Safety Interconnect for a Modular High-Voltage Battery System

Abstract

A safety interconnect for a modular high-voltage battery system comprises: a housing of an electrically insulating material, the housing having a cavity with an opening; and a bus bar housed within the cavity, the bus bar having a first terminal for connection to a first external terminal of a first module of the modular high-voltage battery system, and a second terminal for connection to a second external terminal of a second module of the modular high-voltage battery system adjacent to the first module.

Description

Technical Field

[0001] [Cross - Reference to Related Applications] This application claims priority to U.S. Application No. 18 / 194,218, filed on March 31, 2023, entitled "SAFETY INTERCONNECT FOR A MODULAR HIGH - VOLTAGE BATTERY SYSTEM", which claims the benefit, under 35 U.S.C. § 119, of U.S. Provisional Patent Application No. 63 / 367,954, filed on July 8, 2022, entitled "SAFETY INTERCONNECT FOR A MODULAR HIGH - VOLTAGE BATTERY SYSTEM", the disclosures of which are incorporated herein by reference in their entireties.

[0002] This specification relates to a safety interconnect for a modular high - voltage battery system.

Background Art

[0003] In recent years, transportation worldwide has begun to shift from power trains that are mainly driven by fossil fuels towards more sustainable energy sources. Most of these increasingly popular power trains have electric motors that are powered by on - vehicle energy storage. To make these new modes of transportation available to a larger segment of the population, vehicle manufacturers are striving to reduce the costs of manufacturing, assembling, operating, and maintaining electric vehicles.

[0004] Some existing battery packs for electric vehicles have modules of cells where the modules are electrically coupled to each other by bolted joints. This approach is associated with sacrifices in cost and time during manufacturing and maintenance. Further, disassembling the pack (e.g., removing a module) requires that the maintenance technician receive extensive high - voltage safety training and use special high - voltage equipment.

Summary of the Invention

[0005] In a first aspect, a safety interconnect for a modular high voltage battery system comprises: a housing of an electrically insulating material, the housing having a cavity with an opening; and a bus bar housed within the cavity, the bus bar having a first terminal for connection to a first external terminal of a first module of the modular high voltage battery system and a second terminal for connection to a second external terminal of a second module of the modular high voltage battery system adjacent to the first module.

[0006] The implementation may include any or all of the following features. The housing has (i) side walls that are substantially perpendicular to each other in pairs, and (ii) a bottom wall facing the opening and substantially perpendicular to each of the side walls. The ends of the first terminal and the second terminal are positioned at a distance from the opening inside the cavity. The first terminal and the second terminal are blades. The bus bar is elongated, and the first terminal and the second terminal extend substantially parallel to the longitudinal axis of the bus bar. The safety interconnect is configured to slide the first terminal and the second terminal into contact with the first external terminal and the second external terminal, respectively. The safety interconnect further comprises an electrically insulated grip on the housing. The safety interconnect further comprises an active current breaker within the cavity for severing the bus bar between the first terminal and the second terminal. The active current breaker has a pyrotechnic fuse. The active current breaker is configured to permanently sever the bus bar. The safety interconnect further comprises a receptacle for a connector that provides a signal to actuate the active current breaker, the receptacle being positioned outside the housing. The safety interconnect further comprises a current sensor inside the housing, the current sensor being configured to generate a signal to actuate the active current breaker. The housing has an injection molded material.

[0007] In a second aspect, a method of manufacturing a modular high voltage battery system includes: installing a first module and a second module of the modular high voltage battery system adjacent to each other; and attaching a safety interconnect to the first module and the second module, the safety interconnect comprising (i) a housing of an electrically insulating material, the housing having a cavity with an opening, and (ii) a bus bar housed within the cavity, the bus bar having a first terminal for connection to a first external terminal of the first module and a second terminal for connection to a second external terminal of the second module.

[0008] The implementation may include any or all of the following features. The step of attaching the safety interconnect includes sliding the first terminal and the second terminal into contact with the first external terminal and the second external terminal, respectively. The safety interconnect further includes an active current breaker within the cavity for severing the bus bar between the first terminal and the second terminal. The safety interconnect further includes a receptacle outside the housing, and the step of attaching the safety interconnect further includes coupling a connector to the receptacle, the connector providing a signal for actuating the active current breaker.

[0009] In a third aspect, a method of operating a modular high-voltage battery system includes: detecting a safety-related event related to the modular high-voltage battery system including a first module and a second module adjacent to each other; the modular high-voltage battery system includes a safety interconnect mounted on the first module and the second module, the safety interconnect includes (i) a housing of an electrically insulating material, the housing has a cavity with an opening, (ii) a bus bar stored in the cavity, the bus bar has a first terminal for connecting to a first external terminal of the first module and a second terminal for connecting to a second external terminal of the second module, and (iii) an active current breaker; and actuating the active current breaker in response to the safety-related event.

[0010] The implementation may include any or all of the following features. The safety-related event is detected by the safety interconnect. The safety-related event is detected using a current sensor inside the housing.

[0011] In a fourth aspect, a method of servicing a modular high-voltage battery system includes: providing access to a service technician to the equipment of the modular high-voltage battery system; and removing by the service technician a safety interconnect mounted on a first module and a second module of the modular high-voltage battery system, the second module is adjacent to the first module, the safety interconnect includes (i) a housing of an electrically insulating material, the housing has a cavity with an opening, and (ii) a bus bar stored in the cavity, the bus bar includes a first terminal for connecting to a first external terminal of the first module and a second terminal for connecting to a second external terminal of the second module.

[0012] The implementation may include any or all of the following features. The step of removing the safety interconnect includes sliding the first terminal and the second terminal to disconnect contact with the first external terminal and the second external terminal, respectively. The method further comprises subsequently attaching the safety interconnect to the first module and the second module. The safety interconnect further comprises an active circuit breaker within the cavity for severing the bus bar between the first terminal and the second terminal. The safety interconnect is removed after the active circuit breaker is actuated.

Brief Description of the Drawings

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[0022] Like reference numerals in the various drawings indicate like elements.

DETAILED DESCRIPTION OF THE INVENTION

[0023] This specification describes examples of systems and techniques for providing a safety interconnect between modules of electrochemical cells within a high voltage battery system. Such high voltage battery systems can be used within vehicles and / or within stationary power supplies. The safety interconnect can enable the high voltage of the system to be broken down into smaller chunks. This can enable the safe servicing of individual modules to be performed at a service center without specialized high voltage equipment or training. An active current breaker can be provided within the safety interconnect. In some implementations, the safety interconnect comprises a detachable jumper between modules that includes an active fuse (e.g., a pyrotechnic fuse or simply a pyro fuse). For example, this can enable the battery high voltage circuit to be actively and immediately broken down to a safe value for servicing and / or prevent dangerous situations in the event of damage or flooding. The safety interconnect can be finger safe with respect to removal, meaning that previous connection techniques such as bolted joints are eliminated. This results in a low contact resistance, enables ease of serviceability, and can eliminate the need to rotate bolts and the tracking and associated materials related to these operations. As such, the safety interconnect can enhance the high voltage safety architecture.

[0024] Examples herein refer to a battery system, which is an assembly of electrochemical cells. The battery system may be configured to power an electric motor for motive power or provide a stationary power source, to name just two. Examples herein refer to a battery module, which is an individual component configured to hold and manage a plurality of electrochemical cells during charging, storage, and use. The battery system may have any number of modules. It is possible for a battery module to be intended as the sole power source for one or more loads (e.g., an electric motor), or for more than one battery module of the same or different types to be used. The battery system may have two or more battery modules of the same or different types. A battery module may have a control circuitry configuration for managing the charging, storage, and / or use of electrical energy within the electrochemical cells, or the battery module may be controlled by an external component. For example, a battery management system may be implemented on one or more circuit boards (e.g., a printed circuit board).

[0025] The examples in this specification refer to battery systems having a high voltage, which may be referred to as high-voltage battery systems in some cases. Having a high voltage includes an operating voltage or potential difference that is generally considered lethal if a human comes into contact with it. As used herein, high voltage means at least about 250 volts (V). The voltages specified herein are direct current (DC) voltages. In some implementations, a high-voltage battery system may have a voltage exceeding about 300V. In some implementations, a high-voltage battery system may have a voltage exceeding about 400V. In some implementations, a high-voltage battery system may have a voltage exceeding about 500V. In some implementations, a high-voltage battery system may have a voltage exceeding about 600V. In some implementations, a high-voltage battery system may have a voltage exceeding about 700V. In some implementations, a high-voltage battery system may have a voltage exceeding about 800V. In some implementations, a high-voltage battery system may have a voltage exceeding about 900V. In contrast, battery terminals or other conductive elements that are considered acceptable for maintenance staff without special high-voltage tools or high-voltage training may be referred to as having a non-lethal voltage. For example, making a high-voltage battery system (e.g., one having a voltage exceeding about 900V) maintainable without special high-voltage tools or high-voltage training may include ensuring that the high-voltage terminals are not exposed to maintenance staff and only terminals with non-lethal voltages are exposed to maintenance staff.

[0026] Examples herein refer to an electrochemical cell. An electrochemical cell can have an electrolyte and two electrodes for storing energy and delivering it when in use. In some implementations, the electrochemical cell can be a rechargeable cell. For example, the electrochemical cell can be a lithium-ion cell. In some implementations, the electrochemical cell can function as a galvanic cell when discharged and as an electrolytic cell when charged. The electrochemical cell can have at least one terminal for each of the electrodes. The terminal, or at least a portion thereof, may be positioned at one end of the electrolytic cell. For example, if the electrochemical cell has a cylindrical shape, one of the terminals can be provided at the center of the end of the cell, and the can forming the cylinder can constitute the other terminal and thus also be present at the end. Other shapes of the electrochemical cell can be used, including but not limited to a prismatic shape.

[0027] Examples herein refer to a bus bar, and a safety interconnect or battery module can have at least one bus bar. A bus bar is conductive and is used, for example, to conduct electricity between two modules of a high-voltage battery system. The bus bar is made of a conductive material (e.g., metal) and has dimensions suitable for the intended levels of current and voltage. In some implementations, the bus bar comprises aluminum (e.g., an aluminum alloy). The bus bar can be planar (e.g., flat) or can have one or more bends, to name just a few examples.

[0028] Examples described herein refer to a top surface, a bottom surface, a front surface, or a back surface. These and similar expressions identify an object or aspect relative to a point of view or arbitrary description. That is, these terms are merely exemplary and are used for explanation and do not necessarily indicate the only possible positions, orientations, etc.

[0029] FIG. 1 shows an example of a perspective view of a safety interconnect 100 for a modular high voltage battery system. The safety interconnect 100 can be used with one or more other examples described elsewhere in this specification. The safety interconnect 100 includes a housing 102 of an electrically insulating material. In some implementations, the housing 102 can be molded (e.g., injection molded) from a polymer material, to name just one example. The safety interconnect 100 includes a bus bar 104, with its terminals 104A-104B being visible. The bus bar 104 is housed within a cavity 106 of the housing 102. For example, the housing 102 includes side walls 108A-108D, which are substantially perpendicular to each other in pairs. As another example, the housing 102 includes a bottom wall 110 that faces an opening 112 of the cavity 106 and is substantially perpendicular to each of the side walls 108A-108D.

[0030] The terminals 104A-104B can have any shape. Here, the terminals 104A-104B are blades. For example, the blades can be oriented to be substantially parallel to the longitudinal axis of the bus bar 104. Other shapes, including but not limited to a barrel shape or a cylindrical shape, can be used for the terminals 104A-104B. The terminals 104A-104B are housed within the cavity 106, similar to the rest of the bus bar 104. For example, a distance 114 can extend between respective ends of the terminals 104A-104B and the opening 112.

[0031] The safety interconnect 100 can include an active current breaker 116 coupled to the bus bar 104. The active current breaker 116 can be positioned within the cavity 106. When actuated, the active current breaker 116 can sever the bus bar 104 between the terminals 104A-104B. In some implementations, the active current breaker 116 includes a pyrotechnic fuse. As another example, the active current breaker 116 can include a contactor that can be controlled to interrupt the electrical connection between the terminals 104A-104B.

[0032] The safety interconnect 100 may include a grip 118. The grip 118 may be formed by or otherwise coupled to the housing 102. For example, the grip 118 may include a handle attached to the housing 102 (the remainder thereof) by one or more posts (as shown, for example).

[0033] FIG. 2 shows an example of an electric vehicle (EV) 200 having a high-voltage (HV) battery system 202. The EV 200 is shown in an exploded view for illustrative purposes. The EV 200 and / or the HV battery system 202 may be used with one or more other examples described elsewhere in this specification. The EV 200 has one or more electric traction motors (not shown) powered by the HV battery system 202. Some other components of the EV 200 (including, but not limited to, wheels) are omitted from this figure for clarity.

[0034] The EV 200 includes a vehicle body 204. The vehicle body 204 may include various structural components that together form the framework and a plurality of sections of the EV 200. In some implementations, the EV 200 includes a frame assembled from a plurality of individual sections. In some implementations, the EV 200 includes a chassis 206. For example, the chassis 206 may form a support structure for the vehicle body 204 and may be made using various frame components, rails, rockers, torque boxes, and / or cross-members.

[0035] The EV 200 has a cavity 208 within the vehicle body 204. The cavity 208 is here partially defined by an opening 210. The cavity 208 may be formed within any of various sections or portions of the vehicle body 204. In some implementations, the cavity 208 is formed within the chassis 206 of the vehicle body 204. For example, the cavity 208 may be configured such that the opening 210 faces towards the ground located beneath the EV 200.

[0036] The cavity 208 can have any shape, including but not limited to a shape enclosed by straight lines. In some implementations, the cavity is formed by a plurality of wall portions of the vehicle body 204. For example, the cavity 208 can be at least partially formed by the rear wall 212. As another example, the cavity 208 can be at least partially formed by a side wall 214 (not clear in the current figure). As another example, the cavity 208 can be at least partially formed by a side wall 216 (not clear in the present figure). As another example, the cavity 208 can be at least partially formed by a side wall 218. As another example, the cavity 208 can be at least partially formed by a side wall 220. The rear wall 212 can face (e.g., be substantially parallel to) the opening 210. One or more of the side walls 214-220 can be substantially perpendicular to the rear wall 212. The cavity 106 can have other shapes.

[0037] The HV battery system 202 can include a plurality of modules of electrochemical cells, each of which functions to store a plurality of electrochemical cells and is thus sometimes referred to as a battery cell collector. Here, the HV battery system 202 includes modules 222A-222D of electrochemical cells. The modules 222A-222D are components provided with the HV battery system 202. The modules 222A-222D can be positioned in any arrangement within the cavity 208. Each of the modules 222A-222D can be an individual unit that can be manufactured separately and installed within the cavity 208. For example, each of the modules 222A-222D can be mounted (e.g., abutted) to the rear wall 212. The HV battery system 202 may or may not have a stand-alone pack enclosure (not shown).

[0038] Each of modules 222A - 222D includes a plurality of electrochemical cells. The electrochemical cells can have one or more of a plurality of form factors. In some implementations, the HV battery system 202 can use an electrochemical cell 224 having a cylindrical shape. In some implementations, the HV battery system 202 can use an electrochemical cell 226 having a prismatic shape. Other form factors can be used.

[0039] The HV battery system 202 can include electrical interconnects that couple modules 222A - 222D to each other and / or to other electrical appliances within the cavity 208. Here, the HV battery system 202 includes electrical interconnects 228A - 228C. The electrical interconnects 228A - 228C are components of the HV battery system 202. The electrical interconnects 228A - 228C can serve one or more of a plurality of purposes. For example, the electrical interconnects 228A - 228C can connect two or more of modules 222A - 222D to each other, thereby increasing the overall voltage from a module-level voltage (e.g., a non-lethal voltage) to a battery-system-level voltage (e.g., a lethal voltage). As another example, one or more of the electrical interconnects 228A - 228C can be selectively removed (e.g., during a maintenance session) to reduce the overall voltage from a battery-system-level voltage to a module-level voltage. For example, the safety interconnect 100 (FIG. 1) can be used as one or more of the electrical interconnects 228A - 228C.

[0040] Each of the electrical interconnects 228A - 228C may include a bus bar that is partially covered by an insulator. For example, electrical interconnect 228A includes a bus bar that provides a terminal 230 and also includes an insulator 232 that covers the bus bar. In some implementations, electrical interconnect 228A may electrically connect modules 222A - 222B to each other. In some implementations, electrical interconnect 228B may electrically connect modules 222B - 222C to each other. In some implementations, electrical interconnect 228C may electrically connect modules 222C - 222D to each other.

[0041] EV200 includes a closure 234 configured to close the opening 210 of the cavity 208. The closure 234 may include a member of metal and / or composite material. In some implementations, the closure 234 is in the form of a sheet of material that functions as a shield for the cavity 106. Other shapes may be used for the closure 234.

[0042] The electrical interconnects 228A - 228C can provide advantages regarding the maintainability of the EV200. For example, after removal of the closure 234, the electrical interconnects 228A - 228C remain installed in their respective positions and the high - voltage terminals of the HV battery system 202 are not exposed to the technician. Rather, the insulators of the electrical interconnects 228A - 228C cover the high - voltage terminals or other conductors and thereby function to prevent inadvertent contact with them. The maintenance staff can then remove one or more of the electrical interconnects 228A - 228C. Any of a plurality of removal methods can be used. In some implementations, the electrical interconnects 228A - 228C can be removed by grasping and pulling on an insulated portion of each respective electrical interconnect 228A - 228C. In some implementations, the electrical interconnects 228A - 228C can be removed by rotating or otherwise moving the component. For example, screws of plastic material can be surrounded by the insulator so that removal can be performed using a conventional screwdriver without special tools.

[0043] Removal of the electrical interconnects disconnects the electrical connection between the corresponding ones of the modules 222A - 222D, thereby reducing the voltage from the system voltage level (e.g., lethal voltage) to the module - level voltage (e.g., non - lethal voltage). The subject matter can thus "finger - safe" the HV battery system 202 in that the HV battery system 202 can be maintained without special high - voltage tools or high - voltage training. That is, before any of the modules 222A - 222D become accessible for maintenance, the HV battery system 202 is de - energized and fragmented into complete battery - system voltage pieces. For example, each of the modules 222A - 222D has a voltage lower than the voltage of the HV battery system 202.

[0044] Figure 3 shows an example of a module 300 of an electrochemical cell for a modular high-voltage battery system. Module 300 can be used together with one or more other examples described elsewhere in this specification. Any number of modules can be included. Here, modules 300-1, 300-2, 300-3, …, 300-N are shown, where N is any integer. Modules 300 can be arranged in any configuration relative to each other. For example, here, the modules 300 are arranged in a row, where each of the modules 300 is placed adjacent to one or two of the other modules 300. Each of the modules 300 includes a plurality of electrochemical cells (not shown). For example, each of the modules 300 can include the same number of electrochemical cells. Other methods may be used.

[0045] Figure 4 shows an example of external terminals 400A to 400B that can be used with the module 300 of FIG. 3. For example, the external terminals 400A to 400B are here part of modules 300-2 and 300-3, respectively. The external terminals 400A to 400B can be used together with one or more other examples described elsewhere in this specification.

[0046] Module 300-2 includes a mounting area 402A that can be used to mount a safety interconnect to module 300-2. For example, the mounting area 402A is recessed from the front face 404A of module 300-2. The external terminal 400A is connected to one or more busbars (not shown) inside the module 300-2 and thereby to the electrochemical cells of the module 300-2. The external terminal 400A is here housed by the mounting area 402A.

[0047] Similarly, module 300-3 includes a mounting area 402B that can be used to mount the safety interconnect to module 300-3. For example, the mounting area 402B is recessed from the front face 404B of module 300-3. The external terminals 400B are connected to one or more bus bars (not shown) inside module 300-3 and thereby to the electrochemical cells of module 300-3. The external terminals 400B are here housed by the mounting area 402B. The mounting areas 402A to 402B can be positioned relative to each other. For example, the mounting area 402A is here positioned at the corner of module 300-2 (e.g., the front right corner) closest to the corner of module 300-3 (e.g., the front left corner) where the mounting area 402B is here positioned.

[0048] FIG. 5 shows an example of the safety interconnect 100 of FIG. 1 mounted to modules 300-2 and 300-3 of FIG. 3. That is, the safety interconnect 100 is arranged to slide the terminals 104A to 104B into contact with the external terminals 400A to 400B, respectively. The sliding contact between the terminals 104A to 104B contacting the external terminals 400A to 400B and / or the interfacing connection between the housing 102 and either of modules 300-2 and 300-3 can fix the safety interconnect 100 in its current position.

[0049] The safety interconnect 100 can include a receptacle 500 on the outside of the housing 102. The receptacle 500 can be used for a connector 502 that provides a signal to activate the active current breaker 116. For example, the receptacle 500 and the connector 502 can be so-called squib connectors.

[0050] One or more detected environments or characteristics may trigger the operation of the active current breaker 116. This may include detecting a safety-related event related to the high-voltage battery system. In some implementations, the active current breaker 116 may be actuated by an overcurrent or the intrusion of a foreign object (e.g., liquid) into the high-voltage battery system to disconnect the bus bar in response to the safety-related event. For example, one or more sensors (including, but not limited to, current sensors and / or liquid sensors) may be positioned inside the high-voltage battery system, and a signal may be generated (e.g., by the battery management unit) towards the connector 502, and this signal may trigger the operation of the active current breaker 116. For example, the conductors of the connector 502 may also provide a power source for energizing the active current breaker 116.

[0051] In some implementations, the safety interconnect 100 may include at least one sensor 504 for detecting an environment or characteristic that triggers the operation of the active current breaker 116. For example, the sensor 504 may include a current sensor. Thus, the safety interconnect 100 may trigger the active current breaker 116.

[0052] In a method of manufacturing a modular high-voltage battery system, the modules 300-2 and 300-3 may be installed adjacent to each other (e.g., in the EV200 of FIG. 2). The safety interconnect 100 may be mounted to the modules 300-2 and 300-3. For example, this may include sliding relative to each other between the safety interconnect 100 on the one hand and the modules 300-2 and 300-3 on the other hand.

[0053] In a method of servicing a modular high voltage battery system, a service technician may access the equipment of the modular high voltage battery system (e.g., in EV200 of FIG. 2). The service technician may remove the safety interconnect 100 (e.g., by pulling or pushing). Thereby, the voltage of the battery system is reduced to a non-lethal level. When the servicing is completed, the service technician may subsequently attach the safety interconnect 100 to the module. The removal of the safety interconnect 100 may be done at any time when the modular high voltage battery system is being serviced, including but not limited to after the active current breaker 116 has been actuated.

[0054] FIGS. 6A - 6B show examples of a front view and a rear view of the bus bar 104 of the safety interconnect 100 of FIG. 1. The bus bar 104 may be used with one or more other examples described elsewhere in this specification. The bus bar 104 may be elongated and may include a bus bar body 600 extending between terminals 104A - 104B. The active current breaker 116 may include at least one igniter and at least one cutting tool and may be positioned to lean on the bus bar body 600. In particular, the active current breaker 116 may be configured to cut a portion 600' of the bus bar body 600. Such a cut may be permanent if the safety interconnect 100 does not provide for the bus bar body 600 to be restored to a conductive element. As another example, such a cut may be considered temporary (or reversible) if the safety interconnect 100 provides for the bus bar body 600 to be restored to a conductive element (e.g., by returning a contact to a closed position).

[0055] In other embodiments where the safety interconnect 100 does not include the active current breaker 116, a portion 600' may form a permanent electrical connection between the terminals 104A - 104B.

[0056] In a method of operating a modular high voltage battery system, a safety-related event can be detected (e.g., by the safety interconnect 100 or by a sensor external to the safety interconnect 100). The active current breaker 116 can be actuated in response to a safety-related event.

[0057] Figures 7A - 7B show examples of a top view and a bottom view of the bus bar 104 of the safety interconnect 100 of FIG. 1. The bus bar 104 can be elongated, and the terminals 104A - 104B can extend substantially parallel to the longitudinal axis of the bus bar 104. The active current breaker 116 can be positioned on one side of the bus bar body 600.

[0058] The receptacle 500 can include any electrical contact or terminal configured to interface with a connector 502 (FIG. 5) including, but not limited to, at least two pins configured to receive current and trigger the actuation of the active current breaker 116.

[0059] Figures 8A - 8B show examples of a front view and a rear view of the safety interconnect 100 of FIG. 1. The housing 102 houses the terminals 104A - 104B (FIG. 1). In some implementations, the safety interconnect 100 can make the modular high voltage battery system finger-safe. For example, the distance 114 (FIG. 1) can ensure that the electrical connection formed between the external terminals 400A - 400B (FIG. 4) by the safety interconnect 100 is interrupted (and thus no longer at high voltage) before any portion of the terminals 104A - 104B can be touched by a technician.

[0060] FIG. 9 shows an exemplary cross-sectional view of the safety interconnect 100 of FIG. 1. The housing 102 of the safety interconnect 100 can provide a space 900 that at least partially houses the active current breaker 116. The housing 102 can provide at least one structure 902 or 904 for positioning the bus bar 104. For example, the structure 902 can be a tab that engages (e.g., by friction fit) with the bus bar 104 to hold the bus bar 104 in the correct position within the cavity 106. As another example, the structure 904 can be a catch that engages (e.g., by an interlocking fit) with the bus bar 104 to hold the bus bar 104 in the correct position within the cavity 106. Other techniques may be used.

[0061] The terms "substantially" and "about" as used throughout this specification can be used to describe and account for small variations, such as those due to variations in the process. For example, they can refer to less than or equal to ±5%, for example, less than or equal to ±2%, for example, less than or equal to ±1%, for example, less than or equal to ±0.5%, for example, less than or equal to ±0.2%, for example, less than or equal to ±0.1%, for example, less than or equal to ±0.05%. Also, as used herein, an indefinite article such as "a" or "an" means "at least one".

[0062] It should be understood that all combinations of the foregoing concepts and additional concepts discussed in more detail below are contemplated as being part of the subject matter of the invention disclosed herein, provided such concepts are not mutually inconsistent. In particular, all combinations of the claimed subject matter found at the end of this disclosure are contemplated as being part of the subject matter of the invention disclosed herein.

[0063] Multiple implementations have been described. However, it will be understood that various modifications can be made without departing from the spirit and scope of this specification.

[0064] Furthermore, the logical flows depicted in the figures do not necessarily require the specific order shown, or the sequential order, to achieve the desired result. Additionally, other processes may be provided, or processes may be eliminated from the described flow, other components may be added to, or removed from, the described system. Accordingly, other embodiments are within the scope of the following claims.

[0065] While specific features of the described implementations have been illustrated as described herein, those skilled in the art will now envision many modifications, substitutions, changes, and equivalents. Accordingly, it is understood that the appended claims are intended to cover all such modifications and changes as being within the scope of the implementations. They are presented by way of example only and not by way of limitation, and it should be understood that various changes in form and detail may be made. Any part of the apparatus and / or method described herein may be combined in any combination, except where mutually exclusive. The described implementations may include various combinations and / or sub-combinations of the functions, components, and / or features of the described various implementations.

Claims

1. A safety interconnect for a modular high-voltage battery system, the safety interconnect comprising: a housing of electrically insulating material, the housing having a cavity with an opening; and a bus bar housed within the cavity, the bus bar having a first terminal for connection to a first external terminal of a first module of the modular high-voltage battery system and a second terminal for connection to a second external terminal of a second module of the modular high-voltage battery system adjacent to the first module. A safety interconnect comprising the above.

2. The safety interconnect according to claim 1, wherein the housing has (i) side walls that are substantially perpendicular to each other in pairs, and (ii) a bottom wall facing the opening and substantially perpendicular to each of the side walls.

3. The safety interconnect according to claim 1 or 2, wherein ends of the first terminal and the second terminal are positioned at a distance from the opening inside the cavity.

4. The safety interconnect according to claim 1 or 2, wherein the first terminal and the second terminal are blades.

5. The safety interconnect according to claim 4, wherein the bus bar is elongated and the first terminal and the second terminal extend substantially parallel to the longitudinal axis of the bus bar.

6. The safety interconnect according to claim 1 or 2, wherein the safety interconnect is configured to slide the first terminal and the second terminal into contact with the first external terminal and the second external terminal respectively.

7. The safety interconnect according to claim 1 or 2, further comprising an electrically insulated grip on the housing.

8. The safety interconnect according to claim 1 or 2, further comprising an active current breaker within the cavity for severing the bus bar between the first terminal and the second terminal.

9. The safety interconnect according to claim 8, wherein the active current breaker has an explosive fuse.

10. The safety interconnect according to claim 8, wherein the active current breaker is configured to permanently sever the bus bar.

11. Further comprising a receptacle for a connector that provides a signal for operating the active current breaker, the receptacle being positioned outside the housing, the safety interconnect according to claim 8.

12. Further comprising a current sensor inside the housing, the current sensor being configured to generate a signal for operating the active current breaker, the safety interconnect according to claim 8.

13. The housing has an injection-molded material, the safety interconnect according to claim 1 or 2.

14. A method of manufacturing a modular high-voltage battery system, the method comprising: Installing a first module and a second module of the modular high-voltage battery system adjacent to each other; and Attaching a safety interconnect to the first module and the second module, the safety interconnect comprising (i) a housing of electrically insulating material, the housing having a cavity with an opening, and (ii) a bus bar stored in the cavity, the bus bar having a first terminal for connecting to a first external terminal of the first module and a second terminal for connecting to a second external terminal of the second module. A method comprising.

15. The step of attaching the safety interconnect includes sliding the first terminal and the second terminal into contact with the first external terminal and the second external terminal respectively, the method according to claim 14.

16. The safety interconnect further comprises an active current breaker in the cavity for disconnecting the bus bar between the first terminal and the second terminal, the method according to claim 14 or 15.

17. The safety interconnect further comprises a receptacle outside the housing, and the step of attaching the safety interconnect further includes coupling a connector to the receptacle, the connector providing a signal for operating the active current breaker, the method according to claim 16.

18. A method of operating a modular high-voltage battery system, the method comprising: Detecting a safety-related event related to the modular high-voltage battery system comprising a first module and a second module adjacent to each other, the modular high-voltage battery system comprising a safety interconnect mounted on the first module and the second module, the safety interconnect comprising: (i) a housing of electrically insulating material, the housing having a cavity with an opening; (ii) a busbar housed within the cavity, the busbar having a first terminal for connection to a first external terminal of the first module and a second terminal for connection to a second external terminal of the second module; and (iii) an active current breaker; and Actuating the active current breaker in response to the safety-related event A method comprising the steps of:

19. The method according to claim 18, wherein the safety-related event is detected by the safety interconnect.

20. The method according to claim 19, wherein the safety-related event is detected using a current sensor inside the housing.

21. A method of servicing a modular high-voltage battery system, the method comprising: Providing access to a maintenance technician to the equipment of the modular high-voltage battery system; and Removing by the maintenance technician a safety interconnect mounted on a first module and a second module of the modular high-voltage battery system, the second module being adjacent to the first module, the safety interconnect comprising: (i) a housing of electrically insulating material, the housing having a cavity with an opening; and (ii) a busbar housed within the cavity, the busbar having a first terminal for connection to a first external terminal of the first module and a second terminal for connection to a second external terminal of the second module. A method comprising the steps of:

22. The method according to claim 21, wherein removing the safety interconnect comprises sliding the first terminal and the second terminal to disengage contact with the first external terminal and the second external terminal, respectively.

23. The method according to claim 21 or 22, further comprising subsequently mounting the safety interconnect on the first module and the second module.

24. The method according to claim 21 or 22, wherein the safety interconnect further comprises an active current breaker in the cavity for disconnecting the bus bar between the first terminal and the second terminal.

25. The method according to claim 24, wherein the safety interconnect is removed after the active current breaker has been actuated.

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