Power supply including manual service disconnect with pyrotechnic fuse

Abstract

A power supply includes: a housing having a plurality of walls; a power component disposed in the housing; a first electrical connector connected to the power component; a second electrical connector connected to the power component; a circuit defined between the first electrical connector, the second electrical connector, and the power component; and a manual disconnect device (MSD) including a pyrotechnic fuse connected in the electrical circuit, the MSD disposed on the housing and configured to create an open circuit in the electrical circuit.

Description

Technical Field

[0001] The present disclosure relates to power supplies, and more particularly, to power supplies including a manual service disconnect device having a pyro fuse. Background Art

[0002] Power supplies, particularly battery-type energy storage devices, are used to provide energy to electrical loads. The power supply may include a plurality of batteries that store and release electrical energy. For various reasons, the batteries may discharge through the circuit at a rate exceeding the design threshold, or may be charged through the circuit by a charging device that does not meet the design requirements. At this time, it is necessary to disconnect the power supply from the electrical load.

[0003] Currently, power supplies, especially high-voltage power supplies, include fuses that interrupt or cause an open circuit in response to an overcurrent condition. In many cases, the fuse is a fast-acting fuse that can use a certain amount of pyrotechnic material to disconnect the contacts and open the circuit. After the fuse is triggered, it quickly opens the circuit to protect the internal battery components. The fuse is a disposable device that needs to be replaced once it is triggered. Currently, replacing the fuse is a time-consuming and laborious task that usually requires a large amount of disassembly of the power supply. Therefore, it is desirable to provide a fuse that is easily accessible and easily replaceable. Summary of the Invention

[0004] According to a non-limiting example, a power supply includes: a housing having a plurality of walls; power components disposed in the housing; a first electrical connector connected to the power components; a second electrical connector connected to the power components; a circuit defined between the first electrical connector, the second electrical connector, and the power components; and a manual disconnect device (MSD) including a pyro fuse connected in the circuit, the MSD being disposed on the housing and configured to create an open circuit in the circuit.

[0005] In addition to one or more of the features described herein, the MSD is mounted on one of the plurality of walls.

[0006] In addition to one or more of the features described herein, the housing includes a cover, and the MSD is mounted to the cover.

[0007] In addition to one or more of the features described herein, the power components include a power storage system that includes a plurality of battery cells disposed in the housing.

[0008] In addition to one or more of the features described herein, the MSD includes a base portion mounted to the housing and an electrical contact portion that can be selectively removed from the base portion.

[0009] In addition to one or more of the features described herein, the MSD includes a handle pivotally mounted to the electrical contact portion.

[0010] In addition to one or more features described herein, the MSD includes a latch element that secures the electrical contact portion to the base portion.

[0011] In addition to one or more features described herein, a pyrotechnic fuse is mounted in the electrical contact portion.

[0012] In addition to one or more features described herein, the electrical contact portion includes a low-voltage circuit connected to the pyrotechnic fuse, the low-voltage circuit including a low-voltage connector.

[0013] In addition to one or more features described herein, the circuit includes a positive portion and a negative portion, and the MSD is disposed in the positive portion.

[0014] A manual service disconnect (MSD) for a power source having a circuit includes a pyrotechnic fuse connected in the circuit. The MSD is configured to create an open circuit in the circuit by triggering the pyrotechnic fuse.

[0015] In addition to one or more features described herein, the MSD includes a base portion and an electrical contact portion that is selectively removable from the base portion.

[0016] In addition to one or more features described herein, the electrical contact portion includes a rotatable handle.

[0017] In addition to one or more features described herein, the rotatable handle includes a latch element that secures the electrical contact portion to the base portion.

[0018] In addition to one or more features described herein, a pyrotechnic fuse is mounted in the electrical contact portion.

[0019] In addition to one or more features described herein, the electrical contact portion includes a low-voltage circuit connected to the pyrotechnic fuse, the low-voltage circuit including a first low-voltage connector mounted in the electrical contact portion.

[0020] In addition to one or more features described herein, the base portion includes a second low-voltage connector disposed in the base portion, the second low-voltage connector configured to operably connect with the first low-voltage connector.

[0021] In addition to one or more features described herein, a triggering device is operably connected to the low-voltage circuit, the triggering device configured to send a signal to the pyrotechnic fuse to create an open circuit in the circuit.

[0022] In addition to one or more features described herein, the electrical contact portion includes a first high-voltage contact and a second high-voltage contact connected by a bridging member, and the pyrotechnic fuse includes a cutting blade located at the bridging member.

[0023] In addition to one or more features described herein, a pyrotechnic fuse includes a pyrotechnic charge operably connected to a low-voltage circuit, the pyrotechnic charge configured to selectively drive a cutting blade through a bridging member to create an open circuit in the circuit.

[0024] The above-described features and advantages of the present disclosure, as well as other features and advantages, will become apparent when the following detailed description is read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Other features, advantages, and details appear only by way of example in the following detailed description, which refers to the accompanying drawings, in which:

[0026] Figure 1 is a perspective view of a power supply including a manual service disconnect (MSD) according to a non-limiting example, the manual service disconnect including a pyrotechnic fuse;

[0027] Figure 2 is a schematic diagram showing a circuit of a power supply according to a non-limiting example, the circuit including an MSD connected between a power component and an electrical load of the power supply;

[0028] Figure 3 is a perspective view of an MSD including a base portion and an electrical contact portion according to a non-limiting example Figure 2 ;

[0029] Figure 4 is a bottom view of the electrical contact portion of an MSD according to a non-limiting example Figure 3 ;

[0030] Figure 5 is a cross-sectional schematic diagram showing a pyrotechnic fuse before cutting the circuit according to a non-limiting example;

[0031] Figure 6 is a cross-sectional schematic diagram showing a pyrotechnic fuse after cutting the circuit according to a non-limiting example;

[0032] Figure 7 is a perspective view of an MSD according to a non-limiting example Figure 3 when the latch mechanism is disengaged; and

[0033] Figure 8 is a perspective view of an MSD according to a non-limiting example Figure 6 showing the electrical contact portion removed from the base portion. DETAILED DESCRIPTION

[0034] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that in all the drawings, corresponding reference numerals represent like or corresponding parts and features.

[0035] According to a non - limiting example, the power supply is typically represented as 38 in Figure 1 . The power supply 38 includes a housing 42 having a plurality of walls 44. The walls 44 include at least a first end wall 52, a second end wall (not shown), a first side wall 56, a second side wall 58, and a cover 60. The housing 42 encapsulates power components 68. In the non - limiting example shown, the power components 68 are defined by a plurality of rechargeable battery cells 72. However, it should be understood that the power components 68 can take various forms, including generators, transformers, etc.

[0036] In a non - limiting example, a first electrical connector 80 and a second electrical connector 82 are mounted to the first end wall 52. The first electrical connector 80 and the second electrical connector 82 provide a connection to an electrical load 84 ( Figure 2 ), and the electrical load 84 is connected to the power supply 38. As Figure 2 shown, a circuit 86 is defined between the first electrical connector 80 and the second electrical connector 82. The circuit 86 operably connects the power supply 38 to the electrical load 84. In a non - limiting example, the circuit 86 includes a positive portion 92 extending between a positive terminal (not separately labeled) of the power supply 38 and the first electrical connector 80, and a negative portion 94 extending between a negative terminal (also not separately labeled) of the power supply 38 and the second electrical connector 82.

[0037] In a non - limiting example, the power supply 38 includes a manual service disconnect (MSD) 100 disposed in the circuit 86. In one non - limiting example, the MSD 100 is mounted to the cover 60 ( Figure 1 ), and is positioned to interrupt the current flowing through the positive portion 92 of the circuit 86 to the electrical load 84. Referring to Figure 3 , the MSD 100 includes a base portion 106 and an electrical contact portion 108. The base portion 106 includes a groove or socket 110 ( Figure 8 ) that engages the electrical contact portion 108. With this configuration, the electrical contact portion 108 is removably connected to the base portion 106.

[0038] When the electrical contact portion 108 is connected to the base portion 106, current flows through the circuit 86 from the power supply 38 to the electrical load 84. When the electrical contact portion 108 is removed from the base portion 106, an open circuit is created, interrupting the current flow. In one non - limiting example, the electrical contact portion 108 includes a handle 114 having a latch element 116. The base portion 106 includes a protrusion 119 that is aligned with the handle 114 and is selectively engaged by the latch element 116.

[0039] In Figure 4In the non-limiting example shown, the MSD 100 includes a circuit portion 124 that forms part of the circuit 86. The circuit portion 124 includes a first high-voltage contact 130 and a second high-voltage contact 132, which are connected by a bridging member 134 in the electrical contact portion 108. As Figure 5 shown, a third high-voltage contact 136 and a fourth high-voltage contact 138 are disposed in the base portion 106. The third high-voltage contact and the fourth high-voltage contact 138 are connected to the circuit 86.

[0040] When the electrical contact portion 108 is engaged with the base portion 106, the first high-voltage contact 130 and the third high-voltage contact 136 are electrically connected, and the second high-voltage contact 132 and the fourth high-voltage contact 138 are electrically connected. When separated, the current in the circuit 86 is cut off. In addition to cutting off the current by removing the electrical contact portion 108 from the base portion 106, the MSD 100 further includes a circuit breaker portion 140 that is configured to quickly cut off the current in response to the operating conditions of the power supply 38. In the case where the operating temperature, current, etc. in the power supply 38 exceed the design parameters, the circuit breaker portion 140 can cut off the circuit 86.

[0041] Referring Figure 5 and continuing to refer Figure 4 , the electrical contact portion 108 further includes a circuit breaker portion 140 that has a pyrotechnic fuse 142 arranged to cut off the bridging member 134 and disconnect the circuit 86. As Figure 5 shown, the pyrotechnic fuse 142 includes a cutting blade 144 disposed adjacent to the bridging member 134 and a pyrotechnic charge 146 positioned adjacent to the cutting blade 144. Ignition of the pyrotechnic charge 146 drives the cutting blade 144 through the bridging member 134 to cut off the circuit 86, as Figure 6 shown. In the non-limiting example, the pyrotechnic fuse 142 further includes a low-voltage circuit 148 connected to the pyrotechnic charge 146.

[0042] The low-voltage circuit 148 includes a first low-voltage connector 154 disposed in the electrical contact portion 108 and a second low-voltage connector 156 disposed in the base portion 106. When the electrical contact portion 108 is engaged with the base portion 106, the low-voltage circuit 148 is completed. The low-voltage circuit 148 is connected to a triggering device 160 ( Figure 2 ), and the triggering device 160 sends a signal to the pyrotechnic fuse 142 to ignite the pyrotechnic charge 146, thereby driving the cutting blade 144 through the bridging member 134 and disconnecting the circuit 86. This is when the triggering device causes the pyrotechnic fuse to immediately disconnect the circuit 86 upon detecting out-of-parameter operating conditions. The use of the pyrotechnic charge 146 ensures disconnection within 2 ms or less. At this point, it should be understood that the term "low voltage" describes a voltage that is less than or equal to 30 VAC or 60 VDC, while the term "high voltage" describes a voltage that is greater than 30 VAC or 60 VDC.

[0043] To manually disconnect the power supply 38 from the circuit 86, the electrical contact portion 108 is simply removed from the base portion 106. To remove the electrical contact portion 108 from the base portion 106, the handle 114 is rotated as Figure 7 shown. Rotation of the handle 114 disengages the latch element 116 from the protrusion 119. When the latch element 116 is disengaged from the protrusion 119, the electrical contact portion 108 can be removed from the base portion 106, as Figure 8 shown, to interrupt the current from the power supply 38 to the circuit 86. By arranging the MSD 100 in an easily accessible area (such as the cover 60), the current can be more easily cut off during the repair of any load connected to the power supply 38. In addition, in the case of a fuse failure, replacement of the electrical contact portion 108 can be achieved without the need to disassemble the power supply 38. Further, by incorporating the pyrotechnic fuse 142 into the MSD 100, repair or replacement of the electrical contact portion 108 can be easily accomplished in the case where the pyrotechnic charge 146 is triggered.

[0044] The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items. The term "or" means "and / or" unless the context clearly dictates otherwise. References throughout the specification to "in one aspect" mean that the particular elements (such as features, structures, steps, or characteristics) described in connection with that aspect are included in at least one of the aspects described herein, and may or may not be present in other aspects. Additionally, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0045] The terms "about" and "substantially" are intended to include the degree of error associated with a particular quantity measurement based on the equipment available at the time of filing the application. For example, "about" and / or "substantially" may include a range of ±8% or 5% or 2% of a given value.

[0046] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, no intervening elements are present.

[0047] Unless stated to the contrary herein, all test standards are the most current valid standards as of the filing date of the present application, or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0048] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0049] Although the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can replace its elements without departing from its scope. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope of the disclosure. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A power supply, comprising: A housing having a plurality of walls; Power components disposed in the housing; A first electrical connector connected to the power components; A second electrical connector connected to the power components; A circuit defined between the first electrical connector, the second electrical connector, and the power components; And A manual disconnection device (MSD) including a pyrotechnic fuse connected in the circuit, the MSD being disposed on the housing and configured to create an open circuit in the circuit.

2. The power supply according to claim 1, wherein The MSD is mounted on one of the plurality of walls.

3. The power supply according to claim 1, wherein The housing includes a cover, and the MSD is mounted to the cover.

4. The power supply according to claim 1, wherein The power components include a power storage system, the power storage system including a plurality of battery cells disposed in the housing.

5. The power supply according to claim 1, wherein, The MSD includes a base portion mounted on the housing and an electrical contact portion selectively removable from the base portion.

6. The power supply according to claim 5, wherein, The MSD includes a handle pivotally mounted to the electrical contact portion.

7. The power supply according to claim 6, wherein, The MSD includes a latch element that secures the electrical contact portion to the base portion.

8. The power supply according to claim 5, wherein, The pyrotechnic fuse is mounted in the electrical contact portion.

9. The power supply according to claim 8, wherein, The electrical contact portion includes a low-voltage circuit connected to the pyrotechnic fuse, the low-voltage circuit including a low-voltage connector.

10. The power supply according to claim 1, wherein, The circuit includes a positive portion and a negative portion, and the MSD is disposed in the positive portion.

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