Connector box assembly for traction battery

• US 5,494,459 A
• Filed: 12/07/1992
• Issued: 02/27/1996
• Est. Priority Date: 12/07/1992
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Motor Company
• Inventors: Brown, Robert K., Toepfer, Craig B.
• Primary Examiner(s): PIRLOT, DAVID
• Application Number:
  US07/986,181
• Time in Patent Office: 1,177 Days
• Field of Search: 439/500, 439/736, 439/271-283, 439/487, 429/1, 429/9, 429/178, 429/179
• US Class Current: 439/500
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles

Abstract

The improved connector box assembly of the present invention includes mating male and female connectors, each of which is insulated in a novel manner to prevent manual touching, especially of the male probe during electrical connection, and also to prevent manual touching of the electrically live female conductor when not engaged with the male connector element. The female electrical receptacle is recessed within elongated neck-like electrical insulation means for disposition over one end of the female electrical receptacle and to permit relatively snug entry thereinto of the male electrical probe. The female electrical receptacle is a substantial distance front the orifice of the elongated neck means of such insulation. The female electrical receptacle electrical insulating structure is contained within an insulative housing which mates with an insulative structure at the base of the male electrical probes and which serves as an insulative collar extending a substantial distance along the shaft of the male electrical probes to mate with the female electrical receptacle electrical insulation means.

Claims

1. A connector box assembly for coupling and uncoupling a high voltage battery With a high voltage electrical line, the connector box assembly comprising:

at least one female electrical receptacle, each having a penetrable sleeve thereon formed from a conductive material;

female electrical receptacle electrical insulation means for surrounding the penetrable sleeve to provide exterior electrical insulation to the penetrable sleeve and to provide electrically conductive access to the inner surface of the penetrable sleeve through one end thereof;

at least one male electrical probe which is disposable during electrical connection within the penetrable sleeve, said male electrical probe having an exterior surface formed of a conductive material to provide electrical contact with the inner surface of the penetrable sleeve, the female electrical receptacle and projecting outwardly therefrom, to permit relatively snug entry thereunto of the male electrical probe, and to recess the penetrable sleeve of said female electrical receptacle from said orifice; and

a heat sink disposed within said connector box assembly to convey heat therefrom.

2. The improved connector box assembly of claim 1 wherein the neck means of the female electrical receptacle electrical insulating means is sufficiently small in transverse cross-sectional shape to prevent finger insertion thereinto to prevent manual touching of the penetrable sleeve of the female electrical receptacle.

3. The improved connector box assembly of claim 1 further comprising electrical outputs for functions selected from the group consisting of thermocouple temperature measurement, voltage measurement and heater operation.

4. The improved connector box assembly of claim 1 wherein said high voltage battery comprises a motor vehicle traction battery.

5. The improved connector box assembly of claim 1 further comprising male fuse means disposed in electrical contact with the male electrical probe.

6. The improved connector box assembly of claim 1 having corresponding pairs of the male electrical probes and female electrical receptacles, the paired male electrical probes being carried by an insulative disconnect handle.

7. The improved connector box assembly of claim 2 wherein the insulative disconnect handle includes manual grasping means for imparting a generally downward disengaging motion thereto.

8. The improved connector box assembly of claim 6 wherein the pair of male electrical probes on a surface of the insulative disconnect handle is disposed in staggered array.

9. The improved connector box assembly of claim 2 wherein the female electrical receptacles are disposed within an insulative housing.

10. The improved connector box assembly of claim 4 wherein the male electrical probes have a base thereof, and the insulative housing for the female electrical receptacle includes an elongated housing opening, an elongated insulative collar is disposed about the base and a substantial portion of the length of the male electrical probes, and the elongated insulative collar is disposable within the elongated housing opening for mating engagement therewith.

11. The improved connector box assembly of claim 10 wherein said battery comprises a sodium sulfur traction battery.

12. The improved connector box assembly of claim 10 further comprising sealing means for sealing between the elongated insulative collar and the insulative housing.

13. The improved connector box assembly of claim 10 further comprising male fuse means disposed in electrical contact with the male electrical probe, internally of the elongated insulative collar.

14. The improved connector box assembly of claim 6 wherein the insulative disconnect handle includes a front portion and a projection surface, the pair of male electrical probes thereon, said disconnect handle having a front portion thereof, and said pair of male electric probes being disposed on the projection surface staggered array with respect to the front portion to define a manually grippable portion of the front portion.

15. The improved connector box assembly of claim 14 wherein the female electrical receptacles are disposed within a housing and the housing has a wall disposed adjacent the staggered male electrical probes to expose for manually gripping said manual grippable portion of said front portion of said disconnect handle.

16. The improved connector box assembly of claim 1 further comprising manual isolation means for the male electrical probe for preventing manual touching of the male electrical probe when engaged with the female electrical receptacle.

17. The improved connector box assembly of claim 16 wherein the manual isolation means for the male electrical probe comprises an insulative base in a surface of which a proximal end of the male electric probe is embedded, and side-guard shield means disposed laterally of the surface of the insulative base for preventing manual touching of the male electrical probe during coupling and uncoupling of the male electrical probe with the female electrical receptacle.

18. The improved connector box assembly of claim 17 wherein the side-guard shield means during full engagement of the male electrical probe with the female electrical receptacle is disposed substantially circumferentially about the elongated neck means of the female electrical receptacle electrical insulating means.

19. The improved connector box assembly of claim 17 wherein, during full engagement of the male electrical probe and the female electrical receptacle, the insulative base of the manual isolation means is disposed adjacent to the elongated neck means of the female electrical receptacle insulating means.

20. In combination, an improved connector box assembly, coupled to a high voltage battery, said connector box assembly comprising:

at least one female electrical receptacle, each having a penetrable sleeve thereon formed from a conductive material;

female electrical receptacle electrical insulation means for surrounding the penetrable sleeve to provide exterior electrical insulation to the penetrable sleeve and to provide electrically conductive access to the inner surface of the penetrable sleeve through one end thereof; and

at least one male electrical probe which is disposable during electrical connection within the penetrable sleeve, said male electrical probe having an exterior surface formed of a conductive material to provide electrical contact with the inner surface of the penetrable sleeve, the female electrical receptacle and projecting outwardly therefrom, to permit relatively snug entry thereunto of the male electrical probe, and to recess the penetrable sleeve of said female electrical receptacle from said orifice.