Optimized battery disconnect unit

Abstract

Apparatuses and methods for an optimized battery disconnect unit are disclosed. In a particular embodiment, a battery disconnect unit includes: a housing; a configuration contactor disposed within the housing; a combined contactor and explosive fuse assembly disposed within the housing and electrically coupled to the configuration contactor; a battery charging contactor disposed within the housing and electrically coupled to the combined contactor and explosion fuse assembly; and a bus bar assembly. In some examples, the busbar assembly is layered.

Description

Background Art

[0001] Electromechanical switching devices, such as contactors and relays, are designed to carry a certain amount of current over a certain period of time. Such devices are particularly important in electric vehicles. Typically, electric vehicles have a battery management system that includes a battery disconnect unit (BDU). The BDU is the primary interface between the battery pack and the electrical system. The BDU includes electromechanical switches that open or close the high-current path between the battery pack and the electrical system. The BDU can be a large, complex, and expensive component of an electric vehicle. In some designs, the BDU can be prone to overheating. Summary of the Invention

[0002] Apparatus and methods for an optimized battery disconnect unit are disclosed. In various embodiments, the size and complexity of a battery disconnect unit (BDU) is reduced by encapsulating a configuration contactor, a dual combined contactor and pyrofuse assembly, and dual fast-charging contactors in a single housing. In other embodiments, the size and complexity of the BDU is reduced by encapsulating a configuration contactor, pyrofuse, dual main contactors, dual fast-charging contactors, and dual utility contactors in a single housing. Layered busbars are used to increase power density while also providing a common interface for cooling plates, thereby enhancing the cooling capacity of the BDU. The integrated system also provides electrical isolation from dynamic conditions and improved performance under high loads. The complexity of the assembly process is also reduced.

[0003] Specific embodiments relate to a battery disconnect unit comprising: a housing; a configuration contactor disposed within the housing; a combined contactor and explosive fuse assembly disposed within the housing and electrically coupled to the configuration contactor; a battery charging contactor disposed within the housing and electrically coupled to the combined contactor and explosive fuse assembly; and a busbar assembly. In some examples, the busbar assembly is layered. In some examples, the busbar assembly includes terminals in one or more planes. In some examples, at least two terminals are stacked. In various examples, the busbar assembly includes a plurality of busbars, each having a surface exposed through the bottom of the housing. In these examples, the battery disconnect unit can be configured to be mounted on a cooling plate. In some examples, one or more battery sensors are disposed within the housing.

[0004] Another embodiment relates to a method of assembling a battery disconnect unit. The method includes providing a busbar assembly in a base of a housing; coupling a configuration contactor, a dual combination contactor and explosive fuse assembly, and dual rapid charge contactors to the busbar assembly; and placing a cover of the housing over the configuration contactor, the dual combination contactor and explosive fuse assembly, and the dual rapid charge contactors.

[0005] Yet another embodiment relates to a battery disconnect unit, comprising: a housing; a configuration contactor disposed within the housing; an explosion fuse disposed within the housing and electrically coupled to the configuration contactor; dual main contactors disposed within the housing and electrically coupled to the explosion fuse; dual fast-charging contactors disposed within the housing and electrically coupled to the dual main contactors; dual common contactors; and a busbar assembly coupled to the configuration contactor, the explosion fuse, the dual main contactors, the dual fast-charging contactors, and the dual common contactors. In some examples, the battery disconnect unit further comprises a thermally conductive pad disposed on the bottom surface of the housing. In some examples, the busbar assembly comprises a plurality of busbars, each of which has a surface exposed through the bottom surface of the housing. In some examples, the battery disconnect unit further comprises one or more battery sensors.

[0006] Yet another embodiment relates to a method of assembling a battery disconnect unit. The method includes providing a busbar assembly in a base of a housing; coupling a configuration contactor, an explosive fuse, dual main contactors, dual fast-charging contactors, and dual common contactors to the busbar assembly; and placing a cover of the housing over the configuration contactor, explosive fuse, dual main contactors, dual fast-charging contactors, and dual common contactors. In some examples, the method also includes placing a thermally conductive pad on a bottom surface of the housing. In some examples, the busbar assembly includes a plurality of busbars, each of which has a surface exposed through the bottom surface of the housing. In some examples, the method also includes installing one or more battery sensors.

[0007] The foregoing and other objects, features, and advantages of the invention will be apparent from the following more particular description of exemplary embodiments of the invention, as illustrated in the accompanying drawings, wherein like reference numerals generally represent like parts of exemplary embodiments of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a schematic diagram of an exemplary battery disconnect unit according to at least one embodiment of the present disclosure.

[0009] Figure 2 According to at least one embodiment of the present disclosure Figure 1 Schematic diagram of an example busbar assembly of a battery disconnect unit.

[0010] Figure 3 According to at least one embodiment of the present disclosure Figure 1 Schematic diagram of an example housing base of a battery disconnect unit.

[0011] Figure 4 is installed in accordance with at least one embodiment of the present disclosure Figure 3 In the shell base Figure 2 Schematic diagram of the busbar assembly.

[0012] Figure 5 is partially assembled according to at least one embodiment of the present disclosure Figure 1 Schematic diagram of an example battery disconnect unit.

[0013] Figure 6 is partially assembled according to at least one embodiment of the present disclosure Figure 1 Another schematic diagram of an example battery disconnect unit.

[0014] Figure 7 is fully assembled according to at least one embodiment of the present disclosure Figure 1 Schematic diagram of an example battery disconnect unit.

[0015] Figure 8 According to at least one embodiment of the present disclosure Figure 1 Bottom view of an example battery disconnect unit.

[0016] Figure 9 According to at least one embodiment of the present disclosure Figure 1 Example electrical schematic for an example battery disconnect unit.

[0017] Figure 10 According to at least one embodiment of the present disclosure Figure 1 Example terminal specifications for an example battery disconnect unit.

[0018] Figure 11 is a flow chart of an example method of assembling an example battery disconnect unit according to at least one embodiment of the present disclosure.

[0019] Figure 12A is an exploded view of another example battery disconnect unit in accordance with at least one embodiment of the present disclosure.

[0020] Figure 12B yes Figure 12A Another exploded view of the battery disconnect unit.

[0021] Figure 13 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B A perspective bottom view of an example battery disconnect unit.

[0022] Figure 14 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B A top view of an example battery disconnect unit.

[0023] Figure 15 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B A perspective view of an example battery disconnect unit.

[0024] Figure 16 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Bottom view of an example battery disconnect unit.

[0025] Figure 17 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Another perspective view of an example battery disconnect unit.

[0026] Figure 18 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Another perspective view of an example battery disconnect unit.

[0027] Figure 19 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Front view of an example battery disconnect unit.

[0028] Figure 20 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Side view of an example battery disconnect unit.

[0029] Figure 21 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Example terminal specifications for an example battery disconnect unit.

[0030] Figure 22 According to at least one embodiment of the present disclosure Figure 12A and Figure 12B Example electrical schematic for an example battery disconnect unit.

[0031] Figure 23 is a flow chart of another example method of assembling an example battery disconnect unit according to at least one embodiment of the present disclosure.

[0032] Figure 24 is an example electrical schematic diagram of components including an example battery disconnect unit, in accordance with at least one embodiment of the present disclosure.

[0033] Figure 25A is an exploded view of another example battery disconnect unit in accordance with at least one embodiment of the present disclosure.

[0034] Figure 25B According to at least one embodiment of the present disclosure Figure 25AA top view of the assembly of some components of an example battery disconnect unit.

[0035] Figure 25C According to at least one embodiment of the present disclosure Figure 25A An example of an assembly of some components of a battery disconnect unit and Figure 25B A perspective view of the components.

[0036] Figure 26 Is from Figure 25A An example of an assembly of some components of a battery disconnect unit and Figure 25B An example simplified electrical schematic of the components. DETAILED DESCRIPTION

[0037] For the purpose of describing specific examples, the terms used herein are not intended to limit other examples. Whenever singular forms such as "a", "an", and "the" are used and the use of only a single element is neither explicitly nor implicitly defined as mandatory, other examples may also use plural elements to implement the same function. Similarly, when a function is subsequently described as being implemented using multiple elements, further examples may use a single element or processing entity to implement the same function. It will be further understood that the terms "comprises", "comprising", "includes", and / or "including" when used specify the presence of the feature, whole, step, operation, process, action, element, and / or part, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, processes, actions, elements, parts, and / or any groups thereof.

[0038] It will be understood that when an element is referred to as being "connected" or "coupled" to another element, those elements may be directly connected or coupled or via one or more intermediate elements. If two elements A and B are combined using "or," this should be understood to disclose all possible combinations, i.e., only A, only B, and A and B. An alternative wording for the same combination is "at least one of A and B." The same applies to combinations of more than two elements.

[0039] Accordingly, although further examples are capable of various modifications and alternative forms, certain specific examples thereof are shown in the drawings and will be described in detail subsequently. However, this detailed description does not limit other examples to the specific forms described. Other examples may encompass all modifications, equivalents, and alternatives that fall within the scope of this disclosure. Throughout the description of the drawings, the same reference numerals represent the same or similar elements, which, when compared to each other, may be implemented identically or in modified form while providing the same or similar functions.

[0040] The description of the embodiment begins with Figure 1 start. Figure 1 A schematic diagram of an example battery disconnect unit (BDU) 100 according to at least one embodiment of the present disclosure is illustrated. The example BDU 100 includes a housing formed by a housing base 102 and a housing cover 103 (shown as translucent for clarity). The housing integrates a configuration contactor 110, a dual combination contactor and explosive fuse assembly 120, and a dual fast charging contactor 130. The busbar assembly 200 includes contact plates for connecting the configuration contactor 110, the dual combination contactor and explosive fuse assembly 120, and the dual fast charging contactor 130, and terminals 105 for engaging with external components. The busbar assembly 200, and therefore the terminals 105, are layered such that different terminals can exist in different horizontal planes of the BDU 100. In some examples, the terminals 105 can be stacked in different planes. In Figure 1 In the following figures, direction D represents the reference side and orientation of the BDU.

[0041] exist Figure 1 In the example, the example BDU 100 includes a configuration contactor, a dual combined contactor and explosive fuse assembly, a dual fast-charging contactor, and two battery current sensors in an orientation optimized to accommodate these components. In the example BDU 100, the shared contactor / combined contactor and explosive fuse assembly, as well as the housing, minimizes the height, length, and width of the BDU and maximizes power density. The optimized busbar layout maximizes power density, and the busbars are configurable in sections to meet the needs of different cooling strategies. In the example BDU 100, the busbars share a single surface for mounting on a cooling plate via an electrically insulating pad. The busbars are recessed into the bottom of the housing to allow for a single-plane interface between the cooling pad and the cooling plate. The example BDU 100 includes dedicated busbar ducting for maximum possible creepage clearance and electrical insulation performance. Limited and configurable mounting points reduce installation costs. The example BDU provides optimized thermal efficiency by including cooling pads between the dual combined contactor and the explosive fuse assembly and dual fast-charging contactors. The complexity of the BDU assembly process is reduced and simplified, and copper utilization is reduced due to the compact design.

[0042] To further illustrate, Figure 2A schematic diagram of an example busbar assembly 200 of an example BDU 100 according to at least one embodiment of the present disclosure is illustrated. The example busbar assembly 200 includes busbars 201, 202, 203, 204, 205, 206, 207, 208, 209, 210 having contact plates in different planes. For example, in the example busbar assembly 200, busbar 201 includes an internal component contact plate 201a (e.g., for interfacing with the fast charge contactor 130) in a first plane and an external component contact plate 201b in a different plane. Similarly, busbar 202 includes an internal component contact plate 202a (e.g., for interfacing with the fast charge contactor 130) in a first plane and an external component contact plate 202b in a different plane.

[0043] In some examples, the busbar includes external component contact plates in multiple planes. For example, busbar 203 includes an internal component contact plate 203a in a first plane (e.g., for interfacing with the fast-charging contactor 130 and the combined contactor and explosive fuse assembly 120), an external component contact plate 203b in a second plane, and another external component contact plate 203c in a third plane. External contact plates in multiple planes can also be stacked. For example, busbar 204 includes an internal component contact plate 204a in a first plane (e.g., for interfacing with the fast-charging contactor 130 and the combined contactor and explosive fuse assembly 120), an external component contact plate 204b in a second plane, and another external component contact plate 203c in a third plane, wherein the external component contact plates 204b and 204c are stacked.

[0044] In some examples, one contact plate is perpendicular to the other contact plate. For example, busbar 209 includes an internal component contact plate 209a (e.g., for interfacing with the combined contactor and explosive fuse assembly 120) and another internal component contact plate 209b perpendicular to contact plate 209a (e.g., for interfacing with the configuration contactor 110). Busbar 208 includes an internal component contact plate 208a (e.g., for interfacing with the configuration contactor 110) and another contact plate 208b perpendicular to contact plate 208a for interfacing with another busbar 210.

[0045] Busbar assembly 200 also includes busbar 205 having an inner component contact plate 205a in a first plane (e.g., for interfacing with the combined contactor and explosive fuse assembly 120 and the configuration contactor 110) and an outer component contact plate 205b in a second plane. Busbar 206 includes an inner component contact plate 206a in a first plane (e.g., for interfacing with the configuration contactor 110) and an outer component contact plate 206b in a second plane. Busbar 207 includes an inner component contact plate 207a in a first plane (e.g., for interfacing with the configuration contactor 110) and an outer component contact plate 207b in a second plane. Busbar 210 includes a contact plate 210a for interfacing with busbar 208 and an outer component contact plate 210b.

[0046] In some examples, the internal component contact plates 201a, 202a, 203a, 204a, 205a, 206a, 207a, 208a, 209a are arranged in the same plane, so that these contact plates also serve as cooling pads on the bottom of the BDU 100 (on the surface opposite the internal component interface), where the cooling pads interface with the cooling plates used to cool the BDU. In some examples, the internal component contact plates 202b, 203b, 205b, 207b exist in the same plane. In some examples, the internal component contact plates 201b, 204b, 206b, 208a, 209a exist in the same plane. In some examples, the internal component contact plates 201b, 202b, 203b, 204b, 205b, 206b, 207b, 208b, 209b all exist in the same plane.

[0047] To further illustrate, Figure 3 A schematic diagram of a housing base 102 of an example BDU 100 according to at least one embodiment of the present disclosure is illustrated. The housing base 102 includes corresponding holes 301 for positioning internal component contact plates 201a, 202a, 203a, 204a, 205a, 206a, 207a, 208a, 209a. The internal contact plates are positioned in the holes so that when the BDU 100 is mounted on a cooling plate (not shown), the bottom surfaces of the internal contact plates (opposite the surfaces that interface with the internal components) can engage the cooling plate. The housing base 102 also includes a platform 302 for supporting the external component contact plates described above. The platform 302 may include holes for terminals. To further illustrate, Figure 4 Clarifies the placement Figure 3 On the housing base 102 Figure 2 A schematic diagram of the busbar assembly 200 is shown. Figure 4, each busbar 201, 202, 203, 204, 205, 206, 207, 208, 209, 210 is supported by a corresponding platform 302 (except busbars 208, 209), and each of these busbars is located in a corresponding hole 301 (except busbar 210).

[0048] To further illustrate, Figure 5 、 Figure 6 and Figure 7 illustrates a perspective view of an example BDU 100 in accordance with at least one embodiment of the present disclosure. Figure 5 In FIG, with the housing cover 103 removed, it can be seen that the configuration contactor 110, the combined contactor and explosion fuse assembly 120, and the fast charging contactor 130 are placed on the busbar assembly 200 within the housing base 102. The busbars of the busbar assembly 200 include terminals 105 for interfacing with external components. These terminals can be laser welded or bolted to the external component contact plates of the busbar assembly. Figure 6 It is from Figure 5 A view of an example BDU 100 looking in the opposite direction of the view. Figure 7 , an example BDU 100 is shown with the housing cover 103 assembled.

[0049] To further illustrate, Figure 8 illustrates a perspective bottom view of an example BDU 100 in accordance with at least one embodiment of the present disclosure. Figure 8 In the view of FIG, it can be seen that the bottom surface of the busbars 201, 202, 203, 204, 205, 206, 207, 208, 209 is a cooling pad that provides a common surface for engaging with a cooling plate (not shown). This enhances the cooling capacity of the BDU 100.

[0050] To further illustrate, Figure 9An example electrical schematic 900 of an example battery-powered vehicle (BDU) 100 according to at least one embodiment of the present disclosure is illustrated. The BDU 100 includes dual configuration contactors 906, dual combined contactor and explosive fuse assemblies 908, and dual fast-charge contactors 910. The high-efficiency configuration contactors 906 include a positive battery switch, a negative battery switch, and a main switch connected to battery packs 902 and 904 via respective circuits. Battery pack sensors (BCSs) are connected to battery packs 902 and 904. Configuration contactors 906 are connected to dual combined contactor and explosive fuse assemblies 908, which include main contactors and explosive fuses. Combined contactor and explosive fuse assemblies 908 are connected to dual fast-charge contactors 910, which are connected to onboard chargers 916, a front inverter 912 (e.g., for front-wheel drive), a rear inverter 914 (e.g., for rear-wheel drive), and fast-charge terminals. The BDU 100 is also connected to a DC-DC converter 918 .

[0051] To further illustrate, Figure 10 An example terminal diagram 1000 for an example BDU 100 is illustrated in accordance with at least one embodiment of the present disclosure.

[0052] To further illustrate, Figure 11 A flow chart illustrating an example method for assembling a BDU is set forth in accordance with at least one embodiment of the present disclosure. Figure 11 The method includes providing a busbar assembly 1102 in a base of a housing. For example, Figures 2 to 4 As illustrated, the busbar assembly may be placed in the housing base. Figure 11 The method also includes coupling the configuration contactor, the dual combined contactor and explosion fuse assembly, and the dual rapid charge contactor to the busbar assembly 1104. For example, Figure 5 and Figure 6 As shown, a configuration contactor, a dual combination contactor and explosion fuse assembly, and a dual rapid charge contactor can be coupled to the busbar assembly. Figure 11 The method also includes placing a cover of the housing over the configured contactors, the dual combined contactor and explosion fuse assembly, and the dual fast charging contactors 1106. When the cover is placed on the housing, the external component contact plates and the terminals thereon may remain exposed. In some examples, the external component contact plates may be layered such that the contact plates and terminals are present on different planes of the BDU. In some examples, the external component contact plates may be stacked. In some examples, the bottom surface of the base of the housing exposes the internal component contact plates such that the surfaces of these contact plates form a cooling pad for engaging with the cooling plate.

[0053] Figure 12A and Figure 12BAn exploded view of another example BDU 1200 is illustrated, in accordance with at least one embodiment of the present disclosure. Figure 12A and Figure 12B Different sides of an example BDU 1200 are illustrated. Figure 12A Side A (i.e., the port side) of the BDU 1200 is shown, and Figure 12B Side B (i.e., the terminal side) is shown. The example BDU 100 includes a housing 1204 formed by a housing base 1202 and a housing cover 1203. The housing integrates a configuration contactor 1210, dual main contactors 1214, an explosion fuse 1212, dual fast charging contactors 1216, dual common contactors 1218, an auxiliary fuse 1224, and two battery current sensors 1220 and 1222 including low / high temperature measurement. The busbar assembly 1250 includes busbars (e.g., seventeen in this example) for variously connecting the configuration contactor 1210, dual main contactors 1214, explosion fuses 1212, dual fast charging contactors 1216, dual common contactors 1218, auxiliary fuses 1224, and two battery current sensors 1220 and 1222, as well as terminals 1205 for interfacing with external components. The busbar assembly 1250, and therefore the terminals 1205, are layered so that different terminals can exist in different horizontal planes of the BDU 1200. In some examples, the terminals 105 can be stacked in different planes. In the example BDU 1200, the busbars of the busbar assembly 1250 share a surface in one plane for mounting on a cooling plate via thermal pads 1230. The busbars are sunken into the bottom of the housing base 1202 to allow a single-plane interface between the cooling pad and the cooling plate. The contactors of the BDU 1200 are mounted perpendicular (vertically) relative to the busbar plane, while the current sensors and fuses are mounted parallel (horizontally) relative to the busbar plane.

[0054] exist Figure 12A and Figure 12BIn the example, a shared housing 1204 (e.g., a plastic housing) houses a contactor 1210, dual main contactors 1214, an explosion fuse 1212, dual fast-charging contactors 1216, dual common contactors 1218, an auxiliary fuse 1224, and two battery current sensors 1220, 1222 in an orientation that minimizes the height, length, and width of the housing box, reduces material consumption, and maximizes power density. The BDU 1200 may also include four NTC temperature sensors for hotspot monitoring, a high-voltage (HV) sensor for voltage drop monitoring, and a wiring harness with HV and LV connectors for connecting the low-voltage (LV) and HV to the battery management system. The optimized busbar layout achieves maximum power density, and the busbar is configurable in sections to meet the needs of different cooling strategies. The example BDU 1200 includes dedicated busbar ducts for maximum possible creepage clearance and electrical insulation performance. Limited and configurable mounting points can reduce installation costs. The example BDU 1200 provides optimized thermal efficiency by including cooling pads between the dual combined contactor and explosion fuse assembly and the dual fast charging contactors. This reduces and simplifies the complexity of the BDU assembly process and reduces copper utilization due to the compact design.

[0055] To further illustrate, Figure 13 Shown Figure 12A and Figure 12B Bottom view of the BDU 1200. The layout of the busbar assembly 1250 is shown in Figure 13 1202, including connections for configuration contactor 1210, dual main contactors 1214, explosive fuses 1212, dual fast charging contactors 1216, and dual common contactors 1218. For clarity, housing 1204 is shown as translucent. Each busbar of busbar assembly 1250 is sunken into housing base 1202. As can be seen, each busbar in busbar assembly 1250 includes a surface in a common plane, wherein each busbar is located in housing base 1202 such that the bottom surface of each busbar is exposed through housing base 1202. This orientation provides for connection with Figure 12A and Figure 12B The cooling plate or thermal pad 1230 engages a uniform surface.

[0056] To further illustrate, Figure 14 Shown with housing cover 1203 removed Figure 12A and Figure 12B Schematic diagram of a top view of the BDU 1200. Figure 14 It includes a configuration contactor 1210 located on the housing base 1202 , dual main contactors 1214 , an explosion fuse 1212 , dual fast charging contactors 1216 , dual common contactors 1218 and an auxiliary fuse 1224 . Figure 14Also shown is the layout of the terminals 1205. In addition to the port side A and terminal side B, Figure 14 Transverse side C and transverse side D are also shown.

[0057] To further illustrate, Figure 15 Shown in assembled state Figure 12A and Figure 12B A perspective view of the BDU 1200. Figure 15 The view of FIG shows the terminal side B. FIG shows the terminal 1205 and the housing 1204 .

[0058] To further illustrate, Figure 16 Shown Figure 12A and Figure 12B Bottom plan view of BDU 1200. Shows the layout of busbar assembly 1250.

[0059] To further illustrate, Figure 17 Shown in assembled state Figure 12A and Figure 12B Bottom perspective view of the BDU 1200.

[0060] To further illustrate, Figure 18 Shown in assembled state Figure 12A and Figure 12B Top perspective view of the BDU 1200.

[0061] To further illustrate, Figure 19 Shown in assembled state Figure 12A and Figure 12B Front view of the BDU 1200. Figure 19 The view shows port side A.

[0062] To further illustrate, Figure 20 Shown in assembled state Figure 12A and Figure 12B Side view of the BDU 1200. Figure 20 The view shows Figure 14 The lateral side D of the reference.

[0063] To further illustrate, Figure 21 Shown in assembled state Figure 12A and Figure 12B Example terminal diagram for the BDU 1200. Figure 20In FIG, Group 1+ and Group 1- are the positive and negative terminals of configuration contactor 1210 connected to the first battery pack. Group 2+ and Group 2- are the positive and negative terminals of configuration contactor 1210 connected to the second battery pack. Traction VA-HA+ and Traction VA-HA- are the positive and negative terminals of dual main contactor 1214. DC Charge+ and DC Charge- are the positive and negative terminals of dual fast charge contactor 1216. Utiliti+ and Utiliti- are the positive and negative terminals of dual utility contactor 1218.

[0064] To further illustrate, Figure 22 The present invention illustrates at least one embodiment of the present invention. Figure 12A and Figure 12B An example electrical schematic diagram 2200 of an example BDU 1200 is provided. Figure 22 In the figure, the dashed box diagram shows the switch components of the configuration contactor 1210, dual main contactors 1214, dual fast charging contactors 1216, and dual common contactors 1218 of the BDU 1200. The BDU 1200 is connected to the two battery packs 2220 and 2222 via the configuration contactors. The explosion fuse 1212 is also shown. The dual main contactors 1214 connect the BDU 1200 to the front inverter 2214 and the rear inverter 2216. The dual common contactors 1218 connect the BDU 1200 to the on-board charger (OBC), DC-to-DC converter, and other accessories.

[0065] To further illustrate, Figure 23 A flow chart illustrating an example method of assembling a BDU in accordance with at least one embodiment of the present disclosure is set forth. Figure 11 The method includes providing a busbar assembly 2302 in a base of a housing. For example, the busbar assembly may be placed in the housing base, such as Figure 12A and Figure 12B As shown in the figure. Figure 23 The method further includes coupling the configuration contactor, the explosive fuse, the dual main contactors, the dual fast charging contactors, and the dual common contactors to the bus assembly 2304. For example, the configuration contactor, the explosive fuse, the dual main contactors, the dual fast charging contactors, and the dual common contactors may be coupled to the bus assembly, such as Figure 12A and Figure 12B shown. Figure 11 The method also includes placing a cover of the housing over the configuration contactor, the exploding fuse, the dual main contactors, the dual fast charge contactors, and the dual common contactors 2306 .

[0066] To further illustrate, Figure 24 An example electrical schematic diagram illustrating components including an example battery disconnect unit (BDU) 2400 is illustrated in accordance with at least one embodiment of the present disclosure. Figure 24In the diagram, the terminals of battery pack 2422 are connected to battery current sensor (BCS) 2421 and explosion fuses 2440 and 2412 within BDU 2400. The battery current sensor (BCS) and explosion fuses are connected to refrigerant compressor 2430, front motor inverter 2416, rear motor inverter 2414, and onboard charging (OBC) / DC-to-DC converter module 2480. Dual main contactors 2490 connect BDU 2400 to NACS charging connector 2481 and onboard charging (OBC) / DC-to-DC converter module 2480.

[0067] To further illustrate, Figure 25A An exploded view of another example battery disconnect unit (BDU) 2500 according to at least one embodiment of the present disclosure is illustrated. BDU 2500 includes a top cover 2502, a printed circuit board (PCB) 2504, a contactor cover 2506, uncovered contactors 2508, a contactor adapter 2510, a high efficiency contactor (HEC) 2512, an exploding fuse 2514, a current sensor 2516, a main housing 2518, a busbar assembly 2520, a bottom plastic piece 2522, and a thermal gap filler 2524.

[0068] To further illustrate, Figure 25B Illustrated in accordance with at least one embodiment of the present disclosure Figure 25A A top view of an assembly 2501 of some components of an example battery disconnect unit. Figure 25B In assembly 2501, HEC 2512 and explosive fuse 252 are coupled to busbar assembly 2520. A first shunt 2516 and a second shunt 2515 are also coupled to busbar assembly 2520. Four battery connectors 2550, 2552, 2554, and 2556 are exposed on busbar assembly 2520 for connection to a battery bank. Busbar assembly 2520 also includes a positive direct current (DC) output 2526, a positive main output 2538, a negative DC output 2534, and a second negative output 2532.

[0069] To further illustrate, Figure 25C Illustrated in accordance with at least one embodiment of the present disclosure Figure 25A A perspective view of an assembly 2503 of some components of an example battery disconnect unit (BDU) 2500. Figure 25C Component 2503, shows a PCB placeholder 2560 instead of Figure 25A PCB 2504. Contactor pockets 2540, mounting holes 2530, PCB and cover support 2542, NTC feedthrough 2591 and wiring support 2570 are also shown.

[0070] To further illustrate, Figure 26 Explained from Figure 25A An example of a battery disconnect unit (BDU) 2500 with some components and Figure 25B An example simplified electrical schematic 2601 of an assembly 2501 including a HEC 2512, an exploding fuse 2514, a first shunt 2516, and a second shunt 2515. Figure 26 In the example shown, HEC 2512 acts as a contactor for a group of batteries, which are connected to the positive outputs 2538, 2536 and negative outputs 2532, 2534 of the assembly.

[0071] In view of the above, it will be appreciated that combining these components in a single housing reduces size and increases power density, increases cooling capacity, and increases the insulation characteristics of these components. The simplified design through the use of combined components enhances BDU performance, reduces and simplifies the complexity of the BDU assembly process, and reduces copper utilization due to compact design and optimal cooling.

[0072] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functions and operations of possible implementations of the systems, devices, methods and computer program products according to various embodiments of the present invention. To this end, each box in the flowchart or block diagram may represent a module, segment or portion of an instruction, which includes one or more executable instructions for implementing a specified logical function. In some alternative implementations, the functions marked in the box may not occur in the order marked in the figure. For example, depending on the functions involved, the two boxes shown in succession may actually be executed substantially simultaneously, or the boxes may sometimes be executed in the opposite order. It should also be noted that each box in the block diagram and / or flowchart, and the combination of the boxes in the block diagram and / or flowchart, can be implemented by a dedicated hardware-based system that performs a specified function or action or performs a combination of dedicated hardware and computer instructions.

[0073] The advantages and features of the present disclosure can be further described by the following statements:

[0074] 1. A battery disconnect unit comprising: a housing; a configuration contactor disposed within the housing; a combined contactor and explosive fuse assembly disposed within the housing and electrically coupled to the configuration contactor; a battery charging contactor disposed within the housing and electrically coupled to the combined contactor and explosive fuse assembly; and a busbar assembly.

[0075] 2. The battery disconnect unit of statement 1, wherein the busbar assembly is layered.

[0076] 3. A battery disconnect unit according to statement 1 or 2, wherein the busbar assembly includes terminals in one or more planes.

[0077] 4. A battery disconnect unit according to any one of statements 1 to 3, wherein at least two terminals are stacked.

[0078] 5. The battery disconnect unit of any one of Statements 1 to 4, wherein the busbar assembly comprises a plurality of busbars, each of the plurality of busbars having a surface exposed through the bottom of the housing.

[0079] 6. The battery disconnect unit according to any one of statements 1 to 5, wherein the battery disconnect unit is configurable for mounting on a cooling plate.

[0080] 7. A battery disconnect unit according to any one of statements 1 to 6, further comprising one or more battery current sensors arranged within the housing.

[0081] 8. A method of assembling a battery disconnect unit, the method comprising: providing a busbar assembly in a base of a housing; coupling a configuration contactor, a dual combination contactor and explosive fuse assembly, and a dual rapid charge contactor to the busbar assembly; and placing a cover of the housing over the configuration contactor, the dual combination contactor and explosive fuse assembly, and the dual rapid charge contactor.

[0082] 9. The method of statement 8, wherein the base includes a plurality of holes; wherein the busbar assembly includes a plurality of busbars; and wherein each busbar is located in a corresponding hole.

[0083] 10. A method according to statement 8 or 9, wherein the busbar assembly is layered.

[0084] 11. A method according to any one of statements 8 to 10, wherein the busbar assembly comprises terminals located in one or more planes.

[0085] 12. The method of any one of statements 8 to 11, wherein at least two terminals are stacked.

[0086] 13. The method according to any of statements 8 to 12, wherein the battery disconnect unit is configurable for mounting on a cooling plate.

[0087] 14. A battery disconnect unit, comprising: a housing; a configuration contactor disposed in the housing; an explosion fuse disposed in the housing and electrically connected to the configuration contactor; dual main contactors disposed in the housing and electrically connected to the explosion fuse; dual fast-charging contactors disposed in the housing and electrically connected to the dual main contactors; dual common contactors; and a busbar assembly coupled to the configuration contactor, the explosion fuse, the dual main contactors, the dual fast-charging contactors, and the dual common contactors.

[0088] 15. The battery disconnect unit of statement 14, further comprising a thermally conductive pad disposed on the bottom surface of the housing.

[0089] 16. A battery disconnect unit according to statement 14 or 15, wherein the busbar assembly comprises a plurality of busbars, each of the plurality of busbars having a surface exposed through the bottom surface of the housing.

[0090] 17. A battery disconnect unit according to any of statements 14 to 16, further comprising one or more battery sensors.

[0091] 18. A method of assembling a battery disconnect unit, comprising: providing a busbar assembly in a base of a housing; coupling a configuration contactor, an explosive fuse, dual main contactors, dual fast charging contactors, and dual common contactors to the busbar assembly; and placing a cover of the housing over the configuration contactor, explosive fuse, dual main contactors, dual fast charging contactors, and dual common contactors.

[0092] 19. The method of statement 18, further comprising placing a thermally conductive pad on the bottom surface of the housing.

[0093] 20. The method of statement 18 or 19, wherein the busbar assembly comprises a plurality of busbars, each of the plurality of busbars having a surface exposed through the bottom surface of the housing.

[0094] 21. A method according to any one of statements 18 to 20, further comprising installing one or more battery current sensors.

[0095] It will be understood from the foregoing description that modifications and changes may be made in the various embodiments of the present disclosure without departing from the true spirit of the present disclosure. The description in this specification is for illustrative purposes only and should not be interpreted as limiting. The scope of the present disclosure is limited only by the language of the appended claims.

Claims

1. A battery disconnect unit comprising: case; A configuration contactor is arranged in the housing; a combined contactor and exploding fuse assembly disposed within the housing and electrically coupled to the configuration contactor; a battery charging contactor disposed within the housing and electrically coupled to the combined contactor and exploding fuse assembly; as well as Busbar assembly.

2. The battery disconnect unit according to claim 1, wherein: The busbar assembly is layered.

3. The battery disconnect unit according to claim 2, wherein: The busbar assembly includes terminals in one or more planes.

4. The battery disconnect unit according to claim 3, wherein: At least two terminals are stacked.

5. The battery disconnect unit according to claim 1, wherein: The busbar assembly includes a plurality of busbars, each of the plurality of busbars having a surface exposed through the bottom of the housing.

6. The battery disconnect unit according to claim 5, wherein: The battery disconnect unit can be configured for mounting on a cooling plate.

7. The battery disconnect unit of claim 1, further comprising one or more battery current sensors disposed within the housing.

8. A method of assembling a battery disconnect unit, the method comprising: providing a busbar assembly in a base of the housing; coupling a configuration contactor, a dual combined contactor and explosion fuse assembly, and dual rapid charge contactors to the busbar assembly; as well as The housing cover is placed over the configuration contactor, the dual combined contactor and exploding fuse assembly, and the dual rapid charge contactors.

9. The method according to claim 8, wherein The base includes a plurality of holes; wherein the busbar assembly includes a plurality of busbars; and wherein each busbar is located in a corresponding hole.

10. The method according to claim 8, wherein The busbar assembly is layered.

11. The method according to claim 10, wherein: The busbar assembly includes terminals located in one or more planes.

12. The method according to claim 11, wherein At least two terminals are stacked.

13. The method according to claim 8, wherein The battery disconnect unit can be configured for mounting on a cooling plate.

14. A battery disconnect unit comprising: case; A configuration contactor is arranged in the housing; an explosion fuse disposed within the housing and electrically coupled to the configuration contactor; dual main contactors disposed within the housing and electrically coupled to the explosion fuse; dual rapid charge contactors disposed within the housing and electrically coupled to the dual main contactors; Double common contactor; as well as A busbar assembly is coupled to the configuration contactor, the explosion fuse, the dual main contactors, the dual fast charging contactors, and the dual common contactors.

15. The battery disconnect unit of claim 14, further comprising a thermally conductive pad disposed on a bottom surface of the housing.

16. The battery disconnect unit of claim 14, wherein: The busbar assembly includes a plurality of busbars each having a surface exposed through a bottom surface of the housing.

17. The battery disconnect unit of claim 14, further comprising one or more battery sensors.

18. A method of assembling a battery disconnect unit, comprising: providing a busbar assembly in a base of the housing; connecting a configuration contactor, an explosion fuse, dual main contactors, dual fast charging contactors, and dual common contactors to the busbar assembly; as well as The cover of the housing is placed over the configuration contactor, explosion fuse, dual main contactors, dual fast charging contactors, and dual common contactors.

19. The method of claim 18, further comprising placing a thermally conductive pad on a bottom surface of the housing.

20. The method according to claim 18, wherein The busbar assembly includes a plurality of busbars each having a surface exposed through a bottom surface of the housing.

21. The method according to claim 18, wherein Also included is installing one or more battery current sensors.

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