Contactor equipment and energy storage systems

Abstract

The present 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 series and parallel connections, and to an energy storage system (10) including the contactor device (100). The contactor device (100) includes 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) also includes two first buses (128, 129) and two second buses (138, 139; 238, 239) and a connecting bus (144), each of the first buses being electrically connected to one of the first terminals (102, 104); wherein one of the second buses (138; 238) is electrically connected to one of the second terminals (106), and the other of the second buses (139; 239) is electrically connected to one of the third terminals (112); the connecting bus (144) is electrically isolated from the two first buses (128, 129). At least one actuating element is configured to at least change the state of the contactor device (100) to switch between a series connection state and a parallel connection state, wherein in the series connection state, two second buses (138, 139; 238, 239) are electrically coupled to a connecting bus (144), and in the parallel connection state, a second bus (138; 238) is electrically coupled to a first bus (128), and another of the second buses (139; 239) is electrically coupled to another of the first buses (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 in a high-voltage energy storage system between series and parallel connections, and an energy storage system including the contactor device. Background Technology

[0002] Using contactor devices to connect and disconnect electronic circuits in energy storage systems is known in the prior art. With the advancement of electric vehicles (EVs) or hybrid electric vehicles (HEVs), high-voltage energy storage systems are becoming increasingly prevalent in automobiles. Because these high-voltage systems currently typically supply voltages between 400V and 1kV, and may even supply higher voltages in future applications, they pose a greater risk of electric shock than conventional powertrain systems. Therefore, preventing safety hazards and overcurrent protection are crucial for these systems. For example, ensuring the safety of vehicle passengers, roadside assistance personnel, or maintenance personnel is paramount in the event of a high-voltage energy storage system malfunction or a vehicle accident affecting the system's electronic circuitry.

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

[0004] Conventional contactor devices can reversibly change state between a closed state and an open state. In the closed state, current can flow through the contactor device, and in the open state, current flow is typically prevented by moving at least one movable contact. Furthermore, overcurrent protection devices (such as thermal fuses) can be used to reversibly disconnect the supply to a high-voltage energy storage system when activated, in cases where operating conditions in the energy storage system become unsafe (e.g., due to overcurrent or faults in the electronic circuitry of the energy storage system, or in the event of an accident involving a vehicle powered by energy stored in the energy storage system).

[0005] However, depending on the application using an energy storage system, it may be necessary to switch the contactor device not only between open and closed states. For example, the contactor device may be electrically connected to a high-voltage battery, which is the drive battery for EV or HEV vehicles. To provide a high voltage of 400V and at least 1kV to the motor of an EV or HEV vehicle in driving mode, multiple 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, because the battery voltage can be increased in this way, not all chargers or charging stations are able to charge such high-voltage batteries with the predetermined high voltage, and may only supply voltage levels lower than the predetermined high voltage, making it difficult to charge the high-voltage battery correctly.

[0006] Therefore, it is desirable to switch between a series connection state and a parallel configuration, where the series connection state connects multiple battery modules in series so that the high-voltage battery can, for example, supply the sum of the voltages of the multiple battery modules 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 a predetermined high voltage. Summary of the Invention

[0007] Therefore, the object of the present invention is to provide a contactor device that offers the possibility of changing the connection state of a high-voltage battery. Furthermore, the object of the present invention is to provide a simple and economical solution.

[0008] This objective is achieved through the subject matter of the independent claims. The advantageous aspects of this disclosure are the subject matter of the dependent claims.

[0009] Specifically, this disclosure provides a contactor device including 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 buses, two second buses, a connecting bus, and at least one actuating element. Each first bus is electrically connected to one of the first terminals, and one of the second buses is electrically connected to one of the second terminals. The connecting bus is electrically isolated from the two first buses, and the at least one actuating element is configured to at least change the state of the contactor device, switching it between a series connection state and a parallel connection state. In the series connection state, the two second buses are electrically coupled to the connecting bus. In the parallel connection state, one of the second buses is electrically coupled to one of the first buses, and the other of the second buses is electrically coupled to the other of the first buses.

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

[0011] In this way, the contactor device according to this disclosure allows for the supply of a predetermined high voltage to, for example, an electric motor in a series connection, while simultaneously allowing for the charging of a battery module at a voltage level lower than the predetermined high voltage in a parallel connection. Therefore, due to its simple configuration, the contactor device of this disclosure eliminates the need for complex switching structures between battery modules to allow for switching between series and parallel connections.

[0012] According to an advantageous example, each second busbar includes a deflectable contact area capable of elastically deflecting between a first position and a second position, in which each second busbar is electrically coupled to a connecting busbar, and in the second position, each second busbar is electrically coupled to one of the first buses. In this way, the changing force provided by at least one actuating element for altering the state of the contactor device can be efficiently transmitted because it does not require the entire second busbar to be moved. However, as in an alternative example, the second busbars can move as a whole between the first and second positions.

[0013] In another advantageous example, the contactor device may also include two auxiliary connecting buses, each configured to conductively couple one of the second buses to a corresponding one of the first buses in a parallel connection state of the contactor device. In this way, the contactor device may include only a fixed bus, which allows changing the state of the contactor device between a series connection state and a parallel connection state.

[0014] To allow for efficient force transmission when changing the state of the contactor device, the connecting bus and auxiliary connecting bus are preferably mounted on the connecting frame, and at least one actuating element is configured to move the connecting frame to change the state of the contactor device, switching it between a series connection state and a parallel connection state. Furthermore, in this configuration, the connecting bus and / or auxiliary connecting bus may optionally have a deflectable contact area that can move in addition to moving the connecting frame when at least one actuating element changes the state of the contactor device.

[0015] To reduce contact resistance in both series and parallel connection states, each second busbar preferably includes multiple contact elements arranged on different sides of the second busbar, and each second busbar is preferably configured to be electrically coupled to the connecting busbar at its contact side, which is different from the contact side used for conductive coupling to one of the first busbars. For example, the contact side of the second busbar used for contacting the connecting busbar can be arranged on the second busbar opposite to the contact side used for contacting one of the first busbars. In other words, the connecting busbar can be formed by a double-sided silver-button busbar assembly, wherein the silver button can reduce contact resistance in both series and parallel connection states.

[0016] In another advantageous example, at least one actuating element includes a dedicated actuator for changing the state of the contactor device, switching it between a series connection state and a parallel connection state. In this way, the dedicated actuator can be optimized to provide an efficient force transfer 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 buses, one of which is electrically connected to the other of the second terminals, and the other of the third buses is electrically connected to the other of the third terminals, wherein at least one actuating element is configured to change the state of the contactor device between a closed state and an open state, wherein in the closed state, each third bus is conductively coupled to a corresponding one of the first buses, and in the open state, the two third buses and the two second buses are electrically isolated from the two first buses. In this way, the contactor device also allows current to be prevented from flowing through the contactor device in the open state. Thus, in this example, the contactor device of this disclosure allows at least three voltage levels to be applied between the two first contacts: zero voltage in the open state, the full battery voltage in the series connection state (and the closed state), and a module voltage corresponding to 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 capable of elastically deflecting between an open position and a closed position. In the open position, each third busbar is electrically isolated from the two first buses, and in the closed position, each of the two third buses is conductively coupled to a corresponding one of the first buses. In this way, the transition force provided by at least one actuating element for changing the state of the contactor device from an open state to a closed state can be efficiently transmitted because it does not require the entire second busbar to be moved. In an alternative example, the third busbar may move as a whole between the open and closed positions.

[0019] To prevent current from flowing through the contactor device, the contactor device can be in an open state when it is de-energized, i.e., when at least one actuating element is not energized. This can be achieved, for example, by using at least one electromagnetic actuator to change the state of the contactor device from open to closed. Then, the same or different electromagnetic actuators can also be used to change the state of the contactor device, switching it between a series connection and a parallel connection.

[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 for bistable operation, and when at least one actuating element is suddenly de-energized (e.g., due to a single point of failure, another damaging event, or a communication error), the state of the contactor device does not change, but the contactor device remains in its previous state. This can be achieved, for example, by using a linear motor actuator that remains in its position when not energized, serving as the 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, transitioning it between a series connection state and a parallel connection state.

[0021] In another advantageous example, the contactor device may optionally include at least one pyrotechnic actuator that, when activated, is configured to irreversibly prevent current from flowing through each first bus. Therefore, the contactor device can also integrate the functionality of an overcurrent protection device, since the pyrotechnic actuator can be activated in the event of an overcurrent or other fault in the energy storage system, and can then interrupt the current through the contactor device within a reaction time of milliseconds.

[0022] Preferably, at least one pyrotechnic actuator can be configured, upon activation, to move both first buses to an ignition position, wherein in the ignition position, each of the two first buses is irreversibly displaced or disconnected. This arrangement has the advantage that at least one actuator configured for the conventional operation of the contactor device and a pyrotechnic actuator configured for the safety 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 utilized to displace or disconnect the two first buses, enabling contact separation at faster speeds and over greater distances. Furthermore, the likelihood of simultaneous failure of both actuators is lower, thereby improving the operational reliability of the contactor device.

[0023] In addition, the contactor device may also include at least one arc suppression element that controls the development of the arc when the two first buses are irreversibly displaced or cut off by the ignition pyrotechnic actuator. The arc suppression element may, for example, include one or more mechanical devices, such as an arc-splitting plate array or an arc-extinguishing magnet. Alternatively or additionally, the arc suppression element may also include a gas generator charge that is ignited when the pyrotechnic actuator is activated to generate a gas that cools the arc or mixes the arc with air.

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

[0025] To provide a particularly effective solution for arc suppression when the two third buses and the two second buses are separated, the isolation element may, for example, include at least two isolation caps, wherein, in the ignition position, each of the at least two isolation caps completely surrounds the contact area of ​​the corresponding one of the first buses.

[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 may, for example, be installed in a vehicle to power the vehicle's motor. Alternatively, the energy storage system may be a stationary energy storage system, for example, for storing renewable or conventionally generated energy.

[0027] In this document, the term "terminal" refers to a point where an electronic device, circuit, or electronic component terminates, and a point provided for electrically connecting an external electronic device, circuit, or electronic component to that conductor. Furthermore, the terms "electrical connection" and "conductive coupling" describe establishing an electrical connection between at least two electronic devices, electronic components, or electrical conductors, thereby allowing the flow of current. Therefore, an electrical connection should not be limited to the direct coupling of the terminals of at least two electronic devices, electronic components, or electrical conductors, but may couple other electronic devices, electronic components, or electrical conductors between them. Attached Figure Description

[0028] The accompanying drawings are incorporated into and form part of the specification to illustrate several examples of this disclosure. These drawings, together with the specification, serve to explain the principles of this disclosure. The drawings are only intended to illustrate preferred and alternative examples of how this disclosure is made and used, and should not be construed as limiting this disclosure to the examples shown and described. Furthermore, several aspects of the examples can form solutions according to this disclosure individually or in different combinations. Therefore, the examples described below can be considered individually or in any combination. As illustrated in the drawings, further features and advantages will become apparent from the following more specific description of various examples of this disclosure, wherein similar references refer to similar elements, and wherein:

[0029] Figure 1 A schematic circuit diagram of an exemplary high-voltage energy storage system is shown.

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

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

[0032] Figure 4 A schematic perspective view of a first exemplary contact device in a parallel connection state of contactor equipment is shown;

[0033] Figure 5 A schematic side view of a first exemplary contact device in a parallel connection state of contactor equipment is shown;

[0034] Figure 6 A schematic perspective view of a first exemplary contact device in the disconnected state of a contactor device is shown;

[0035] Figure 7 A schematic side view of a first exemplary contact device in the disconnected state of the contactor equipment is shown;

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

[0037] Figure 9 A schematic cross-sectional view of a second exemplary contact device in a series connection state of a contactor device is shown;

[0038] Figure 10 A schematic perspective view of a second exemplary contact device in a parallel connection state of contactor equipment is shown;

[0039] Figure 11 A schematic cross-sectional view of a second exemplary contact device in a parallel connection state of contactor equipment is shown;

[0040] Figure 12 A schematic perspective view of a second exemplary contact device in the disconnected state of the contactor equipment is shown;

[0041] Figure 13 A schematic cross-sectional view of a second exemplary contact device in the open state of the contactor device is shown;

[0042] Figure 14 Another schematic perspective view of the second exemplary contact device is shown;

[0043] Figure 15 Another schematic perspective view of the second exemplary contact device is shown;

[0044] Figure 16 A schematic perspective view of a second exemplary contactor device is shown;

[0045] Figure 17 A schematic side view of a second exemplary contactor device in the disconnected position is shown.

[0046] Figure 18 A schematic side view of a second exemplary contactor device in its closed position is shown.

[0047] Figure 19 A schematic side view of an exemplary actuating element is shown;

[0048] Figure 20 Another schematic side view of an exemplary actuating element is shown;

[0049] Figure 21 A schematic top view of a second exemplary contactor device is shown;

[0050] Figure 22 Another schematic top view of the second exemplary contactor device is shown;

[0051] Figure 23 A cross-section of an exemplary isolation element is shown;

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

[0053] This disclosure will now be further explained with reference to the accompanying drawings, and firstly with reference to... Figure 1 . Figure 1 A schematic circuit diagram of an exemplary high-voltage energy storage system 10 from which the ideas of this disclosure may be benefited is shown. In the application scenarios described below, the energy storage system 10 can be used in electric vehicles as a power source for an electric load (such as an electric motor) powered by a predetermined high voltage. However, the energy storage system 10 can also be used in other application scenarios where high-voltage energy needs to be stored and / or supplied in multiple battery modules that form a battery for supplying a predetermined high voltage. Detailed Implementation

[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 In an alternative to the example shown, the number of battery modules 502(1) and 502(2) forming battery 500 can be greater than two, so the number of battery modules 502 forming high-voltage battery is typically N, where N is a natural number and is greater than or equal to 2. Since battery modules 502(1) and 502(2) are sub-units of high-voltage battery 500, they provide module voltages whose sum is a predetermined high voltage that can be output by high-voltage battery 500 to 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 high-voltage battery 500 by N, where N can be the number of battery modules 502. For example, when battery 500 outputs a predetermined high voltage value of 800V and N=2, battery modules 502 share and output a module voltage of (800V / 2)=400V. On a smaller scale, each battery module 502 includes multiple battery cells electrically connected in series. Therefore, a battery cell can be a physical battery cell, or it can include several physical battery cells that are electrically connected in parallel at the cell level.

[0055] As from Figure 1As can be seen, the contactor device 100 is configured to electrically connect the high-voltage battery 500 to the high-voltage bus 105, which can be electrically connected to the electric motor of an electric vehicle to supply a predetermined high voltage, or can be connected to a charger to charge the high-voltage battery 500. Therefore, the contactor device 100 allows the voltage applied from the high-voltage battery 500 to the high-voltage bus 105 to be varied according to the state of the contactor device, as described below.

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

[0057] Furthermore, the contactor device 100 includes terminals 108 and 110, which can be electrically connected to the terminals of the battery modules 502, corresponding respectively to the terminals of the high-voltage battery 500 on the high-potential side (+) and the low-potential side (-). For example, in Figure 1 In this configuration, terminal 108 is electrically connected on the low-potential side to terminal 504 of the high-voltage battery 500, which corresponds to the low-potential side terminal of the battery module 502 (1) located on the low-potential side of the high-voltage battery 500. In other words, terminal 504 of the high-voltage battery 500 corresponds to... Figure 1 The low-potential side terminal of the battery module 502 (1). Similarly, in Figure 1 In this configuration, terminal 110 is electrically connected on the high-potential side to terminal 506 of the high-voltage battery 500, which corresponds to the high-potential side terminal of the battery module 502 (2) disposed on the high-potential side of the high-voltage battery 500. In other words, terminal 506 of the high-voltage battery 500 corresponds to... Figure 1 The high potential side terminal of the battery module 502 (2).

[0058] Furthermore, 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 terminals 504 and 506, corresponding respectively to the terminals of the high-voltage battery 500 on the high-potential side (+) and low-potential side (-). For example, in Figure 1 In this configuration, terminal 106 of contactor device 100 is electrically connected to high-potential side terminal 508 of battery module 502 (1), which is located on the low-potential side of high-voltage battery 500. Similarly, in... Figure 1 In the middle, terminal 112 is electrically connected to the low potential side terminal 510 of battery module 502 (2), which is arranged on the high potential side of high voltage battery 500.

[0059] In other words, the contactor device 100 includes two terminals 106 and 108 (“second terminals”) for electrically connecting 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 low-potential side terminal 504 of the high-voltage battery 500. Furthermore, the contactor device 100 includes two terminals 110 and 112 (“third terminals”) for electrically connecting 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 high-potential side terminal 506 of the high-voltage battery 500.

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

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

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

[0063] Preferably, the movable busbars 126 and 127 can be formed of flexible busbars, which include rigid regions 130 and 131 and flexible regions 132 and 133. When the movable busbars 126 and 127 are in the disconnected position (e.g., Figure 6 and Figure 7 (as shown) and closed position (as shown) Figures 2 to 5 When moving between the rigid regions 130 and 131 (as shown), the rigid regions 130 and 131 hardly move, and the flexible regions 132 and 133 are capable of elastically deflecting between the open and closed positions. Preferably, this can be achieved by forming a multi-layered structure of movable busbars 126 and 127 in at least the flexible regions 132 and 133, the multi-layered structure comprising, for example, 10 to 15 layers of copper or other suitable conductive material. In another example, the movable busbars 126 and 127 may consist of fixed busbars in the rigid regions 130 and 131 and movable busbars in the flexible regions 132 and 133, which can, for example, rotate about a rotation axis to move the movable busbars 126 and 127 between the open and closed positions. Alternatively, when the movable busbars 126 and 127 move between the open and closed positions, they can move as a whole.

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

[0065] Figures 2 to 5 The movable buses 126 and 127 are shown in the closed position, such that the movable buses 126 and 127 are electrically coupled to the fixed buses 128 and 129 at least at the first contact 134 of the contactor device. To reduce contact resistance, a contact element 136, for example made of silver or any silver alloy, can be mounted on both the movable buses 126 and 127 and the fixed buses 128 and 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 the closed state of the contactor device 100 with the movable buses 126 and 127 in the closed position and the open state of the contactor device 100 with the movable buses 126 and 127 in the open position, the contactor device 100 also allows switching between a parallel connection state and a series connection state. In the parallel connection state, at least two battery modules 502(1) and 502(2) can be connected in parallel to the high-voltage bus 105, and in the series connection state, 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 buses 138 and 139 and a connecting bus 144. In a first example of the contactor device 100, the second bus 138 is electrically connected to terminal 106, which is electrically connected to a high-potential side terminal 508 of a battery module 502 (1) disposed on the low-potential side of the high-voltage battery 500. Similarly, in the first example, the second bus 139 is electrically connected to terminal 112, which is electrically connected to a low-potential side terminal 510 of a battery module 502 (2) disposed on the high-potential side of the high-voltage battery 500.

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

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

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

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

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

[0073] To reduce the contact resistance between the second busbars 138, 139 and the connecting busbar 144, a contact element 148, for example made of silver or any silver alloy, can be mounted on the first contact side of the second busbars 138, 139 and in the area of ​​the second contact 146 to the connecting busbar 144. Alternatively, other suitable conductive materials can be used to form the contact element 146.

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

[0075] Therefore, in the parallel connection state of the contactor device 100, terminals 106 and 112 provide a conductive path from terminal 106 through the second bus 138 to the fixed bus 128 and from terminal 112 through the first connecting contact 139 to the fixed bus 129, thus electrically connecting battery modules 502(1) and 502(2) in parallel. 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 buses 126, 127 and the fixed buses 128, 129 (i.e., the closed contacts 122 and 124). Ideally, for the case where two battery modules 502(1) and 502(2) are electrically connected to the contactor device 100, the generated voltage is half 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] To reduce contact resistance in the parallel connection state, a contact element 152, for example made of silver or any silver alloy, can be mounted on the second contact side of the second busbars 138 and 139 for contacting the fixed busbars 128 and 129, and mounted to the fixed busbars 128 and 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 connecting busbar 144, this disclosure allows for the distinction between two additional states when the contactor device is in a closed state, namely a series connection state and a parallel connection state. In the series connection state, two battery modules 502(1) and 502(2) can be electrically connected in series, and in the parallel connection state, two battery modules 502(1) and 502(2) can be electrically connected in parallel.

[0078] Figure 6 and Figure 7 The contactor device 100 in the open state is shown, with movable buses 126 and 127 in the open position and electrically isolated from fixed buses 128 and 129. Second buses 138 and 139 are electrically coupled to connecting bus 144 and are therefore also electrically isolated from fixed buses 128 and 129. Thus, in the open state of the contactor device 100, no voltage is applied to the fixed buses 128 and 129.

[0079] To move movable buses 126 and 127 between open and closed positions, and to move second buses 138 and 139 between series and parallel connection positions, the contactor device 100 includes at least one actuator. Figures 2 to 7 (Not shown in the image). Therefore, movable buses 126 and 127 and second buses 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 buses 126 and 127 individually, and a dedicated second actuator can be provided to move the second buses 138 and 139 individually. See below for further details. Figures 16 to 20 Describe the possible configurations of at least one actuator provided in contactor 100.

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

[0081] In particular, Figure 8 and Figure 9 The contact device 220 of the contactor device 100 in a series connection state is shown. Figure 10 and Figure 11 The contactor device 100 in a parallel connection state is shown with contact contacts 220, while Figure 12 and Figure 13 The contact device 220 of the contactor 100 in the off state is shown.

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

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

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

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

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

[0087] Furthermore, the contact device 220 includes two auxiliary connecting buses 258 and 260, which can be formed from a rigid bus similar to the connecting bus 144. Each auxiliary connecting bus 258 and 260 can be formed, for example, from a rigid bus fixed to the underside of the cover plate 262 of the movable connecting frame 254. Thus, the auxiliary connecting buses 258 and 260 are mounted to the underside of the cover plate 262 in such a way that when the auxiliary connecting buses 258 and 260 are brought into the parallel connection position via the movable connecting frame 254, the auxiliary bus 258 is electrically coupled to each of the second bus 238 and the fixed bus 128, and the auxiliary bus 260 is electrically coupled to each of the second bus 239 and the fixed bus 129. Preferably, the auxiliary connecting buses 258 and 260 extend in a direction substantially perpendicular to the extending direction of the second buses 238 and 239. However, other extension directions of the auxiliary connecting buses 258 and 260 are also possible, as long as the second buses 258 and 260 can be electrically coupled to the second bus 238 and the fixed bus 128 or the second bus 239 and the fixed bus 129, respectively.

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

[0089] Figure 8 and Figure 9The diagram illustrates the contact device 220 when the connecting bus 144 is in the series connection position, thus placing the contactor device 100 in a series connection state. In the series connection position, by moving the connecting frame 254, the connecting bus 144 is pressed against each of the second buses 238 and 239, such that each of the second buses 238 and 239 is electrically coupled to the connecting bus 144 at the second contact 246. Therefore, in the series connection state of the contactor device 100, the second buses 238 and 239 are electrically connected in series. On the other hand, in the series connection state, since the auxiliary connecting buses 258 and 260 are moved away from the second buses 238 and 239 by the connecting frame 254, the second buses 238 and 239 are electrically isolated from the auxiliary connecting bus 258. Therefore, the second buses 238 and 239 are also electrically isolated from the fixed buses 128 and 129.

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

[0091] To reduce the contact resistance between the second busbars 238, 239 and the connecting busbar 144, a contact element 248, for example made of silver or any silver alloy, can be mounted on the first contact side of the second busbars 238, 239 and in the area of ​​the second contact 246 to the connecting busbar 144. Alternatively, other suitable conductive materials can be used to form the contact element 246.

[0092] Figure 10 and Figure 11The diagram illustrates a contact device 220 when auxiliary connecting buses 258 and 260 are simultaneously in parallel, placing the contactor device 100 in a parallel connection state. In the parallel connection position, by moving the connecting frame, auxiliary connecting bus 258 is pressed against the second bus 238 and the fixed bus 128, causing auxiliary bus 258 to be electrically coupled to the second bus 238 at the third contact 250 and to the fixed bus 128 at the fourth contact 268. Simultaneously, by moving the connecting frame, auxiliary connecting bus 260 is pressed against the second bus 239 and the fixed bus 129, causing auxiliary bus 260 to be electrically coupled to the second bus 239 at the third contact 250 and to the fixed bus 129 at the fourth contact 268. On the other hand, in the parallel connection state, the connecting bus 144 is moved away from the second bus 238 and 239 by the connecting frame 254, so that the second bus 238 and 239 are electrically isolated from the connecting bus 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 auxiliary connecting element 258) and vice versa, and the second busbar 238 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 auxiliary connecting 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 busesbars 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 terminal 106 through the second bus 238 and auxiliary connecting element 258 to the fixed bus 128, and a conductive path from terminal 112 through the second bus 239 and auxiliary connecting element 260 to the fixed bus 129, terminals 106 and 112 are electrically connected in parallel to battery modules 502(1) and 502(2). Therefore, by conductively coupling the movable buses 126, 127 and the fixed buses 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] To reduce contact resistance in the parallel connection state, contact element 252, for example made of silver or any silver alloy, can be mounted to the second contact side of the second busbars 238 and 239 to contact auxiliary connection buses 258 and 260 respectively, and is mounted to the auxiliary connection buses 258 and 260 in the region of the third contact 250. Similarly, a contact element 270, for example made of silver or any silver alloy, can be mounted to the auxiliary connection buses 258 and 260 respectively, and is 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 contact elements 252 and 270.

[0096] Figure 12 and 13 The contact device 220 is shown in an open state, with the connecting frame 254 in the open position, such that the second buses 238 and 239 are not electrically coupled to either the connecting bus 144 or the auxiliary connecting buses 258 and 260. Therefore, in the open position of the connecting frame 254, the second buses 238 and 239 are electrically isolated from the fixed buses 128 and 129, and simultaneously electrically isolated from each other, thereby interrupting the electrical connection between the terminals 106 and 112 of the contactor device 100.

[0097] Those skilled in the art will understand that, at the disconnected position of the connection frame 254, it is also necessary to interrupt the electrical connection between the terminal 506 on the high potential side of the high voltage battery 500 and the high potential side of the high voltage bus 105, as well as the electrical connection between the terminal 504 on the low potential side of the high voltage battery 500 and the low potential side of the high voltage bus 105. Although Figure 12 Not shown, but for this purpose, the movable buses 126 and 127 of the contactor can be moved to an open position, in which the movable buses 126 and 127 are electrically isolated from the fixed buses 128 and 129. Alternatively, the contactor device 100 can be used in conjunction with a second contactor device (e.g., as described later). Figure 14 and Figure 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 connecting bus 144 and auxiliary connecting buses 258 and 260 to connecting frame 254, the second exemplary contact device 220 of contactor 100 allows differentiation between two additional states when the contactor device is in a closed state: a series connection state and a parallel connection state, wherein the state of contactor device 100 can be changed by moving the connecting frame with an actuator. Thus, connecting frame 254 can be moved by the same actuators as movable buses 126 and 127 to change the state of contactor device 100, or a dedicated actuator can be provided to move connecting frame 254 separately. Reference will be made later to the second exemplary contactor device 300 and... Figures 16 to 24 Possible configurations of such an actuator are described. Thus, the configuration of the second exemplary contact device 220 allows each of the connecting buses 144, 258, and 260, as well as the two second buses 238 and 239, to be configured as fixed-mount buses, and only the connecting frame 254 is moved to change the state of the contactor device 100.

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

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

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

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

[0103] Figure 16 Movable buses 326 and 327 in the closed position are shown, each of which is electrically coupled to one of fixed buses 328 and 329, allowing current to flow from terminal 310 integrally formed with movable bus 326 to terminal 304 integrally formed with fixed bus 328, and from terminal 308 integrally formed with movable bus 327 to terminal 302 integrally formed with fixed bus 329. Terminals 308 and 310 can be electrically connected to terminals 504 and 506 of high-voltage battery 500, and terminals 302 and 304 can be electrically connected to high-voltage bus 105, and vice versa. To reversibly connect and disconnect the current path through contactor device 300, contactor device 300 includes an electromagnetic actuator 372 capable of reversibly moving movable buses 326 and 327 between the closed and open positions.

[0104] To facilitate a reversible transition between the open and closed positions, movable buses 326 and 327 are formed in such a way that they are capable of elastically deflecting between the open and closed positions, at least within the flexible contact region 333. For this purpose, movable buses 326 and 327 can be formed of a multi-layered structure comprising, for example, 10 to 15 layers of copper or other suitable conductive material. Furthermore, each of movable buses 326 and 327 may include a protrusion 374 for supporting the deflection capability of the movable buses 326 and 327. The protrusion 374 can also help apply a preload to the movable buses 326 and 327, which pushes the movable buses 326 and 327 toward the open position.

[0105] Electromagnetic actuator 372 is configured to hold movable buses 326 and 327 in a closed position when energized. For this purpose, each flexible contact area 333 of the movable buses 326 and 327 can be moved individually by electromagnetic actuator 372, for example via shaft 376, which is arranged on the top side of the movable buses 326 and 327 in the flexible contact areas 333. Additional spring elements can be arranged around shaft 376, which helps to absorb small misalignments or imbalances between the movable buses 326 and 327 during operation of the contactor device 300, preventing such misalignments from affecting electromagnetic actuator 372 or significantly affecting the forces applied between fixed buses 328 and 329 and the movable buses 326 and 327. Therefore, tolerances between fixed buses 328 and 329 and the movable buses 326 and 327 introduced during the manufacture of the contactor device 100 can be better compensated. Furthermore, the spring is located below each of the movable busbars 326 and 327, i.e. on the bottom side of the movable busbars 326 and 327, and when no force is applied to the shaft 376, i.e. when the electromagnetic actuator 372 is not energized, the spring biases the movable busbars 326 and 327 to the disconnected position.

[0106] Figure 17A contactor device 300 in a de-energized state is shown, where the electromagnetic actuator 372 is not energized, thus the movable buses 326 and 327 are simultaneously in the open position. Therefore, the contact elements 336 of the movable buses 326 and 327 are electrically isolated from the contact elements 336 of the fixed buses 328 and 329 by a spatial gap, thereby preventing current from flowing through the contactor device 300. Due to the design of the movable buses 326 and 327, sufficient electrical isolation can be provided between the movable buses 326 and 327 and the fixed buses 328 and 329, even under normal atmospheric conditions. Therefore, the need to provide the movable buses 326 and 327 and the fixed buses 328 and 329 in a sealed housing or to use an electronegative gas can be eliminated, thus significantly simplifying the contactor device 300. However, at least a portion of the movable buses 326 and 327 and the fixed buses 328 and 329 can also be provided in the area surrounding the contact elements 336 in the sealed housing to enhance electrical isolation.

[0107] Figure 18 A contactor device 300 in an energized state is shown, wherein movable buses 326 and 327 are in the closed position, such that the contacts 336 of the movable buses 327 and 326 are electrically coupled to the contacts 336 of the fixed buses 328 and 329.

[0108] In order to bring the movable buses 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 buses 326 and 327, for example, through the shaft 376, and pushes the movable buses 326 and 327 in the direction of the closing force 378, that is, toward the fixed buses 328 and 329.

[0109] For example, the contactor device 300 may be equipped with a linear motor actuator 472 instead of an electromagnetic actuator 372, which, for example, is via... Figure 19 and 20 The drive shaft 476 is shown schematically, so that the movable buses 326 and 327 are in the disconnected position (e.g., Figure 20 (as shown) and closed position (as shown) Figure 19 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 buses 326 and 327 only between the open and closed positions, and when the linear motor actuator 472 is not energized, the movable buses 326 and 327 remain in their previous positions. Therefore, the linear motor actuator 472 functions as a bistable actuator, which allows the introduction of open and closed states of the contactor device 300 as a bistable state that changes only when the linear motor actuator 472 is energized.

[0110] Therefore, unlike the contactor device 300 with electromagnetic actuator 372 (which is brought to the open state), when electromagnetic actuator 372 experiences power loss (e.g., due to a damage event or due to loss of communication), contactor device 300 can remain in the closed state (or open state) when linear motor actuator 472 experiences power loss, so that it can still drive the electric vehicle after the power loss of linear motor driver 472.

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

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

[0113] The pyrotechnic actuator 380 may include two or more pyrotechnic terminals 382, ​​sometimes referred to as pyrotechnic pins, which ignite the pyrotechnic charge in response to the receipt of an electrical control signal. The pyrotechnic charge may be an explosive directly ignited by an electrical control signal, or a gas generator charge that expands suddenly upon receiving an 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 terminal 382 can, for example, be connected 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 can be represented by a current level that is dangerous to the function of the contactor device 300, the current sensing controller can transmit an electrical control signal to ignite the pyrotechnic charge.

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

[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. Driven by the generated force, the piston structure 384 drives a displacement element 386 supported in the actuator housing 388 of the pyrotechnic actuator 380 to simultaneously push the fixed buses 328 and 329 away from the ignition position of the movable buses 326 and 327. For example, studs or bolts driven by the energy of the piston structure 384 to displace or serve the fixed buses 328 and 329 can be used as the displacement element 386.

[0117] like Figure 16 As further shown, each fixed busbar 328 and 329 may include a hinged flexible element 381, which may be disposed between the terminal 302 and the contact element 336 of the fixed busbar 329 and between the terminal 304 and the contact element 336 of the fixed busbar 328. When the pyrotechnic actuator 380 is actuated, the hinged flexible element 381 allows the contact area 379 of the fixed buses 328 and 329 to swing away from the movable buses 326 and 327 in a defined manner. Thus, each hinged flexible element 381 of the fixed buses 328 and 329 provides an axis of mechanical movement about which the corresponding fixed busbar 328 and 329 rotates during movement to the ignition position. Therefore, the position of the hinged flexible elements 381 of the fixed buses 328 and 329 can be adjusted to change the swing radius of the contact area 381 of the fixed buses 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, the actuator housing 388 can also provide a receiving space for the piston structure 384 before the pyrotechnic actuator 380 is actuated. The actuator housing 388 can also provide a piston stop device for stopping the piston structure 380 when it reaches the end position and the stationary busbars 328 and 329 are in the ignition position. In this way, the contactor device 300 can provide a clearly defined path for the piston structure 384. The actuator housing 388 can also provide a holding device for holding the piston structure 384 in the end position to prevent it from moving back to the rest position after the pyrotechnic actuator is actuated. In this way, when the pyrotechnic actuator is activated, the piston structure 384 can help hold the stationary busbars 328 and 329 in the ignition position. Additionally or alternatively, the actuator housing 388 can also provide a holding device for holding the stationary 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 the current-carrying path when the pyrotechnic actuator 380 is activated. For example, the contactor device 300 may include one or more arc-extinguishing magnets used to control the development of the arc, or may include an array of arc-splitting plates 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 can be inserted between fixed buses 328 and 329 and movable buses 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 referred to below. Figure 21 and Figure 22 To explain, Figure 21 and Figure 22 A schematic top view of the contactor device 300 is shown. Figure 21 The contactor device 300 is shown in the closed position of movable buses 326 and 327 and in a state prior to the activation of the pyrotechnic actuator 380. A holding force in the direction 378 (i.e., from the contact elements 336 of movable buses 326 and 327 toward the contact elements 336 of fixed buses 328 and 329) holds the movable buses 326 and 327 in the closed position. Figure 21 and Figure 22 As shown in cross 378, the holding force is directed towards the horizontal plane of the paper.

[0121] Figure 22 A top view of the contactor device 100 is shown with the pyrotechnic actuator 380 activated. Although in Figure 22 In the diagram, only the stationary busbar 329 is shown in the ignition position, but after the pyrotechnic actuator 380 is triggered, the stationary busbar 328 also moves to the ignition position simultaneously. The force generated when the piston structure 384 is ignited by the pyrotechnic charge drives it away from its rest position. The generated force drives the displacement element to irreversibly move the stationary buses 328 and 329 to the ignition position, wherein the stationary buses 328 and 329 are electrically isolated from the movable buses 326 and 327. As indicated by arrow 390, the movement of the stationary buses 328 and 329, or the contact area 379 of the stationary buses 328 and 329, preferably occurs in a plane perpendicular to the direction 378 of the holding force applied to the movable buses 326 and 327 by the electromagnetic actuator 372.

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

[0123] In this way, without affecting the actuation mechanism used to move and hold the movable buses 326 and 327 in the closed position, it can be ensured that the fixed buses 328 and 329 can be moved to the ignition position. Similarly, the movement of the fixed buses 328 and 329 into the ignition position is prevented from being affected by the actuation mechanism used to move and hold the movable buses 326 and 327 in the closed position, because the force generated by the pyrotechnic actuator 380 is transmitted to the fixed buses 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 motion. However, the fixed busbars 328 and 329 or the contact area 379 of the fixed busbars 328 and 329 can also move linearly to the ignition position along a movement path independent of the movement path of the movable busbars 326 and 327 between the open and closed positions.

[0125] Therefore, the contactor device 300 can reversibly move the movable buses 326 and 327 between open and closed positions by controlling the operation of the electromagnetic actuator 372 (or the linear motor actuator 472). Furthermore, when the pyrotechnic actuator 380 is activated, the stationary buses 328 and 329 are moved to the ignition position, thereby permanently displacing or disconnecting the stationary buses 328 and 329 to permanently interrupt the current flowing through the contactor device 300. In other words, while the electromagnetic actuator 372 (or the linear motor actuator 472) is configured to reversibly move and hold the movable buses 326 and 327 to reversibly change the conductivity state of the contactor device 300, the pyrotechnic actuator 380 is configured to irreversibly move the stationary buses 328 and 329 to the ignition position to irreversibly disconnect the current flowing through the contactor device 300. It is worth noting that the activation of the pyrotechnic actuator can be independent of the positions of the movable buses 326 and 327 and the electromagnetic actuator 372 (or the linear motor actuator 472).

[0126] Figure 23 and Figure 24 An alternative contact separation mechanism that can be implemented in contactor device 300 is illustrated schematically, instead of mechanically moving fixed busbars 328 and 329 to the ignition position. This mechanism is exemplarily shown for irreversibly separating fixed busbar 328 and movable busbar 326, but of course, the same separation mechanism can also be provided to irreversibly separate fixed busbar 329 and movable busbar 327. Here, 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 configured to drive the displacement element 386 to move the fixed busbar 328, but rather to move the isolation cap 494, formed of electrically insulating material, from its normal position after the pyrotechnic actuator has been triggered. Figure 23 Move to the ignition position ( Figure 24 ).

[0128] like Figure 23 As shown, as long as the isolation cap 494 is in the normal position, i.e., before the pyrotechnic actuator is triggered, the contact elements 336 of the movable bus 326 and the fixed bus 328 can be electrically coupled to allow current to flow through the contactor device 300, and the movable bus 326 can move between the open and closed positions. However, after the pyrotechnic actuator is triggered, the pyrotechnic piston drives the isolation cap 494 along the direction of the fixed bus 328 (in... Figure 23 and Figure 24As indicated by arrow 496, the isolation cap 494 completely surrounds the end region of the fixed bus 328 until the ignition position. Therefore, in the ignition position, the isolation cap 494 is pushed between the contact elements 336 of the movable bus 326 and the fixed bus 328, and thus electrically isolates the movable bus 326 and the fixed bus 328 from each other.

[0129] In this way, the isolation cap 494 can interrupt the current flowing through the movable bus 326 and the fixed bus 328, while simultaneously suppressing the formation of an electric arc. For this purpose, preferably, the isolation cap 494 completely surrounds the end region of the fixed bus 328, which includes the contact element 336, and may overlap with the electrical isolation layer 492. However, complete encapsulation of the end region is not necessary for alternative contact separation mechanisms, provided that the isolation cap provides sufficient electrical isolation between the movable bus 326 and the fixed bus 328.

[0130] Although not shown in the figure, two second buses 138 and 139 and a connecting bus 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 buses 238 and 239 and a connection frame 254 having corresponding connecting buses 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 device 220 is shown. In other words, the contactor device 300 or a single component of the contactor device 300 can form the basis for constructing the contactor device 100, with additional components of the first exemplary contact device 120 or the second exemplary contact arrangement 220 added to the contactor device 100. Thus, for example, two second busbars 138 and 139 can be formed similarly to the movable busbars 326 and 327 of the contactor device 300.

[0131] This 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 including the contactor device 100 or the 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 can monitor the operating conditions of the energy storage system 10. For example, the controller or 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 battery management system to change the state of the contactor device 100, causing it to transition between a series connection state and a parallel connection state, and / or causing it to transition between an open state and a self-closing state. Similarly, the controller or 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 battery management system to at least change the state of the contactor device, causing it to transition between a closed state and an open state. In addition, in the event of operation outside of safe operating conditions (unsafe operating conditions) (such as overcurrent, overheating of battery 500 or accident), the controller or battery management system can trigger the pyrotechnic actuator 380 (or 280) of contactor device 300 (or contactor 100) by providing the appropriate control signal.

[0132] Reference figures

[0133] 10 Energy storage system 100、300 Contactor equipment 102、104、106、108、110、112、302、304、308、310 Terminals of contactor equipment 105 High-voltage bus 120、220 Contact device 122、124 Contact 126、127、326、327 Movable busbar (third busbar) 128、129、328、329 Fixed busbar (first busbar) 130、131 Rigid area of ​​movable bus 132、133、333 Flexible area of ​​movable bus 134 First contact point 136、148、152、248、252、270、336 Contact elements 138、139、238、239 Second busbar 140、141 Rigid region of the second busbar 142、143 The flexible area of ​​the second busbar 144 (Main) connecting busbar 146、246 Second contact point 150、250 Third contact point 254 Connection frame 256 base plate 258、260 Auxiliary connecting bus 262 cover plate 264、266 Side panel 268 Fourth contact point 280、380 pyrotechnic actuator 372 electromagnetic actuator 374 protrusion 376 axis 378 Direction of closing force 379 Contact area of ​​fixed busbar 381 Hinges and flexible components 382 Pyrotechnic electrical terminals 384 Piston structure 386 shift element 388 Actuator housing 390、496 arrow 472 Linear motor actuator 492 Electrical isolation layer 494 isolation cap

Claims

1. A contactor device, the contactor device comprising: Two first terminals for electrically connecting at least one of the load and the charger; Two second terminals used for electrical connection of the first battery module; For electrically connecting two third terminals of a second battery module; two first buses, each first bus electrically connected to one of the first terminals; two second buses, wherein one of the second buses is electrically connected to one of the second terminals, and the other of the second buses is electrically connected to one of the third terminals; a connecting bus, the connecting bus being electrically isolated from the two first buses; and at least one actuating element configured to at least change the state of the contactor device to switch between a series connection state and a parallel connection state, wherein in the series connection state, the two second buses are electrically coupled to the connecting bus, and in the parallel connection state, one of the second buses is electrically coupled to one of the first buses, and the other of the second buses is electrically coupled to the other of the first buses.

2. The contactor device according to claim 1, wherein, Each of the second busbars includes a deflectable contact area that is elastically deflectable between a first position and a second position, in which each of the second busbars is electrically coupled to the connecting busbar, and in the second position, each of the second busbars is electrically coupled to one of the first busbars.

3. The contactor device according to claim 1, further comprising two auxiliary connecting buses, each of the auxiliary connecting buses being configured to conductively couple one of the second buses to a corresponding one of the first buses in the parallel connection state of the contactor device.

4. The contactor device according to claim 3, wherein, The connecting bus and the auxiliary connecting bus are mounted to the connecting frame, and the at least one actuating element is configured to move the connecting frame to change the state of the contactor device, causing it to switch between a series connection state and a parallel connection state.

5. The contactor device according to claim 1, wherein, Each of the second busbars includes a plurality of contact elements arranged on different sides of the second busbar, and wherein each of the second busbars is configured to be electrically coupled to the connecting busbar at a contact side of the second busbar, the contact side of the second busbar being different from the contact side electrically coupled to one of the first busbars.

6. The contactor device according to claim 1, wherein, The at least one actuating element includes a dedicated actuator for changing the state of the contactor device, switching it between a series connection state and a parallel connection state.

7. The contactor device according to claim 1, wherein the contactor device further comprises two third busbars, wherein, One of the third buses is electrically connected to the other of the second terminals, and the other of the third buses is electrically connected to the other of the third terminals; and wherein the at least one actuating element is configured to change the state of the contactor device between a closed state and an open state, wherein in the closed state each of the third buses is electrically coupled to a corresponding one of the first buses, and in the open state the two third buses and the two second buses are electrically isolated from the two first buses.

8. The contactor device according to claim 7, wherein, Each of the third buses includes a deflectable contact area that is elastically deflectable between an open position and a closed position, wherein in the open position each of the third buses is electrically isolated from the two first buses, and in the closed position the two third buses are electrically coupled to a corresponding one of the first buses.

9. The contactor device according to claim 7, wherein, When the at least one actuating element is not energized, the contactor device is in the disconnected state.

10. The contactor device according to claim 1, wherein, The state of the contactor device changes only when the at least one actuating element is energized.

11. The contactor device of claim 1, further comprising at least one pyrotechnic actuator configured, when activated, to irreversibly prevent current from flowing through each of the first busbars.

12. The contactor device of claim 7, further comprising at least one pyrotechnic actuator configured, when activated, to move the two first buses to an ignition position, wherein in the ignition position, each of the two first buses is irreversibly displaced or disconnected.

13. The contactor device of claim 7, further comprising at least one pyrotechnic actuator configured, when activated, to irreversibly drive at least one isolation element to an ignition position, wherein in the ignition position, the isolation element electrically isolates the two third buses from the two first buses.

14. The contactor device according to claim 13, wherein, The isolation element includes at least two isolation caps, wherein at the ignition position, each of the at least two isolation caps completely surrounds the contact area of ​​a corresponding one of the first busbars.

15. An energy storage system, the energy storage system comprising: A battery, the battery being formed of at least a first battery module and a second battery module; The contactor device according to claim 1; 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.

Images