Manual service disconnect switch for battery systems

Abstract

A manual service disconnect switch (106) for a battery system (100), the manual service disconnect switch (106) comprising: a disconnect switch base (110) configured for mounting near a battery pack (102), the disconnect switch base (110) comprising a housing (122) forming a socket (128), a high-current terminal connector (130) within the socket (128), a high-voltage interlocking or HVIL connector (132) within the socket (128), and a control device terminal connector (134) within the socket (128); a disconnect switch plug (112) removably coupled to the disconnect switch base (110), the disconnect switch plug (112) comprising a high-current fuse electrically connected to the high-current terminal connector (130). (140) and an HVIL shunt terminal (138) electrically connected to the HVIL connector (132);anda power control device (136) received in the socket (128), the power control device (136) being electrically connected to the control device connector (134), the power control device (136) being exposed for maintenance purposes when the circuit breaker plug (112) is removed from the circuit breaker base (110), and access to the power control device (136) not being possible when the circuit breaker plug (112) is coupled to the circuit breaker base (110);

Description

The present subject matter relates generally to manual service separators (known as MSDs in the English language) for battery systems. Batteries, such as those for electric vehicles or hybrid vehicles, typically include a plurality of cells grouped together as a battery pack. The battery pack includes battery distribution units that are responsible for managing the power capacity as well as the functionality of the battery pack. The battery distribution units are typically mounted inside a housing in which the battery pack is housed. The battery pack also includes manual service isolation switches that enable isolation of the high current power circuit of the battery pack, for example, for servicing the battery pack. The manual disconnect switches include a high current fuse that provides a fused electrical path for the battery pack coupled to a high voltage latch (known as HVIL) that controls operation of the high current electrical circuit. The high current fuse may have an ampere range of 50 A to 200 A.The battery pack typically includes low current fuses that provide fused electrical paths for accessory components, such as an air conditioner and / or the DC / DC converter. The low current fuses may have an ampere range up to 50 A. The low current fuses are typically located inside the battery distribution unit inside the battery pack housing. The maintenance of the low current fuses is not easy. Maintenance of the low current fuses requires opening the battery pack housing and then either removing the entire battery manifold unit or opening the battery manifold unit to replace the low current fuses. The maintenance of such fuses is time consuming and difficult.Moreover, moving the low current fuses to the outside of the battery pack requires cutting an additional opening into the outer housing. The outer housing of the battery pack is used to provide electrical shielding for components of the battery pack. Any openings through the outer housing for maintenance of the fuses result in the creation of areas for EMI leakage, thereby reducing the effectiveness of the electrical shield and increasing costs.The solution is a battery system with a manual service disconnect switch as disclosed herein that enables maintenance and replacement of fuses without cutting additional openings into the battery pack housing. The manual service disconnect switch for a battery system includes a disconnect switch socket configured for external attachment proximate a battery pack. The circuit breaker socket includes a housing forming a socket, a high current terminal connector within the socket, a high voltage latch (HVIL) connector within the socket, and a controller terminal connector within the socket. A circuit breaker plug is releasably coupled to the circuit breaker socket. The circuit breaker plug includes a high current fuse electrically connected to the high current terminal connector and a shunt HVIL terminal electrically connected to the HVIL connector. A current power control device is accommodated in the socket. The current power controller is electrically connected to the controller connector. The power control device is exposed for maintenance purposes when the circuit breaker plug is removed from the circuit breaker socket, while access to the power control device is not possible when the circuit breaker plug is coupled to the circuit breaker socket.The invention will now be described by way of example with reference to the accompanying drawings, in which: FIG. 1 illustrates a battery system formed in accordance with an exemplary embodiment; FIG. 2 is a top perspective view of a manual service disconnect switch (MSD) showing a disconnect plug removed from a disconnect socket; FIG. 3 is an illustration of the electrical components of the manual service disconnect switch with the housings removed for clarity; FIG. 4 is a bottom perspective view of the circuit breaker connector formed according to an exemplary embodiment; FIG. 5 is a bottom perspective view of the circuit breaker base formed according to an exemplary embodiment; FIG. 6 is a sectional view of the manual service disconnect switch in a position in which the disconnect plug is fully connected and locked to the disconnect socket; FIG. 7 is a sectional view of the manual service disconnect switch showing the disconnect plug in a partially connected / partially disconnected position; FIG. 8 is a cross-sectional view of the manual service disconnect switch showing the disconnect plug in an initial connected / disconnected position; FIG. 9 illustrates a manual service disconnect switch formed according to an exemplary embodiment; and FIG. 10 illustrates a manual service disconnect switch formed according to an exemplary embodiment.FIG. 1 illustrates a battery system 100 formed according to an exemplary embodiment. The battery system 100 includes a battery pack 102 contained within a chassis or outer housing 104, and a manual service disconnect switch (MSD) 106 mounted proximate the battery pack 102. For example, the manual service disconnect switch 106 may be directly mounted to the outer housing 104. The manual service disconnect switch 106 may also be mounted to another structure proximate the battery pack 102.The battery pack 102 may be part of a high voltage energy storage system. For example, the battery pack 102 may be deployed in an automotive application, such as part of an electric vehicle or a hybrid electric vehicle.In an exemplary embodiment, the battery system 100 uses a battery distribution unit 108 for managing the power capacity and functionality of the battery system 100, for example, by measuring the current and regulating the power distribution of the battery pack 102. The battery system 100 may include both a high current power circuit and a low current power circuit, both electrically connected to the battery pack 102 and / or the battery distribution unit 108. Low current and high current or low voltage and high voltage can be considered relative to each other and do not require any particular range or threshold. Optionally, the manual service disconnect switch 106 may operatively disconnect the high current power circuit while the low current power circuit may remain connected when the manual service disconnect switch 106 is disconnected.The manual service disconnect switch 106 is electrically connected to the battery distribution unit 108. The battery distribution unit 108 may be provided inside the outer case 104 or may be attached to an outside of the outer case 104. The battery distribution unit 108 is electrically connected to the battery pack 102. In an exemplary embodiment, the battery distribution unit 108 is provided on the battery pack 102. Alternatively, the battery distribution unit 108 may be provided at a location remote from the battery pack 102 and may be part of a centralized system that manages the individual battery pack 102 from such a central location.The battery distribution unit 108 may monitor and / or control the operation of the components of the battery system 100. The battery distribution unit 108 may measure or respond to the battery health of the battery pack 102. The battery distribution unit 108 may measure or respond to the battery state of the battery pack 102. The battery distribution unit 108 may monitor or respond to overvoltage and / or low voltage situations at the battery pack 102. The battery distribution unit 108 may react due to the temperature change of the battery pack 102. The battery distribution unit 108 may handle charging functions of the battery pack 102.The manual service disconnect switch 106 includes a disconnect switch socket 110 and a disconnect switch plug 112 that is releasably coupled to the disconnect switch socket 110. The manual service disconnect switch 106 is used to disconnect or open the power circuit of the battery system 100, for example during service or maintenance operations. For example, the circuit breaker plug 112 may be disconnected from and removed from the circuit breaker socket 110. In an exemplary embodiment, the manual service disconnect switch 106 includes fuses for providing over-current protection for the power circuit(s) and a high voltage latch (HVIL) circuit for controlling the high current power circuit during opening and closing of the manual service disconnect switch 106, such as during extraction and insertion of the disconnect plug 112 from and into the disconnect socket 110. The manual service disconnect switch 106 allows easy access to the fuses for maintenance and / or replacement of the fuses. For example, when the circuit breaker plug 112 is pulled out, access to the fuses is possible. Access to the fuses by the manual service disconnect switch 106 allows maintenance without requiring access to the battery pack 102. For example, the technician does not need to open the outer housing 104 to maintain the fuses. No additional openings need be provided in the outer housing 104 to provide access to the fuses, thereby allowing better sealing and shielding of the battery module 102. The manual service disconnect switch 106 may include relays or other types of power control devices in addition to or as an alternative to the fuses, and may be maintained when the manual service disconnect switch 106 is broken and opened.In an exemplary embodiment, the manual service disconnect switch 106 uses a two-stage lever to open the HVIL circuit prior to disconnecting the high current power circuit. Optionally, the manual service disconnect switch 106 provides a tool-free solution for disconnecting the disconnect switch plug 112, such as a manually operated lever. In an exemplary embodiment, all high current conductive surfaces on the manual service disconnect switch 106 are finger proof and touch proof.In an exemplary embodiment, the battery pack 102 includes a plurality of battery cells 114 housed inside the outer housing 104. The battery cells 114 may be any type of battery cells. For example, the battery cells 114 can be pouch battery cells or prism-shaped battery cells. In alternative embodiments, other types of battery cells may be used. Optionally, the battery cells 114 may be narrow plates arranged in a stacked configuration. Any number of battery cells 114 may be present in the battery pack 102. Each of the battery cells 114 may be electrically connected to the battery distribution unit 108.FIG. 2 is a top perspective view of the manual service disconnect switch 106 illustrating the disconnect plug 112 detached from the disconnect socket 110. The circuit breaker base 110 includes a base 120 and a housing 122 extending from a top 124 of the base 120. The base 120 includes a bottom 126 opposite the top 124. The housing 122 defines a bushing 128 generally above the base 120. The disconnect plug 112 is configured to couple to the housing 122, with a portion of the disconnect plug 112 received in the socket 128 when connected thereto.The circuit breaker socket 110 includes a high current terminal connector 130 within the socket 128. The circuit breaker socket 110 includes an HVIL connector 132 within the socket 128. The disconnect base 110 includes one or more controller connectors 134 within the socket 128. A current power controller 136 is electrically connected to the controller connectors 134. In the illustrated embodiment, the controller connectors 134 are low current connectors 134, and the current power controller forms serviceable fuses 136 that form fused electrical paths for the low current connectors 134. The following description may be made with reference to controller connectors 134 as low current connectors 134; however, it will be appreciated that other types of controller connectors may be used in addition to or alternatively to the low current type, such as high current types. The following description may be made with reference to current power control devices as serviceable fuses; however, it will be appreciated that other types of current power control devices may be used in addition to or alternatively to the serviceable fuses, such as relays, contactors, and the like.In an exemplary embodiment, the housing 122 includes a space 137 formed between the HVIL connector 132 and the high current terminal connector 130, or between the connectors 130, 132 and the walls of the housing 122. The serviceable fuses 136 are disposed in the space at 137. The serviceable fuses 136 are exposed for maintenance and replacement when the circuit breaker plug 112 is removed from the circuit breaker socket 110. When the circuit breaker plug 112 is connected to the circuit breaker socket 110, the serviceable fuses 136 are concealed and access to them is not possible.The circuit breaker connector 112 carries a HVIL shunt terminal (shown in FIG. 3 ) configured to be electrically connected to the HVIL connector 133 when the circuit breaker connector 112 is connected to the circuit breaker socket 110. The HVIL connector 132 and the HVIL shunt terminal 138 form an electrical shunt path when the circuit breaker plug 112 is coupled to the circuit breaker socket 110. The circuit breaker plug 112 carries a high current fuse 140 (shown in FIG. 3 ) configured to be electrically connected to the high current connector 130 when the circuit breaker plug 112 is connected to the circuit breaker socket 110. The high current connector 130 and the high current fuse 140 create a fused electrical path when the circuit breaker plug 112 is coupled to the circuit breaker socket 110.In the illustrated embodiment, the housing 122 is generally rectangular in shape with sidewalls having rounded corners therebetween. The housing 122 may have other shapes in alternative embodiments. The circuit breaker plug 112 is shaped complementary to the housing 122 for connection to the circuit breaker socket 110. The circuit breaker plug 112 is inserted into the housing 122 to close the open top thereof. In the illustrated embodiment, studs 150 extend outwardly from the housing 122.The circuit breaker connector 112 includes a cover 152 that extends around the housing 122 when the circuit breaker connector 112 is coupled to the circuit breaker socket 110. Portions of the circuit breaker plug 112 are received in the socket 128 when the circuit breaker plug 112 is connected to the circuit breaker socket 110. The circuit breaker connector 112 includes a lever 154 rotatably coupled to the cover 152. The lever 154 includes latch members 156 which cooperate with the posts 150 to secure the circuit breaker plug 112 to the circuit breaker base 110. Optionally, when the lever 154 is rotated to the closed state, the circuit breaker plug 112 is pulled into the circuit breaker socket 110. The lever 154 locks the circuit breaker plug 112 to the circuit breaker socket 110. Optionally, as the lever 154 rotates to the open state, the disconnect plug 112 is pushed away from the disconnect socket 110, which can result in automatic disconnection of one or more connectors, such as the HVIL connector 132 and the high current terminal connector 130.FIG. 3 illustrates the electrical components of the manual service disconnect switch 106 with the enclosures removed for clarity. FIG. 3 shows the serviceable fuses 136, the HVIL shunt terminal 138, and the high current fuse 140. Further, FIG. 3 shows portions of the low current terminal connector 134, the HVIL connector 132, and the high current terminal connector 130.The high current terminal connector 130 includes a pair of high current terminals 160 configured to be electrically connected to the high current fuse 140 when the circuit breaker plug 112 is coupled to the circuit breaker socket 110. In the illustrated embodiment, the high current terminals 160 are socket-type terminals having a box-shaped connection portion that receives corresponding contacts 162 of the high current fuse 140. In the illustrated embodiment, the contacts 162 are blade-like contacts. In alternative embodiments, the high current terminals 160 and the contacts 162 may have structures other than socket-type and blade-type structures. The high current terminals 160 have terminal ends 164 configured to connect to other electrical conductors, such as cables, wires, bus bars, or other types of conductors. The conductors may be electrically connected to the battery distribution unit 108. A fused electrical path is formed between the high current terminals 160 and the high current fuse 140. Any type of high current fuse 140 may be used. Optionally, the high current fuse 140 may be disconnected from the high current terminal 160 when the disconnect plug 112 is removed from the disconnect socket 110 for servicing the battery pack 100. Optionally, the high-current fuse 140 can be designed to be detachable from the circuit breaker plug 112, for example for replacing the high-current fuse 140 after the high-current fuse 140 has burned through. In the illustrated embodiment, the high current fuse 140 is a 125A fuse, however, fuses for other rated currents may also be used in alternative embodiments.The HVIL connector 132 includes a pair of HVIL terminals 170 that may be connected to ends of respective HVIL cables 172. The HVIL cables 172 may be electrically connected to the battery distribution unit 108 (shown in FIG. 1 ). In the illustrated embodiment, the HVIL terminals 170 have socket-type terminals at their connection ends, but other types of connection ends may also be provided in alternative embodiments. The HVIL shunt terminal 138 is configured to connect to the HVIL terminals 170 to form the electrical shunt path. In the illustrated embodiment, the HVIL shunt terminal 138 includes pins 174 extending therefrom that are configured to be received within corresponding HVIL terminals 170. The HVIL shunt terminal 138 electrically connects the pair of HVIL terminals 170.In an exemplary embodiment, the high current power circuit of the battery system 100 is inoperative before the HVIL shunt terminal 136 is not electrically connected to the HVIL terminals 170, after the generation of the high current power circuit (e.g., after coupling of the contacts 162 to the high current terminals 160). The high current power circuit stops operating when the HVIL shunt terminal 138 is pulled out of the HVIL terminals 170, prior to pulling the high current fuse 140 out of the high current terminals 160. In this manner, the high current power circuit is stopped before the high current fuse 140 is disconnected from the high current terminals 160, which reduces and / or eliminates arcing.The low current terminal connectors 134 each include a pair of low current terminals 180. The serviceable fuses 136 are releasably positioned between the respective low current terminals 160 to provide fused electrical paths between the low current terminals 180. In the illustrated embodiment, the low current terminals 180 are two-part terminals each having a blade 182 and a contact 184. The knife 182 provides a bonding interface for directly engaging the serviceable fuse 136. For example, the metallic end cap of the serviceable fuse 136 directly cooperates with the connecting portion of the blade 182. The contact 184 is coupled to the other end of the knife 182. In the illustrated embodiment, contact 184 is a socket-type contact that receives a portion of knife 182. The other end of the contact 184 is adapted for electrical connection to another electrical conductor, such as a low current power cable or other electrical conductor. In the illustrated embodiment, the contact 184 includes a crimp barrel configured to be crimped onto the corresponding low current conductor. The low current conductor is configured for electrical connection to the battery distribution unit 108 (shown in FIG. 1 ). In alternative embodiments, other types of low current terminals 180 may be used, including a one-piece terminal.In the illustrated embodiment, the serviceable fuses 136 are generally perpendicular to the high current fuse 140. The serviceable fuses 136 extend laterally across the socket 128 (shown in FIG. 2 ), while the high current fuse extends longitudinally across the socket 128. The high current fuse 140 is a larger fuse in size and rated current than the serviceable low current fuses 136. For example, the high current fuse 140 may be a fuse of 50 A to 200 A, while the serviceable low current fuses 136 may be fuses in the range of up to 50 mA. In the battery system 100, fuses of any type as well as for any rated current may be used. For example, the serviceable fuses 136 may be cartridge fuses, ferrule fuses, blade fuses, or other types of fuses. In the illustrated embodiment, the serviceable fuses 136 are ferrule fuses that include a cylindrical body with metallic end caps.FIG. 4 is a bottom perspective view of the disconnect plug 112 formed in accordance with an exemplary embodiment. The circuit breaker connector 112 includes the cover 152 and a holder 190 accommodated in the cover 152. The retainer 190 is used to retain the high current fuse 140 and the HVIL shunt terminal 138. In the illustrated embodiment, the contacts 162 of the high current fuse 140 extend through the retainer 190 and are exposed below the retainer 190 for connection to the circuit breaker socket 110 (shown in FIG. 2 ) when the circuit breaker plug 112 is coupled to the circuit breaker socket 110.A portion of the HVIL shunt terminal 138 is exposed below the retainer 190 for connection to the circuit breaker socket 110 when the circuit breaker plug 112 is coupled to the circuit breaker socket 110. For example, the pins 174 are exposed below the holder 190. In an exemplary embodiment, a HVIL jacket 192 encloses the HVIL shunt terminal 138 to protect the HVIL shunt terminal 138 from damage. In the illustrated embodiment, the HVIL jacket 192 is box-shaped, however, in alternative embodiments, the HVIL jacket 192 may have other shapes.FIG. 5 is a bottom perspective view of the circuit breaker base 110 formed according to an exemplary embodiment. The bottom 126 of the base 120 is illustrated in FIG. 5. In an exemplary embodiment, a seal 200 encloses a connector portion of the circuit breaker base 110 at the floor 126. The seal 200 is used to seal the circuit breaker base 110 from the outer housing 104 or another construction to which the circuit breaker base 110 is coupled. Alternatively, the seal 200 may not be required, for example, for placement inside a manual service disconnect switch.Portions of the high current terminal connector 130, the HVIL connector 132, and the low current terminal connectors 134 extend beyond the bottom 126 of the base 120. For example, the connectors may include connector bodies 202 used to hold the respective electrical conductors. The connector bodies 202 may be integrally formed with the base 120 and / or the housing 122. For example, the connector bodies 202 may be molded together with the base 120 and the housing 122. Alternatively, the connector bodies 202 may be formed separately and separately from the base 120 and the housing 102 and coupled to the base 120 and / or the housing 122 to hold the respective conductors in position for connection to the disconnect plug 112 (shown in FIG. 4 ).Optionally, the HVIL terminals 170, the high current terminals 160, and the low current terminals 180 may be inserted into the corresponding connector bodies 202 from below. The wires or cables or other conductors connected to these terminals 160, 170, 180 may extend below the base 120 away therefrom and be routed to the battery distribution unit 108.FIG. 6 shows a cross-sectional view of the manual service disconnect switch 106 showing the disconnect plug 112 in a fully connected and locked position with the disconnect socket 110, with the HVIL connector 132 and the high current terminal connector 130 fully engaged. FIG. 7 shows a cross-sectional view of the manual service disconnect switch 106 showing the disconnect plug 112 in a partially connected / partially disconnected position in which the HVIL connector 132 is fully disconnected while the high current terminal connector 130 is still connected. FIG. 8 shows a cross-sectional view of the manual service disconnect switch 106 showing the disconnect plug 112 in an initial connected / disconnected position in which the HVIL connector 132 and the high current terminal connector are fully disconnected. The serviceable fuses 136 are enclosed in the circuit breaker base 110. The serviceable fuses 136 are disposed in the space 137, which is a space that is otherwise unnecessary and not used by other components. The serviceable fuses 136 are disposed in the spaces 137 between the HVIL connector 132 and the high-current terminal connector 130.In an exemplary embodiment, the lever 154 is used to connect the circuit breaker plug 112 to the circuit breaker socket 110 or to disconnect the circuit breaker plug 112 from the circuit breaker socket 110. For example, actuation of the lever 154 in an opening direction moves the disconnect plug 112 relative to the disconnect socket 110 by pulling the disconnect plug 112 into the disconnect socket 110, for example, from the position shown in FIG. 8 passing through the position shown in FIG. 7 to the position shown in FIG. 6. Actuation of the lever 154 in a closing direction moves the circuit breaker plug 112 relative to the circuit breaker socket 110 by pulling the circuit breaker plug 112 away from the circuit breaker socket 110, for example, from the position shown in FIG. 6, passing through the position shown in FIG. 7 to the position shown in FIG. 8.In the initial connection position (FIG. 8 ), the cover 152 cooperates with the housing 122. The high current terminals 160 are fully disconnected from the contacts 162 and the HVIL shunt terminal 138 is fully disconnected from the HVIL terminals 170. During connection, the circuit breaker plug 112 is inserted into the circuit breaker socket 110 into the partially connected position (FIG. 7 ), and the high current terminals 160 first cooperate with the contacts 162 to create a fused electrical path through the high current fuse 140. In the partially connected state, the HVIL shunt terminal 138 is still fully disconnected from the HVIL terminals 170. In the partially connected position, since the HVIL circuit is open, the battery system 100 (shown in FIG. 1 ) does not allow operation of the high current circuit. As the disconnect plug 112 continues to be inserted into the disconnect socket 110, for example, to the fully mated position (FIG. 6 ), the HVIL shunt terminal 138 will connect to the HVIL terminals 170. Once the HVIL circuit is closed or connected, the battery system 100 allows operation of the high current circuit.The disconnection of the circuit breaker plug 112 from the circuit breaker socket 110 is performed in the reverse order. The HVIL shunt terminal 138 is initially disconnected from the HVIL terminals 170, which results in the battery system terminating operation of the high current circuit. Further disengagement of the disconnect switch plug 112 results in disconnection of the contacts 162 from the high current terminals 160 but only after the high current circuit is off, thus eliminating arcing. After the circuit breaker plug 112 is fully removed from the circuit breaker socket 110, access to or removal of the serviceable fuses 136 is possible. The high current fuse 140 may also be maintained after the circuit breaker plug 112 is completely removed from the circuit breaker socket 110.FIG. 9 illustrates a manual service disconnect switch 206 formed according to an exemplary embodiment. The manual service disconnect switch is similar to the manual service disconnect switch 106 (shown in FIG. 1 ), however, the manual service disconnect switch 206 has a different configuration of the serviceable fuses 136 as well as a different position of the HVIL connector 132. The serviceable fuses 136 are still positioned below the high current fuse 140, however, the serviceable fuses 136 are arranged side-by-side, generally parallel to the high current fuse 140. The serviceable fuses 136 and the high current fuse 140 extend in the longitudinal direction. Both serviceable fuses 136 are disposed between the HVIL connector 132 and one of the contacts 162 of the high current fuse 140. In alternative embodiments, other configurations are possible.FIG. 10 illustrates a manual service disconnect switch 208 formed according to an exemplary embodiment. The manual service disconnect 208 is similar to the manual service disconnect 106 (shown in FIG. 1 ), however, the manual service disconnect 206 has a different position of the HVIL connector 132 as well as a different configuration of the power controllers 136. For example, the current power control devices 136 include both the serviceable fuses 136 and a relay 210. The relay 210 is disposed in the housing 122. The relay 210 may be serviced once the disconnect plug 112 (shown in FIG. 2 ) is disconnected from the disconnect socket 110. Relay 210 includes two high current meters and two coil control meters (not shown). The blades cooperate with corresponding controller connector connectors, such as relay blade connectors, to form their respective electrical circuits and are similarly configured as serviceable fuses.The embodiments described herein use serviceable fuses or additional relays in the unused space under the high current fuse. Such an arrangement allows maintenance of the low current fuses and / or the relay without adding an additional cutting opening in the battery pack case 104. The shielding properties of the housing 104 are not degraded and the cost is minimized.It is to be understood that the present description is intended for purposes of illustration and is not intended to be limiting. For example, the above-described embodiments (and / or aspects thereof) may be used in combination with each other. Moreover, numerous modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Dimensions, types of materials, orientations of the various components, as well as the number and positions of the various components described herein are intended to define parameters of particular embodiments and are not to be considered limiting, but are merely exemplary embodiments. Those skilled in the art will, upon reading the foregoing description, appreciate numerous other embodiments and modifications that are within the spirit and scope of the claims.

Claims

A manual service disconnect switch (106) for a battery system (100), the manual service disconnect switch (106) comprising: a disconnect base (110) configured for mounting proximate a battery pack (102), the disconnect base (110) comprising a housing (122) forming a socket (128), a high current terminal connector (130) within the socket (128), a high voltage latch or HVIL connector (132) within the socket (128), and a controller terminal connector (134) within the socket (128); a circuit breaker plug (112) releasably coupled to the circuit breaker socket (110), the circuit breaker plug (112) comprising a high current fuse (140) electrically connected to the high current terminal connector (130) and a shunt HVIL terminal (138) electrically connected to the HVIL connector (132); A power control device (136) housed within the jack (128), the power control device (136) being electrically connected to the control device connector (134), the power control device (136) being exposed for maintenance purposes when the disconnect plug (112) is removed from the disconnect plug (110), and access to the power control device (136) being impossible when the disconnect plug (112) is coupled to the disconnect plug (110).The manual service disconnect switch (106) of claim 1, wherein a space (137) is formed in the socket (128) between the HVIL connector (132) and the high current terminal connector (130), and wherein the current power controller (136) is disposed in the space (137).The manual service disconnect switch (106) of claim 1, wherein the housing (122) has an open top, wherein the disconnect plug (112) is plugged into the housing (122) to close the open top, and wherein the power controller (136) is covered by the disconnect plug (112).The manual service disconnect switch (106) of claim 1, wherein the disconnect switch socket (110) includes a base (120) configured for mounting directly to the battery pack (102), and wherein the high current terminal connector (130), the high voltage latch connector (132), and the controller terminal connector (136) extend through the base (120) into the battery pack (102).The manual service disconnect switch (106) of claim 1, wherein the disconnect base (110) includes a base (120) having a top (124) and a bottom (126), wherein the housing (122) extends away from the top (124) and the bottom (126) is configured for mounting directly to the battery pack (102), and wherein the high current terminal connector (130), the HVIL connector (132), and the controller terminal connector (136) extend downwardly from the base (124) beyond the bottom (124).The manual service disconnect switch (106) of claim 1, wherein the current power controller (136) is configured to be disconnected from the controller connector (134) and removed from the disconnect switch socket (110) when the disconnect switch plug (112) is removed from the disconnect switch socket (110) and after the HVIL shunt terminal (138) and the high current fuse (140) are disconnected from the HVIL connector (132) and the high current connector (130), respectively.The manual service disconnect switch (106) of claim 1, wherein the high current connector (130) includes a pair of high current terminals (160), the high current fuse (140) including a pair of contacts (162) electrically connected to the high current terminals (160) when the disconnect plug (112) is coupled to the disconnect socket (110), the high current fuse (140) forming a fused electrical path between the contacts (162).The manual service disconnect switch (106) of claim 1, wherein the HVIL connector (132) includes a pair of HVIL terminals (170), the HVIL shunt terminal (138) forming an electrical shunt path between the HVIL terminals (170) when the disconnect switch plug (112) is coupled to the disconnect switch socket (110).The manual service disconnect switch (106) of claim 1, wherein the controller connector (134) includes a pair of low current terminals (180), the current power controller (136) having a serviceable fuse (136), the serviceable fuse (136) electrically connecting the low current terminals (180) when the disconnect plug (112) is coupled to the disconnect plug (110), the serviceable fuse (136) forming a secured electrical path between the low current terminals (180).The manual service disconnect switch (106) of claim 1, further comprising a second controller connector (134) and a second power controller (136) in the disconnect switch socket (110), the HVIL connector (132) being positioned between the power controller (136) and the second power controller (136).

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