the one or more alignment guide119, the opposing sides of the lower mounting plate125engage with the lower support slots118, and the opposing sides of the mounting plate122engage with the support slots117.

The internal cartridge120slides into the external casing110until the faceplate121makes contact with the rim112A of the open end112. The contact between the faceplate121and the rim112A seals the enclosure100as the internal cartridge120is fixed to the external casing110. In an example embodiment, a gasket may be placed between the rim112A and the faceplate121to perform the sealing of the enclosure100.

In this configuration, the power distributing means200can be protected from the external environment inside the enclosure110. Additionally, the modularity of the power distribution unit10allows for the power distribution unit10to be mounted remotely in the vehicle from the battery, which provides easier servicing or maintenance without exposing persons to a high voltage of the battery directly.

The power distribution unit10can be disassembled by removing the internal cartridge120from the external casing110in a reversed process. The opposing sides of the mounting plate122can slide outward along the support slots and the mounting plate122can slide outward along the one or more alignment guides119while the external casing110remains fixed in the vehicle.

Further, in this configuration, the power distribution unit10can be mounted in the vehicle with the faceplate121facing an upward direction such that, during disassembly, the internal cartridge120can be loosened and removed, removing all of the power distributing means200at once, without needing to remove the entire power distribution unit10from the vehicle.

The present disclosure is not limited to the above description, and various other modifications may be implemented within a range not departing from the spirit of the present disclosure.