Description:FIELD
[0001] Various embodiments of the present disclosure relate generally to manual service disconnects for battery systems.
BACKGROUND
[0002] Batteries, such as those for electric vehicles or hybrid vehicles, typically include a plurality of cells grouped together as a battery pack. The battery pack includes battery distribution units that manage the power capacity and functionality of the battery pack. These battery distribution units are typically mounted within the outer casing of the battery pack along with other electronic components. The battery pack also includes manual service disconnects that allow disconnecting a high current power circuit of the battery pack from its load, for service of the battery pack. Traditional Manual Service Disconnects do not have fuse at all,
it is Modern Service Disconnects which have fuse in the form of expensive electronic circuit breakers, but it is still not a removable/serviceable one.
[0003] Known manual service disconnect device includes a rotatable body having a non-conductive handle and a conductive shaft, a first terminal, a second terminal, a third terminal, a first wire electrically coupled to the third terminal, a second wire electrically coupled to the second terminal, and a resistor electrically coupled to the first wire and the first terminal. The rotatable body is inserted so that the conductive shaft makes electrical contact between the first terminal and the second terminal so that electrical current can flow between the first wire and the second wire through the resistor and so that the conductive shaft makes electrical contact between the second terminal and the third terminal so that electrical current flows directly between the first wire and the second wire. The rotatable body is rotated during the insertion operation to provide a delay for the pre-charge function.
[0004] A need remains for a service disconnect assembly having a fuse component mounted externally to a battery pack such that the manual service disconnect assembly electrically couples the fuse to load carrying terminals of electrical components coupled to the battery pack thereby allowing current flow from the battery pack to the electrical components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Fig. 1 is an exploded view of Manual Service Disconnect assembly;
[0006] Fig. 2 illustrates mounting of detachably attached fuse 115 on the bottom disc
[0007] Fig. 3 (a) to Fig. 3(g) shows a sliding movement of sliding member from an engaged position to disengaged position;
[0008] Fig.4 (a) is a planar view of top disc showing ball catch mechanism;
[0009] Fig. 4(b) is cross sectional view of ball catch mechanism;
[0010] Fig. 5 is a top view of sliding member in an engaged position;
[0011] Fig. 6 is a top view of sliding member in an disengaged position;
[0012] Fig. 7 is an assembled view of manual service disconnect;
[0013] Fig. 8 is an illustration for connection of manual service disconnect with the battery pack;
[0014] Fig. 9 is a lateral view of packaging of manual service disconnect within the battery pack casing;
[0015] Fig. 10 is a bottom view of the bottom disc showing connection of load terminals with the fuse.
PROBLEM TO BE SOLVED
[0016] Available solutions are silent over the use of a manual service disconnect assembly for a battery pack which comprises of a fuse element which is externally mounted on the battery casing enabling user to easily attach and detach it from the manual service disconnect.
OBJECT OF INVENTION
[0017] Main object of the invention is to provide a fuse element within the manual service disconnect.
[0018] Another object of the invention is to provide a fuse element which can be serviced.
[0019] Another object of the invention is to provide a fuse element which can be removed and replaced from the manual service disconnect.
[0020] Yet another object of the invention is to provide a fuse element which can be mounted externally to battery pack.

SUMMARY OF THE INVENTION
[0021] This invention relates to a manual service disconnect assembly for a battery pack including a detachably attached fuse element. The manual service disconnect assembly further comprises of a sliding member assembly. The manual service disconnect assembly also has a top rotating switch coupled to the manual service disconnect assembly. The top rotating switch has a relative rotational movement with respect to the manual service disconnect assembly. The top rotating switch can move between an initial engaged position and a disengaged position of the sliding member assembly. When the rotating switch is rotated from engaged to a disengaged position, it disables current flow from battery pack to various electronic components thereby reducing the risk of electric shock during removal of battery pack.
DETAILED DESCRIPTION
[0022] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of embodiments. However, it will be understood by those of ordinary skill in the art that the embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components and circuits have not been described in detail so as not to obscure the embodiments.
[0023] In various embodiments, a battery pack is provided. The battery pack includes a plurality of battery cells. The pluralities of battery cells are coupled in series by connecting a positive polarity terminal of a battery cell to a negative polarity terminal of another battery cell to form the battery pack. The battery pack further comprises a manual service disconnect assembly mainly comprising of one or more non-rotating members along with one or more rotating members, having at least a first manual service disconnect assembly operating state and a second manual service disconnect assembly operating state. The first manual service disconnect assembly operating state allow current conduction between the load carrying terminals. The second manual service disconnect assembly operating state prevents current conduction between the load carrying terminals.
[0024] Fig. 1 illustrates a manual service disconnect assembly 100, in accordance with an exemplary embodiment. The manual service disconnect assembly 100 includes a bottom disc 101 provided with overmolded terminals and fuse mounting provisions. The bottom disc 101 further contains a sliding channel 104 for articulation of a sliding member 103. The sliding member 103 is configured to slide within the sliding channel 104 from an engaged position to a disengaged position. The sliding member 103 is in constant contact with overmolded terminals by a pair of elastic members 102. The manual service disconnect assembly 100 further includes a top disc 106 positioned over the bottom disc 101. The top disc 106 includes a second sliding channel 117. In one embodiment, the sliding channel 117 is similar to the sliding channel 104 of the bottom disc 101. The top disc 106 further comprises a plurality of ball catches 105 to arrest the movement of the sliding member 103 at engaged and disengaged position. The top disc 106 also includes a raised portion 113 on its top surface which acts as a guiding means for the top cover 110. A bottom rotor 107 is then assembled over the top disc 106. The bottom rotor 107 includes a hollow shaft portion to mate with cylindrical projections 113 from the sliding member 103 when placed over the bottom disc 101. The bottom rotor 107 includes a groove running through its circumference, where a first rubber gasket 108 is inserted. The groove and the first rubber gasket prevent water ingress into the electrical component. Further, the first rubber gasket 108 separates the top cover 110 from the bottom rotor 107 in an assembled condition. The top cover 110 includes an extension in the form of flanges. The extension abuts against the battery pack casing 200 (not shown in the figure).
[0025] Further, a flange gasket 109 is placed between the top cover 110 and the battery pack casing 200. The top cover 110 includes a step structure 114, which engages with the raised portion 113 of the top disc 106. This step structure 114 locks the orientation of the top cover 110. Further, the top cover 110 is fastened to the battery casing 200 using plurality of fastening means. Furthermore, a circular groove is provided on an inner circumference of the top cover 110 which is used to accommodate a second gasket 111. Further, a top rotor 112 is assembled on top of the bottom rotor 107 and secured by fastening means in such a manner that the rotation of the top rotor 112 is passed to the bottom rotor 107 which has a hollow shaft portion to mate with the cylindrical projections of the sliding member 103.
[0026] Fig 2 illustrates mounting of detachably attached fuse 115 on the bottom disc 101. The fuse 115 is mounted on one of the two load carrying overmolded terminals 118 and 119 at one end and to a neutral overmolded terminal 120 on the other end. The fuse 115 which provides protection to battery from adverse conditions such as over discharge, short circuit during fast charging when the current in the circuit exceeds 200 amperes and which may lead to catastrophic failure to the battery components, this fuse 115 is fastened by fastening means which makes replacement of fuse easy, further, the fuse 115 is placed outside of the battery pack casing 200 (not shown in the figure) which reduces the overall time for servicing the fuse.
[0027] Fig 3(a) to Fig 3(g) illustrates the sliding movement of sliding member 103 assembled within the bottom disc 101. Sliding channel 104 and sliding member is provided with minimum clearance for smooth sliding of the sliding member 103 within the sliding channel 104. The top rotor 112 (not shown in the figure), the bottom rotor 107 (not shown in the figure) and the sliding member 103 have a common central axis of rotation. In some embodiments, torque applied on the top rotor 112, in clockwise or anti-clockwise direction is passed on to the sliding member 103 through the bottom rotor 107. Degree of movement of sliding member 103 within the sliding channel 104 from one extreme end to the other extreme end of sliding channel 104 as depicted in fig 3(a) to 3(g) falls within 0-90 degree. In one embodiment, at 0 degree the engaged position of the sliding member 103 occurs, as shown in fig 3(a). Fig 3(g) shows a disengaged position of the sliding member 103, within the sliding channel at 90 degrees.
[0028] Fig 4(a) depicts the top view of top disc 106 consisting of more than one ball-catch 105. The ball-catch 105 is deployed over the top disc 106 to arrest the movement of sliding member 103 at 0 degree and at 90 degrees. Angles 0 and 90 degrees respectively relates to an engaged position and disengaged position of the sliding member 103. Fig 4(b) is a cross sectional view of top disc 106 assembled over bottom disc 103.
[0029] Fig 5 illustrates an engaged configuration of sliding member 103 with one end of the sliding member 103 in contact with one of the load carrying overmolded terminal and the other end of the sliding member 103 is in contact with the fuse 115. The fuse 115 is detachably attached to the bottom disc 101 by fastening means. A ball catch mechanism 105 restricts the movement of sliding member 103 to an engaged position wherein both the load carrying overmolded terminals are in contact condition via a fuse 115.
[0030] Fig 6 illustrates a disengaged configuration of sliding member 103 with both the ends of the sliding member 103 getting disconnected. The fuse 115 is detachably attached to the bottom disc 101 by fastening means. A ball catch mechanism 105 restricts the movement of sliding member 103 to a disengaged position wherein the connection between the two load carrying overmolded terminals is discontinued. In such a condition, the battery pack casing 200 (not shown in the figure) can be removed for servicing.
[0031] Fig 8 illustrates the connection of manual service disconnect assembly 100 with the batteries present within the battery pack casing 200, where the fuse 115 is a detachably attached member and electrical connections are performed using crimped harness onto cladded bus-bar 116, crimped harness provide much needed flexibility through the slack provided onto them, the slack in the harness enables the user to pull out the manual service disconnect assembly 100 without affecting any of the connection within it.
[0032] Fig 9 illustrates packaging of manual service disconnect assembly 100 on to the battery pack casing 200, externally mounted manual service disconnect assembly have to be compact, for this reason the overall height of the manual service disconnect assembly 100 is less than 55 mm. In an assembled condition, approximately 1/3 of manual service disconnect assembly 100 is projected outside a surface of the battery pack casing 200. For better serviceability of fuse 115, the fuse 115 is detachably attached on the outside of manual service disconnect assembly 100 on to the bottom disc 101. This ensures permanent contact of the fuse 115 with the manual service disconnect assembly 100. Battery pack casing 200 consists of a raised structure similar to that of the top cover 110 on which a flange gasket 109 is placed. Over the flange gasket 109, the top cover 110 is assembled, which imparts IP-67 protection to the entire manual service disconnect assembly 100 and completes the packaging of manual service disconnect assembly 100 on to the battery pack casing 200.
[0033] Fig 10 illustrates the electrical connection of the fuse 115 with load carrying terminals 118 and 119, wherein fuse 115 is mounted on the bottom disc 101 providing connection between one load carrying terminal 118 and a neutral terminal 120, the sliding member 103 slides within the sliding channel 104 from an engaged position to a disengaged position.
, Claims:CLAIMS
What is claimed is:
1. A manual service disconnect assembly for a battery pack, comprising:
a plurality of non-rotating members, the plurality of non-rotating members form a sliding channel;
a plurality of rotating members, the plurality of rotating members rotatable about the plurality of non-rotating members;
a fuse functionally coupled to batteries of the battery pack; and
a sliding member slidable within the sliding channel, wherein the sliding member is movable within the sliding channel upon rotating the plurality of rotating members from an engaged position to a disengaged position, and in the engaged position, the sliding member electrically couples the fuse to load carrying terminals of electrical components coupled to the battery pack thereby allowing current flow from the battery pack to the electrical components.

2. The manual service disconnect assembly of claim 1, wherein the plurality of non-rotating members includes a bottom disc, wherein the bottom disc forms lowermost part of the manual service disconnect assembly

3. The manual service disconnect assembly of claim 1, wherein one of the plurality of non-rotating members called as top disc is aligned over the bottom disc forming a sliding channel.

4. The manual service disconnect assembly of claim 3, wherein the said top disc comprises of a plurality of ball catches to arrest the movement of sliding member at the engaged position and at the disengaged position.

5. The manual service disconnect assembly of claim 1, wherein the plurality of rotating members includes a bottom rotor assembled over the top disc.

6. The manual service disconnect assembly of claim 1, wherein the plurality of rotating members includes a top rotor, wherein the top rotor is aligned with the bottom rotor such that the torque applied on the top rotor is transferred to the sliding member through bottom rotor.

7. The manual service disconnect assembly of claim 1, wherein the said top cover is assembled over the bottom rotor comprising plurality of flange like extensions for matting with exterior of a battery casing.

8. sliding membersliding membersliding membersliding memberThe manual service disconnect assembly of claim 1, wherein the bottom surface of the said bottom disc comprises an overmolded load carrying terminals along with fuse mounting provisions.

9. The manual service disconnect assembly of claim 3, wherein the top surface of the said top disc have a raised pip portion for receiving a step formation provided on the top cover.

10. The manual service disconnect assembly of claim 3, wherein the said sliding channel having its one end at 0 degree and the other end at 90 degrees.

11. The manual service disconnect assembly of claim 1, wherein the said sliding member comprises of raised cylindrical projections at its proximal and distal ends.

12. The manual service disconnect assembly of claim 3, wherein the said top disc have one or more ball-catch mechanism to restrict the movement of sliding member at the engaged position and the disengaged position of the manual service disconnect assembly.

13. The manual service disconnect assembly of claim 6, wherein the said bottom rotor comprises of one or more hollow shaft portion to mate with one or more cylindrical projections of the sliding member.

14. The manual service disconnect assembly of claim 14, wherein the said bottom rotor has a groove at an outer circumference thereof to accommodate a first gasket.

15. The manual service disconnect assembly of claim 14, wherein the said bottom rotor has a raised portion situated at a central axis thereof, wherein the said raised portion locks with the top rotor and transfers the torque applied at the top rotor to the sliding member via the bottom rotor.

16. The manual service disconnect assembly of claim 8, wherein, the said top cover further comprises a groove at an inner circumference thereof to accommodate a second gasket thereby protects against any water ingress.

17. The manual service disconnect assembly of claim 8, wherein the said top cover has a step formation that receives the raised pip provided on a top surface of the top disc which locks the orientation of the top cover in a desired position.

18. The manual service disconnect assembly of claim 1, wherein the said top rotor applies a rotational torque that is passed to the sliding member via the bottom rotor for engaging and disengaging electrical contact of the battery pack with the electric components.

Dated- 8th Day of November 2022 Signature of the Agent
Rajat Chaudhary IN/PA-3136