Repairable fuse for battery assembly

Abstract

A rechargeable energy storage system (RESS) includes a housing having a plurality of walls defining a cell receiving region. A plurality of battery cells are arranged in the battery cell receiving area. A first electrical connector is connected to the plurality of battery cells, a second electrical connector is connected to the plurality of battery cells, and an electrical circuit is defined between the first electrical connector, the second electrical connector, the plurality of battery cells, and an electrical load. And the fuse is connected in a circuit. A fuse is disposed on the housing and configured to create an open circuit in an electrical circuit.

Description

Technical Field

[0001] The present invention relates to a power supply, and more particularly to a repairable fuse for a battery assembly. Background Art

[0002] Many new vehicles are being manufactured with electric propulsion systems. Electric propulsion systems, whether fully electric or hybrid electric, rely on electric motors powered by energy stored in a rechargeable energy storage system (RESS) or battery. The battery receives, stores electrical energy and releases the electrical energy to a load, such as a drive unit that provides motive energy for the vehicle.

[0003] A battery typically includes a plurality of battery cells that store and release electrical energy. For various reasons, the battery may release energy through a circuit at a rate exceeding the design threshold, or may be charged through a circuit by an energy source that does not meet the design requirements. At this time, it is desirable to disconnect the battery cells from the electric motor.

[0004] Currently, the battery includes a fuse that interrupts or creates 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. The fuse quickly opens the circuit after being triggered to protect the internal battery components. The fuse is a one-time device and needs to be replaced once it is triggered. Currently, replacing the fuse is a time-consuming and laborious task, usually requiring the removal of the vehicle floorboard and the removal and disassembly of the battery. Therefore, it is desirable to provide a fuse that is easily accessible and easy to replace. Summary of the Invention

[0005] According to a non-limiting example, a rechargeable energy storage system (RESS) includes a housing having a plurality of walls that define a battery cell receiving area. A plurality of battery cells are disposed in the battery cell receiving area. A first electrical connector is connected to the plurality of battery cells, a second electrical connector is connected to the plurality of battery cells, and a circuit is defined between the first electrical connector, the second electrical connector, the plurality of battery cells, and an electrical load. A fuse is connected in the circuit. The fuse is disposed on the housing and is configured to create an open circuit in the circuit.

[0006] In addition to one or more features described herein, the fuse is mounted to one of the plurality of walls.

[0007] In addition to one or more features described herein, the housing includes a cover, and the fuse is mounted to the cover.

[0008] In addition to one or more features described herein, a battery disconnect unit is disposed in the housing, and the fuse is mounted to the battery disconnect unit.

[0009] In addition to one or more features described herein, the fuse includes a base mounted to the RESS and an electrical contact removably selectively from the base.

[0010] In addition to one or more features described herein, the fuse includes a handle pivotally mounted to the electrical contact.

[0011] In addition to one or more features described herein, the fuse includes a latch element that secures the electrical contact to the base.

[0012] In addition to one or more features described herein, the fuse is a pyrotechnic fuse that includes a pyrotechnic (pyro) element that selectively creates an open circuit.

[0013] In addition to one or more features described herein, the pyrotechnic element is part of the electrical contact.

[0014] In addition to one or more features described herein, the circuit includes a positive portion and a negative portion, and the fuse is disposed in the positive portion between a plurality of battery cells and an electrical load.

[0015] According to a non-limiting example, a vehicle includes a body, an electric drive unit supported in the body, and a rechargeable energy storage system (RESS) electrically connected to the electric drive unit. The RESS includes a housing having a plurality of walls defining a battery cell receiving area, and a plurality of battery cells are disposed in the battery cell receiving area. A first electrical connector is connected to the plurality of battery cells, a second electrical connector is connected to the plurality of battery cells, and a circuit is defined between the first electrical connector, the second electrical connector, the plurality of battery cells, and the electric drive unit. A fuse is connected in the circuit. The fuse is disposed on the housing and configured to create an open circuit in the circuit.

[0016] In addition to one or more features described herein, the fuse is mounted to one of the plurality of walls.

[0017] In addition to one or more features described herein, the housing includes a cover, and the fuse is mounted to the cover.

[0018] In addition to one or more features described herein, a battery disconnect unit is disposed in the housing, and the fuse is mounted to the battery disconnect unit.

[0019] In addition to one or more features described herein, the fuse includes a base mounted to the RESS and an electrical contact removably selectively from the base.

[0020] In addition to one or more features described herein, the fuse includes a handle pivotally mounted to the electrical contact.

[0021] In addition to one or more features described herein, the fuse includes a latch element that secures an electrical contact to a base.

[0022] In addition to one or more features described herein, the fuse is a pyrotechnic fuse that includes a pyrotechnic element that selectively creates an open circuit.

[0023] In addition to one or more features described herein, the pyrotechnic element is part of the electrical contact.

[0024] In addition to one or more features described herein, the circuit includes a positive portion and a negative portion, and the fuse is disposed in the positive portion between a plurality of battery cells and an electric drive unit.

[0025] The above and other features and advantages of the present disclosure will become apparent when the following detailed description is read in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Other features, advantages, and details appear only by way of example in the following detailed description, which refers to the accompanying drawings, in which:

[0027] Figure 1 is a left side view of a vehicle including a battery assembly having a serviceable fuse according to a non - limiting example;

[0028] Figure 2 is a perspective view of a battery assembly including a serviceable fuse according to a non - limiting example;

[0029] Figure 3 is a schematic diagram according to a non - limiting example showing a serviceable fuse connected between a battery cell and a load of a Figure 2 battery assembly;

[0030] Figure 4 is a perspective view of a Figure 2 serviceable fuse according to a non - limiting example;

[0031] Figure 5 is a perspective view of a Figure 4 serviceable fuse according to a non - limiting example with the latch mechanism disengaged;

[0032] Figure 6 is a perspective view of a Figure 5 serviceable fuse according to a non - limiting example showing the electrical contact removed from the base;

[0033] Figure 7 shows a serviceable fuse installed to a battery disconnect unit of a battery assembly according to a non - limiting example; and

[0034] Figure 8Shows a serviceable fuse mounted to a sidewall of a housing of a battery assembly according to a non - limiting example. Detailed Description

[0035] 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 figures, corresponding reference numerals represent the same or corresponding components and features.

[0036] According to a non - limiting example, a vehicle is generally designated as 10 in Figure 1 The vehicle 10 includes a body 12 supported on a plurality of wheels 16. The body 12 partially defines a passenger compartment 20 that has a seat 23 located behind an instrument panel 26. A steering controller 30 is disposed between the seat 23 and the instrument panel 26. The steering controller 30 is operated to control the orientation of a selected one of the plurality of wheels 16. The vehicle 10 includes an electrical load shown in the form of an electric drive unit 34. The electric drive unit 34 provides power to one or more of the plurality of wheels 16.

[0037] A rechargeable energy storage system (RESS) or battery assembly 38 is disposed in the body 12 and provides power to the electric drive unit 34. In other arrangements, a fuel cell may be used to provide power to the electric drive unit 34. In this regard, it should be understood that the positions of the electric drive unit 34 and the battery assembly 38 can vary. In Figure 2 the non - limiting example shown, the RESS 38 includes a housing 42 that has a plurality of walls 44 defining a battery cell receiving area 48. In this regard, it should be understood that although the battery assembly 38 is shown in relation to the vehicle 10, the non - limiting examples described herein can be used for battery assemblies used in a wide range of applications and should not be considered limited to vehicle powertrains.

[0038] Continuing to refer to Figure 2 , the plurality of walls 44 at least include a first end wall 52, a second end wall 54 ( Figure 8 ), a first side wall 56, and a second side wall 58. The housing 42 encapsulates a plurality of battery cells 60 and a battery disconnect unit (BDU) 64 ( Figure 7 ). The BDU 64 is disposed between the plurality of battery cells 60 and the first end wall 52. A cover 66 is disposed on the housing 42 to protect the plurality of battery cells 60 and the BDU 64.

[0039] In the non - limiting example, a first electrical connector 70 and a second electrical connector 72 are mounted to the first end wall 52. As Figure 3As shown, circuit 80 is defined between a first electrical connector 70 and a second electrical connector 72. Circuit 80 couples a plurality of battery cells 60 to high-voltage vehicle components such as an electric drive unit 34. In a non-limiting example, circuit 80 includes a positive portion 82 extending between a positive terminal (not separately labeled) of battery assembly 38 and the first electrical connector 70, and a negative portion 84 extending between a negative terminal (also not separately labeled) of battery assembly 38 and the second electrical connector 72.

[0040] In a non-limiting example, battery assembly 38 includes a fuse 90 disposed in circuit 80. In one non-limiting example, fuse 90 is mounted to cover 66 ( Figure 2 ) and positioned to interrupt current flowing through positive portion 82 of circuit 80 to electric drive unit 34.

[0041] Referring Figure 4 to, fuse 90 includes a base 96 and an electrical contact 98. Electrical contact 98 is removably connected to base 96. When electrical contact 98 is connected to base 96, current flows through circuit 80 from the plurality of battery cells 60 to electric drive unit 34. When electrical contact 98 is removed from base 96, an open circuit is created, interrupting current flow. In a non-limiting example, electrical contact 98 includes a handle 104 having a latch element 106. Base 96 includes a projection 109 that is aligned with handle 104 and is selectively engaged by latch element 106.

[0042] To remove electrical contact 98 from base 96, rotate handle 104 as Figure 5 shown. Rotation of handle 104 causes latch element 106 to disengage from projection 109. When latch element 106 disengages from projection 109, electrical contact 98 can be removed from base 96, as Figure 6 shown, to interrupt current from battery assembly 38 to circuit 80. By disposing fuse 90 in an easily accessible area (such as cover 66), current can be more easily cut off during maintenance of vehicle 10. Additionally, in the event of a fuse failure, replacement of electrical contact 98 can be achieved without removing battery assembly 38 from vehicle 10.

[0043] In addition to interrupting current flow by removing electrical contact 98 from base 96, fuse 90 will also interrupt current flow when an overcurrent condition is detected. That is, if the current draw on the first plurality of battery cells 60 exceeds a defined threshold, fuse 90 will trip, creating an open circuit in the first circuit 80. In a non-limiting example, current detection can be performed by an additional circuit (not shown) located inside electrical contact 98.

[0044] Current detection may also be performed by a circuit (not shown) external to the electrical contact portion 98, where a discrete signal is used to trip the fuse 90. It should be understood that tripping the fuse 90 is not limited to the case of overcurrent within the battery. For various situations where a high-voltage circuit needs to be quickly disconnected, including, for example, when a force that may trigger an airbag is detected, the fuse 90 may be triggered by various discrete signals from an external source.

[0045] In a non-limiting example, the fuse 90 takes the form of a pyrotechnic fuse 116 having a pyrotechnic element 118 as shown in Figure 3 The pyrotechnic element 118 is selectively activated to create an open circuit 80. The pyrotechnic element 118 ensures that the first fuse 90 responds quickly to the need to disconnect the high voltage of the battery (such as an overcurrent condition, airbag deployment, etc.). In a non-limiting example, the pyrotechnic element 118 will disconnect the circuit 80 within 2 milliseconds or less. The use of the pyrotechnic element 118 ensures a quick response to overcurrent conditions or other triggering events with limited response variability.

[0046] At this point, it should be understood that the location of the fuse 90 may vary. That is, depending on the vehicle make, model, and / or accessories, the fuse 90 may be arranged at different positions on the battery assembly 38. For example, as shown in Figure 7 In one non-limiting example, the fuse 90 may be mounted to the BDU 64 under the cover 66. When mounted to the BDU 64, the fuse 90 may be accessed through the cover 66. In another non-limiting example, the fuse 90 may be mounted to the second end wall 54, as shown in Figure 8 The mounting location is selected to facilitate access to the fuse 90 by technicians and other maintenance personnel. In another non-limiting example, several battery cells may supply power to the BDU. In such a non-limiting example, the battery assembly 38 may include multiple fuses. In any case, it should be understood that by being located in an easily accessible area, in addition to interrupting power when a triggering event (such as an overcurrent condition, collision force, etc.) is detected, the fuse may also be used as a manual service disconnect (MSD), which allows technicians to isolate electrical components from the high-voltage power source during maintenance.

[0047] The terms "a" and "an" do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. 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 properties) 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.

[0048] 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" can include a range of ±8% or 5% or 2% of a given value.

[0049] 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, there are no intervening elements.

[0050] Unless stated to the contrary herein, all test standards are the latest 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.

[0051] 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.

[0052] 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 substitute 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 rechargeable energy storage system (RESS), the RESS comprising: A housing having a plurality of walls defining a battery cell receiving area; A plurality of battery cells disposed in the battery cell receiving area; A first electrical connector connected to the plurality of battery cells; A second electrical connector connected to the plurality of battery cells; A circuit defined between the first electrical connector, the second electrical connector, the plurality of battery cells, and an electrical load; And A fuse connected in the circuit, the fuse being disposed on the housing and configured to create an open circuit in the circuit.

2. The RESS according to claim 1, wherein, The fuse is mounted to one of the plurality of walls.

3. The RESS according to claim 1, wherein, The housing includes a cover, and the fuse is mounted to the cover.

4. The RESS according to claim 1, further comprising a battery disconnect unit disposed in the housing, the fuse being mounted to the battery disconnect unit.

5. The RESS according to claim 1, wherein The fuse includes a base mounted to the RESS and an electrical contact portion selectively removable from the base.

6. The RESS according to claim 5, wherein, The fuse includes a handle pivotally mounted to the electrical contact portion.

7. The RESS according to claim 6, wherein, The fuse includes a latch element securing the electrical contact portion to the base.

8. The RESS according to claim 5, wherein, The fuse is a pyrotechnic fuse including a pyrotechnic element selectively creating the open circuit.

9. The RESS according to claim 8, wherein, The pyrotechnic element is part of the electrical contact portion.

10. A vehicle, comprising: A body; An electric drive unit supported in the body; And The rechargeable energy storage system (RESS) according to claim 1, electrically connected to the electric drive unit.

Images