Switch-Type Battery Pack Disconnect with Spark-Free Interlock Sequencing
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Solution Overview
Problem
Existing power disconnection devices for battery packs are inconvenient to use and costly due to the need for frequent detachment and attachment of plugs and sockets, and they pose safety risks from high voltage sparks during disconnection.
Innovation Solution
A switch-type power disconnection device with a housing, interlock terminals, high voltage terminals, and switch levers that allow safe and convenient disconnection of power by operating a switch lever, sequentially disconnecting interlock and high voltage terminals using a seesaw mechanism and elastic members to prevent sparks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plug and socket type power disconnection device is used, then the device can be manually operated to disconnect power, but the device requires frequent detachment and attachment which is inconvenient and increases manufacturing cost
Solution Approach 1:
The patent combines the plug and socket into a single integrated housing structure. The first and second switches are housed within a common housing that includes integrated first and second housings, eliminating the need for separate plug and socket components. This merging reduces the number of parts, simplifies the device structure, and makes operation more convenient while maintaining the power disconnection function.
2Ease of manufacture
If a plug and socket type power disconnection device is used, then the device can disconnect power, but the manufacturing cost is high due to separate manufacturing and assembly of plug and socket
Solution Approach 1:
The patent integrates multiple components including the first housing, second housing, first switch, and second switch into a single unified power disconnection device. This consolidation reduces the number of manufacturing steps, eliminates the need for separate assembly of plug and socket, and simplifies production while maintaining all necessary functional components.
3Reliability
If the plug is removed from the socket, then the power can be disconnected, but a spark is generated at the high voltage terminal which causes safety problems
Solution Approach 1:
The patent employs an interlock mechanism where the first switch (disconnecting the interlock loop) must be actuated before the second switch (disconnecting the high voltage terminals) can be operated. This preliminary action ensures that the interlock loop is broken first, preventing spark generation when the high voltage terminals are disconnected, thereby eliminating the safety hazard while maintaining power disconnection functionality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The switch-type power disconnection device enables safe and easy disconnection of battery pack power with a simple finger-operated switch lever, reducing manufacturing costs and eliminating the risk of high voltage sparks during disconnection.
Implementation Method 1
elastic members to prevent sparks
Data Source
AI summary
A power disconnection device for manually disconnecting power of a battery pack, the device including a housing, first and second interlock terminals provided in the housing and connectable to an interlock circuit of the battery pack, first and second high voltage terminals connectable to a high voltage line of the battery pack, a switch lever disposed over inner and outer portions of the housing, a first switch module in contact with the first and second interlock terminals, and upon an off operation of the switch lever, configured to be separated from any one of the first and second interlock terminals, and a second switch module configured to interlock with the first switch module, the second switch module being in contact with the first and second high voltage terminals, separated from any one of the first and second interlock terminals, and then separated from the first and second high voltage terminals.