Contactor device and energy storage system

Abstract

The present invention relates to a contactor device (100) capable of changing a connection state of at least two battery modules (502(1), 502(2)) of a high-voltage energy storage system (10) between a series connection and a parallel connection, and an energy storage system (10) including the contactor device (100). The contactor device (100) includes two first terminals (102, 104) for electrically connecting at least one of a load and a charger, two second terminals (106, 108) for electrically connecting the first battery module (502(1)), and two third terminals (110, 112) for electrically connecting the second battery module (502(2)). The contactor device (100) further includes two first bus bars (128, 129), each electrically connected to one of the first terminals (102, 104), two second bus bars (138, 139; 238, 239), one of the second bus bars (138; 238) electrically connected to one of the second terminals (106) and another of the second bus bars (139; 239) electrically connected to one of the third terminals (112), and a connecting bus bar (144) electrically insulated from the two first bus bars (128, 129). The at least one actuating element is configured to change the state of the contactor device (100) between at least a series connection state in which the two second bus bars (138, 139; 238, 239) are conductively coupled to the connecting bus bar (144), and a parallel connection state in which one of the second bus bars (138; 238) is conductively coupled to one of the first bus bars (128) and another of the second bus bars (139; 239) is conductively coupled to another of the first bus bars (129).

Description

[Technical field]

[0001] The present invention relates to a contactor device capable of changing the connection state of at least two battery modules of a high-voltage energy storage system between a series connection and a parallel connection, and to an energy storage system including the contactor device. [Background technology]

[0002] The use of contactor devices to connect and disconnect electronic circuits in an energy storage system is a known state of the art. With the advanced development of electric vehicles (EVs) or hybrid electric vehicles (HEVs), high voltage energy storage systems are becoming more and more common in vehicles. Currently, such high voltage systems can generally provide voltages ranging from 400V to 1kV, and may even provide higher voltages in future applications. These high voltage energy storage systems pose a greater risk of electric shock than traditional powertrains. Therefore, prevention of safety hazards and overcurrent protection are of utmost importance for these systems. For example, it is important to ensure the safety of vehicle occupants, roadside assistance, and maintenance workers in the event of a malfunction of the high voltage energy storage system or a vehicle accident affecting the electronic circuits of the energy storage system.

[0003] Therefore, there are increasing safety requirements for the contactor devices used to control the flow of current in energy storage systems, especially when the energy storage systems are used to store energy for driving vehicles.

[0004] Conventional contactor devices can reversibly change state between a closed state, in which current is allowed to flow through the contactor device, and an open state, in which current is prevented from flowing through the contactor device, usually by moving at least one movable contact. Additionally, an overcurrent protection device, such as a pyrofuse, may be used to irreversibly interrupt the voltage supply in the high-voltage energy storage system when the overcurrent protection device is activated, for example, when operating conditions in the high-voltage energy storage system become unsafe due to an overcurrent or a fault occurring in the electronic circuitry of the energy storage system, or when a vehicle powered by energy stored in the energy storage system is involved in an accident.

[0005] However, depending on the application in which the energy storage system is used, it may be desirable to switch the contactor device not only between an open state or a closed state. For example, the contactor device may be electrically connected to a high-voltage battery, which is a driving battery of an EV or HEV vehicle. In order to supply a high voltage in the range between 400V and at least 1 kV to a motor of the EV or HEV vehicle during a driving state, a plurality of battery modules (or battery packs) are electrically connected to form a high-voltage battery, which supplies a predetermined high voltage as a sum of the module voltages. However, since the battery voltage can be increased and increased in this manner, it becomes difficult to properly charge such high-voltage batteries, since not all chargers or charging stations can charge such high-voltage batteries at the predetermined high voltage, but may only supply voltage at a voltage level below the predetermined high voltage.

[0006] It is therefore desirable to switch the battery arrangement between a series connection state in which the multiple battery modules are connected in series so that the high-voltage battery can supply the sum of the voltages of the multiple battery modules, for example during driving conditions, and a parallel arrangement in which at least some of the multiple battery modules are connected in parallel, thereby enabling the high-voltage battery to be charged at a voltage level below a predetermined high voltage. Summary of the Invention [Problem to be solved by the invention]

[0007] It is therefore an object of the present invention to provide a contactor device which gives the possibility to change the connection state of a high voltage battery. Furthermore, it is an object of the present invention to provide a simple and economical solution. [Means for solving the problem]

[0008] This object is solved by the subject matter of the independent claims. Advantageous aspects of the present disclosure are the subject matter of the dependent claims.

[0009] In particular, the present disclosure provides a contactor device including two first terminals for electrically connecting at least one of a load and a charger, two second terminals for electrically connecting a first battery module, and two third terminals for electrically connecting a second battery module. The contactor device further includes: two first bus bars, each electrically connected to one of the first terminals; two second bus bars, one of the second bus bars electrically connected to one of the second terminals and another of the second bus bars electrically connected to one of the third terminals; a connecting bus bar electrically insulated from the two first bus bars; and at least one actuating element configured to change a state of the contactor device between a series connection state, in which the two second bus bars are conductively coupled to the connecting bus bars, and a parallel connection state, in which one of the second bus bars is conductively coupled to one of the first bus bars and the other of the second bus bars is conductively coupled to the other of the first bus bars.

[0010] By providing the second bus bar and the connecting bus bar as the second set of bus bars, the contactor device allows to switch the arrangement of the connected battery modules between a state in which the opposite potential terminals of the battery modules are electrically connected in series, since the bus bars of the second set are electrically connected to the connecting bus bars, and a parallel connection state in which the same potential terminals of the battery modules are electrically connected in parallel, since each of the second bus bars can be electrically connected to a respective one of the first bus bars. Thus, the contactor device allows to switch in a simplified manner between a series connection state, in which the full voltage of the batteries connected to the contactor device is applied between the two first bus bars of the connector device, and a parallel connection state, in which a voltage corresponding to the module voltage of the battery modules forming the battery is applied between the two first bus bars of the connector device.

[0011] Thus, in a series connection state, the contactor device according to the present disclosure makes it possible to supply a predetermined high voltage, for example to an electric motor of an electric vehicle, and in a parallel connection state makes it possible to charge the battery modules of a battery at a voltage level below the predetermined high voltage, thereby making it possible, due to its simple configuration, to eliminate the need to provide complex switching structures between the battery modules in order to change between a series connection and a parallel connection of the battery modules.

[0012] According to an advantageous embodiment, each of the second bus bars includes a flexible contact area that can be elastically deflected between a first position in which each of the second bus bars is conductively coupled to the connecting bus bar and a second position in which each of the second bus bars is conductively coupled to one of the first bus bars. In this way, it is possible to effectively transmit a transition force provided by at least one actuating element to change the state of the contactor device, since it is not necessary to move the entire second bus bar. However, as an alternative, the second bus bar may move as a whole between the first and second positions.

[0013] In another advantageous example, the contactor device may further include two secondary connection bus bars, each of the two secondary connection bus bars configured to conductively couple one of the second bus bars to a respective one of the first bus bars in a parallel connection state of the contactor device. In this way, the contactor device may include only a fixed bus bar that allows changing the state of the contactor device between a series connection state and a parallel connection state.

[0014] To allow an effective force transmission when changing the state of the contactor device, the connecting busbar and the secondary connecting busbar are preferably mounted on a connecting frame, and the at least one actuating element is configured to move the connecting frame to change the state of the contactor device between a series connection state and between a parallel connection state. Furthermore, in this case the connecting busbar and / or the secondary connecting busbar may optionally have a flexible contact area that can move in addition to moving the connecting frame when the at least one actuator element changes the state of the contactor device.

[0015] To reduce the contact resistance in the series and parallel connection states, each of the second busbars preferably includes a plurality of contact elements arranged on different sides of the second busbar, and each of the second busbars is preferably configured to be conductively coupled to the connecting busbars at a contact side of the second busbar different from the contact side for conductively coupling to one of the first busbars. For example, the contact side of the second busbar that contacts the connecting busbar may be arranged on the second busbar opposite the contact side for contacting one of the first busbars. In other words, the connecting busbars may be formed from a busbar set with double-sided silver buttons, the silver buttons allowing to reduce the contact resistance in the series and parallel connection states.

[0016] In another advantageous example, at least one actuation element includes a dedicated actuator for changing the state of the contactor device between a series connection state and between a parallel connection state. In this way, it is possible to optimize the dedicated actuator for providing an efficient force transition when changing the state of the contactor device between the series connection state and the parallel connection state.

[0017] In another advantageous example, the contactor device may further include two third bus bars, one of which is electrically connected to another of the second terminals and the other of which is electrically connected to another of the third terminals, and the at least one actuating element is configured to change the state of the contactor device between a closed state, in which each of the third bus bars is conductively coupled to a respective one of the first bus bars, and an open state, in which the two third bus bars and the two second bus bars are electrically insulated from the two first bus bars. In this way, the contactor device also makes it possible to prevent the flow of current through the contactor device in the open state. Thus, in this example, the contactor device of the present disclosure makes it possible to apply at least three voltage levels between the two first contacts, namely zero voltage in the open state, full battery voltage in the series connection state (and closed state), and voltage corresponding to module voltage of the battery modules forming the battery in the parallel connection state (and closed state).

[0018] According to another advantageous example, each of the third bus bars may include a flexible contact area that can be elastically deflected between an open position in which each of the third bus bars is electrically insulated from the two first bus bars, and a closed position in which each of the two third bus bars is conductively coupled to a respective one of the first bus bars. In this way, a transitional force provided by at least one actuating element for changing the state of the contactor device from an open state to a closed state can be effectively transmitted, since it is not necessary to move the entire second bus bar. In an alternative example, the third bus bar may move as a whole between the open and closed positions.

[0019] When the contactor device is not powered, the contactor device may be in an open state when at least one actuating element is not powered to prevent current flow through the contactor device. For example, this can be achieved by using at least one electromagnetic actuator to change the state of the contactor device from an open state to a closed state. The same or different electromagnetic actuators can also be used to change the state of the contactor device between series connection states and between parallel connection states.

[0020] In another advantageous example, the state of the contactor device can only change if power is supplied to at least one actuating element. In this way, the contactor device allows to provide a bistable state, such that if a sudden loss of power to at least one actuating element occurs, for example due to a single point fault, another damaging event, or a communication error, but the contactor device remains in its previous state, the state of the contactor device does not change. For example, this can be realized by using a linear motor actuator, which remains in its position when no power is supplied, as an actuating element for changing the state of the contactor device from an open state to a closed state. The same or a second linear motor actuator may be used to change the state of the contactor device between a series connection state and between a parallel connection state.

[0021] In another advantageous example, the contactor device optionally includes at least one pyrotechnic actuator configured to, upon activation, irreversibly prevent the flow of current through each of the first bus bars. Thus, the contactor device can further integrate the functionality of an overcurrent protection device, since the pyrotechnic actuator can, for example, be activated in the event of an overcurrent in the energy storage system or another malfunction of the energy storage system and can then interrupt the current through the contactor device within a reaction time in the range of a few milliseconds.

[0022] Preferably, the at least one pyrotechnic actuator may be configured to move the two first bus bars to a post-ignition position when actuated, in which each of the two first bus bars is irreversibly displaced or cut off. This arrangement has the advantage that the at least one actuator configured for normal operation of the contactor device and the pyrotechnic actuator configured for safe operation of the contactor device can be designed and operated independently of each other. Thus, when a force is generated by the pyrotechnic actuator and can be used to completely displace or cut off the two first bus bars, contact separation at a greater speed and distance can be achieved. Furthermore, the operational reliability of the contactor device can be increased, since there is less chance of both actuation mechanisms failing at the same time.

[0023] Furthermore, the contactor device may further include at least one arc suppression element, which may control arcing when the two first bus bars are irreversibly displaced or disconnected by igniting the pyrotechnic actuator. The arc suppression element may comprise one or more mechanical devices, such as, for example, an array of arc splitter plates or an arc blow-out magnet. Alternatively or additionally, the arc suppression element may comprise a gas generator charge that is ignited when the pyrotechnic actuator is activated to generate a gas that cools the arc or mixes the arc with air.

[0024] In another advantageous example, the at least one pyrotechnic actuator may be configured, upon actuation, to irreversibly drive the at least one insulating element to a post-ignition position, in which the insulating element electrically isolates the two third bus bars and the two first bus bars from each other. In this way, the insulating element, when irreversibly driven between the two third bus bars and the two second bus bars, can irreversibly prevent current flow through the contactor device and at the same time function as an arc suppression element.

[0025] In order to achieve a particularly effective solution for providing arc suppression when the two third bus bars and the two second bus bars are separated, the insulating element may for example comprise at least two insulating caps, each of which in the post-ignition position completely surrounds one contact area of ​​a respective one of the first bus bars.

[0026] The present invention also relates to an energy storage system including a battery formed from at least a first battery module and a second battery module, and a contactor device according to the present disclosure, the first battery module being electrically connected to two second terminals of the contactor device and the second battery module being electrically connected to a third terminal of the contactor device. The energy storage system can be provided, for example, in a vehicle to power a motor of the vehicle. Alternatively, the energy storage system can be a stationary energy storage system, for example used to store renewable or conventionally generated energy.

[0027] Throughout this document, the term "terminal" is meant to represent a point at which a conductor of an electrical device, electrical circuit, or electrical component terminates, the point being provided for electrically connecting the conductor to an external electrical device, electrical circuit, or external electrical component. Furthermore, the terms "electrically connected" and "conductively coupled" represent the establishment of an electrical connection between at least two electrical devices, electrical components, or conductors that allows for the flow of electrical current. Here, electrical connection should not be limited to the direct coupling of terminals of at least two electrical devices, electrical components, or conductors, but other electrical devices, electrical components, or conductors may be coupled in between.

[0028] The accompanying drawings are incorporated herein and form a part of this specification to illustrate several examples of the present disclosure. These drawings, together with the description, serve to explain the principles of the present disclosure. The drawings are only intended to illustrate preferred and alternative examples of how the present disclosure can be made and used, and should not be construed as limiting the present disclosure to only the examples shown and described. Furthermore, several aspects of the examples can be formed individually or in different combinations to form solutions according to the present disclosure. Thus, the examples described below can be considered alone or in any combination thereof. Further features and advantages will become apparent from the following more particular description of various examples of the present disclosure, as illustrated in the accompanying drawings, in which like reference numerals refer to like elements. [Brief description of the drawings]

[0029] [Figure 1] FIG. 1 illustrates a schematic circuit diagram of an exemplary high voltage energy storage system. [Diagram 2] FIG. 2 shows a schematic perspective view of an exemplary first contact arrangement in a series connection of contactor devices. [Diagram 3] FIG. 2 shows a schematic side view of an exemplary first contact arrangement in a series connection of contactor devices. [Figure 4] FIG. 2 shows a schematic perspective view of an exemplary first contact arrangement in a parallel connection state of a contactor device. [Diagram 5] FIG. 2 illustrates a schematic side view of an exemplary first contact arrangement in a parallel connection state of a contactor device. [Figure 6] FIG. 2 shows a schematic perspective view of an exemplary first contact arrangement of a contactor device in an open state. [Figure 7] FIG. 2 shows a schematic side view of an exemplary first contact arrangement of a contactor device in an open state. [Figure 8] 1 shows a schematic perspective view of an exemplary second contact arrangement in a series connection of contactor devices; [Figure 9] 1 shows a schematic cross-sectional view of an exemplary second contact arrangement in a series connection of contactor devices; [Figure 10]FIG. 13 shows a schematic perspective view of an exemplary second contact arrangement in a parallel connection state of a contactor device. [Figure 11] 1 shows a schematic cross-sectional view of an exemplary second contact arrangement in a parallel connection state of a contactor device. [Figure 12] FIG. 2 shows a schematic perspective view of an exemplary second contact arrangement of a contactor device in an open state. [Figure 13] 1 shows a schematic cross-sectional view of an exemplary second contact arrangement of a contactor device in an open state. [Figure 14] 3 shows another schematic perspective view of an exemplary second contact arrangement; [Figure 15] 3 shows another schematic perspective view of an exemplary second contact arrangement; [Figure 16] 1 shows a schematic perspective view of an exemplary second contactor device. [Figure 17] 1 illustrates a schematic side view of an exemplary second contactor device in an open position. [Figure 18] 1 illustrates a schematic side view of an exemplary second contactor device in a closed position. [Figure 19] 1 illustrates a schematic side view of an exemplary actuation element. [Figure 20] 1 illustrates another schematic side view of an exemplary actuation element. [Figure 21] 1 shows a schematic top view of an exemplary second contactor device. [Figure 22] 1 illustrates another schematic top view of an exemplary second contactor device. [Figure 23] 1 illustrates a cross-sectional view of an exemplary insulating element. [Figure 24] 3 shows another schematic cross-sectional view of an exemplary insulating element. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0030] The present disclosure will now be further described with reference to the drawings, initially with reference to FIG. 1. FIG. 1 shows a schematic circuit diagram of an exemplary high-voltage energy storage system 10 that can benefit from the ideas of the present disclosure. In an application scenario exemplarily described below, the energy storage system 10 may be used in an electric vehicle as a power source for an electric load, such as an electric motor, that is supplied with a predetermined high voltage. However, the energy storage system 10 may also be used in other application scenarios that require the storage and / or supply of high-voltage energy in multiple battery modules forming a battery to supply the predetermined high voltage.

[0031] The energy storage system 10 includes the contactor device 100, and first and second battery modules (or battery packs) 502(1) and 502(2) forming a high-voltage battery 500. Instead of the example shown in FIG. 1, the number of battery modules 502(1) and 502(2) forming the battery 500 may be more than two, so in general, the number of battery modules 502 forming the high-voltage battery is N, where N is a natural number equal to or greater than two. Since the battery modules 502(1) and 502(2) are subunits of the high-voltage battery 500, they provide module voltages that can be output by the high-voltage battery 500 to the high-voltage bus 105 when their sum reaches a predetermined high voltage. The value of the module voltage provided by each of the battery modules 502 can be obtained by dividing the predetermined high voltage value output from the high-voltage battery 500 by N, where N can be the number of battery modules 502. For example, if the battery 500 outputs a predetermined high voltage value of 800 V and N=2, the battery modules 502 share and output a module voltage of (800 V / 2)=400 V. On a smaller scale, each of the battery modules 502 includes a number of battery cells electrically connected in series, where a battery cell may be a physical battery cell or may include several physical battery cells electrically connected in parallel at the cell level.

[0032] 1, the contactor device 100 is configured to electrically connect a high-voltage battery 500 to a high-voltage bus 105, which may be electrically connected to an electric motor of an electric vehicle to provide a predetermined high voltage, or may be connected to a charger to charge the high-voltage battery 500. Here, the contactor device 100 allows the voltage applied to the high-voltage bus 105 by the high-voltage battery 500 to be varied depending on the state of the contactor device, as will be described below.

[0033] The contactor device 100 includes load side terminals 102 and 104 (which may also be referred to as “first terminals”) for electrically connecting a high potential side (+) and a low potential side (−) of a high voltage bus 105 .

[0034] Furthermore, the contactor device 100 includes terminals 108 and 110 that can be electrically connected to the terminals of those battery modules 502, which terminals 108 and 110 correspond to the high potential side (+) and low potential side (-) terminals of the high voltage battery 500, respectively. For example, in FIG. 1, the terminal 108 is electrically connected to a terminal 504 on the low potential side of the high voltage battery 500, which terminal 504 corresponds to the low potential side terminal of the battery module 502(1) disposed on the low potential side of the high voltage battery 500. That is, the terminal 504 of the high voltage battery 500 corresponds to the low potential side terminal of the battery module 502(1) in FIG. 1. Similarly, in FIG. 1, the terminal 110 is electrically connected to a terminal 506 on the high potential side of the high voltage battery 500, which terminal 506 corresponds to the high potential side terminal of the battery module 502(2) disposed on the high potential side of the high voltage battery 500. That is, the terminal 506 of the high-voltage battery 500 corresponds to the high-potential side terminal of the battery module 502(2) in FIG.

[0035] Furthermore, the contactor device 100 includes terminals 106 and 112, which can be electrically connected to remaining terminals 508 and 510, other than terminals 504 and 506, of the battery modules 502(1) and 502(2), which correspond to the high potential side (+) and low potential side (-) terminals, respectively, of the high voltage battery 500. For example, in FIG. 1, the terminal 106 of the contactor device 100 is electrically connected to the high potential side terminal 508 of the battery module 502(1), which is disposed on the low potential side of the high voltage battery 500. Similarly, in FIG. 1, the terminal 112 is electrically connected to the low potential side terminal 510 of the battery module 502(2), which is disposed on the high potential side of the high voltage battery 500.

[0036] In other words, the contactor device 100 includes two terminals 106 and 108 ("second terminals") for electrically connecting the terminals 504 and 508 of the first battery module 502(1), where the low-potential side terminal 504 of the first battery module 502(1) corresponds to the low-potential side terminal 504 of the high-voltage battery 500. Furthermore, the contactor device 100 includes two terminals 110 and 112 ("third terminals") for electrically connecting the terminals 506 and 510 of the second battery module 502(2), where the high-potential side terminal 506 of the second battery module 502(2) corresponds to the high-potential side terminal 506 of the high-voltage battery 500.

[0037] Next, a first example of the contactor device 100 will be described with reference to Figures 2 to 7. Figures 2 to 7 respectively show a first example of the contact arrangement 120 of the contactor device 100 in different states of the contactor device 100. In particular, Figures 2 and 3 show the contact arrangement 120 in a series connection state of the contactor device 100, Figures 4 and 5 show the contact arrangement 120 in a parallel connection state of the contactor device 100, and Figures 6 and 7 show the contact arrangement 120 in an open state of the contactor device 100.

[0038] 2 to 7, the contact arrangement 120 includes two contacts 122 and 124, each of which may include two movable busbars (or "third busbars") 126, 127 and two fixed busbars (or "first busbars") 128, 129, so that the contactor device 100 can function as a two-pole single-break type contactor. Here, the functions of the respective fixed busbars 128, 129 and the respective movable busbars 126, 127 are mirrored. However, it should be noted here that the two movable busbars 126, 127 and the two fixed busbars 128, 129 are not limiting of the present disclosure, and the present disclosure is applicable to contactor devices having more than two contacts 122, 124 and therefore more than two movable busbars 126, 127 and more than two fixed busbars 128, 129.

[0039] The movable bus bars 126, 127 and the fixed bus bars 128, 129 may preferably be formed from a metallic material such as copper or one of its alloys, although other suitable conductive materials known in the art and capable of supporting continuous currents of 500 A or more, current peaks of up to 5 kA for at least 1 second or up to 10 kA or more for at least 50 ms through the movable bus bars 126, 127 and the fixed bus bars 128, 129 may also be used.

[0040] Preferably, the movable bus bars 126, 127 may be formed from flexible bus bars including rigid regions 130, 131 that move very little as the movable bus bars 126, 127 move between the open (shown in Figures 6 and 7) and closed (shown in Figures 2 to 5) positions, and flexible regions 132, 133 that can resiliently flex between the open and closed positions. Preferably, this can be achieved by forming the movable bus bars 126, 127 from a multi-layer structure, including, for example, 10 to 15 layers of copper or other suitable conductive material, at least in the flexible regions 132, 133. In another example, the movable bus bars 126, 127 may be comprised of fixed bus bars in rigid regions 130, 131 and movable bus bars in flexible regions 132, 133, which may move in a rotational motion about an axis of rotation, for example, to move the movable bus bars 126, 127 between the open and closed positions. Alternatively, the movable bus bars 126, 127 may move as a whole when moving between the open and closed positions.

[0041] In the first example of the contactor device 100, the movable bus bar 126 is electrically connected to the terminal 506 of the high voltage battery 500 at the high potential side of the high voltage battery 500, i.e., the terminal 110 electrically connected to the high potential side terminal 506 of the battery module 502(2), the fixed bus bar 128 is electrically connected to the load side terminal 104 electrically connected to the high potential side of the high voltage bus 105. The movable bus bar 127 is electrically connected to the terminal 504 of the high voltage battery 500 at the low potential side of the high voltage battery 500, i.e., the terminal 108 electrically connected to the low potential side terminal 504 of the battery module 502(1), and the fixed bus bar 129 is electrically connected to another of the load side terminals 102 electrically connected to the low potential side of the high voltage bus 105.

[0042] 2 to 5 show the movable busbars 126, 127 in a closed position, where the movable busbars 126, 127 are conductively coupled to the fixed busbars 128, 129 at at least a first contact 134 of a contactor device. In order to reduce the contact resistance, a contact element 136, for example made of silver or any silver alloy, may be attached to both the movable busbars 126, 127 and the fixed busbars 128, 129 in the region of the first contact 134. Of course, other suitable conductive materials may also be used to form the contact element 136.

[0043] In addition to allowing the contactor device 100 to switch between a closed state when the movable bus bars 126, 127 are in a closed position and an open state when the movable bus bars 126, 127 are in an open position, the contactor device 100 also allows the contactor device 100 to switch between a parallel connection state, in which at least two battery modules 502(1) and 502(2) can be connected in parallel to the high-voltage bus 105, and a series connection state, in which the battery modules 502(1) and 502(2) can be connected in series to the high-voltage bus 105.

[0044] For this purpose, the contactor device 100 includes two second bus bars 138 and 139 as well as a connecting bus bar 144. In a first example of the contactor device 100, the second bus bar 138 is electrically connected to the terminal 106, which is electrically connected to a high-potential side terminal 508 of a battery module 502(1) arranged on the low-potential side of the high-voltage battery 500. Similarly, in the first example, the second bus bar 139 is electrically connected to the terminal 112, which is electrically connected to a low-potential side terminal 510 of a battery module 502(2) arranged on the high-potential side of the high-voltage battery 500.

[0045] The two second bus bars 138, 139 and the connecting bus bar 144 may be made of the same material as the movable bus bars 126, 127 and the fixed bus bars 128, 129 and may be provided at a level of the contactor device different from the level at which the movable bus bars 126, 127 and the fixed bus bars 128, 129 are provided. As shown in Figures 2 to 7, the two second bus bars 138, 139 may extend in the same direction as the contacts 122 and 124. However, the second bus bars 138, 139 may have a different extension direction.

[0046] Preferably, the second bus bars 138, 139 may be formed as a second set of movable bus bars in the same manner as the movable bus bars 126, 127. For example, the second set of bus bars 138, 139 may include rigid regions 140, 141 that move little when the second bus bars 138, 139 move between a series connection position (shown in Figures 2 and 3) and a parallel connection position (shown in Figures 4 and 5), and flexible regions 142, 143 that can be elastically deflected between the series connection position and the parallel connection position. In another example, the second bus bars 138, 139 may be composed of fixed bus bars in the rigid regions 140, 141 and movable bus bars in the flexible regions 142, 143, which may move in a rotational motion about a rotation axis, for example, to move the second bus bars 138, 139 between the series connection position and the parallel connection position. Alternatively, the second bus bars 138, 139 may move as a whole when moving between the series connection position and the parallel connection position.

[0047] The connecting bus bar 144 may for example be formed from a rigid bus bar fixed in place in the contact arrangement 120, electrically insulated from the movable bus bars 126, 127 and the fixed bus bars 128, 129 forming the contacts 122 and 124. Preferably, the connecting bus bar 144 extends in a direction substantially perpendicular to the extension direction of the second bus bars 138, 139 and substantially perpendicular to the direction of the flexible regions 142, 143. However, other extension directions of the connecting bus bar 144 are possible, as long as the second bus bars 138, 139 can be conductively coupled to the connecting bus bar 144.

[0048] 2 and 3 show the contactor device 100 in a series connection state, with the second busbars 138 and 139 in the series connection position, each of the second busbars 138 and 139 conductively coupled to the connecting busbar 144 at the second contact 146. Thus, in this state, the second busbar 138 and the second busbar 139 are electrically connected in series. That is, in the series connection state, the contactor device 100 allows current to flow from the second busbar 138 to the second busbar 139 and vice versa, and the second busbars 138 and 139 are at the same potential. Meanwhile, the second busbars 138 and 139 are electrically isolated from the movable busbars 126, 127 and the fixed busbars 128, 129 in the series connection state.

[0049] Thus, in the series connection state of contactor device 100, terminals 106 and 112 electrically connect battery modules 502(1) and 502(2) in series by providing a conductive path through second bus bars 138 and 139, which are both conductively coupled to connecting bus bar 144. Thus, a predetermined high voltage of battery 500, which is the sum of the module voltages of battery modules 502(1) and 502(2), can be applied to high voltage bus 105 by conductively coupling movable bus bars 126, 127 and fixed bus bars 128, 129, i.e., by closing contacts 122 and 124.

[0050] In order to reduce the contact resistance between the second bus bars 138, 139 and the connecting bus bar 144, contact elements 148, for example made of silver or any silver alloy, may be attached to the first contact sides of the second bus bars 138, 139 in the area of ​​the second contacts 146 and to the connecting bus bar 144. Of course, other suitable conductive materials may also be used to form the contact elements 146.

[0051] 4 and 5 show the contactor device 100 in a parallel connection state, where the second busbars 138 and 139 are simultaneously in the parallel connection position at the third contact 150. Thus, in this state, the second busbar 138 is electrically connected in parallel with the movable busbar 126, and the second busbar 139 is electrically connected in parallel with the movable busbar 127. In other words, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 138 to the movable busbar 126 and the fixed busbar 128 and vice versa, and the second busbar 138, the movable busbar 126 and the fixed busbar 128 are at the same potential. Similarly, in the parallel connection state, the contactor device 100 allows current to flow from the second bus bar 139 to the movable bus bar 127 and the fixed bus bar 129 and vice versa, and the second bus bar 139, the movable bus bar 127 and the fixed bus bar 129 are at the same potential. However, in the parallel connection state, the second bus bars 138 and 139 are electrically isolated from the connecting bus bar 144.

[0052] Thus, in the parallel connection state of contactor device 100, terminals 106 and 112 electrically connect battery modules 502(1) and 502(2) in parallel by providing a conductive path from terminal 106 to fixed bus bar 128 via second bus bar 138 and a conductive path from terminal 112 to fixed bus bar 129 via first connecting contact 139. As a result, a voltage resulting from electrically connecting battery modules 502(1) and 502(2) in parallel can be applied to high voltage bus 105 by conductively coupling movable bus bars 126, 127 and fixed bus bars 128, 129, i.e., by closing contacts 122 and 124. Ideally, when the two battery modules 502(1) and 502(2) are electrically connected to the contactor device 100, the resulting voltage is half the predetermined high voltage of the high voltage battery 500, for example, 400V if the battery 500 outputs a predetermined high voltage value of 800V.

[0053] In order to reduce the contact resistance in the parallel connection state, contact elements 152, for example made of silver or any silver alloy, may be attached to the second contact side of the second bus bar 138, 139 for contacting the fixed bus bar 128, 128, or to the fixed bus bar 128, 129 in the region of the third contact 150. Of course, other suitable conductive materials may also be used to form the contact elements 138.

[0054] Thus, by providing at least partially movable second bus bars 138 and 139 as well as connecting bus bar 144, the present disclosure makes it possible to distinguish between two additional states when the contactor device is in a closed state: a series connection state, which allows for the two battery modules 502(1) and 502(2) to be electrically connected in series, and a parallel connection state, which allows for the two battery modules 502(1) and 502(2) to be electrically connected in parallel.

[0055] 6 and 7 show the contactor device 100 in an open state, with the movable bus bars 126, 127 in an open position and electrically isolated from the fixed bus bars 128 and 129. The second bus bars 138 and 139 are also electrically isolated from the fixed bus bars 128, 129 as they are conductively coupled to the connecting bus bar 144. Thus, in the open state of the contactor device 100, no voltage is applied to the fixed bus bars 128, 129.

[0056] To move the movable bus bars 126 and 127 between the open and closed positions and to move the second bus bars 138 and 139 between the series and parallel connection positions, the contactor device 100 comprises at least one actuator (not shown in Figures 2 to 7), whereby the movable bus bars 126 and 127 and the second bus bars 138 and 139 may be moved individually by the same actuator to change the state of the contactor device, or a first actuator may be provided dedicated to moving the two movable bus bars 126 and 127 individually and a second actuator may be provided dedicated to moving the second bus bars 138 and 139 individually. Possible arrangements of the at least one actuator provided in the contactor 100 will be described below with reference to Figures 16 to 20.

[0057] A second example of a contact arrangement 220 for the contactor device 100 will now be described with reference to Figures 8 to 13. The exemplary second contact arrangement 220 differs from the exemplary first contact arrangement 120 in that the connecting bus bar 144 is moveably arranged on a connecting frame, which is moveable to place the contactor device 100 in a parallel or series connected state.

[0058] In particular, Figures 8 and 9 show the contact arrangement 220 in a series connection state of the contactor device 100, Figures 10 and 11 show the contact arrangement 220 in a parallel connection state of the contactor device 100, and Figures 12 and 13 show the contact arrangement 220 in an open state of the contactor device 100.

[0059] In contrast to the first example, in the contact arrangement 220, the fixed bus bar 128 is electrically connected to the terminal 110, which is electrically connected to the terminal 506 of the high-voltage battery 500 on the high-potential side of the high-voltage battery 500, i.e., to the high-potential side terminal 506 of the battery module 502(2). The fixed bus bar 128 may be conductively coupled to the movable bus bar 126 at the first contact 134, which may be electrically connected to the load side terminal 104 of the contactor device 100.

[0060] The fixed busbar 129 is electrically connected to the terminal 108, which is electrically connected to the terminal 504 of the high-voltage battery 500 on the low-potential side of the high-voltage battery 500, i.e., to the low-potential side terminal 504 of the battery module 502(1). The fixed busbar 129 may be conductively coupled to the movable busbar 127 at the first contact 134, which may be electrically connected to the load side terminal 102 of the contactor device 100. However, it is not necessary for the contact arrangement 220 to include the movable busbars 126, 127, and the fixed busbar 128 may be electrically connected directly to the load side terminal 104, and the fixed busbar 129 may be electrically connected directly to the load side terminal 102.

[0061] Furthermore, the contact arrangement 220 includes two second bus bars 238 and 239 and a connecting bus bar 144. The second bus bar 238 is electrically connected to the terminal 106, which is electrically connected to a high potential side terminal 508 of the battery module 502(1) arranged on the low potential side of the high voltage battery 500. The second bus bar 239 is electrically connected to the terminal 112, which is electrically connected to a low potential side terminal 510 of the battery module 502(2), which is arranged on the high potential side of the high voltage battery 500.

[0062] The two second bus bars 238, 239 and the connecting bus bar 144 may be made of the same material as the fixed bus bars 128, 129, and the two second bus bars 238, 239 may be provided on the contactor device 100 at the same level as the fixed bus bars 128, 129. As shown in Figures 8 to 13, the two second bus bars 238, 239 may extend in the same direction as the fixed bus bars 128 and 129, but may have a different extension direction.

[0063] In the second example, the second bus bars 238, 239 may be formed in the same way as the fixed bus bars 128, 129, i.e. the second set of fixed bus bars. The connecting bus bar 144 may be formed, for example, from a rigid bus bar, which is fixed to the base plate 256 of the movable connecting frame 254. This mounts the connecting bus bar 144 to the base plate 256 in such a way that the connecting bus bar 144 can be conductively coupled to each of the second bus bars 238 and 239 when the connecting bus bar 144 is brought into the series connection position by moving the connecting frame 254. Preferably, the connecting bus bar 144 extends in a direction substantially perpendicular to the extension direction of the second bus bars 238, 239. However, other extension directions of the connecting bus bar 144 are also possible, as long as the second bus bars 238, 239 can be conductively coupled to the connecting bus bar 144.

[0064] Furthermore, the contact arrangement 220 includes two secondary connecting bus bars 258 and 260, which may be formed from rigid bus bars similar to the connecting bus bar 144. Each of the secondary connecting bus bars 258 and 260 may be formed from a rigid bus bar, for example, fixed to the bottom side of the cover plate 262 of the movable connecting frame 254. Thereby, the secondary connecting bus bars 258 and 260 are attached to the bottom side of the cover plate 262 in such a way that the secondary bus bar 258 can be conductively coupled to the second bus bar 238 and the fixed bus bar 128, respectively, and the secondary bus bar 260 can be conductively coupled to the second bus bar 239 and the fixed bus bar 129, respectively, when the secondary connecting bus bars 258 and 260 are in the parallel connecting position by moving the connecting frame 254. Preferably, the secondary connecting bus bars 258 and 260 extend substantially perpendicular to the extension direction of the second bus bars 238, 239. However, other extension directions of the secondary connecting bus bars 258, 260 are possible as long as the second bus bars 258 and 260 can be conductively coupled to the second bus bar 238 and the fixed bus bar 128 or the second bus bar 239 and the fixed bus bar 129, respectively.

[0065] To enable simultaneous movement of the connecting bus bar 144 and the two secondary connecting bus bars 258 and 260, the connecting frame 254 may include side plates 264 and 266 attached to opposite ends of the base plate 256 and the cover plate 262, supporting the cover plate 262 and following the movement of the base plate 254 and vice versa. With such an arrangement, the connecting frame 254 may surround the fixed bus bars 128, 129 and the second bus bars 238, 239 on all sides.

[0066] 8 and 9 show the contact arrangement 220 when the contactor device 100 is in a series connection state since the connecting bus bar 144 is in the series connection position. In the series connection position, the connecting bus bar 144 is pressed against each of the second bus bars 238 and 239 by moving the connecting frame 254, so that each of the second bus bars 238 and 239 is conductively coupled to the connecting bus bar 144 at the second contacts 246. Thus, in the series connection state of the contactor device 100, the second bus bars 238 and 239 are electrically connected in series. On the other hand, in the series connection state, the secondary connecting bus bars 258 and 260 are moved away from the second bus bars 238 and 239 by the connecting frame 254, so that the second bus bars 238 and 239 are electrically isolated from the secondary connecting bus bar 258. As a result, the second bus bars 238 and 239 are also electrically isolated from the fixed bus bars 128,129.

[0067] Thus, in the series connection state of contactor device 100, terminals 106 and 112 electrically connect battery modules 502(1) and 502(2) in series by providing a conductive path through second bus bars 238 and 239, which are conductively coupled to connecting bus bar 144. Thus, a predetermined high voltage of battery 500, which is the sum of the module voltages of battery modules 502(1) and 502(2), can be applied to high voltage bus 105 at first contact 134 by conductively coupling movable bus bars 126, 127 and fixed bus bars 128, 129.

[0068] In order to reduce the contact resistance between the second bus bars 238, 239 and the connecting bus bar 144, contact elements 248, for example made of silver or any silver alloy, may be attached to the first contact side of the second bus bars 238, 239 in the area of ​​the second contacts 246 and to the connecting bus bar 144. Of course, other suitable conductive materials may also be used to form the contact elements 246.

[0069] 10 and 11 show the contact arrangement 220 when the contactor device 100 is in a parallel connection state, since the secondary connection busbars 258 and 260 are simultaneously in the parallel connection position. In the parallel connection position, the secondary connection busbar 258 is pressed against the second busbar 238 and the fixed busbar 128 by moving the connection frame, so that the secondary busbar 258 is conductively coupled to the second busbar 238 at the third contact 250 and to the fixed busbar 128 at the fourth contact 268. At the same time, the secondary connection busbar 260 is pressed against the second busbar 239 and the fixed busbar 129 by moving the connection frame, so that the secondary busbar 260 is conductively coupled to the second busbar 239 at the third contact 250 and to the fixed busbar 129 at the fourth contact 268. On the other hand, in the parallel connection state, the connecting bus bar 144 is separated from the second bus bars 238 and 239 by the connecting frame 254, so that the second bus bars 238 and 239 are electrically insulated from the connecting bus bar 144 and from each other.

[0070] Thus, in the parallel connection state, the second busbar 238 is electrically connected in parallel with the fixed busbar 128, and the second busbar 239 is electrically connected in parallel with the fixed busbar 129. In other words, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 238 to the fixed busbar 128 (via the secondary connection element 258) and vice versa, and the second busbar 138 and the fixed busbar 128 share the same potential. Similarly, in the parallel connection state, the contactor device 100 allows current to flow from the second busbar 239 to the fixed busbar 129 (via the secondary connection element 260) and vice versa, and the second busbar 239 and the fixed busbar 129 share the same potential. Meanwhile, in the parallel connection state, the second busbars 238 and 239 are electrically isolated from the connecting busbar 144.

[0071] Thus, in the parallel connection state of contactor device 100, terminals 106 and 112 electrically connect battery modules 502(1) and 502(2) in parallel by providing a conductive path from terminal 106 through second bus bar 238 and secondary connection element 258 to fixed bus bar 128, and a conductive path from terminal 112 through second bus bar 239 and secondary connection element 260 to fixed bus bar 129. As a result, a voltage resulting from electrically connecting battery modules 502(1) and 502(2) in parallel can be applied to high voltage bus 105 by conductively coupling movable bus bars 126, 127 and fixed bus bars 128, 129. Ideally, when the two battery modules 502(1) and 502(2) are electrically connected to the contactor device 100, the resulting voltage is half the predetermined high voltage of the high voltage battery 500, for example, 400V if the battery 500 outputs a predetermined high voltage value of 800V.

[0072] In order to reduce the contact resistance in the parallel connection situation, a contact element 252, for example made of silver or any silver alloy, may be attached to the second contact side of the second bus bars 238, 239 for contacting the secondary connecting bus bars 258 and 260, respectively, and to the secondary connecting bus bars 258 and 260 in the region of the third contact 250. A similar contact element 270, for example made of silver or any silver alloy, may be attached to the secondary connecting bus bars 258 and 260, respectively, and to the fixed bus bars 258 and 260 in the region of the fourth contact 268. Naturally, other suitable conductive materials may also be used to form the contact elements 252 and 270.

[0073] 12 and 13 show the contactor arrangement 220 in an open state, with the connecting frame 254 in an open position such that the second bus bars 238 and 239 are not conductively coupled to the connecting bus bars 144 nor to the secondary connecting bus bars 258 and 260. Thus, in the open position of the connecting frame 254, the second bus bars 238 and 239 are electrically isolated from the fixed bus bars 128 and 129, while at the same time the second bus bars 238 and 239 are electrically isolated from each other, thereby interrupting the electrical connection between the terminals 106 and 112 of the contactor device 100.

[0074] It is also clear to a person skilled in the art that in the open position of the connection frame 254, it is necessary not only to interrupt the electrical connection between the high-side terminal 506 of the high-voltage battery 500 and the high-side of the high-voltage bus 105, but also to interrupt the electrical connection between the low-side terminal 504 of the high-voltage battery 500 and the low-side of the high-voltage bus 105. Although not shown in FIG. 12, for this purpose the movable bus bars 126 and 127 of the contact arrangement can be moved to an open position in which the movable bus bars 126 and 127 are electrically isolated from the fixed bus bars 128 and 129. Alternatively, the contactor device 100 can be used in combination with a second contactor device (for example, as shown in FIGS. 14 and 15 described below), which can be in a state in which it interrupts the flow of current between the high-voltage battery 500 and the high-voltage bus 105.

[0075] Thus, by mounting the connecting bus bar 144 as well as the secondary connecting bus bars 258 and 260 on the connecting frame 254, the exemplary second contact arrangement 220 of the contactor 100 allows to distinguish between two additional states when the contactor device is in the closed state, namely a series connection state and a parallel connection state, and it is possible to change the state of the contactor device 100 by moving the connecting frame by means of an actuator. Thus, the connecting frame 254 may be moved by the same actuator as the movable bus bars 126 and 127 to change the state of the contactor device 100, or a dedicated actuator may be provided to move the connecting frame 254 individually. Possible arrangements of such actuators are described below with reference to the exemplary second contactor device 300 and Figures 16 to 24. The configuration of the exemplary second contact arrangement 220 therefore enables each of the connecting bus bars 144, 258 and 260, as well as the two second bus bars 238, 239, to be provided as fixedly mounted bus bars and only the connecting frame 254 to move to change the state of the contactor device 100.

[0076] Furthermore, as shown diagrammatically in Figures 8, 10 and 12, the contactor device 100 may include a pyrotechnic actuator 280, which when triggered is configured to permanently interrupt the flow of current through the contactor device 100, as an additional safety feature for the contact arrangement 220. Of course, a pyrotechnic actuator may also be used in the contact arrangement 120. Possible implementations of the pyrotechnic actuator 280, and possible contact separation mechanisms performed by triggering the pyrotechnic actuator 280, may be implemented in the contact arrangements 120 and 220, and are described below with reference to an exemplary second contactor device 300 and Figures 16 to 24.

[0077] 14 and 15 show a contact arrangement 220 conductively coupled to a second contactor device 400, where the contact arrangement 220 has the function of switching the connection state of the battery modules 502(1) and 502(2) of the battery 500 between a parallel connection state (FIG. 14) and a series connection state (FIG. 15). The second contactor device 400 can be any contactor device having at least the function of switching between an open state, in which the flow of current from the battery 500 to the high voltage bus 105 is prevented, and a closed state, in which the flow of current from the battery 500 to the high voltage bus 105 is possible. For example, the contactor device described in detail in European patent application EP20184037.8 can be used as the second contactor device 400.

[0078] The second exemplary contactor device 300 will now be described with reference to Figures 16 to 24, where elements of the contactor device 300 and elements of the contactor device 100 having substantially the same function are given like reference numbers and the same or similar component names. The contactor device 300 differs from the exemplary first contact arrangement 120 of the contactor device 100 in that it lacks the connecting busbar 144 and the two second busbars 138, 139, and from the exemplary first contact arrangement 220 of the contactor device 100 in that it lacks the connecting frame 254, the corresponding connecting busbars 144, 258 and 260, and the two second busbars 238, 239.

[0079] 16 shows a schematic perspective view of a contactor device 300, which preferably includes two fixed busbars 328 and 329 and two movable busbars 326 and 327, so that the contactor device 300 can function as a two-pole combination contactor that functions as a two-pole single-break type contactor under normal operating conditions. However, the number of two movable busbars and two fixed busbars is not essential to the function of the contactor device 300, but the contactor device 300 may have more than two movable and fixed contacts, or one movable and one fixed busbar. The fixed busbars 328 and 329 and the movable busbars 326 and 327 may form an exemplary implementation of the fixed busbars 128, 129 and the movable busbars 126, 127 of the first contact arrangement 120 and the second contact arrangement 220, respectively, and the remaining described components can be added.

[0080] 16 shows the movable bus bars 326 and 327 in a closed position, where each of the movable bus bars 326 and 327 is conductively coupled to one of the fixed bus bars 328 and 329, thereby allowing current to flow from terminal 310 formed integrally with the movable bus bar 326 to terminal 304 formed integrally with the fixed bus bar 328, and from terminal 308 formed integrally with the movable bus bar 327 to terminal 302 formed integrally with the fixed bus bar 329. Terminals 308 and 310 may be electrically connected to terminals 504 and 506 of the high voltage battery 500, and terminals 302 and 304 may be electrically connected to the high voltage bus 105, or vice versa. To reversibly connect and disconnect the current path through the contactor device 300, the contactor device 300 includes an electromagnetic actuator 372 that is capable of reversibly moving the movable bus bars 326 and 327 between closed and open positions.

[0081] To facilitate reversible transition between the open and closed positions, the movable bus bars 326 and 327 are formed in a manner such that they can resiliently flex between the open and closed positions, at least at the flexible contact area 333. To this end, the movable bus bars 326 and 327 may be formed from a multi-layer structure, for example including 10-15 layers of copper or other suitable conductive material. Additionally, each of the movable bus bars 326 and 327 may include a protrusion 374 to support the flexing capability of the movable bus bars 326 and 327. The protrusion 374 may also contribute to applying a preload to the movable bus bars 326 and 327 that urges the movable bus bars 326 and 327 toward the open position.

[0082] The electromagnetic actuator 372 is configured to hold the movable bus bars 326 and 327 in a closed position when power is applied. For this purpose, each of the flexible contact areas 333 of the movable bus bars 326 and 327 may be moved individually by the electromagnetic actuator 372, for example by a shaft 376 arranged on the upper side of the movable bus bars 326 and 327 in the flexible contact area 333. An additional spring element may be arranged around the shaft 376 to help absorb small misalignments or imbalances between the movable bus bars 326 and 327 during operation of the contactor device 300, preventing such misalignments from affecting the electromagnetic actuator 372 or significantly affecting the force applied between the fixed bus bars 328 and 329 and the movable bus bars 326 and 327. Thus, the tolerances between the fixed bus bars 328 and 329 and the movable bus bars 326 and 327 introduced during the manufacture of the contactor device 100 can be better compensated for. Furthermore, the springs are located below each of the movable bus bars 326 and 327, i.e., above the bottom side of each of the movable bus bars 326 and 327, thereby biasing the movable bus bars 326 and 327 to an open position when no force is being applied by the shaft 376, i.e., when no power is supplied to the electromagnetic actuator 372.

[0083] 17 shows the contactor device 300 in a de-energized state, with the electromagnetic actuator 372 not energized, so that the movable bus bars 326 and 327 are simultaneously in an open position. Thus, the contact elements 336 of the movable bus bars 326 and 327 are electrically isolated from the contact elements 336 of the fixed bus bars 328 and 329 by a space gap, preventing current flow through the contactor device 300. The design of the movable bus bars 326 and 327 allows sufficient electrical insulation between the movable bus bars 326 and 327 and the fixed bus bars 328 and 329, even under normal atmosphere. Thus, the contactor device 300 can be significantly simplified, since the need to provide the movable bus bars 326 and 327 and the fixed bus bars 328 and 329 in a sealed housing or the need to use an electronegative gas can be eliminated. However, to provide increased electrical insulation, it is also possible to provide at least a portion of the movable bus bars 326 and 327 and the fixed bus bars 328 and 329 within the sealed housing in the area surrounding the contact element 336 .

[0084] FIG. 18 shows contactor device 300 in an energized state with movable bus bars 326 and 327 in a closed position such that contacts 336 of movable bus bars 326 and 327 are conductively coupled to contacts 336 of fixed bus bars 328 and 329 .

[0085] To move the moveable bus bars 326 and 327 from the open position to the closed position, the armature of the electromagnetic actuator 372 applies a closing force, e.g., via a shaft 376, to the moveable bus bars 326 and 327, urging the moveable bus bars 326 and 327 in the direction 378 of the closing force, i.e., towards the fixed bus bars 328 and 329.

[0086] Instead of the electromagnetic actuator 372, for example, the contactor device 300 may comprise a linear motor actuator 472, which moves the movable bus bars 326 and 327 between an open position (shown in FIG. 20) and a closed position (shown in FIG. 19) by driving a shaft 476, for example as shown diagrammatically in FIGS. 19 and 20. Here, the shaft 476 moves only when the linear motor actuator 472 is powered. In this exemplary embodiment, when the linear motor actuator 472 is powered, the linear motor actuator 472 moves the movable bus bars 326 and 327 only between the open and closed positions, and when the linear motor actuator 472 is not powered, the movable bus bars 326 and 327 remain in their previous positions. Thus, the linear motor actuator 472 functions as a bistable actuator, making it possible to introduce open and closed states of the contactor device 300 as bistable states of the contactor device 300 that change only when power is supplied to the linear motor actuator 472.

[0087] Thus, unlike a contactor device 300 with an electromagnetic actuator 372 that opens when the electromagnetic actuator 372 experiences a power loss, e.g., due to a damage event or due to communication loss, the contactor device 300 can remain in a closed (or open) state when the linear motor actuator 472 experiences a power loss, thereby enabling the electric vehicle to be driven even after the linear motor actuator 472 loses power.

[0088] Here, the actuator 372 and / or the actuator 472 may also be provided in the exemplary first contact arrangement 120 as an actuator(s) for moving the movable bus bars 126 and 127 between an open position and a closed position and / or for moving the second bus bars 138 and 139 between a series connection position and a parallel connection position between the second bus bars 138, 139. Similarly, the actuator 372 or the actuator 472 may also be provided in the exemplary second contact arrangement 220 as an actuator for moving the connection frame 254 to change the state of the contactor device 100 and / or for moving the movable bus bars 126 and 127 between an open position and a closed position.

[0089] 16, it is shown that the contactor device 300 further includes a pyrotechnic actuator 380 configured to permanently displace the fixed bus bars 328 and 329 to a post-ignition position in which the fixed bus bars 328 and 329 are permanently electrically isolated from the movable bus bars 326 and 327 when triggered. Thus, displacing the fixed bus bars 328 and 329 can refer to displacing the entire fixed bus bars 328 and 329, or can refer to displacing the fixed bus bars 328 and 329 within at least the contact area 379 of the fixed bus bars 328 and 329, including the contact element 336, for example by irreversibly disconnecting the fixed bus bars 328 and 329 as described below. In this way, it can be prevented that the movable bus bars 326 and 327 can be conductively coupled to the fixed bus bars 328 and 329 even after the actuation of the pyrotechnic actuator 380. As a result, the flow of electrical current through the contactor device 300 can be permanently interrupted by actuation of the pyrotechnic actuator 380.

[0090] The pyrotechnic actuator 380 may include two or more pyrotechnic electrical terminals 382, ​​sometimes referred to as pyrotechnic pins, that cause ignition of a pyrotechnic charge in response to receiving an electrical control signal. The pyrotechnic charge may be an explosive that is directly ignited by the electrical control signal, or it may be a gas generator charge that expands suddenly after receiving an electrical control signal. Alternatively, the pyrotechnic charge may have a multiple charge configuration including, for example, an initiator charge and a secondary gas generator charge.

[0091] The pyrotechnic electrical terminal 382 may be connected to a current sensing controller integrated in the contactor device 300, for example configured to detect the current flowing through the contactor device 300 in the closed position. When the detected current exceeds a predetermined threshold, which may be represented by a level of current dangerous to the functioning of the contactor device 300, the current sensing controller may send an electronic control signal to ignite the pyrotechnic charge.

[0092] Alternatively, the pyrotechnic electrical terminal 382 may be connected to an external controller or a controller of the high voltage battery 500, such as a battery management system of the high voltage battery 500, which may provide an electrical control signal to trigger the pyrotechnic actuator 380, for example, in response to detection of an overcurrent or malfunction in the energy storage system 10. An electrical control signal may also be received in response to an anomaly or malfunction detected in any other circuit component of the electrical circuit to which the contactor device 300 is conductively coupled. As another alternative, the pyrotechnic electrical terminal 382 may be connected to a vehicle's electronic control unit (ECU) or crash sensor that includes the contactor device 300, and may receive an electronic control signal in response to detection of a vehicle accident.

[0093] The pyrotechnic actuator 380 further comprises a piston structure 384 that can be driven away from a rest position by the force generated when the pyrotechnic charge is ignited. When the piston structure 384 is propelled by the generated force, it drives a displacement element 386 supported within an actuator housing 388 of the pyrotechnic actuator 380 to push the fixed bus bars 328 and 329 together and away from the movable bus bars 326 and 327 into a post-ignition position. For example, a stud or bolt driven by the energy of the piston structure 384 to displace or act as the fixed bus bars 328 and 329 can function as the displacement element 386.

[0094] 16, each of the fixed busbars 328 and 329 may include a hinge flexure 381 between the terminal 302 and the contact element 336 of the fixed busbar 329, and between the terminal 304 and the contact element 336 of the fixed busbar 328. The hinge flexure 381 allows the contact area 379 of the fixed busbars 328 and 329 to swing away from the movable busbars 326 and 327 in a well-defined manner when the pyrotechnic actuator 380 is triggered. Thus, each of the hinge flexures 381 of the fixed busbars 328 and 329 provides an axis of mechanical motion about which the respective fixed busbar 328 and 329 rotates during movement to the post-fire position. This allows the positions of the hinge bends 381 of the fixed bus bars 328 and 329 to be adjusted so as to change the swing radius of the contact areas 381 of the fixed bus bars 328 and 329. Thus, the movement path of the fixed bus bars 328 and 329, or at least the contact areas 379 of the fixed bus bars 328 and 329, from the normal position to the post-ignition position can be clearly defined.

[0095] The actuator housing 388 can accommodate the piston structure 384 when it is in a rest position before the pyrotechnic actuator 380 is triggered. The actuator housing 388 can also provide a piston stop means for stopping the piston structure 380 when it reaches the final position and the fixed bus bars 328 and 329 are in a post-fire position. In this way, the contactor device 300 can provide a clear path for the piston structure 384. The actuator housing 388 can also provide a retention means for holding the piston structure 384 in the final position and prevent the piston structure 384 from returning to the rest position after the pyrotechnic actuator is triggered. In this way, the piston structure 384 can help to hold the fixed bus bars 328 and 329 in a post-fire position when the pyrotechnic actuator is actuated. Additionally or alternatively, the actuator housing 388 can also provide a retention means for holding the fixed bus bars 328 and 329 in a post-fire position.

[0096] The contactor device 300 may also include arc suppression elements to extinguish arcs that may occur due to the rapid interruption of the current carrying path when the pyrotechnic actuator 380 is actuated. For example, the contactor device 300 may include one or more arc blow-out magnets used to control the occurrence of arc discharges or may include an array of arc splitting plates configured to split and cool the arc into multiple individual arcs of lower energy. Alternatively, the arc suppression elements may include mechanical devices that may be inserted between the fixed bus bars 328 and 329 and the movable bus bars 326 and 327 when the pyrotechnic actuator 380 is actuated. Alternatively or additionally, the arc suppression elements may include a gas generator charge that is ignited when the pyrotechnic actuator 380 is actuated to generate a gas that cools the arc or mixes the arc with air.

[0097] The operation of the pyrotechnic actuator 380 will now be described with reference to Figures 21 and 22, which show schematic top views of the contactor device 300. Figure 21 shows the contactor device 300 with the movable bus bars 326 and 327 in a closed position and before the pyrotechnic actuator 380 has been activated. The holding force is oriented in the direction 378, i.e. from the contact elements 336 of the movable bus bars 326 and 327 towards the contact elements 336 of the fixed bus bars 328 and 329, and holds the movable bus bars 326 and 327 in the closed position. As indicated by the crosses 378, the holding force is oriented into the plane of the paper in the example of Figures 21 and 22.

[0098] FIG. 22 shows a top view of the contactor device 100 with the pyrotechnic actuator 380 triggered. Although in FIG. 22 only the fixed bus bar 329 is shown in the post-ignition position, after triggering the pyrotechnic actuator 380, the fixed bus bar 328 also moves to the post-ignition position at the same time. The piston structure 384 is driven away from its rest position by the force generated when the pyrotechnic charge is ignited. The generated force drives the displacement elements to irreversibly move the fixed bus bars 328 and 329 to the post-ignition position where the fixed bus bars 328 and 329 are electrically isolated from the movable bus bars 326 and 327. As indicated by arrow 390 , movement of the fixed bus bars 328 and 329 or the contact areas 379 of the fixed bus bars 328 and 329 preferably occurs in a plane perpendicular to the direction 378 of the retention force applied by the electromagnetic actuator 372 to the movable bus bars 326 and 327 .

[0099] However, it is not essential that the plane in which the fixed bus bars 328 and 329 or the contact areas 379 of the fixed bus bars 328 and 329 move to the post-ignition position is perpendicular to the direction 378 of the holding force, but this plane need only subtend a certain angle with respect to the direction 378, so that the direction of movement of the fixed bus bars 328 and 329 or the contact areas 379 of the fixed bus bars 328 and 329 at least constitutes an angle with respect to the direction of movement of the movable bus bars 326 and 327 between the open and closed positions.

[0100] In this way, it can be ensured that the fixed bus bars 328 and 329 move to the post-ignition position without affecting the actuation mechanism for moving and holding the movable bus bars 326 and 327 in the closed position. Similarly, if the force generated by the pyrotechnic actuator 380 is transferred to the fixed bus bars 328 and 329 in such a way that it does not act against the force generated by the electromagnetic actuator 372 (or linear motor actuator 472), the movement of the fixed bus bars 328 and 329 to the post-ignition position is prevented from being influenced by the actuation mechanism for moving and holding the movable bus bars 326 and 327 in the closed position.

[0101] It should be noted that the movement of the fixed bus bars 328 and 329 or the contact areas 379 of the fixed bus bars 328 and 329 to the post-fire position is not limited to rotational movement, but the fixed bus bars 328 and 329 or the contact areas 379 of the fixed bus bars 328 and 329 may also move linearly to the post-fire position, for example on a movement path that is independent from the movement path of the movable bus bars 326 and 327 between the open and closed positions.

[0102] Thus, the contactor device 300 allows the movable bus bars 326 and 327 to be reversibly moved between the open and closed positions by controlling the operation of the electromagnetic actuator 372 (or the linear motor actuator 472). Furthermore, when the pyrotechnic actuator 380 is actuated, the fixed bus bars 328 and 329 are moved to the post-ignition position, thereby permanently displacing or disconnecting the fixed bus bars 328 and 329 and permanently interrupting the flow of current through the contactor device 300. In other words, the electromagnetic actuator 372 (or the linear motor actuator 472) is configured to reversibly move and hold the movable bus bars 326 and 327 to reversibly change the conductive state of the contactor device 300, while the pyrotechnic actuator 380 is configured to irreversibly move the fixed bus bars 328 and 329 to the post-ignition position to irreversibly interrupt the flow of current through the contactor device 300. Notably, actuation of the pyrotechnic actuator is possible independent of the position of the moveable bus bars 326 and 327 and the electromagnetic actuator 372 (or linear motor actuator 472).

[0103] Instead of mechanically moving the fixed busbars 328 and 329 to a post-ignition position, Figures 23 and 24 show, in schematic form, an alternative contact separation mechanism that may be implemented in the contactor device 300. This mechanism is exemplarily shown for irreversibly separating the fixed busbar 328 and the movable busbar 326, but it will be appreciated that the same separation mechanism may be provided for irreversibly separating the fixed busbar 329 and the movable busbar 327. Here, the fixed busbar 328 is at least partially surrounded by an electrically insulating layer 492, preferably of cylindrical cross-section and formed of an electrically insulating material.

[0104] In order to irreversibly separate the fixed bus bar 328 from the movable bus bar 326, the piston structure of the pyrotechnic actuator, instead of driving the displacement element 386 to move the fixed bus bar 328, is here configured to move an insulating cap 494 formed of an electrically insulating material from a normal position (FIG. 23) to a post-ignition position (FIG. 24) after the pyrotechnic actuator is triggered.

[0105] As shown in Fig. 23, as long as the insulating cap 494 is in the normal position, i.e., before triggering the pyrotechnic actuator, it conductively couples the contact elements 336 of the movable bus bar 326 and the fixed bus bar 328 to allow current to flow through the contactor device 300 and the movable bus bar 326 may move between the open and closed positions. However, when the pyrotechnic actuator is triggered, the pyrotechnic piston drives the insulating cap 494 in the direction of the fixed bus bar 328 (indicated by arrow 496 in Figs. 23 and 24) until the insulating cap 494 completely surrounds the end region of the fixed bus bar 328 in the post-ignition position. As a result, in the post-ignition position, the insulating cap 494 is pressed between the contact elements 336 of the movable bus bar 326 and the fixed bus bar 328, thereby electrically insulating the movable bus bar 326 and the fixed bus bar 328 from each other.

[0106] In this manner, the insulating cap 494 can inhibit the formation of electrical arcs while simultaneously interrupting the flow of current through the movable bus bar 326 and the fixed bus bar 328. To this end, preferably, the insulating cap 494 completely surrounds the termination area of ​​the fixed bus bar 328, including the contact elements 336, and may overlap the electrical insulation layer 492. However, complete encapsulation of the termination area is not required for the alternative contact isolation mechanism, so long as the insulating cap can provide sufficient electrical insulation between the movable bus bar 326 and the fixed bus bar 328.

[0107] Although not shown, it is possible to add two second bus bars 138 and 139 as well as the connecting bus bar 144 to the contact arrangement of the contactor device 300 to form the exemplary first contact arrangement 120 shown in Figures 2 to 7. Similarly, it is possible to add two second bus bars 238 and 239 as well as the connecting frame 254 with the corresponding connecting bus bars 144, 258 and 260 to the contact arrangement of the contactor device 300 to form the exemplary second contact arrangement 220 shown in Figures 8 to 13. In other words, the contactor device 300 or a single component of the contactor device 300 may form the basis for building the contactor device 100 to which the additional components of the exemplary first contact arrangement 120 or the exemplary second contact arrangement 220 are added. This makes it possible, for example, that the two second bus bars 138 and 139 may be formed in the same way as the movable bus bars 326 and 327 of the contactor device 300.

[0108] The present disclosure also relates to an energy storage system 10 comprising the contactor device 100 or the contactor device 300. The energy storage system 10 may be an energy storage device, for example, including the contactor device 100 or the contactor device 300 and a battery 500. The energy storage system 10 may further comprise a controller or a battery management system that controls the operation of the battery 500 and the contactor device 100 or the contactor device 300, and may monitor the operating state of the energy storage system 10. For example, the controller or the battery management system may control at least one actuator of the contactor device 100 to change the state of the contactor device 100 at least between a series connection state and a parallel connection state, and / or between a closed state and an open state, in response to a control signal provided by the controller or the battery management system. Similarly, the controller or the battery management system may control at least one actuator of the contactor device 300 to change the state of the contactor device at least between a closed state and an open state, in response to a control signal provided by the controller or the battery management system. Further, in case of operation outside of safe operating conditions (hazardous operating conditions), such as overcurrent, overheating of the battery 500, or an accident, the controller or battery management system may trigger the pyrotechnic actuator 380 (or 280) of the contactor device 300 (or contactor 100) by providing a respective control signal. [Explanation of symbols]

[0109] 10 Energy Storage Systems 100, 300 Contactor Devices 102, 104, 106, 108, 110, 112, 302, 304, 308, 310 Contactor device terminals 105 High Voltage Bus 120, 220 contact arrangement 122, 124 contacts 126, 127, 326, 327 Movable busbar (third busbar) 128, 129, 328, 329 Fixed busbar (first busbar) 130, 131 Movable busbar rigidity area 132, 133, 333 Flexible area of ​​movable busbar 134 First contact 136, 148, 152, 248, 252, 270, 336 contact elements 138, 139, 238, 239 Second busbar 140, 141 Second busbar rigidity area 142, 143 Second busbar flexible area 144 (primary) connecting busbar 146, 246 Second contact 150, 250 Third contact 254 connection frames 256 Base Plate 258, 260 Secondary connecting busbar 262 Cover Plate 264, 266 Side Plate 268 Fourth contact 280, 380 Pyrotechnic Actuator 372 Electromagnetic Actuator 374 Convex 376 Shaft 378 Closing force direction 379 Fixed busbar contact area 381 Hinge bend 382 Pyrotechnic Electrical Terminals 384 Piston Structure 386 Displacement Element 388 Actuator Housing 390, 496 Arrow 472 Linear Motor Actuator 492 Electrical insulation layer 494 Insulating Cap TIFF0007610762000001.tif223161TIFF0007610762000002.tif53161

Claims

1. two first terminals (102, 104) for electrically connecting at least one of a load and a charger; two second terminals (106, 108) for electrically connecting the first battery module (502(1)); two third terminals (110, 112) for electrically connecting a second battery module (502(2)); two first bus bars (128, 129), each electrically connected to one of the first terminals (102, 104); two second bus bars (138, 139; 238, 239), one of the second bus bars (138; 238) being electrically connected to one of the second terminals (106) and another of the second bus bars (139; 239) being electrically connected to one of the third terminals (112); a connecting bus bar (144) electrically insulated from the two first bus bars (128, 129); and at least one actuating element configured to change a state of the contactor device (100) between a series connection state, in which the two second bus bars (138, 139; 238, 239) are conductively coupled to the connecting bus bar (144), and between a parallel connection state, in which one of the second bus bars (138; 238) is conductively coupled to one of the first bus bars (128) and another of the second bus bars (139; 239) is conductively coupled to another of the first bus bars (129).

2. 2. The contactor device (100) of claim 1, wherein each of the second bus bars (138, 139) includes a flexible contact area (142, 143), the flexible contact area being resiliently deflectable between a first position in which each of the second bus bars (138, 139) is conductively coupled to the connecting bus bar (144) and a second position in which each of the second bus bars (138, 139) is conductively coupled to one of the first bus bars (128, 129).

3. 2. The contactor device (100) of claim 1, further comprising two secondary connection bus bars (258, 260), each of the two secondary connection bus bars configured to conductively couple one of the second bus bars (238, 239) to one of the first bus bars (128, 129), respectively, in the parallel connection state of the contactor device (100).

4. 4. The contactor device (100) of claim 3, wherein the connecting bus bar (144) and the secondary connecting bus bars (258, 260) are mounted to a connecting frame (254), and the at least one actuating element is configured to move the connecting frame (254) to change the state of the contactor device (100) between the series connection state and between the parallel connection state.

5. 2. The contactor device (100) of claim 1, wherein each of the second bus bars (138, 139; 238, 239) comprises a plurality of contact elements (148, 152, 248, 252) arranged on different sides of the second bus bar (138, 139; 238, 239), each of the second bus bars (138, 139; 238, 239) configured to be conductively coupled to the connecting bus bar (144) on a contact side of the second bus bar (138, 139; 238, 239) that is different from a contact side for conductively coupling to one of the first bus bars (128, 129).

6. 2. The contactor device (100) of claim 1, wherein the at least one actuating element includes a dedicated actuator (372, 472) for changing the state of the contactor device (100) between the series connection state and between the parallel connection state.

7. further comprising two third bus bars (126, 127), one of the third bus bars (126) being electrically connected to another of the second terminals (110) and the other of the third bus bars (127) being electrically connected to another of the third terminals (108); 2. The contactor device (100) of claim 1, wherein the at least one actuating element is configured to change a state of the contactor device (100) between a closed state in which each of the third bus bars (126, 127) is conductively coupled to one of the first bus bars (128, 129), respectively, and an open state in which the two third bus bars (126, 127) and the two second bus bars (138, 139; 238, 239) are electrically isolated from the two first bus bars.

8. 8. The contactor device (100) of claim 7, wherein each of the third bus bars (126, 127) includes a flexible contact area (132, 133), the flexible contact area being resiliently deflectable between an open position in which each of the third bus bars (126, 127) is electrically insulated from the two first bus bars (128, 129) and a closed position in which each of the two third bus bars (126, 127) is conductively coupled to one of the first bus bars (128, 129), respectively.

9. The contactor device (100) of claim 7, wherein the contactor device is in the open state when power is not supplied to the at least one actuation element.

10. The contactor device (100) of claim 1, wherein the contactor device changes state only when power is supplied to the at least one actuation element.

11. 2. The contactor device (100) of claim 1, further comprising at least one pyrotechnic actuator (280, 380), said at least one pyrotechnic actuator configured, upon actuation, to irreversibly prevent a flow of electrical current through each of said first bus bars (128, 129).

12. 8. The contactor device (100) of claim 7, further comprising at least one pyrotechnic actuator (280, 380), the at least one pyrotechnic actuator being configured, upon actuation, to move the two first bus bars (128, 129) to a post-ignition position, in which each of the two first bus bars (128, 129) is irreversibly displaced or disconnected.

13. 8. The contactor device (100) of claim 7, further comprising at least one pyrotechnic actuator (280), the at least one pyrotechnic actuator configured, upon actuation, to irreversibly drive at least one insulating element to a post-ignition position, wherein in the post-ignition position, the insulating element electrically isolates the two third bus bars (126, 127) and the two first bus bars (128, 129) from each other.

14. 14. The contactor device (100) of claim 13, wherein the insulating element includes at least two insulating caps (494), and in the post-ignition position, each of the at least two insulating caps (494) completely surrounds a contact area of ​​a respective one of the first bus bars (128, 129).

15. a battery (500) formed from at least a first battery module (502(1)) and a second battery module (502(2)); A contactor device (100) according to claim 1; An energy storage system (10) comprising: the first battery module (502(1)) is electrically connected to the two second terminals (106, 108) of the contactor device (100), and the second battery module (502(2)) is electrically connected to the third terminals (110, 112) of the contactor device.

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