Integrated high voltage service disconnect for traction batteries

• US 9,577,230 B2
• Filed: 03/27/2014
• Issued: 02/21/2017
• Est. Priority Date: 03/27/2014
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Gibeau, John Paul
• Primary Examiner(s): Alejandro, Raymond
• Application Number:
  US14/226,971
• Publication Number:
  US 20150280182A1
• Time in Patent Office: 1,062 Days
• US Class Current: 1/1
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/209 adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/211 adapted for pouch cells
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/505 comprising a single busbar
• CPC Class Codes: H01M 50/51 Connection only in series
• CPC Class Codes: H01M 50/512 Connection only in parallel
• CPC Class Codes: H01M 50/588 outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 50/591 Covers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A traction battery includes a battery housing having a tray and a cover cooperating to define an interior. A plurality of battery cells are arranged in an array and disposed on the tray within the interior. A service disconnect base is disposed on an exterior surface of the housing and includes a uni-terminal connector having a receptacle disposed within the base and electrically connected to the battery cells. A service disconnect plug is integrally incorporated with a single high voltage cable that is partially disposed in the plug. The service disconnect plug includes a body configured to mechanically engage the base and a prong mechanically connected to the high voltage cable and configured to be received within the receptacle to create an electrical connection between the battery cells and a high voltage bus when the body is engaged with the base. The plug may include a cover portion that enclosures a terminal disposed on the housing.

Claims

1. A traction battery comprising:

a battery housing including a tray and a cover cooperating to define an interior;

a plurality of battery cells arranged in an array and disposed on the tray within the interior;

a service disconnect base disposed on an exterior surface of the battery housing, and including a uni-terminal connector having a receptacle disposed within the service disconnect base and electrically connected to the plurality of battery cells; and

a service disconnect plug integrally incorporated with a single high voltage cable that is partially disposed in the service disconnect plug, the service disconnect plug including a body configured to mechanically engage the service disconnect base, and a prong mechanically connected to the single high voltage cable and configured to be received within the receptacle to create an electrical connection between the battery cells and a high voltage bus when the body is engaged with the service disconnect base.

2. The traction battery of claim 1 further comprising an interlock switch including an interlock connector and an interlock receptacle, wherein the interlock switch is configured to de-energize the uni-terminal connector when the interlock connector is removed from the interlock receptacle.

3. The traction battery of claim 1 wherein the service disconnect base is disposed on an exterior surface of the cover.

4. The traction battery of claim 3 wherein the service disconnect plug and the cover are arranged such that the cover cannot be removed from the tray unless the service disconnect plug is removed from the service disconnect base.

5. The traction battery of claim 1 further comprising an interlock switch including a interlock connector attached to the service disconnect plug and an interlock receptacle disposed in the service disconnect base, and arranged such that the interlock connector is removed from the interlock receptacle when the service disconnect plug is at least partially removed from the service disconnect base, wherein the uni-terminal connector is de-energized when the interlock connector is removed from the interlock receptacle.

6. The traction battery of claim 1 wherein the uni-terminal connector is a negative uni-terminal connector.

7. The traction battery of claim 1 wherein the service disconnect plug further includes a cover portion cooperating with the battery housing to form an enclosure around a second terminal to limit access to the second terminal.

8. The traction battery of claim 7 wherein the uni-terminal connector is a negative uni-terminal connector and the second terminal is a positive terminal.

9. A traction battery comprising:

a housing defining an interior and at least one sidewall;

battery cells disposed in the interior;

a service disconnect base disposed on the sidewall and including a uni-terminal connector electrically connected to the battery cells;

a terminal disposed on exterior surface of the sidewall and electrically connected with the battery cells, wherein the terminal and the uni-terminal connector have opposite polarities;

a first high voltage cable mechanically connected to the terminal to electrically connect the terminal to an electric machine; and

a service disconnect plug including a second high voltage cable having a polarity opposite a polarity of the first high voltage cable and mechanically engageable with the uni-terminal connector to electrically connect the uni-terminal connector with the electric machine, wherein the service disconnect plug further includes a cover portion cooperating with the sidewall to form an enclosure around the terminal to limit access to the terminal when the service disconnect plug engages the service disconnect base.

10. The traction battery of claim 9 further comprising an interlock switch including an interlock connector and an interlock receptacle, wherein the interlock switch is configured to de-energize the terminal when the interlock connector is removed from the interlock receptacle.

11. The traction battery of claim 9 wherein the cover portion includes a top and sidewalls defining at least a portion of the enclosure.

12. The traction battery of claim 9 wherein the second high voltage cable includes a prong that projects outwardly from the service disconnect plug and is receivable within the uni-terminal connector.

13. The traction battery of claim 12 wherein the uni-terminal connector includes a female receptacle configured to receive the prong when the service disconnect plug is connected with the service disconnect base.

14. The traction battery of claim 9 wherein the terminal is a threaded stud and the first high voltage cable is secured to the terminal by a fastener.