Abstract:
A battery interface includes an interface housing which encloses an electrical connector for an electrically powered device and a fuse electrically connected to the electrical connector. The fuse is preselected to match the electrically powered device to which electrical power is to be supplied via the electrical connector. The interface housing is configured to be disposed on a battery housing and to be operatively connected thereto.

Description:
[0001]    The present application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 61/235,418 (filed on Aug. 20, 2009), the full contents of which is hereby incorporated by reference in its entirety. 
     
    
     BACKGROUND 
       [0002]    Generally, in electrical systems, the connector-interface and its connector housing and the fuse with its fuse housing are located at different areas, and as a result, must be separately manufactured, shipped and assembled. The use of such a structure may lead to several undesirable occurrences. For instance, during the final assembly, both the connector and fuse must be separately installed and appropriately connected. Accordingly, the integration of the fuse is only one of a number of parts which are pre-assembled by a supplier. Moreover, for each purpose the circuit must be inspected to determine if the correct fuse is installed. Meaning, it must be determined if the fuse is built in a polarized housing to prevent mismatching during the assembly phase. Even still, it is necessary to ensure there is sufficient space to install the separate packages, which may become complicated when reduced overall spacing is required. Yet and still, maintenance becomes complicated in instance, for example, when the fuse must be replaced or maintained care must be taken to ensure that it is carried out without a plugged connection and that the change is not made an inappropriately closed circuit. Finally, use of separate housing for the fuse and the connector requires separate sealing, which increases overall manufacturing costs. 
       SUMMARY 
       [0003]    Embodiments relate to a battery system such as a high voltage (HV) battery system adapted for use in hybrid and/or fully electrical vehicles and the like. 
         [0004]    Embodiments relate to a HV battery system that includes a compact, modular battery interface including a hermetically sealed protective housing that encloses a fuse and a connector electrically connected to the fuse. 
         [0005]    In accordance with embodiments, a battery interface for a battery may include at least one of the following: an interface housing mounted on and/or over and operatively connected to a battery, the interface housing defining an interior space; an electrical connector provided in the interior space; and a fuse provided in the interior space adjacent and electrically connected to the electrical connector. 
         [0006]    In accordance with embodiments, a battery interface for a battery may include at least one of the following: an interface housing defining an interior space therein and including a lid which encloses the interior space; a seal which hermetically seals the interior space; an electrical connector provided in the interior space and adapted for electrical connection to an electrical device powered by the battery; and a fuse provided in the interior space and electrically connected to the electrical connector. 
         [0007]    In accordance with embodiments, a battery interface for a high voltage battery may include at least one of the following: an interface housing having a first interface housing section, a second interface housing section which encloses an interior space defined by the first interface housing section and the second interface housing section; a seal which hermetically seals the interior space at an interface between the first interface housing section and the second interface housing section; a fuse supported in the interior space; and an electrical connector supported in the interior space and electrically connected at a first end to the fuse and at a second end to an electrical device powered by the high voltage battery. 
         [0008]    In accordance with embodiments, a battery interface for a battery may include at least one of the following: a connector configured to electrically connect the battery to an electrical device powered by the battery; a fuse electrically connected to the connector and matched to the electrical device; and an interface housing enclosing the connector and the fuse and configured for connection to the battery. 
         [0009]    In accordance with embodiments, a high voltage battery system may include at least one of the following: a high voltage battery enclosed in a battery housing; and a battery interface housing which encloses a fuse and a plug electrically connected to the fuse to enable a plugged connection between the battery and a device utilizing the power available from the battery. 
         [0010]    In accordance with embodiments, a high voltage battery system may include at least one of the following: a battery housing; a high voltage battery supported in the battery housing; a battery interface housing operatively connected to the battery housing; an electrical connector supported in the battery interface housing and adapted for electrical connection to an electrically powered device powered by the high voltage battery; and a fuse supported in the battery interface housing and electrically connected to the electrical connector. 
         [0011]    In accordance with embodiments, a battery system may include at least one of the following: a battery housing which supports a battery therein; an interface housing mounted on and/or over the battery housing; an electrical connector supported in the interface housing; and a fuse supported in the interface housing and electrically connected to the electrical connector. 
         [0012]    In accordance with embodiments, a battery system may include at least one of the following: a battery housing which supports a battery therein; an interface housing which interfaces with the battery housing via battery connections projecting therefrom which establish an electrical connection with poles of the battery; a multi-pole connector supported in the interface housing and electrically connected to the battery connections, the multi-pole connector being configured for electrical connection to a device to which electrical power from the battery is to be supplied; a fuse supported in the interface housing and electrically connected to the multi-pole connector; and a seal which hermetically seals the interface connector housing. 
         [0013]    The battery system in accordance with embodiments establishes a battery connection that extends through a wall of an interface housing that houses a fuse and a connector and which is configured to establish an electrical connection between the fuse, the connector and the battery that is housed in a battery housing. In this arrangement, a single seal effectuates hermetic sealing of the interface housing from undesirable dust, moisture, debris and the like. The interface housing permits access to an interior space therein to enable routine maintenance, replacement, etc. to be performed on the fuse and/or connector. 
     
    
     
       DRAWINGS 
         [0014]    Example  FIG. 1  illustrates a circuit diagram of a high voltage battery system, in accordance with embodiments. 
           [0015]    Example  FIGS. 2 and 3  illustrate a modular fuse/connector arrangement for a high voltage battery system, in accordance with embodiments. 
       
    
    
     DESCRIPTION 
       [0016]    Example  FIG. 1  illustrates a schematic circuit diagram of a high voltage (HV) battery system  100  in accordance with embodiments which is adapted for use in hybrid and/or fully electrical vehicles and the like. HV battery system  100  includes high voltage (HV) battery  101  and contactors  106  housed or otherwise supported within battery housing  104 . Battery housing  104  is provided with a set of main contacts which are configured in this case to provide an electrical connection with electrical motor EM. Electrical device  140  is electrically connected to HV battery  101  via battery interface  200 . Electrical device  140  may be any electrical component for a vehicle. Such devices may be used, for example, for power steering, air conditioning, windshield wipers, headlights, or the like. Main fuse  102  is housed in battery housing  104  and is electrically connected in series with HV battery  101  which, for example, can be capable of outputting a range of between 200-500V. 
         [0017]    As illustrated in example  FIGS. 2 and 3 , battery interface  200  includes protective housing  210  which encloses or otherwise supports fuse  206  and electrical connector  208  in an interior space therein. 
         [0018]    Housing  210  for battery interface  200  may be operatively connected to battery housing  104  via battery connections  203 ,  204  which extend from housing  210  of battery interface  200 . Battery connections  203 ,  204  may having arms extending therefrom which provide that are respectively connected to fuse  206  and at least one of the pins of electrical connector  208 . The second of the pins of electrical connector  208  may be serially connected to fuse  206 . 
         [0019]    The portion of the interior space of interface housing  200  that supports fuse  206  may be enclosed by lid  201 . In accordance with embodiments, housing  200  may be provided with one or more apertures permitting plug  211  of electrical device  140  to be inserted therethrough to establish an electrical connection between electrical device  140  and multi-pole electrical connector  208 . Lid  201  may be arranged in a manner such that plug  211  must be disconnected from multi-pole electrical connector  208  before lid  201  can be removed or otherwise displaced from interface housing  200 . This, as will be appreciated, ensures that an unplugged connection exists before fuse  206  can be accessed and/or removed/replaced. 
         [0020]    Housing  210  may, alternatively or additionally, be provided with seal  202  to hermetically seal the interior space thereof. Seal  202  may be a single gasket or the like-type seal and may be disposed about the periphery at an interface between lid  201  and interface housing  210 . Seal  202  may provide an IP6K9K-type seal, and therefore, render the interior space of housing  200  impervious to undesirable, dust, debris, moisture and the like. As is well known the IP6K9K term is such as to denote 6K=dustproof and 9K=resistant to high-pressure/steam cleaning. As will be understood, embodiments are not limited to this particular level and may differ as the case demands. 
         [0021]    Fuse  206 , by way of example, can have a nominal voltage of about 800V and a nominal current in a range between 15-50A. Electrical connector  208  may have a structure that includes a connector body having at a front side thereof a male/female connector component  208   a  and on an opposite rear side thereof interlock contacts  217  arranged for connection with circuitry associated with battery  101 . In accordance with embodiments, electrical connector  206  may be a multi-pole connector having at least two male/female connector components. 
         [0022]    As illustrated in example  FIG. 3 , battery interface  200  may be mounted or otherwise positioned on and/or over battery housing  104 . In such a case, battery-side connectors  203 ,  204  are electrically connected to battery  101  to provide an operative connection therebetween. 
         [0023]    Accordingly, the integration of a fuse and a connector in a modular housing structure results in the need to preassemble only one part by a supplier. Moreover, since the fuse is provided in a polarized housing, mismatching of the fuse during assembly of the battery can be prevented. The disclosed embodiment also reduces the number of sites which must be provided, and thus, reduces the demand for space on the exterior of the battery housing. Moreover, the mechanical connection between the plug of the electrical device and connector must be removed prior to removal of the lid for the interface housing. This provides safety to the design since it obviates an attempt to change the fuse while the electrical device with which the fuse is associated is still plugged into the battery housing  104 . Inasmuch as one seal/gasket is provided to seal the fuse and connector in the interface housing, the simplicity of production and maintenance is enhanced and the number of minor parts that need to be inventoried can be reduced. 
         [0024]    Accordingly, embodiments provide a fuse and a connector supported in the same housing. Use of a single housing obviates the need for separate housing for the fuse and connector, which in turn, reduces overall package space requirements and manufacturing costs. Such a structure also obviates a mismatch of the fuse with the device which is to be connected to the connector. It also reduces the number of seals to one and is such that the connection between the device and the connector must be disconnected before the lid can be removed and the fuse accessed and replaced. Battery connections which extend through a wall of the interface housing are configured to provide an electrical connection between a fuse, a connector and a battery which is housed in the battery housing. The connector in this instance may include a multi-pole connector which is electrically connected to the fuse and a pair of interlock contacts which are operatively connected to the multi-pole connector. 
         [0025]    Although embodiments have been described herein, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.