Contactor device and energy storage system

Abstract

The invention relates to a contactor device (100) capable of changing the connection state of at least two battery modules (502 (1), 502 (2)) of a high-voltage energy storage system (10) between a series connection and a parallel connection, and to an energy storage system (10) comprising a contactor device (100). The contactor device (100) comprises two first terminals (102, 104) for electrically connecting at least one of a load and a charger, two second terminals (106, 108) for electrically connecting a first battery module (502 (1)), and two third terminals (110, 112) for electrically connecting a second battery module (502 (2)). The contactor device (100) further comprises two first busbars (128, 129) and two second busbars (138, 139; a plurality of first busbars (238, 239) and connection busbars (144), each of the first busbars being electrically connected to one of the first terminals (102, 104); wherein the second bus bar (138; 238) is electrically connected to one of the second terminals (106), and the second bus (139; 239) is electrically connected to one of the third terminals (112); the connection bus (144) is electrically isolated from the two first buses (128, 129). The at least one actuating element is configured to change at least a state of the contactor device (100), transitioning it between a series-connected state in which the two second busbars (138, 139; 238, 239) is conductively coupled to the connection bus (144), the second bus (138; 238) is conductively coupled to the first bus bar (128), and the second bus bar (139; 239) is conductively coupled to another one of the first busbars (129).

Description

Technical Field

[0001] The present invention relates to a contactor device capable of changing the connection state of at least two battery modules of a high-voltage energy storage system between a series connection and a parallel connection, and an energy storage system comprising the contactor device. Background Art

[0002] The use of contactor devices to connect and disconnect electronic circuits in energy storage systems is known in the prior art. With the advanced development of electric vehicles (EV) or hybrid electric vehicles (HEV), high-voltage energy storage systems are becoming more and more common in automobiles. Since such high-voltage systems are currently typically capable of supplying voltages in a typical range between 400V and 1kV, and may even be able to supply higher voltages in future applications, these high-voltage energy storage systems pose a greater risk of electric shock than traditional power systems. Therefore, prevention of safety hazards and overcurrent protection are critical for these systems. For example, in the event of a failure of the high-voltage energy storage system or an accident in the vehicle that affects the electronic circuits of the energy storage system, it is very important to ensure the safety of vehicle passengers, road rescue personnel or maintenance personnel.

[0003] Therefore, safety requirements for contactor devices used to control current in energy storage systems are increasing, especially in the case where the energy storage systems are used to store energy to drive vehicles.

[0004] Conventional contactor devices are capable of reversibly changing state between a closed state, in which current can flow through the contactor device, and an open state, in which current is prevented from flowing through the contactor device, typically by moving at least one movable contact. In addition, overcurrent protection devices (such as thermal fuses) may be used that, when activated, allow reversible disconnection of the supply in the high-voltage energy storage system in the event that operating conditions in the energy storage system become unsafe (e.g. due to an overcurrent or fault occurring in the electronic circuit of the energy storage system, or in the event of an accident involving a vehicle driven by energy stored in the energy storage system).

[0005] However, depending on the application in which the energy storage system is used, it may be necessary to switch the contactor device not only between the open state or the closed state. For example, the contactor device may be electrically connected to a high-voltage battery, which is a drive battery for an EV or HEV vehicle. In order to provide a high voltage in the range of 400V and at least 1kV to the motor of an EV or HEV vehicle in a driving state, a plurality of battery modules (or battery packs) are electrically connected to form a high-voltage battery, thereby providing a predetermined high voltage as the sum of the module voltages. However, since the battery voltage can be increasingly increased in this way, not all chargers or charging stations are able to charge such high-voltage batteries with a predetermined high voltage, but may only supply a voltage at a voltage level lower than the predetermined high voltage, making it difficult to charge the high-voltage battery correctly.

[0006] Therefore, it is expected that the battery configuration can be switched between a series connection state and a parallel configuration, wherein the series connection state connects multiple battery modules in series so that the high-voltage battery can supply the sum of the total voltages of the multiple battery modules, for example in a driving state, and the parallel configuration connects at least some of the multiple battery modules in parallel, which will allow the high-voltage battery to be charged at a voltage level lower than the predetermined high voltage. Summary of the invention

[0007] Therefore, it is an object of the present invention to provide a contactor device which provides the possibility to change the connection state of a high voltage battery. Furthermore, it is an object of the present invention to provide a simple and economical solution.

[0008] This object is solved by the subject matter of the independent claims. Advantageous aspects of the disclosure are the subject matter of the dependent claims.

[0009] In particular, the present disclosure provides a contactor device, which includes two first terminals for electrically connecting at least one of a load and a charger, two second terminals for electrically connecting a first battery module, and two third terminals for electrically connecting a second battery module. The contactor device also includes two first busbars, two second busbars, a connecting busbar, and at least one actuating element, each first busbar being electrically connected to one of the first terminals, one of the second busbars being electrically connected to one of the second terminals, the connecting busbar being electrically isolated from the two first busbars, and the at least one actuating element being configured to at least change the state of the contactor device so that it switches between a series connection state and a parallel connection state, in which the two second busbars are conductively coupled to the connecting busbars, and in which one of the second busbars is conductively coupled to one of the first busbars, and the other of the second busbars is conductively coupled to the other of the first busbars.

[0010] By setting the second busbars as the second group busbars and the connecting busbars, the contactor device allows the configuration of the connected battery modules to be switched between two states: one is a state in which the terminals of opposite potentials of the battery modules are electrically connected in series because the second group busbars are electrically connected to the connecting busbars; and the other is a parallel connection state in which the terminals of the same potential of the battery modules are electrically connected in parallel because each second busbar can be electrically connected to a corresponding one of the first busbars. Therefore, the contactor device allows switching between a series connection state and a parallel connection state in a simplified manner, in which the full voltage of the battery connected to the contactor device is applied between the two first busbars of the connector device, and in which a voltage corresponding to the module voltage of the battery module forming the battery is applied between the two first busbars of the connector device.

[0011] In this way, the contactor device according to the present disclosure allows a predetermined high voltage to be supplied to, for example, an electric motor of an electric vehicle in a series connection state, while allowing a battery module of a battery to be charged at a voltage level lower than the predetermined high voltage in a parallel connection state. Therefore, due to its simple configuration, the contactor device of the present disclosure allows the need to provide a complicated switch structure between battery modules to change between series connection and parallel connection of the battery modules to be eliminated.

[0012] According to an advantageous example, each second busbar comprises a deflectable contact area that is elastically deflectable between a first position in which each second busbar is conductively coupled to the connecting busbar and a second position in which each second busbar is conductively coupled to one of the first busbars. In this way, the transition force provided by at least one actuating element for changing the state of the contactor device can be effectively transmitted, since it does not require the second busbar to be moved as a whole. However, as in an alternative example, the second busbar can be moved as a whole between the first position and the second position.

[0013] In another advantageous example, the contactor device may further include two auxiliary connecting busbars, each auxiliary connecting busbar being configured to conductively couple one of the second busbars to a corresponding one of the first busbars in the parallel connection state of the contactor device. In this way, the contactor device may include only fixed busbars that allow the state of the contactor device to be changed between the series connection state and the parallel connection state.

[0014] In order to allow effective force transmission when changing the state of the contactor device, the connecting busbar and the auxiliary connecting busbar are preferably mounted on a connecting frame, and at least one actuating element is configured to move the connecting frame to change the state of the contactor device so that it switches between a series connection state and a parallel connection state. In addition, in this case, the connecting busbar and / or the auxiliary connecting busbar can optionally have a deflectable contact area, which can be moved in addition to moving the connecting frame when the at least one actuating element changes the state of the contactor device.

[0015] In order to reduce the contact resistance in the series connection state and the parallel connection state, each second busbar preferably includes a plurality of contact elements arranged on different sides of the second busbar, and each second busbar is preferably configured to be conductively coupled to the connecting busbar at the contact side of the second busbar, and the contact side of the second busbar is different from the contact side for conductive coupling to one of the first busbars. For example, the contact side of the second busbar for contacting the connecting busbar can be arranged on the second busbar opposite to the contact side for contacting one of the first busbars. In other words, the connecting busbar can be formed by a double-sided silver buckle busbar group, wherein the silver buckle can reduce the contact resistance in the series connection state and the parallel connection state.

[0016] In another advantageous example, at least one actuating element comprises a dedicated actuator for changing the state of the contactor device so that it switches between the series connection state and the parallel connection state. In this way, the dedicated actuator can be optimized to provide an effective force transition when changing the state of the contactor device between the series connection state and the parallel connection state.

[0017] In another advantageous example, the contactor device may further include two third busbars, wherein one of the third busbars is electrically connected to the other of the second terminals, and the other of the third busbars is electrically connected to the other of the third terminals, and wherein at least one actuating element is configured to change the state of the contactor device so that it switches between a closed state and an open state, in which each third busbar is conductively coupled to a corresponding one of the first busbars, and in which the two third busbars and the two second busbars are electrically isolated from the two first busbars. In this way, the contactor device also allows current to be prevented from flowing through the contactor device in the open state. Therefore, in this example, the contactor device of the present disclosure allows at least three voltage levels of voltage to be applied between the two first contacts, namely, zero voltage in the open state, full battery voltage in the series connection state (and the closed state), and a voltage corresponding to the module voltage of the battery module forming the battery in the parallel connection state (and the closed state).

[0018] According to another advantageous example, each third busbar may include a deflectable contact area that is elastically deflectable between an open position and a closed position, in which each third busbar is electrically isolated from the two first busbars, and in the closed position, each of the two third busbars is conductively coupled to a corresponding one of the first busbars. In this way, the transition force provided by at least one actuating element for changing the state of the contactor device from the open state to the closed state can be effectively transmitted because it does not require the second busbar to be moved as a whole. In an alternative example, the third busbar can be moved as a whole between the open position and the closed position.

[0019] In order to prevent current from flowing through the contactor device, when the contactor device is powered off, when at least one actuating element is not powered, the contactor device can be in an open state. For example, this can be achieved by using at least one electromagnetic actuator to change the state of the contactor device from an open state to a closed state. Then, the same or different electromagnetic actuators can also be used to change the state of the contactor device so that it switches between a series connection state and a parallel connection state.

[0020] In another advantageous example, the state of the contactor device can be changed only when at least one actuating element is energized. In this way, the contactor device allows providing a bistable state, and when at least one actuating element is suddenly de-energized (for example due to a single point failure, another damage event or a communication error), the state of the contactor device does not change, but the contactor device remains in its previous state. For example, this can be achieved by using a linear motor actuator, which remains in its position when not energized, as an actuating element for changing the state of the contactor device from an open state to a closed state. The same or a second linear motor actuator can also be used to change the state of the contactor device, so that it switches between a series connection state and a parallel connection state.

[0021] In another advantageous example, the contactor device optionally includes at least one pyrotechnic actuator, which is configured to irreversibly prevent current from flowing through each first busbar when activated. Therefore, the contactor device can also integrate the function of an overcurrent protection device, because the pyrotechnic actuator can be activated in the event of an overcurrent in the energy storage system or other faults in the energy storage system, and then the current through the contactor device can be cut off within a reaction time in the range of a few milliseconds.

[0022] Preferably, at least one pyrotechnic actuator can be configured to move the two first busbars to an ignition position after activation, wherein in the ignition position, each of the two first busbars is irreversibly displaced or cut off. This arrangement has the advantage that at least one actuator configured for conventional operation of the contactor device and a pyrotechnic actuator configured for safe operation of the contactor device can be designed and operated independently of each other. Therefore, the force generated by the pyrotechnic actuator can be fully used to displace or cut off the two first busbars, and contact separation at a faster speed and a greater distance can be achieved. In addition, the possibility of two actuating mechanisms failing at the same time is small, thereby improving the operational reliability of the contactor device.

[0023] Furthermore, the contactor device may further comprise at least one arc suppression element which may control the development of the arc when the two first busbars are irreversibly displaced or cut by igniting the pyrotechnic actuator. The arc suppression element may, for example, comprise one or more mechanical devices, such as an array of arc splitters or arc extinguishing magnets. Alternatively or additionally, the arc suppression element may further comprise a gas generator charge which is ignited when the pyrotechnic actuator is activated in order to generate a gas which cools the arc or mixes the arc with air.

[0024] In another advantageous example, at least one pyrotechnic actuator can be configured to irreversibly drive at least one isolating element to an ignition position when activated, wherein in the ignition position, the isolating element electrically isolates the two third busbars and the two first busbars from each other. In this way, the isolating element irreversibly driven between the two third busbars and the two second busbars can irreversibly prevent current from flowing through the contactor device and can simultaneously function as an arc suppression element.

[0025] In order to provide a particularly effective solution for arc suppression when the two third busbars and the two second busbars are separated, the isolating element can, for example, comprise at least two isolating caps, wherein in the ignition position each of the at least two isolating caps completely surrounds the contact area of ​​a respective one of the first busbars.

[0026] The present invention also relates to an energy storage system comprising a battery formed by at least a first battery module and a second battery module and a contactor device according to the present disclosure, wherein the first battery module is electrically connected to two second terminals of the contactor device and the second battery module is electrically connected to a third terminal of the contactor device. The energy storage system can, for example, be arranged in a vehicle for powering an electric motor of the vehicle. Alternatively, the energy storage system can be a fixed energy storage system, for example for storing renewable or conventionally generated energy.

[0027] In this document, the term "terminal" refers to the point from which an electronic device, circuit or electronic component terminates, as well as a point provided for electrically connecting an external electronic device, an external circuit or an external electronic component to the conductor. In addition, the terms "electrically connect" and "conductively couple" describe the establishment of an electrical connection between at least two electronic devices, electronic components or electrical conductors, thereby allowing current to flow. Therefore, electrical connection should not be limited to the direct coupling of terminals of at least two electronic devices, electronic components or electrical conductors, but other electronic devices, electronic components or electrical conductors may be coupled between them. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings are incorporated into the specification and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the specification, are used to explain the principles of the present disclosure. The drawings are only used to illustrate how to make and use the preferred and alternative examples of the present disclosure, and should not be interpreted as limiting the present disclosure to only the examples shown and described. In addition, several aspects of the examples can form solutions according to the present disclosure alone or in different combinations. Therefore, the examples described below can be considered alone or in any combination. As shown in the drawings, further features and advantages will become apparent from the following more specific description of various examples of the present disclosure, in which similar references refer to similar elements, and in which:

[0029] Figure 1 shows a schematic circuit diagram of an exemplary high voltage energy storage system;

[0030] Figure 2 A schematic perspective view showing a first exemplary contact arrangement in a series connection state of a contactor device;

[0031] Figure 3 shows a schematic side view of a first exemplary contact arrangement in a series connection state of a contactor device;

[0032] Figure 4 shows a schematic perspective view of a first exemplary contact arrangement in a parallel connection state of a contactor device;

[0033] Figure 5 shows a schematic side view of a first exemplary contact arrangement in a parallel connection state of a contactor device;

[0034] Figure 6 shows a schematic perspective view of a first exemplary contact arrangement in an open state of a contactor device;

[0035] Figure 7 shows a schematic side view of a first exemplary contact arrangement in an open state of a contactor device;

[0036] Figure 8a schematic perspective view showing a second exemplary contact arrangement in a series connection state of a contactor device;

[0037] Fig. 9 shows a schematic cross-sectional view of a second exemplary contact arrangement in a series connection state of a contactor device;

[0038] Fig.10 shows a schematic perspective view of a second exemplary contact arrangement in a parallel connection state of a contactor device;

[0039] Fig.11 shows a schematic cross-sectional view of a second exemplary contact arrangement in a parallel connection state of a contactor device;

[0040] Fig.12 a schematic perspective view showing a second exemplary contact arrangement in an open state of a contactor device;

[0041] Fig.13 shows a schematic cross-sectional view of a second exemplary contact arrangement in an open state of a contactor device;

[0042] Fig.14 shows another schematic perspective view of a second exemplary contacting device;

[0043] Fig.15 shows another schematic perspective view of a second exemplary contacting device;

[0044] Fig.16 shows a schematic perspective view of a second exemplary contactor apparatus;

[0045] Fig.17 showing a schematic side view of a second exemplary contactor device in an open position of the second exemplary contactor device;

[0046] Fig.18 showing a schematic side view of a second exemplary contactor device in a closed position of the second exemplary contactor device;

[0047] Fig.19 shows a schematic side view of an exemplary actuation element;

[0048] Fig. 20 shows another schematic side view of an exemplary actuation element;

[0049] Fig.21 shows a schematic top view of a second exemplary contactor apparatus;

[0050] Fig. 22 shows another schematic top view of a second exemplary contactor apparatus;

[0051] Fig.23 shows a cross section of an exemplary isolation element;

[0052] Fig.24 Another schematic cross-section of an exemplary isolation element is shown.

[0053] The present disclosure will now be further explained with reference to the accompanying drawings and first with reference to Figure 1 . Figure 1 A schematic circuit diagram of an exemplary high-voltage energy storage system 10 that can benefit from the ideas of the present disclosure is shown. In the application scenario described below as an example, the energy storage system 10 can be used in an electric vehicle as a power source for an electric load (such as an electric motor) powered at a predetermined high voltage. However, the energy storage system 10 can also be used in other application scenarios that require storing and / or supplying high-voltage energy in multiple battery modules that form a battery for supplying a predetermined high voltage. DETAILED DESCRIPTION

[0054] The energy storage system 10 includes a contactor device 100 and first and second battery modules (or battery packs) 502(1) and 502(2) forming a high voltage battery 500. Figure 1 Alternatively to the illustrated example, the number of battery modules 502(1) and 502(2) forming the battery 500 may be greater than two, and thus the number of battery modules 502 forming the high voltage battery is generally N, where N is a natural number and is greater than or equal to 2. Since the battery modules 502(1) and 502(2) are subunits of the high voltage battery 500, they provide module voltages, the sum of which is a predetermined high voltage that can be output by the high voltage battery 500 to the high voltage bus 105. The value of the module voltage provided by each battery module 502 can be obtained by dividing the predetermined high voltage value output from the high voltage battery 500 by N, where N can be the number of battery modules 502. For example, when the battery 500 outputs a predetermined high voltage value of 800V and N=2, the battery modules 502 share and output a module voltage of (800V / 2)=400V. On a smaller scale, each battery module 502 includes a plurality of battery cells electrically connected in series. Thus, a battery cell may be a physical battery cell, or may comprise several physical battery cells electrically connected in parallel on a cell level.

[0055] As from Figure 1It can be seen that the contactor device 100 is configured to electrically connect the high-voltage battery 500 to the high-voltage bus 105, which may be electrically connected to the electric motor of the electric vehicle for supplying a predetermined high voltage, or may be connected to a charger for charging the high-voltage battery 500. Therefore, the contactor device 100 allows the voltage applied by the high-voltage battery 500 to the high-voltage bus 105 to be changed according to the state of the contactor device, as will be described below.

[0056] The contactor device 100 includes load-side terminals 102 and 104 (also referred to as “first terminals”) for electrically connecting a high potential side (+) and a low potential side (−) of a high voltage bus 105 .

[0057] In addition, the contactor device 100 includes terminals 108 and 110, which can be electrically connected to the terminals of the battery module 502, which correspond to the terminals of the high voltage battery 500 on the high potential side (+) and the low potential side (-), respectively. Figure 1 , the terminal 108 is electrically connected on the low potential side to the terminal 504 of the high voltage battery 500, which corresponds to the low potential side terminal of the battery module 502 (1) arranged at the low potential side of the high voltage battery 500. In other words, the terminal 504 of the high voltage battery 500 corresponds to Figure 1 The low potential side terminal of the battery module 502 (1). Figure 1 , the terminal 110 is electrically connected on the high potential side to the terminal 506 of the high voltage battery 500, which corresponds to the high potential side terminal of the battery module 502 (2) arranged on the high potential side of the high voltage battery 500. In other words, the terminal 506 of the high voltage battery 500 corresponds to Figure 1 The high potential side terminal of the middle battery module 502 ( 2 ).

[0058] In addition, the contactor device 100 includes terminals 106 and 112, which can be electrically connected to the remaining terminals 508 and 510 of the battery modules 502 (1) and 502 (2), which are terminals other than the terminals 504 and 506, and which correspond to the terminals of the high voltage battery 500 on the high potential side (+) and the low potential side (-), respectively. Figure 1 In FIG. 1 , the terminal 106 of the contactor device 100 is electrically connected to the high potential side terminal 508 of the battery module 502 ( 1 ), which is arranged on the low potential side of the high voltage battery 500 . Figure 1 , the terminal 112 is electrically connected to a low potential side terminal 510 of the battery module 502 ( 2 ), which is arranged on the high potential side of the high voltage battery 500 .

[0059] In other words, the contactor device 100 includes two terminals 106 and 108 ("second terminals") for electrically connecting the terminals 504 and 508 of the first battery module 502 (1), wherein the low potential side terminal 504 of the first battery module 502 (1) corresponds to the terminal 504 of the high voltage battery 500 on the low potential side. In addition, the contactor device 100 includes two terminals 110 and 112 ("third terminals") for electrically connecting the terminals 506 and 510 of the second battery module 502 (2), wherein the high potential side terminal 506 of the second battery module 502 (2) corresponds to the terminal 506 of the high voltage battery 500 on the high potential side.

[0060] Now refer to Figures 2 to 7 A first example of the contactor device 100 is described. Figures 2 to 7 Each shows a first example of a contact device 120 of a contactor device 100 in different states of the contactor device 100. In particular, Figure 2 and Figure 3 The contact device 120 of the contactor device 100 is shown in a series connection state. Figure 4 and Figure 5 The contact device 120 of the contactor device 100 is shown in a parallel connection state, and Figure 6 and Figure 7 The contact device 120 of the contactor system 100 is shown in an open state.

[0061] exist Figures 2 to 7 In the example shown, the contact device 120 includes two contacts 122 and 124, each of which may include two movable busbars (or "third busbars") 126, 127 and two fixed busbars (or "first busbars") 128, 129, so that the contactor device 100 can be used as a 2-pole single-break contactor. Here, the functions of each fixed busbar 128, 129 and each movable busbar 126, 127 are mirrored. However, it should be noted here that the number of two movable busbars 126, 127 and two fixed busbars 128, 129 is not limited to the present disclosure, but the present disclosure is applicable to contactor devices having more than two contacts 122, 124, and therefore also applicable to contactor devices having more than two movable busbars 126 and 127 and more than two fixed busbars 128 and 129.

[0062] The movable busbars 126, 127 and the fixed busbars 128, 129 can preferably be formed of a metal material such as copper or its alloys, however, other suitable conductive materials known in the art may also be used, and these conductive materials support a continuous current of 500A or more, a current peak of up to 5kA for at least 1 second, or a current peak of up to 10kA or more for at least 50ms through the movable busbars 126, 127 and the fixed busbars 128, 129.

[0063] Preferably, the movable busbars 126, 127 may be formed by flexible busbars, which include rigid regions 130, 131 and flexible regions 132, 133. Figure 6 and Figure 7 as shown) and the closed position (as Figures 2 to 5 , 133) between the rigid regions 130, 131 and the flexible regions 132, 133. When the movable busbars 126, 127 are moved between the open position and the closed position, the rigid regions 130, 131 hardly move, and the flexible regions 132, 133 are able to elastically deflect between the open position and the closed position. Preferably, this can be achieved by forming a movable busbar 126, 127 of a multilayer structure at least in the flexible regions 132, 133, the multilayer structure including, for example, 10 to 15 layers of copper or other suitable conductive materials. In another example, the movable busbars 126, 127 can be composed of fixed busbars in the rigid regions 130, 131 and movable busbars in the flexible regions 132, 133, which can, for example, perform rotational motion around a rotation axis to move the movable busbars 126, 127 between the open position and the closed position. Alternatively, when the movable busbars 126, 127 move between the open position and the closed position, they can move as a whole.

[0064] In the first example of the contactor device 100, the movable busbar 126 is electrically connected to the terminal 110 electrically connected to the terminal 506 of the high-voltage battery 500 at the high potential side of the high-voltage battery 500, that is, the high-voltage side terminal 506 of the battery module 502(2), and the fixed busbar 128 is electrically connected to the load side terminal 104 electrically connected to the high potential side of the high-voltage bus 105. The movable busbar 127 is electrically connected to the terminal 108 electrically connected to the terminal 504 of the high-voltage battery 500 at the low potential side of the high-voltage battery 500, that is, the low potential side terminal 504 of the battery module 502(1), and the fixed busbar 129 is electrically connected to the other of the load side terminals 102 electrically connected to the low potential side of the high-voltage bus 105.

[0065] Figures 2 to 5 The movable busbars 126, 127 are shown in a closed position, so that the movable busbars 126, 127 are conductively coupled to the fixed busbars 128, 129 at least at the first contact 134 of the contactor device. In order to reduce the contact resistance, a contact element 136, for example made of silver or any silver alloy, can be mounted to both the movable busbars 126, 127 and the fixed busbars 128, 129 in the region of the first contact 134. Of course, other suitable conductive materials can also be used to form the contact element 136.

[0066] In addition to allowing switching between a closed state of the contactor device 100 in which the movable busbars 126, 127 are in a closed position and an open state of the contactor device 100 in which the movable busbars 126, 127 are in an open position, the contactor device 100 also allows switching between a parallel connection state and a series connection state, in which at least two battery modules 502(1) and 502(2) can be connected in parallel to the high-voltage bus 105, and in which the battery modules 502(1) and 502(2) can be connected in series to the high-voltage bus 105.

[0067] For this purpose, the contactor device 100 includes two second busbars 138 and 139 and a connecting busbar 144. In the first example of the contactor device 100, the second busbar 138 is electrically connected to the terminal 106, which is electrically connected to the high potential side terminal 508 of the battery module 502 (1) arranged on the low potential side of the high voltage battery 500. Similarly, in the first example, the second busbar 139 is electrically connected to the terminal 112, which is electrically connected to the low potential side terminal 510 of the battery module 502 (2) arranged on the high potential side of the high voltage battery 500.

[0068] The two second busbars 138, 139 and the connecting busbar 144 may be formed of the same material as the movable busbars 126, 127 and the fixed busbars 128, 129, and may be arranged at a level of the contactor device different from the level at which the movable busbars 126, 127 and the fixed busbars 128, 129 are arranged. Figures 2 to 7 As shown, the two second busbars 138, 139 may extend in the same direction as the contacts 122 and 124. However, the second busbars 138, 139 may also have different extending directions.

[0069] Preferably, the second busbars 138, 139 can be formed as a second group of movable busbars in the same manner as the movable busbars 126, 127. For example, the second group of busbars 138, 139 can include rigid regions 140, 141 and flexible regions 142, 143. Figure 2 and Figure 3 shown) and parallel connection position ( Figure 4 and Figure 5When moving between the series connection position and the parallel connection position, the rigid regions 140, 141 hardly move, and the flexible regions 142, 143 are able to elastically deflect between the series connection state and the parallel connection state. In another example, the second busbars 138, 139 may be composed of fixed busbars in the rigid regions 140, 141 and movable busbars in the flexible regions 142, 143, which may be moved, for example, in a rotational motion around a rotation axis to move the second busbars 138, 139 between the series connection position and the parallel connection position. Alternatively, the second busbars 138, 139 may move as a whole when moving between the series connection position and the parallel connection position.

[0070] The connecting busbar 144 may be formed, for example, by a rigid busbar that is fixed to the contact device 120 at a position electrically isolated from the movable busbars 126, 127 and the fixed busbars 128, 129 that form the contacts 122 and 124. Preferably, the connecting busbar 144 extends in a direction substantially perpendicular to the extension direction of the second busbars 138, 139 and substantially perpendicular to the flexible regions 142, 143. However, other extension directions of the connecting busbar 144 are also possible, as long as the second busbars 138, 139 can be conductively coupled to the connecting busbar 144.

[0071] Figure 2 and Figure 3 The contactor device 100 is shown in a series connection state, wherein the second busbars 138 and 139 are in a series connection position, and each of the second busbars 138 and 139 is conductively coupled to the connecting busbar 144 at the second contact 146. Therefore, in this state, the second busbar 138 and the second busbar 139 are electrically connected in series. In other words, in the series connection state, the contactor device 100 allows current to flow from the second busbar 138 to the second busbar 139, and vice versa, and the second busbars 138 and 139 are at the same potential. On the other hand, in the series connection state, the second busbars 138 and 139 are electrically isolated from the movable busbars 126, 127 and the fixed busbars 128, 129.

[0072] Therefore, in the series connection state of the contactor device 100, the terminals 106 and 112 electrically connect the battery modules 502(1) and 502(2) in series by providing a conductive path through the second busbars 138 and 139, both of which are conductively coupled to the connecting busbar 144. Therefore, a predetermined high voltage of the battery 500 (which is the sum of the module voltages of the battery modules 502(1) and 502(2)) can be applied to the high voltage bus 105 by conductively coupling the movable busbars 126, 127 and the fixed busbars 128, 129 (i.e., closing the contacts 122 and 124).

[0073] In order to reduce the contact resistance between the second busbars 138, 139 and the connecting busbar 144, a contact element 148 made of, for example, silver or any silver alloy can be mounted to the first contact side of the second busbars 138, 139 and to the connecting busbar 144 in the region of the second contact point 146. Of course, other suitable conductive materials can also be used to form the contact element 146.

[0074] Figure 4 and Figure 5 The contactor device 100 is shown in a parallel connection state, wherein the second busbars 138 and 139 are simultaneously in a parallel connection position at the third contact 150. Therefore, in this state, the second busbar 138 is electrically connected in parallel with the movable busbar 126, and the second busbar 139 is electrically connected in parallel with the movable busbar 127. In other words, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 138 to the movable busbar 126 and the fixed busbar 128, and vice versa, and the second busbar 138, the movable busbar 126, and the fixed busbar 128 are at the same potential. Similarly, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 139 to the movable busbar 127 and the fixed busbar 129, and vice versa, and the second busbar 139, the movable busbar 127, and the fixed busbar 129 are at the same potential. On the other hand, in the parallel connection state, the second bus bars 138 and 139 are electrically isolated from the connection bus bar 144 .

[0075] Therefore, in the parallel connection state of the contactor device 100, the terminals 106 and 112 electrically connect the battery modules 502(1) and 502(2) in parallel by providing a conductive path from the terminal 106 through the second busbar 138 to the fixed busbar 128 and a conductive path from the terminal 112 through the first connecting contact 139 to the fixed busbar 129. Therefore, the voltage generated by the parallel electrically connected battery modules 502(1) and 502(2) can be applied to the high voltage bus 105 by conductively coupling the movable busbars 126, 127 and the fixed busbars 128, 129 (i.e., closing the contacts 122 and 124). Ideally, for the case where the two battery modules 502(1) and 502(2) are electrically connected to the contactor device 100, the generated voltage is half of the predetermined high voltage of the high voltage battery 500, and for example, when the battery 500 outputs a predetermined high voltage value of 800V, the generated voltage is 400V.

[0076] In order to reduce the contact resistance in the parallel connection state, a contact element 152 made of, for example, silver or any silver alloy can be installed on the second contact side of the second busbars 138, 139 for contacting the fixed busbars 128, 129 and mounted to the fixed busbars 128, 129 in the area of ​​the third contact 150. Of course, other suitable conductive materials can also be used to form the contact element 138.

[0077] Therefore, by providing at least partially movable second busbars 138 and 139 and a connecting busbar 144, the present disclosure allows for distinguishing two additional states when the contactor device is in a closed state, namely a series connection state and a parallel connection state, in which the two battery modules 502(1) and 502(2) can be electrically connected in series, and in the parallel connection state, the two battery modules 502(1) and 502(2) can be electrically connected in parallel.

[0078] Figure 6 and Figure 7 The contactor device 100 is shown in an open state, wherein the movable busbars 126, 127 are in an open position and are electrically isolated from the fixed busbars 128 and 129. The second busbars 138 and 139 are conductively coupled to the connecting busbar 144 and are therefore also electrically isolated from the fixed busbars 128, 129. Therefore, in the open state of the contactor device 100, no voltage is applied to the fixed busbars 128, 129.

[0079] In order to move the movable busbars 126 and 127 between the open position and the closed position, and in order to move the second busbars 138 and 139 between the series connection position and the parallel connection position, the contactor device 100 includes at least one actuator ( Figures 2 to 7 ). Therefore, the movable busbars 126 and 127 and the second busbars 138 and 139 can be moved individually by the same actuator to change the state of the contactor device, or a dedicated first actuator can be provided to move the two movable busbars 126 and 127 individually, and a dedicated second actuator can be provided to move the second busbars 138 and 139 individually. Figures 16 to 20 Possible configurations of at least one actuator provided in the contactor 100 are described.

[0080] Now refer to Figures 8 to 13 A second example of a contact arrangement 220 of the contactor device 100 is described. The second exemplary contact arrangement 220 differs from the first exemplary contact arrangement 120 in that the connecting busbar 144 is movably arranged on a connecting frame that is movable to place the contactor device 100 in a parallel connection state or a series connection state.

[0081] In particular, Figure 8 and Fig. 9 FIG. 2 shows the contact device 220 of the contactor device 100 in a series connection state. Fig.10 and Fig.11 FIG. 2 shows the contact 220 of the contactor device 100 in a parallel connection state, and FIG. Fig.12 and Fig.13 The contact device 220 of the contactor 100 is shown in the open state.

[0082] In contrast to the first example, in the contact device 220, the fixed busbar 128 is electrically connected to the terminal 110, which is electrically connected to the terminal 506 of the high-voltage battery 500, that is, the high-potential side terminal 506 of the battery module 502 (2) at the high-potential side of the high-voltage battery 500. The fixed busbar 128 can be conductively coupled to the movable busbar 126 at the first contact point 134, and the movable busbar 126 can be electrically connected to the load-side terminal 104 of the contactor device 100.

[0083] The fixed busbar 129 is electrically connected to the terminal 108, and the terminal 108 is electrically connected to the terminal 504 of the high-voltage battery 500 at the low potential side of the high-voltage battery 500, that is, the low potential side terminal 504 of the battery module 502 (1). The fixed busbar 129 can be conductively coupled to the movable busbar 127 at the first contact 134, and the movable busbar 127 can be electrically connected to the load side terminal 102 of the contactor device 100. However, the contact device 220 does not necessarily include the movable busbars 126, 127, but the fixed busbar 128 can be directly electrically connected to the load side terminal 104, and the fixed busbar 129 can be directly electrically connected to the load side terminal 102.

[0084] In addition, the contact device 220 includes two second busbars 238 and 239 and a connecting busbar 144. The second busbar 238 is electrically connected to the terminal 106, which is electrically connected to the high potential side terminal 508 of the battery module 502 (1) arranged at the low potential side of the high voltage battery 500. The second busbar 239 is electrically connected to the terminal 112, which is electrically connected to the low potential side terminal 510 of the battery module 502 (2) arranged at the high potential side of the high voltage battery 500.

[0085] The two second busbars 238, 239 and the connecting busbar 144 may be formed of the same material as the fixed busbars 128, 129, and the two second busbars 238 and 239 may be arranged at the same level of the contactor device 100 as the fixed busbars 128, 129. Figures 8 to 13 As shown, the two second busbars 238 , 239 may extend in the same direction as the fixed busbars 128 and 129 , but may also have different extending directions.

[0086] In the second example, the second busbars 238, 239 can be formed in the same manner as the fixed busbars 128, 129, i.e. as a second set of fixed busbars. The connecting busbar 144 can be formed, for example, by a rigid busbar that is fixed to the bottom plate 256 of the movable connecting frame 254. Therefore, the connecting busbar 144 is mounted on the bottom plate 256 in such a manner that when the connecting busbar 144 is in a series connection position by moving the connecting frame 254, the connecting busbar 144 can be conductively coupled to each of the second busbars 238 and 239. Preferably, the connecting busbar 144 extends in a direction substantially perpendicular to the extension direction of the second busbars 238, 239. However, other extension directions of the connecting busbar 144 are also possible, as long as the second busbars 238, 239 can be conductively coupled to the connecting busbar 144.

[0087] Furthermore, the contact device 220 comprises two auxiliary connecting busbars 258 and 260, which can be formed by rigid busbars similar to the connecting busbar 144. Each auxiliary connecting busbar 258 and 260 can be formed by a rigid busbar, for example, which is fixed to the bottom side of the cover plate 262 of the movable connecting frame 254. Therefore, the auxiliary connecting busbars 258 and 260 are mounted to the bottom side of the cover plate 262 in such a way that when the auxiliary connecting busbars 258 and 260 are brought into the parallel connection position by moving the connecting frame 254, the auxiliary busbar 258 can be conductively coupled to each of the second busbar 238 and the fixed busbar 128, and the auxiliary busbar 260 can be conductively coupled to each of the second busbar 239 and the fixed busbar 129. Preferably, the auxiliary connecting busbars 258 and 260 extend in a direction substantially perpendicular to the extension direction of the second busbars 238, 239. However, other extension directions of the auxiliary connecting busbars 258 , 260 are also possible as long as the second busbars 258 and 260 can be conductively coupled to the second busbar 238 and the fixed busbar 128 or the second busbar 239 and the fixed busbar 129 , respectively.

[0088] In order to allow simultaneous movement of the connecting busbar 144 and the two auxiliary connecting busbars 258 and 260, the connecting frame 254 may include side plates 264 and 266, which are mounted at opposite ends of the bottom plate 256 and the cover plate 262 and support the cover plate 262 to follow the movement of the bottom plate 254, and vice versa. With this configuration, the connecting frame 254 can surround the fixed busbars 128, 129 and the second busbars 238, 239 on four sides.

[0089] Figure 8 and Fig. 9The contact device 220 is shown when the connecting busbar 144 is in the series connection position, so that the contactor device 100 is in the series connection state. In the series connection position, by moving the connecting frame 254, the connecting busbar 144 is pressed against each of the second busbars 238 and 239, so that each of the second busbars 238 and 239 is conductively coupled with the connecting busbar 144 at the second contact 246. Therefore, in the series connection state of the contactor device 100, the second busbars 238 and 239 are electrically connected in series. On the other hand, in the series connection state, since the auxiliary connecting busbars 258 and 260 are moved away from the second busbars 238 and 239 by the connecting frame 254, the second busbars 238 and 239 are electrically isolated from the auxiliary connecting busbar 258. Therefore, the second busbars 238 and 239 are also electrically isolated from the fixed busbars 128, 129.

[0090] Therefore, in the series connection state of the contactor device 100, the terminals 106 and 112 electrically connect the battery modules 502(1) and 502(2) in series by providing a conductive path through the second busbars 238 and 239 conductively coupled to the connecting busbar 144. Therefore, a predetermined high voltage of the battery 500 (which is the sum of the module voltages of the battery modules 502(1) and 502(2)) can be applied to the high voltage bus 105 by conductively coupling the movable busbars 126, 127 and the fixed busbars 128, 129 at the first contact point 134.

[0091] In order to reduce the contact resistance between the second busbars 238, 239 and the connecting busbar 144, a contact element 248 made of, for example, silver or any silver alloy can be mounted to the first contact side of the second busbars 238, 239 and to the connecting busbar 144 in the region of the second contact point 246. Of course, other suitable conductive materials can also be used to form the contact element 246.

[0092] Fig.10 and Fig.11The contact device 220 is shown when the auxiliary connecting busbars 258 and 260 are in the parallel position at the same time, so that the contactor device 100 is in the parallel connection state. In the parallel connection position, the auxiliary connecting busbar 258 is pressed against the second busbar 238 and the fixed busbar 128 by moving the connecting frame, so that the auxiliary busbar 258 is conductively coupled with the second busbar 238 at the third contact 250, and conductively coupled with the fixed busbar 128 at the fourth contact 268. At the same time, the auxiliary connecting busbar 260 is pressed against the second busbar 239 and the fixed busbar 129 by moving the connecting frame, so that the auxiliary busbar 260 is conductively coupled with the second busbar 239 at the third contact 250, and conductively coupled with the fixed busbar 129 at the fourth contact 268. On the other hand, in the parallel connection state, the connection busbar 144 is moved away from the second busbars 238 and 239 by the connection frame 254 so that the second busbars 238 and 239 are electrically isolated from the connection busbar 144 and from each other.

[0093] Therefore, in the parallel connection state, the second busbar 238 is electrically connected in parallel with the fixed busbar 128, and the second busbar 239 is electrically connected in parallel with the fixed busbar 129. In other words, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 238 to the fixed busbar 128 (through the auxiliary connection element 258), and vice versa, and the second busbar 138 and the fixed busbar 128 share the same potential. Similarly, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 239 to the fixed busbar 129 (through the auxiliary connection element 260), and vice versa, and the second busbar 239 and the fixed busbar 129 share the same potential. On the other hand, in the parallel connection state, the second busbars 238 and 239 are electrically isolated from the connecting busbar 144.

[0094] Therefore, in the parallel connection state of the contactor device 100, by providing a conductive path from the terminal 106 through the second busbar 238 and the auxiliary connecting element 258 to the fixed busbar 128, and a conductive path from the terminal 112 through the second busbar 239 and the auxiliary connecting element 260 to the fixed busbar 129, the terminals 106 and 112 electrically connect the battery modules 502 (1) and 502 (2) in parallel. Therefore, by conductively coupling the movable busbars 126, 127 and the fixed busbars 128, 129, the voltage generated by the parallel electrically connected battery modules 502 (1) and 502 (2) can be applied to the high-voltage bus 105. Ideally, for the case where the two battery modules 502 (1) and 502 (2) are electrically connected to the contactor device 100, the generated voltage is half of the predetermined high voltage of the high-voltage battery 500, and for example, when the battery 500 outputs a predetermined high voltage value of 800V, the generated voltage is 400V.

[0095] In order to reduce the contact resistance in the parallel connection state, a contact element 252 made of, for example, silver or any silver alloy can be mounted to the second contact side of the second busbars 238, 239 to contact the auxiliary connecting busbars 258 and 260, respectively, and mounted to the auxiliary connecting busbars 258 and 260 in the region of the third contact 250. A similar contact element 270 made of, for example, silver or any silver alloy can be mounted to the auxiliary connecting busbars 258 and 260, respectively, and mounted to the fixed busbars 258 and 260 in the region of the fourth contact 268. Of course, other suitable conductive materials can also be used to form the contact elements 252 and 270.

[0096] Fig.12 and 13 The contact device 220 is shown in an open state, wherein the connecting frame 254 is in the open position, so that the second busbars 238 and 239 are neither conductively coupled to the connecting busbar 144 nor conductively coupled to the auxiliary connecting busbars 258 and 260. Therefore, in the open position of the connecting frame 254, the second busbars 238 and 239 are electrically isolated from the fixed busbars 128 and 129, and at the same time the second busbars 238 and 239 are electrically isolated from each other, so that the electrical connection between the terminals 106 and 112 of the contactor device 100 is interrupted.

[0097] It is clear to those skilled in the art that, in the disconnected position of the connection frame 254, it is also necessary to interrupt the electrical connection between the terminal 506 at the high potential side of the high voltage battery 500 and the high potential side of the high voltage bus 105, and interrupt the electrical connection between the terminal 504 at the low potential side of the high voltage battery 500 and the low potential side of the high voltage bus 105. Fig.12 1, but for this purpose, the movable busbars 126 and 127 of the contact device can be moved to an open position, in which the movable busbars 126 and 127 are electrically isolated from the fixed busbars 128 and 129. Alternatively, the contactor device 100 can be used in combination with a second contactor device (for example, as described later). Fig.14 and Fig.15 As shown), and the second contactor device can enter a state in which the current between the high-voltage battery 500 and the high-voltage bus 105 is interrupted.

[0098] Therefore, by mounting the connecting busbar 144 and the auxiliary connecting busbars 258 and 260 to the connecting frame 254, the second exemplary contact device 220 of the contactor 100 allows two additional states, namely the series connection state and the parallel connection state, to be distinguished when the contactor device is in the closed state, wherein the state of the contactor device 100 can be changed by moving the connecting frame with an actuator. Therefore, the connecting frame 254 can be moved by the same actuator as the movable busbars 126 and 127 to change the state of the contactor device 100, or a dedicated actuator can be provided to move the connecting frame 254 alone. Reference will be made later to the second exemplary contactor device 300 and Figures 16 to 24 Thus, the configuration of the second exemplary contact device 220 makes it possible to set each of the connecting busbars 144, 258 and 260 and the two second busbars 238, 239 as fixedly mounted busbars and only move the connecting frame 254 to change the state of the contactor device 100.

[0099] In addition, if Figure 8 , Fig.10 and Fig.12 As shown schematically, the contactor device 100 may include a pyrotechnic actuator 280, which is configured to permanently interrupt the current flowing through the contactor device 100 when the pyrotechnic actuator 280 is triggered, as an additional safety mechanism for the contact device 220. Of course, a pyrotechnic actuator may also be used in the contact device 120. Reference will be made later to the second exemplary contactor device 300 and Figures 16 to 24 Possible implementations of the pyrotechnic actuator 280 , which may be implemented in the contact devices 120 and 220 , and possible contact-disconnection mechanisms performed by triggering the pyrotechnic actuator 280 are described.

[0100] Fig.14 and Fig.15 4 shows a contact device 220 conductively coupled to a second contactor device 400. Here, the contact device 220 has a parallel connection state ( Fig.14 ) and series connection state ( Fig.15 ) between the battery modules 502(1) and 502(2) of the battery 500. The second contactor device 400 may be any contactor device that has at least a function of switching between an open state and a closed state, in which the current is prevented from flowing from the battery 500 to the high-voltage bus 105, and in which the current may flow from the battery 500 to the high-voltage bus 105. For example, the contactor device described in detail in European patent application EP 20184037.8 may be used as the second contactor device 400.

[0101] Next, refer to Figures 16 to 24A second exemplary contactor device 300 is described. Therefore, elements of the contactor device 300 and elements of the contactor device 100 having substantially the same function are provided with similar reference numerals and identical or similar component names. The contactor device 300 differs from the first exemplary contact device 120 of the contactor device 100 in that the connecting busbar 144 and the two second busbars 138, 139 are missing, and differs from the first exemplary contact device 220 of the contactor device 100 in that the connecting frame 254, the corresponding connecting busbars 144, 258 and 260 and the two second busbars 238, 239 are missing.

[0102] Fig.16 A schematic perspective view of a contactor device 300 is shown, which preferably includes two fixed busbars 328 and 329 and two movable busbars 326 and 327, so that the contactor device 300 can be used as a 2-pole combination contactor and as a 2-pole single-break contactor under normal operating conditions. However, the number of two movable busbars and two fixed busbars is not essential for the function of the contactor device 300, but the contactor device 300 can have more than two movable contacts and fixed contacts, or one movable busbar and one fixed busbar. The fixed busbars 328 and 329 and the movable busbars 326 and 327 can form an exemplary embodiment of the fixed busbars 128, 129 and the movable busbars 126, 127 of the first contact device 120 and the second contact device 220, respectively, to which the remaining described parts can be added.

[0103] Fig.16 The movable busbars 326 and 327 are shown in a closed position, wherein each of the movable busbars 326 and 327 is conductively coupled to one of the fixed busbars 328 and 329, so that current can flow from the terminal 310 formed integrally with the movable busbar 326 to the terminal 304 formed integrally with the fixed busbar 328, and from the terminal 308 formed integrally with the movable busbar 327 to the terminal 302 formed integrally with the fixed busbar 329. The terminals 308 and 310 can be electrically connected to the terminals 504 and 506 of the high-voltage battery 500, and the terminals 302 and 304 can be electrically connected to the high-voltage bus 105, and vice versa. In order to reversibly connect and disconnect the current path through the contactor device 300, the contactor device 300 includes an electromagnetic actuator 372 that can reversibly move the movable busbars 326 and 327 between the closed position and the disconnected position.

[0104] In order to facilitate the reversible transition between the open position and the closed position, the movable busbars 326 and 327 are formed in such a way that they can be elastically deflected between the open and closed positions, at least in the flexible contact area 333. To this end, the movable busbars 326 and 327 can be formed by a multilayer structure, which includes, for example, 10 to 15 layers of copper or other suitable conductive materials. In addition, each of the movable busbars 326 and 327 can include a protrusion 374 for supporting the deflection ability of the movable busbars 326 and 327. The protrusion 374 can also help to apply a preload to the movable busbars 326 and 327, which pushes the movable busbars 326 and 327 toward the open position.

[0105] The electromagnetic actuator 372 is configured to hold the movable busbars 326 and 327 in a closed position when energized. To this end, each flexible contact area 333 in the movable busbars 326 and 327 can be individually moved by the electromagnetic actuator 372, for example, by a shaft 376, which is arranged on the top side of the movable busbars 326 and 327 in the flexible contact area 333. An additional spring element can be arranged around the shaft 376, which helps to absorb small misalignments or imbalances between the movable busbars 326 and 327 during operation of the contactor device 300 to prevent such misalignments from affecting the electromagnetic actuator 372 or greatly affecting the force applied between the fixed busbars 328 and 329 and the movable busbars 326 and 327. Therefore, tolerances between the fixed busbars 328 and 329 and the movable busbars 326 and 327 introduced during the manufacture of the contactor device 100 can be better compensated. In addition, a spring is located below each of the movable busbars 326 and 327, i.e., located on the bottom side of the movable busbars 326 and 327, and when the shaft 376 does not apply force, i.e., when the electromagnetic actuator 372 is not energized, the spring biases the movable busbars 326 and 327 to the disconnected position.

[0106] Fig.17The contactor device 300 is shown in a de-energized state, wherein the electromagnetic actuator 372 is not energized, so the movable busbars 326 and 327 are simultaneously in the disconnected position. Therefore, the contact elements 336 of the movable busbars 326 and 327 are electrically isolated from the contact elements 336 of the fixed busbars 328 and 329 by a spatial gap, thereby preventing current from flowing through the contactor device 300. Due to the design of the movable busbars 326 and 327, sufficient electrical isolation can be provided between the movable busbars 326 and 327 and the fixed busbars 328 and 329 even under normal atmosphere. Therefore, the need to provide the movable busbars 326 and 327 and the fixed busbars 328 and 329 in a sealed housing or to use an electronegative gas can be omitted, so that the contactor device 300 can be significantly simplified. However, at least a portion of the movable busbars 326 and 327 and the fixed busbars 328 and 329 can also be provided in the area around the contact element 336 in the sealed housing to enhance electrical isolation.

[0107] Fig.18 The contactor device 300 is shown in an energized state, with the movable busbars 326 and 327 in a closed position such that the contacts 336 of the movable busbars 327 and 326 are conductively coupled with the contacts 336 of the fixed busbars 328 and 329 .

[0108] In order to bring the movable busbars 326 and 327 from the open position to the closed position, the armature of the electromagnetic actuator 372 applies a closing force to the movable busbars 326 and 327, for example through the shaft 376, and pushes the movable busbars 326 and 327 along the direction of the closing force 378, that is, toward the fixed busbars 328 and 329.

[0109] For example, the contactor device 300 may be equipped with a linear motor actuator 472 instead of the electromagnetic actuator 372, the linear motor actuator 472 being actuated by, for example, Fig.19 and 20 The schematically shown drive shaft 476 causes the movable bus bars 326 and 327 to be in the disconnected position (eg Fig. 20 19). Here, the shaft 476 moves only when the linear motor actuator 472 is energized. In this exemplary embodiment, when the linear motor actuator 472 is energized, the linear motor actuator 472 moves the movable bus bars 326 and 327 only between the open position and the closed position, and when the linear motor actuator 472 is not energized, the movable bus bars 326 and 327 remain in the previous position. Therefore, the linear motor actuator 472 acts as a bistable actuator, which allows the open state and the closed state of the contactor device 300 to be introduced as a bistable state in which the contactor device 300 changes only when the linear motor actuator 472 is energized.

[0110] Thus, unlike a contactor device 300 having an electromagnetic actuator 372 (which is brought to an open state), when the electromagnetic actuator 372 experiences power loss (for example due to a damage event or due to loss of communication), the contactor device 300 can remain in a closed state (or open state) when the linear motor actuator 472 experiences power loss, thereby still being able to drive the electric vehicle after the power loss of the linear motor actuator 472.

[0111] Here, it should be noted that the actuator 372 and / or the actuator 472 may also be provided as an actuator in the first exemplary contact device 120 as one or more actuators for moving the movable busbars 126 and 127 between the open position and the closed position and / or for moving the second busbars 138 and 139 between the series connection position and the parallel connection position. Similarly, the actuator 372 or the actuator 472 may also be provided as an actuator in the second exemplary contact device 220 as one or more actuators for moving the connection frame 254 to change the state of the contactor device 100 and / or for moving the movable busbars 126 and 127 between the open position and the closed position.

[0112] Return to reference Fig.16 , it can be seen that the contactor device 300 also includes a pyrotechnic actuator 380, which is configured to permanently displace the fixed busbars 328 and 329 to an ignition position, wherein the fixed busbars 328, 329 are permanently electrically isolated from the movable busbars 326, 327 when triggered. Therefore, displacing the fixed busbars 328 and 329 can refer to displacing the fixed busbars 328 and 329 as a whole, or can refer to displacing the fixed busbars 328 and 329 at least in the contact area 379 (which includes the contact element 336) of the fixed busbars 328 and 329, for example, by irreversibly cutting off the fixed busbars 328 and 329, as described later. In this way, it can be prevented that after activation of the pyrotechnic actuator 380, the movable busbars 326 and 327 can still be conductively coupled to the fixed busbars 328 and 329. Thus, by activation of the pyrotechnic actuator 380 , the current flowing through the contactor device 300 may be permanently interrupted.

[0113] The pyrotechnic actuator 380 may include two or more pyrotechnic electrical terminals 382, ​​sometimes also referred to as pyrotechnic pins, which cause ignition of the pyrotechnic charge in response to receipt of an electrical control signal. The pyrotechnic charge may be an explosive that is directly ignited by the electrical control signal, or may be a gas generator charge that suddenly expands upon receipt of the electrical control signal. Alternatively, the pyrotechnic charge may have a multi-charge structure, including, for example, an initiator charge and an auxiliary gas generator charge.

[0114] The pyrotechnic electrical terminal 382 may be connected, for example, to a current sensing controller integrated in the contactor device 300, which is configured to detect the current flowing through the contactor device 300 in the closed position. When the detected current exceeds a predetermined threshold, which may be represented by a current level that is dangerous to the function of the contactor device 300, the current sensing controller may transmit an electrical control signal to ignite the pyrotechnic charge.

[0115] Alternatively, the pyrotechnic electrical terminal 382 may be connected to an external controller or a controller of the high voltage battery 500, such as a battery management system in the high voltage battery 500, which may provide an electrical control signal for triggering the pyrotechnic actuator 380, for example in response to detection of an overcurrent or fault in the energy storage system 10. The electrical control signal may also be received in response to a detected anomaly or fault in any other circuit component of the circuit to which the contactor device 300 is conductively coupled. Alternatively, the pyrotechnic electrical terminal 382 may be connected to an electronic control unit (ECU) or a collision sensor of a vehicle including the contactor device 300, and may receive an electrical control signal in response to detection of an accident of the vehicle.

[0116] The pyrotechnic actuator 380 also includes a piston structure 384 that can be driven away from its rest position by the force generated when the pyrotechnic charge is ignited. Under the force generated, the piston structure 384 drives a displacement element 386 supported in an actuator housing 388 of the pyrotechnic actuator 380 to simultaneously push the fixed busbars 328 and 329 to a firing position away from the movable busbars 326 and 327. For example, a stud or bolt driven by the energy of the piston structure 384 to displace or service the fixed busbars 328 and 329 can be used as the displacement element 386.

[0117] like Fig.16 As further shown, each fixed busbar 328 and 329 may include a hinge flexure 381 that may be disposed between the terminal 302 of the fixed busbar 329 and the contact element 336 and between the terminal 304 of the fixed busbar 328 and the contact element 336. When the pyrotechnic actuator 380 is triggered, the hinge flexure 381 allows the contact area 379 of the fixed busbars 328 and 329 to swing away from the movable busbars 326 and 327 in a well-defined manner. Thus, each hinge flexure 381 of the fixed busbars 328 and 329 provides an axis of mechanical movement around which the corresponding fixed busbars 328 and 329 rotate during movement to the ignition position. Thus, the position of the hinge flexure 381 of the fixed busbars 328 and 329 may be adjusted so as to change the swing radius of the contact area 381 of the fixed busbars 328 and 329. Therefore, the movement path of the fixed busbars 328 and 329 or at least the contact area 379 of the fixed busbars 328 and 329 from the normal position to the ignition position can be clearly defined.

[0118] When the piston structure 384 is in the rest position, before the pyrotechnic actuator 380 is triggered, the actuator housing 388 can also provide a space for accommodating the piston structure 384. The actuator housing 388 can also provide a piston stopper for stopping the piston structure 380 when the piston structure 380 reaches the end position and the fixed busbars 328 and 329 are in the ignition position. In this way, the contactor device 300 can provide a well-defined path for the piston structure 384. The actuator housing 388 can also provide a retaining device for keeping the piston structure 384 in the end position to prevent the piston structure 384 from moving back to the rest position after the pyrotechnic actuator is triggered. In this way, when the pyrotechnic actuator is activated, the piston structure 384 can help keep the fixed busbars 328 and 329 in the ignition position. Additionally or alternatively, the actuator housing 388 can also provide a retaining device for keeping the fixed busbars 328 and 329 in the ignition position.

[0119] The contactor device 300 may also include an arc suppression element to extinguish an arc that may be generated by a rapid interruption of a current-carrying path when the pyrotechnic actuator 380 is activated. For example, the contactor device 300 may include one or more arc extinguishing magnets that are used to control the development of the arc, or may include an array of arc splitters that are configured to split and cool the arc into multiple individual arcs with lower energy. Alternatively, the arc suppression element may include a mechanical device that may be inserted between the fixed busbars 328 and 329 and the movable busbars 326 and 327 when the pyrotechnic actuator 380 is activated. Alternatively or additionally, the arc suppression element may also include a gas generator charge that is ignited when the pyrotechnic actuator 380 is activated to generate a gas that cools the arc or mixes the arc with air.

[0120] The operation of the pyrotechnic actuator 380 will be described below with reference to Fig.21 and Fig. 22 To explain, Fig.21 and Fig. 22 A schematic top view of a contactor device 300 is shown. Fig.21 The contactor device 300 is shown in the closed position of the movable busbars 326 and 327 and in a state before the pyrotechnic actuator 380 is activated. The retaining force pointing in the direction 378 (i.e., from the contact element 336 of the movable busbars 326 and 327 toward the contact element 336 of the fixed busbars 328 and 329) retains the movable busbars 326 and 327 in the closed position. Fig.21 and Fig. 22 As shown by the cross 378 in FIG. 1 , the retaining force is directed toward the horizontal plane of the paper.

[0121] Fig. 22 FIG. 2 shows a top view of the contactor device 100 in a state where the pyrotechnic actuator 380 has been triggered. Fig. 22 In the figure, only the fixed busbar 329 is shown in the ignition position, but after the pyrotechnic actuator 380 is triggered, the fixed busbar 328 is also moved to the ignition position at the same time. The piston structure 384 is driven away from its static position by the force generated when the pyrotechnic charge is ignited. The generated force drives the displacement element to irreversibly move the fixed busbars 328 and 329 to the ignition position, wherein the fixed busbars 328, 329 are electrically isolated from the movable busbars 326, 327. As indicated by the arrow 390, the movement of the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 preferably occurs in a plane that is perpendicular to the direction 378 of the holding force applied to the movable busbars 326 and 327 by the electromagnetic actuator 372.

[0122] However, it is not important that the plane in which the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 move to the ignition position is perpendicular to the direction 378 of the retaining force, but the plane can only form a predetermined angle with the direction 378 so that the movement direction of the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 at least includes an angle relative to the movement direction of the movable busbars 326, 327 between the open position and the closed position.

[0123] In this way, it is ensured that the fixed busbars 328 and 329 can be moved to the ignition position without affecting the actuation mechanism for moving and holding the movable busbars 326 and 327 in the closed position. Similarly, the movement of the fixed busbars 328 and 329 into the ignition position is prevented from being affected by the actuation mechanism for moving and holding the movable busbars 326 and 327 in the closed position because the force generated by the pyrotechnic actuator 380 is transmitted to the fixed busbars 328 and 329 in such a way that it does not resist the force generated by the electromagnetic actuator 372 (or the linear motor actuator 472).

[0124] It should be noted that the movement of the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 into the ignition position is not limited to rotational movement, but the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 can also, for example, be moved linearly to the ignition position on a movement path that is independent of the movement path of the movable busbars 326 and 327 between the open position and the closed position.

[0125] Therefore, the contactor device 300 is capable of reversibly moving the movable busbars 326 and 327 between the open position and the closed position by controlling the operation of the electromagnetic actuator 372 (or the linear motor actuator 472). In addition, when the pyrotechnic actuator 380 is activated, the fixed busbars 328 and 329 are moved to the ignition position, thereby permanently displacing or cutting the fixed busbars 328 and 329 to permanently interrupt the current flowing through the contactor device 300. In other words, although the electromagnetic actuator 372 (or the linear motor actuator 472) is configured to reversibly move and hold the movable busbars 326 and 327 so as to reversibly change the conductive state of the contactor device 300, the pyrotechnic actuator 380 is configured to irreversibly move the fixed busbars 328 and 329 to the ignition position so as to irreversibly disconnect the current flowing through the contactor device 300. It is noteworthy that activation of the pyrotechnic actuator may be independent of the position of the movable busbars 326 and 327 and the electromagnetic actuator 372 (or linear motor actuator 472).

[0126] Fig.23 and Fig.24 Schematically shows an alternative contact separation mechanism that can be implemented in the contactor device 300, instead of mechanically moving the fixed busbars 328 and 329 to the ignition position. The mechanism is exemplarily shown for irreversibly separating the fixed busbar 328 and the movable busbar 326, but of course, the same separation mechanism can also be provided to irreversibly separate the fixed busbar 329 and the movable busbar 327. Here, the fixed busbar 328 preferably has a cylindrical cross-section and is at least partially surrounded by an electrical isolation layer 492 formed of an electrically insulating material.

[0127] In order to irreversibly separate the fixed busbar 328 from the movable busbar 326, the piston structure of the pyrotechnic actuator is not to drive the displacement element 386 to move the fixed busbar 328, but is configured to move the isolation cap 494 formed of an electrically insulating material from the normal position ( Fig.23 ) moves to the ignition position ( Fig.24 ).

[0128] like Fig.23 As shown, as long as the isolation cap 494 is in the normal position, that is, before the pyrotechnic actuator is triggered, the contact elements 336 of the movable busbar 326 and the fixed busbar 328 can be conductively coupled so that current flows through the contactor device 300, and the movable busbar 326 can move between the open position and the closed position. However, after the pyrotechnic actuator is triggered, the pyrotechnic piston drives the isolation cap 494 in the direction of the fixed busbar 328 (in the direction of the fixed busbar 328). Fig.23 and Fig.24496) until, in the firing position, the isolating cap 494 completely surrounds the end region of the fixed busbar 328. Thus, in the firing position, the isolating cap 494 is pushed between the contact elements 336 of the movable busbar 326 and the fixed busbar 328 and thus electrically isolates the movable busbar 326 and the fixed busbar 328 from each other.

[0129] In this way, the isolation cap 494 can interrupt the current flowing through the movable busbar 326 and the fixed busbar 328, and at the same time inhibit the formation of an arc. To this end, preferably, the isolation cap 494 completely surrounds the end region of the fixed busbar 328, which includes the contact element 336 and can overlap the electrical isolation layer 492. However, as long as the isolation cap provides sufficient electrical isolation between the movable busbar 326 and the fixed busbar 328, complete encapsulation of the end region is not necessary for the alternative contact separation mechanism.

[0130] Although not shown in the figure, two second busbars 138 and 139 and a connecting busbar 144 can be added to the contact device of the contactor device 300 to form Figures 2 to 7 The first exemplary contact device 120 is shown. Similarly, two second busbars 238 and 239 and a connecting frame 254 with corresponding connecting busbars 144, 258 and 260 can also be added to the contact device of the contactor device 300 to form Figures 8 to 13 The second exemplary contact arrangement 220 is shown. In other words, the contactor device 300 or individual components of the contactor device 300 can form the basis for building the contactor device 100, to which the additional components of the first exemplary contact arrangement 120 or the second exemplary contact arrangement 220 are added. Thus, for example, the two second busbars 138 and 139 can be formed similarly to the movable busbars 326 and 327 of the contactor device 300.

[0131] The present disclosure also relates to an energy storage system 10, which includes a contactor device 100 or a contactor device 300. The energy storage system 10 may be, for example, an energy storage device, which includes a contactor device 100 or a contactor device 300 and a battery 500. The energy storage system 10 may also include a controller or a battery management system that controls the operation of the battery 500 and the contactor device 100 or the contactor device 300, and may monitor the operating conditions of the energy storage system 10. For example, the controller or the battery management system may control at least one actuator of the contactor device 100 in response to a control signal provided by the controller or the battery management system to change the state of the contactor device 100 so that it switches between a series connection state and a parallel connection state, and / or between a disconnected state and a self-closing state. Similarly, the controller or the battery management system may control at least one actuator of the contactor device 300 in response to a control signal provided by the controller or the battery management system to at least change the state of the contactor device so that it switches between a closed state and a disconnected state. In addition, in the event of operation outside of safe operating conditions (unsafe operating conditions) (such as overcurrent, overheating of the battery 500, or an accident), the controller or battery management system can trigger the pyrotechnic actuator 380 (or 280) of the contactor device 300 (or contactor 100) by providing a corresponding control signal.

[0132] Reference Numbers

[0133]

[0134]

Claims

1. A contactor device (100), comprising: two first terminals (102, 104) for electrically connecting at least one of a load and a charger; Two second terminals (106, 108) for electrically connecting the first battery module (502(1)); two third terminals (110, 112) for electrically connecting to a second battery module (502(2)); two first busbars (128, 129), each first busbar being electrically connected to one of the first terminals (102, 104); two second busbars (138, 139; 238, 239), wherein one of the second busbars (138; 238) is electrically connected to one of the second terminals (106) and the other of the second busbars (139; 239) is electrically connected to one of the third terminals (112); a connecting busbar (144), the connecting busbar (144) being electrically isolated from the two first busbars (128, 129); and At least one actuating element, wherein the at least one actuating element is configured to at least change the state of the contactor device (100) so that it switches between a series connection state and a parallel connection state, wherein in the series connection state, the two second busbars (138, 139; 238, 239) are conductively coupled to the connecting busbar (144), and in the parallel connection state, one of the second busbars (138; 238) is conductively coupled to one of the first busbars (128), and the other of the second busbars (139; 239) is conductively coupled to the other of the first busbars (129).

2. The contactor device (100) according to claim 1, wherein: Each of the second busbars (138, 139) includes a deflectable contact area (142, 143), which is capable of elastically deflecting between a first position and a second position, in which each of the second busbars (138, 139) is conductively coupled to the connecting busbar (144), and in which each of the second busbars (138, 139) is conductively coupled to one of the first busbars (128, 129).

3. The contactor device (100) according to any one of claims 1 or 2, further comprising two auxiliary connecting busbars (258, 260), each of the auxiliary connecting busbars (258, 260) being configured to conductively couple one of the second busbars (238, 239) to a corresponding one of the first busbars (128, 129) in a parallel connection state of the contactor device (100).

4. The contactor device (100) according to claim 3, wherein: The connecting busbar (144) and the auxiliary connecting busbars (258, 260) are mounted to a connecting frame (254), and wherein the at least one actuating element is configured to move the connecting frame (254) to change the state of the contactor device (100) so that it switches between a series connection state and a parallel connection state.

5. The contactor device (100) according to any one of claims 1 to 4, wherein: Each of the second busbars (138, 139; 238, 239) includes a plurality of contact elements (148, 152; 248, 252) arranged on different sides of the second busbar (138, 139; 238, 239), and wherein each of the second busbars (138, 139; 238, 239) is configured to be conductively coupled to the connecting busbar (144) at a contact side of the second busbar (138, 139; 238, 239), the contact side of the second busbar (138, 139; 238, 239) being different from a contact side conductively coupled to one of the first busbars (128, 129).

6. The contactor device (100) according to any one of claims 1 to 5, wherein: The at least one actuating element comprises a dedicated actuator (372, 472) for changing the state of the contactor device (100) so that it switches between a series connection state and a parallel connection state.

7. The contactor device (100) according to any one of claims 1 to 6, further comprising two third busbars (126, 127), wherein: One of the third bus bars (126) is electrically connected to another of the second terminals (110), and another of the third bus bars (127) is electrically connected to another of the third terminals (108); and Wherein, the at least one actuating element is configured to change the state of the contactor device (100) so that it switches between a closed state and an open state, in which each of the third busbars (126, 127) is conductively coupled to a corresponding one of the first busbars (128, 129), and in which the two third busbars (126, 127) and the two second busbars (138, 139; 238, 239) are electrically isolated from the two first busbars.

8. The contactor device (100) according to claim 7, wherein: Each of the third busbars (126, 127) includes a deflectable contact area (132, 133), and the contact area (132, 133) is capable of elastically deflecting between an open position and a closed position, in which each of the third busbars (126, 127) is electrically isolated from the two first busbars (128, 129) and in which the two third busbars (126, 127) are conductively coupled to a corresponding one of the first busbars (128, 129).

9. The contactor device (100) according to claim 7 or 8, wherein: The contactor device is in the open state when the at least one actuating element is not energized.

10. The contactor device (100) according to any one of claims 1 to 8, wherein: The state of the contactor device changes only when the at least one actuating element is energized.

11. The contactor device (100) according to any one of claims 1 to 10, further comprising at least one pyrotechnic actuator (280, 380) which, when activated, is configured to irreversibly prevent current from flowing through each of the first busbars (128, 129).

12. A contactor device (100) according to any one of claims 7 to 11, wherein the contactor device (100) further comprises at least one pyrotechnic actuator (280, 380), which when activated is configured to move the two first busbars (128, 129) to an ignition position, wherein in the ignition position, each of the two first busbars (128, 129) is irreversibly displaced or cut off.

13. A contactor device (100) according to any one of claims 7 to 11, wherein the contactor device (100) further comprises at least one pyrotechnic actuator (280), which when activated is configured to irreversibly drive at least one isolating element to an ignition position, wherein in the ignition position, the isolating element electrically isolates the two third busbars (126, 127) from the two first busbars (128, 129) from each other.

14. The contactor device (100) according to claim 13, wherein: The isolating element comprises at least two isolating caps (494), wherein in the ignition position, each of the at least two isolating caps (494) completely surrounds a contact area of ​​a respective one of the first busbars (128, 129).

15. An energy storage system (10), comprising: A battery (500), the battery (500) being formed by at least a first battery module (502(1)) and a second battery module (502(2)); and The contactor device (100) according to any one of claims 1 to 14; Wherein, the first battery module (502(1)) is electrically connected to two second terminals (106, 108) of the contactor device (100), and the second battery module (502(2)) is electrically connected to the third terminal (110, 112) of the contactor device.

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