Battery disconnect unit and method of assembling the battery disconnect unit

• US 8,288,031 B1
• Filed: 03/28/2011
• Issued: 10/16/2012
• Est. Priority Date: 03/28/2011
• Status: Active Grant

• Current Assignee: LG Energy Solution Limited (LG Corporation)
• Original Assignee: LG Chem Limited (LG Corporation)
• Inventors: Matejek, Bob, Niedzwiecki, Mark, Phillips, Greg, Yang, Hee Kook, Symons, Bryan, Merriman, Bob
• Primary Examiner(s): Alejandro, Raymond
• Application Number:
  US13/073,000
• Publication Number:
  US 20120251866A1
• Time in Patent Office: 568 Days
• Field of Search: 429/149, 429/150, 429/156, 429/158, 429/160, 429/175, 429/7, 429/123, 429/121, 320/107, 320/112, 320/113, 320/118, 320/119, 320/124, 320/125
• US Class Current: 429/123
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: H02J 7/0045 concerning the insertion or the connection of the batteries
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A battery disconnect unit for selectively coupling a battery pack to a load is provided. The unit includes a base portion that holds first and second contactors, a pre-charging relay, and a charging relay, thereon. The unit further includes a circuit board having first, second, third and fourth bus bars disposed thereon. The first and second bus bars are coupled to first and second terminals, respectively, of the first contactor. The first bus bar is further coupled to the battery pack, and the second bus bar is further coupled to the load. The third and fourth bus bars are coupled to third and fourth terminals, respectively, of the second contactor. The third bus bar is further coupled to the battery pack, and the fourth bus bar is further coupled to the load.

Claims

1. A battery disconnect unit for selectively coupling a battery pack to a load, comprising:

a base portion configured to hold first and second contactors, a pre-charging relay, and a charging relay, thereon;

a circuit board having first, second, third, and fourth bus bars coupled thereto extending outwardly from the circuit board;

the first and second bus bars being coupled to first and second terminals, respectively, of the first contactor, the first bus bar further configured to be electrically coupled to a first voltage terminal of the battery pack, the second bus bar further configured to be electrically coupled to a first end of the load;

the third and fourth bus bars being coupled to first and second terminals, respectively, of the second contactor, the third bus bar further configured to be electrically coupled to a second voltage terminal of the battery pack, the fourth bus bar further configured to be electrically coupled to a second end of the load; and

the circuit board further includes a pre-charging resistor disposed thereon, the pre-charging relay and the pre-charging resistor being coupled in series with one another, and further coupled in parallel to the first contactor, such that a first control signal induces the pre-charging relay to electrically couple the first voltage terminal of the battery pack through the pre-charging resistor to the first end of the load, and a second control signal induces the second contactor to electrically couple the second voltage terminal of the battery pack to the second end of the load, for pre-charging the load.

2. The battery disconnect unit of claim 1, wherein a third control signal induces the first contactor to electrically couple the first voltage terminal of the battery pack to the first end of the load to energize the load.

3. The battery disconnect unit of claim 1, wherein the circuit board further includes first and second connector terminal assemblies coupled thereto.

4. The battery disconnect unit of claim 3, wherein the first connector terminal assembly is electrically coupled to a pre-charging relay coil in the pre-charging relay, and the first connector terminal assembly is further electrically coupled to a charging relay coil in the charging relay.

5. The battery disconnect unit of claim 3, wherein the second connector terminal assembly is electrically coupled to a first contactor coil of the first contactor, and the second connector terminal assembly is further electrically coupled to a second contactor coil of the second contactor.

6. The battery disconnect unit of claim 1, further comprising a cover portion configured to be attached to the base portion.

7. A method for assembling a battery disconnect unit, comprising:

disposing first and second contactors, a pre-charging relay, and a charging relay, on a base portion;

disposing a circuit board having first, second, third and fourth bus bars, above the base portion;

coupling the first bus bar to a first terminal of the first contactor such that the first terminal of the first contactor is configured to be electrically coupled to a first voltage terminal of a battery pack utilizing the first bus bar;

coupling the second bus bar to a second terminal of the first contactor such that the second terminal of the first contactor is configured to be electrically coupled to a first end of a load utilizing the second bus bar;

coupling the third bus bar to a first terminal of the second contactor such that the first terminal of the second contactor is configured to be electrically coupled to a second voltage terminal of the battery pack utilizing the third bus bar;

coupling the fourth bus bar to a second terminal of the second contactor such that the second terminal of the second contactor is configured to be electrically coupled to a second end of the load utilizing the fourth bar; and

coupling a cover portion to the base portion such that the first and second contactors, the charging relay, and the circuit board are disposed between the base portion and the cover portion, further comprising coupling the pre-charging relay and a pre-charging resistor in series with one another, and further coupling the pre-charging relay and the pre-charging resistor in parallel to the first contactor, such that a first control signal induces the pre-charging relay to electrically couple the first voltage terminal of the battery pack through the pre-charging resistor to the first end of the load, and a second control signal induces the second contactor to electrically couple the second voltage terminal of the battery pack to the second end of the load, for pre-charging the load.

8. A battery disconnect unit for selectively coupling a battery pack to a load, comprising:

a base portion configured to hold first and second contactors, a pre-charging relay, and a charging relay, thereon;

a circuit board having first, second, third, and fourth bus bars coupled thereto extending outwardly from the circuit board;

the first and second bus bars being coupled to first and second terminals, respectively, of the first contactor, the first bus bar further configured to be electrically coupled to a first voltage terminal of the battery pack, the second bus bar further configured to be electrically coupled to a first end of the load;

the third and fourth bus bars being coupled to first and second terminals, respectively, of the second contactor, the third bus bar further configured to be electrically coupled to a second voltage terminal of the battery pack, the fourth bus bar further configured to be electrically coupled to a second end of the load; and

a pre-charging resistor electrically coupled in series with the pre-charging relay, the pre-charging resistor and the pre-charging relay being further electrically coupled in parallel to the first contactor, such that a first control signal induces the pre-charging relay to electrically couple the first voltage terminal of the battery pack through the pre-charging resistor to the first end of the load, and a second control signal induces the second contactor to electrically couple the second voltage terminal of the battery pack to the second end of the load, for pre-charging the load.

9. The battery disconnect unit of claim 8, wherein a third control signal induces the first contactor to electrically couple the first voltage terminal of the battery pack to the first end of the load to energize the load.

10. The battery disconnect unit of claim 8, wherein the circuit board further includes first and second connector terminal assemblies coupled thereto.

11. The battery disconnect unit of claim 10, wherein the first connector terminal assembly is electrically coupled to a pre-charging relay coil in the pre-charging relay, and the first connector terminal assembly is further electrically coupled to a charging relay coil in the charging relay.

12. The battery disconnect unit of claim 11, wherein the second connector terminal assembly is electrically coupled to a first contactor coil of the first contactor, and the second connector terminal assembly is further electrically coupled to a second contactor coil of the second contactor.

13. The battery disconnect unit of claim 8, further comprising a cover portion configured to be attached to the base portion.