Sealed Manual Disconnect System with Tool-Free Lever Mechanism
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Solution Overview
Problem
Existing manual disconnect systems for high current connections are not sealed, require a large footprint, and necessitate the use of tools for connector removal.
Innovation Solution
A sealed manual disconnect system with a compact design that includes a battery part, disconnect part, circuit assembly, fuse assembly, and connectors, allowing for tool-free disconnection by leveraging a shielding cover and lever mechanism to facilitate electrical disconnection without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a manual disconnect unit is designed to be sealed, then protection against fluid and fume ingress is improved, but device complexity increases
Solution Approach 1:
The patent implements nesting by placing the circuit assembly inside the disconnect part cavity, which is itself contained within the disconnect part. The fuse assembly is nested within the battery part's fuse assembly subcompartment. This nested structure allows the disconnect unit to be sealed while maintaining a compact form factor and avoiding excessive complexity.
Solution Approach 2:
The disconnect unit is segmented into distinct functional modules: the battery part with fuse assembly subcompartment, the disconnect part with shielding cover and cavity, and the circuit assembly. This segmentation allows each component to be optimized independently for sealing while simplifying the overall design and assembly process.
2Area of stationary object
If the disconnect unit is designed to occupy a small footprint, then space efficiency is improved, but manufacturing complexity may increase
Solution Approach 1:
The circuit assembly is nested within the disconnect part cavity, and the fuse assembly is nested within the battery part's fuse assembly subcompartment. This nesting arrangement maximizes space utilization and minimizes the overall footprint of the disconnect unit while maintaining a relatively simple manufacturing process through modular assembly.
Solution Approach 2:
The patent combines multiple functions into integrated components: the shielding cover both shields and defines the disconnect part cavity; the disconnect part serves as both a structural housing and a circuit carrier; the fuse assembly subcompartment integrates fuse storage and electrical connection functions. This merging reduces the overall footprint while keeping manufacturing complexity manageable.
3Ease of operation
If the disconnect unit requires tool-free removal, then ease of operation is improved, but reliability may deteriorate due to potential accidental disconnection
Solution Approach 1:
The disconnect part is designed with dynamic characteristics, allowing it to be easily removed from the battery part when needed. The releasable connection mechanism provides controlled movement between connected and disconnected states, enabling tool-free operation while maintaining stability during normal use through the engineered interface between components.
Data Source
AI summary
A manual disconnect system includes a battery part, a disconnect part, a circuit assembly and a fuse assembly with a fuse connector and a circuit connector connected to the battery part. The battery part has a main compartment and a fuse assembly subcompartment. The disconnect part is releasably connected to the battery part. The fuse assembly is releasably received by the fuse assembly subcompartment. When the disconnect part is connected to the battery part, the fuse assembly and the fuse connector are electrically connected together and the circuit assembly and the circuit connector are electrically connected together. Upon detaching the disconnect part and the battery part from each other, the circuit assembly and the circuit connector are electrically disconnected from one another while the fuse assembly remains releasably connected to the battery part in the fuse assembly subcompartment and electrically connected to the fuse connector.