Patent Publication Number: US-2010124850-A1

Title: Manual disconnect system

Description:
FIELD OF THE INVENTION 
     The present invention relates to a manual disconnect system. More particularly, the present invention is directed to a manual disconnect system that, if desired, can be sealed. 
     BACKGROUND OF THE INVENTION 
     Manual disconnect units that facilitate electrical disconnection, particularly from high current connections, are known in the art. One such manual disconnect unit is disclosed in U.S. Pat. No. 6,773,307. This high current disconnect unit includes a fuse, a current limiting resistor, a manual disconnection device and a pair of connection elements for connecting the high current disconnect system to an electrical circuit. The manual disconnect unit is wired in series with the fuse and provides a user selectable circuit interrupt. The current limiting resistor is wired in parallel with the manual disconnection unit and in series with the fuse. The manual disconnection unit is wired in series with the fuse and provides a user selectable circuit. 
     However, there are drawbacks in prior art manual disconnect units. For instance, the disconnect unit is not sealed. Also, the disconnect unit requires a large footprint for installation. Further, this particular disconnect unit requires a hand tool or a power tool to remove the connector. 
     It would be beneficial to provide a manual disconnect system that, if desired, can be sealed, occupies a relatively small footprint and enables a user to remove the connector without using any tools. The present invention provides these benefits. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     It is an object of the invention to provide a manual disconnect system that, if desired, can be sealed. 
     It is another object of the invention to provide a manual disconnect system that occupies a relatively small footprint. 
     It is another object of the invention to provide a manual disconnect system that enables a user to remove the connector without using any tools. 
     Accordingly, a manual disconnect system of the present invention is hereinafter described and includes a battery part, a disconnect part, a circuit assembly, a fuse assembly, a fuse connector and a circuit connector. The battery part has a main compartment with fuse assembly subcompartment disposed in the main compartment. The disconnect part has a shielding cover that defines a disconnect part cavity with the disconnect part being releasably connected to the battery part. The circuit assembly is disposed in the disconnect part cavity and is connected to the shielding cover. The fuse assembly is sized and adapted to be releasably received by the fuse assembly subcompartment. The fuse connector and a circuit connector are connected to the battery part. When the disconnect part is releasably connected to the battery part, the fuse assembly and the fuse connector are electrically connected together and the circuit assembly and the circuit connector are electrically connected together. Upon detaching the disconnect part and the battery part from each other, the circuit assembly and the circuit connector are electrically disconnected from one another while the fuse assembly remains releasably connected to the battery part in the fuse assembly subcompartment and electrically connected to the fuse connector. 
     These objects and other advantages of the present invention will be better appreciated in view of the detailed description of the exemplary embodiments of the present invention with reference to the accompanying drawings, in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top-down perspective view an exemplary embodiment of a manual disconnect system of the present invention. 
         FIG. 2  is a bottom-up perspective view the manual disconnect system of the present invention shown in  FIG. 1 . 
         FIG. 3  is an exploded perspective view of the manual disconnect system shown in  FIG. 1  with  FIG. 3A  being an upper portion thereof and  FIG. 3B  being a lower portion thereof. 
         FIG. 4A  is a side elevation view of the manual disconnect system shown in  FIG. 1 . 
         FIG. 4B  is a partial cross-sectional view of the manual disconnect system taken along line  4 B- 4 B in  FIG. 4A . 
         FIG. 4C  is a diagrammatical view of the manual disconnect system mounted to a support surface with a disconnect part releasably connected to a battery part and with a lever member in a locked state. 
         FIG. 5A  is a side elevation view of the manual disconnect system similar to  FIG. 4A  with the lever member moving from the locked state to a release state. 
         FIG. 5B  is a partial cross-sectional view of the manual disconnect system taken along line  5 B- 5 B in  FIG. 5A . 
         FIG. 5C  is a diagrammatical view of the manual disconnect system mounted to the support surface with the lever member moving from a locked state to the release state. 
         FIG. 6A  is a side elevation view of the manual disconnect system similar to  FIG. 4A  with the lever member in the release state. 
         FIG. 6B  is a partial cross-sectional view of the manual disconnect system taken along line  5 B- 5 B in  FIG. 5A . 
         FIG. 6C  is a diagrammatical view of the manual disconnect system mounted to the support surface with the lever member in the release state. 
         FIG. 7A  is a side elevation view of the manual disconnect system with the disconnect part detached from the battery part. 
         FIG. 7B  is a perspective view of the manual disconnect system with the disconnect part detached from the battery part while fuse assembly remains connected to the battery part. 
         FIG. 7C  is a diagrammatical view of the manual disconnect system with the disconnect part detached from the battery part thereby disconnecting a circuit assembly from a circuit connector while the fuse assembly remaining in the battery part remains connected to a fuse connector. 
         FIG. 8A  is a side elevation view of the manual disconnect system with the fuse assembly detached from the battery part. 
         FIG. 8B  is a perspective view of the manual disconnect system with the fuse assembly detached from the battery part. 
         FIG. 8C  is a diagrammatical view of the manual disconnect system with the fuse assembly detached from the battery part and disconnected from the fuse connector. 
         FIG. 9  is a partial side elevation view in cross-section taken along line  9 - 9 - 9  in  FIG. 1 . 
         FIG. 10  is a front elevation view of the manual disconnect system in cross-section emphasizing the seals thereof. 
     
    
    
     DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS 
     Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. The structural components common to those of the prior art and the structural components common to respective embodiments of the present invention will be represented by the same symbols and repeated description thereof will be omitted. 
     Also, throughout the detailed description of the exemplary embodiments, more descriptive terms such as “above”, “top”, “front”, “bottom” and the like are used in reference to the drawing figures and shall not be construed to limit the scope of the invention. These terms are considered to be more descriptive of the invention particularly as the orientation of the embodiments of the invention is shown the drawing figures. It is believed that the detailed description of the exemplary embodiments is easier for a reader to comprehend using the more descriptive terms rather than non-descriptive terms. However, one of ordinary skill in the art would easily comprehend that non-descriptive terms such as “first”, “second” and the like could be used in their stead. 
     A first exemplary embodiment of a manual disconnect system  10  of the present invention is hereinafter described with reference to  FIGS. 1-7B . As shown in  FIGS. 1-3 , the manual disconnect system  10  is adapted for mounting to a support member  12  such as, for example, a battery cover. The support member  12  has a top support surface  12   a,  an opposite bottom support surface  12   b,  a support member opening  12   c  ( FIGS. 3A and 3B ) formed through and between the top support surface  12   a  and the bottom support surface  12   b  and a plurality of support member attachment holes  12   d  disposed outwardly relative to the support member opening  12   c.  As shown in  FIGS. 4A-7C , the manual disconnect system  10  includes a battery part  14 , a disconnect part  16 , a circuit assembly,  18  a fuse assembly  20 , a fuse connector  22  and a circuit connector  24 . A skilled artisan would appreciate that the circuit assembly  18  can be, for example, a conventional interlock loop circuit assembly while the circuit connector  24  can be, for example, a conventional interlock loop circuit connector. By way of example only and not by way of limitation, high voltage wires  26   a - 26   b  are connected to the fuse connector  22  and circuit wires  28   a - 28   d  are connected to the circuit connector  24 . 
     In  FIGS. 3-7C , the battery part  14  has a main compartment  14   a  and a fuse assembly subcompartment  14   b.  The fuse assembly subcompartment  14   b  is disposed in the main compartment  14   a.  The disconnect part  16  has a shielding cover  16   a  that defines a disconnect part cavity  16   b.  As best illustrated in  FIGS. 4A-6A , the disconnect part  16  is connected to the battery part  14  and is detachable therefrom as shown in  FIGS. 7A-7C . One of ordinary skill in the art would appreciate that the disconnect part  16  is releasably connected to the battery part  14 . 
     As best shown in  FIGS. 4C ,  5 C and  6 C, the circuit assembly  18  is disposed in the disconnect part cavity  16   b  and is also connected to the shielding cover  16   a.  The fuse assembly  20  is sized and adapted to be releasably received by the fuse assembly subcompartment  14   b.  The fuse connector  22  and the circuit connector  24  are connected to the battery part  14 . 
     In  FIGS. 4A ,  4 C,  5 A,  5 C,  6 A and  6 C, when the disconnect part  16  is releasably connected to the battery part  14 , the fuse assembly  20  and the fuse connector  22  are electrically connected together and the circuit assembly  18  and the circuit connector  24  are electrically connected together. In  FIGS. 7A-7C , upon detaching the disconnect part  16  and the battery part  14  from each other, the circuit assembly  18  and the circuit connector  24  are electrically disconnected from one another while the fuse assembly  20  remains releasably connected to the battery part  14  in the fuse assembly subcompartment  14   b  and electrically connected to the fuse connector  22 . After the disconnect part  16  and the battery part  14  are detached from each other and the circuit assembly  18  and the circuit connector  24  are disconnected from one another, the fuse assembly  20  is exposed as shown in  FIGS. 7A-7C  so that the fuse assembly  20  is accessible for disconnection from the fuse connector  22  and removal from the fuse assembly subcompartment  14   b.  Thereafter, the fuse assembly  20  can be detached from the fuse connector  22  and removed from the fuse assembly subcompartment  14   b  as shown in  FIGS. 8A-8C   
     As shown in  FIGS. 1 ,  3  and  4 A- 7 C the disconnect part  16  includes a lever member  30  that is operably connected to the disconnect part  16 . The lever member  30  pivots to and between a lock position (best illustrated in  FIGS. 4A-4C ) and a release position (illustrated in  FIGS. 6A-6C ). As discussed in more detail below, in the lock position, the lever member  30  engages the battery part  14  to prevent detachment of the disconnect part  16  and the battery  14  part from each other. In the release position, the disconnect part  16  and the battery part  14  are detachable from one another. 
     The following specifically describes the disconnect part  16  for the manual disconnect system  10 . 
     In  FIGS. 1 ,  3 ,  4 A,  5 A,  6 A,  7 A,  7 B and  8 B, the disconnect part  16  includes the shielding cover  16   a  that has a generally box-shaped configuration. The shielding cover  16   a  has a base wall  16   a   1 , a front wall  16   a   2 , a rear wall  16   a   3  and a pair of opposing side walls  16   a   4  that are connected to each other to define the disconnect part cavity  16   b  ( FIGS. 3A and 3B ) which, in turn, also has a generally box-shaped configuration. The disconnect part cavity  16   b  has a circuit assembly compartment  16   c  enclosed in the disconnect part cavity  16   b  as that shown in  FIGS. 3A ,  3 B,  4 C,  5 C,  6 C and  7 C. The disconnect part  16  also includes the lever member  30  that has a generally U-shaped configuration as that shown in  FIGS. 3A and 3B . The lever member  30  is pivotally connected to the shielding cover  16   a  as shown in FIGS.  1  and  4 A- 7 C. The U-shaped lever member  30  has a pair of arm members  30   a  and a cross-member  30   b  interconnecting the pair of arm members  30   a.  Respective ones of the pair of arm members  30   a  are pivotally connected to respective ones of the pair of opposing side walls  16   a   4 . As discussed above, the lever member  30  is operative to move to and between lock position (as best illustrated in  FIG. 4A-C ) and the release position (as illustrated in  FIG. 6A-C ). 
     As shown in  FIGS. 3A and 3B , the disconnect part  16  also includes a pair of pivot pins  32  that are disposed apart from one another and aligned coextensively along a common pivot axis PA. Respective ones the pivot pins  32  interconnect respective ones of the pair of side walls  16   a   4  and arm members  30   a  as best shown in  FIG. 1 . In  FIGS. 3A and 3B , each one of the pair of arm members  30   a  includes a free end arm portion  30   a   1  and each free end arm portion  30   a   1  having a pair of tabs  30   a   1   a  and  30   a   1   b  that are disposed apart from one another to define a recess  34  therebetween. 
     Also, as shown in  FIGS. 1 and 9 , the disconnect part  16  includes a latch mechanism  36 . The latch mechanism  36  is operative to retain the cross-member  30   b  forwardly of front wall  16   a   2  when the lever member  30  is in the lock position ( FIGS. 4A-4C ). 
     As best shown in  FIG. 9 , the front wall  16   a   2  includes a latch projection  38 . The latch projection  38  extends from the front wall  16   a   2 . Note that the cross-member  30   b  includes a living hinge piece  40  that has a latch hole  40   a  that is sized to receive the latch projection  38 . As shown in  FIG. 9 , the living hinge piece  40  is moveable to and between a latched state (drawn in solid lines) and an unlatched state (drawn in phantom). In the latched state, the latch projection  38  is received by the latch hole  40   a.  In the unlatched state, the living hinge piece  40  moves away from the front wall (drawn in phantom) so that the latch projection  38  is disposed apart from the latch hole  40   a.  As understood by one of ordinary skill in the art, the living hinge piece  40  has a normally relaxed condition (drawn in solid lines) and a flexed condition (drawn in phantom). As would be understood by one of ordinary skill in the art in view of  FIG. 9 , the living hinge piece  40  is resiliently biased to the normally relaxed condition, is in the normally relaxed condition when in the latched state and is in the flexed condition when in the unlatched state. 
     By way of example only and not by way of limitation, when the cross-member  30   b  is in the lock position, the cross-member  30   b  is positioned forwardly of the front wall  16   a   2  as shown in  FIGS. 1 ,  4 A and  4 C. In the release position, the cross member  30   b  is positioned above the base wall  16   a   1  as shown in  FIGS. 6A ,  6 B,  7 A and  7 B. 
     The following specifically describes the battery part  14  for the manual disconnect system  10 . With reference to  FIGS. 2 and 3 , the battery part  14  includes a battery part body member  42 , a fuse connector housing unit  44  and a circuit connector housing unit  46 . The battery part body member  42  has a mounting plate  48 . The mounting plate  48  has a top mounting plate surface  48   a  and a bottom mounting plate surface  48   b  that is disposed apart from the top mounting plate surface  48   a.  The top mounting plate surface  48   a  and the bottom mounting plate surface  48   b  define a mounting plate thickness  48   c  therebetween. The battery part body member  42  also includes an outer circumferential wall  50  that projects from the top mounting plate surface  48   a  to define the main compartment  14   a  and an inner circumferential wall  52  that is disposed apart from the outer circumferential wall  50  and inside the main compartment  14   a  to define the fuse assembly subcompartment  14   b  that is disposed in the main compartment  14   a.    
     In  FIG. 2 , the fuse connector housing unit  44  is connected to the bottom mounting plate surface  48   b  of the mounting plate  48  and is in communication with the fuse assembly subcompartment  14   b.  The circuit connector housing unit  46  projects from the bottom mounting plate surface  48   b  of the mounting plate  48  and extends into and is in communication with the main compartment  14   a.    
     With reference to  FIGS. 3A and 3B , the outer circumferential wall  50  is generally rectangularly shaped as viewed in plan view and has a pair of opposing short side walls  50   a  and a pair of opposing long side walls  50   b  that interconnect the respective ones of the pair of opposing short side walls  50   a.  Each one of the pair of opposing long side walls  50   b  is longer than respective ones of the pair of opposing short side walls  50   a.    
     Again with reference to  FIGS. 3A and 3B , the battery part  14  includes a pair of latch pins  54  that are disposed apart from one another. Respective ones of the pair of latch pins  54  are connected to and extend outwardly from respective ones of the pair of short side walls  50   a.  Further, the pair of latch pins  54  extend coexistently along a common latch pin axis LPA as best shown in  FIGS. 3A and 3B . 
     As illustrated in  FIGS. 3A and 3B , the mounting plate  48  has an endless groove  56  formed into the top mounting plate surface  48   a  that encircles the outer circumferential wall  50 . The mounting plate  48  includes a plurality of mounting plate holes  58  that are formed therethrough. The plurality of mounting plate holes  58  are disposed between the endless groove  56  and the outer circumferential wall  50 . The battery part  14  also has a plurality of caps  60 . As best shown in  FIGS. 2 ,  3 ,  4 A,  5 A,  6 A and  10 , each one of the plurality of caps  60  is integrally connected to the bottom mounting plate surface  48   b.  Also, in  FIG. 10 , each cap  60  has a cap hole  60   a  that extends partially into the cap  60 . Again, with reference to  FIG. 10 , the cap hole  60   a  is in registration with a respective one of the plurality of the mounting plate holes  58 . 
     As that shown in  FIGS. 3A and 3B , the battery part  14  further includes a pair of internally-threaded tubes  62  that are disposed apart from one another in the main compartment  14   a.  The pair of internally-threaded tubes  62  are integrally connected to and exteriorly of the inner circumferential wall  52  on opposing sides thereof. Also, the battery part  14  has a circuit connector conduit  64 . The circuit connector conduit  64  is connected to the mounting plate  48  and is disposed in the main compartment  14   a.  The circuit connector conduit  64  defines a circuit connector passageway  64   a  that extends to and between the main compartment  14   a  and exteriorly of the bottom mounting plate surface  48   b.  The circuit connector housing unit  46  is in communication with the circuit connector passageway  64   a.  The circuit connector housing unit  46  includes a circuit connector housing  46   a,  a circuit connector terminal position assurance device  46   b  and a circuit connector O-ring seal  46   c.  The circuit connector housing  46   a  first receives the circuit connector ring seal  46   c  and then the circuit connector housing  46   a  receives the circuit connector terminal position assurance device  46   b.  The circuit connector terminal position assurance device  46   b  retains the circuit connector ring seal  46   c  in the circuit connector housing  46   a.    
     In  FIGS. 3 ,  4 A,  5 A,  6 A and  7 A, the circuit connector housing  46   a  includes a circuit connector terminal arrangement  46   a   1 , a pair of circuit connector internally-threaded tubes  46   a   2  connected to the circuit connector terminal arrangement  46   a   1  and a pair of circuit connector thumb screws  46   a   3 . Respective ones of the circuit connector threaded tubes  46   a   2  rotatably receive respective ones of the pair of circuit connector thumb screws  46   a   3  for releasably connecting the circuit connector housing unit  46  to the bottom mounting plate surface  48   b  by threadably engaging mounting plate thumb screw holes  48   d  shown in  FIG. 2 . 
     As best shown in  FIGS. 3 ,  7 B and  8 B, the following specifically describes the fuse assembly  20  of the manual disconnect system  10 . By way of example only and not by way of limitation, the fuse assembly  20  includes a generally box-shaped fuse assembly housing  20   a  that has a base section  20   a   1  forming a fuse-receiving compartment  20   a   2 , a cover section  20   a   3 , a pair of tube elements  20   a   4 , a pair of thumb screws  20   a   5 , a fuse  20   a   6  ( FIGS. 3A and 3B ) and a pair of busbars  20   a   7  electrically connected to the fuse  20   a   6 . The cover section  20   a   3  is sized for removably covering the base section  20   a   1  in order to enclose the fuse-receiving compartment  20   a   2 . The base section  20   a   1  has a first pair of opposing base section side walls  20   a   1   a,  a second pair of opposing base section side walls  20   a   1   b  that are connected to the first pair of opposing base section side walls  20   a   1   a  and a base section bottom wall  20   a   1   c  ( FIGS. 3A and 3B ) connected thereto. Respective ones of the tube elements  20   a   4  are integrally connected exteriorly to respective ones of the first pair of opposing base section side walls  20   a   1   a.  Respective ones of the pair of thumb screws  20   a   5  are rotatably disposed in respective ones of the tube elements  20   a   4 . The fuse  20   a   6  is disposed in the fuse-receiving compartment  20   a   2  such that the busbars  20   a   7  extend from the fuse-receiving compartment  20   a   2 , through busbar-receiving holes  20   a   8 . The busbar-receiving holes  20   a   8  are formed through the bottom wall  20   a   1   c  to communicate exteriorly of the base section bottom wall  20   a   1   c  of the base section  20   a   1 . 
     The manual disconnect system  10  of the present invention as particularly illustrated in  FIGS. 3 and 10  is a sealed manual disconnect system  10  that includes the components described hereinabove. A detailed discussion of the components already described above is not deemed necessary for the understanding of the sealed manual disconnect system  10  and those additional components necessary for understanding the sealed manual disconnect system  10  are hereinafter described. The sealed manual disconnect system  10  includes the battery part  14 , the circuit connector housing unit  46 , the fuse connector housing unit  44 , the fuse assembly  20 , the disconnect part  16  and the circuit assembly  18  described above. Additionally, the sealed manual disconnect system  10  also includes the circuit connector O-ring seal  46   c,  a fuse assembly O-ring seal  68 , a mounting plate O-ring seal  70 , a circuit assembly O-ring seal  72  and a plurality of fasteners  74 . 
     Again, with reference to  FIGS. 4A ,  5 A,  6 A and  7 A, the fuse connector housing unit  44  is connected to the bottom mounting plate surface  48   b  of the mounting plate  48  and is in communication with the fuse assembly subcompartment  14   b.  Again, with reference to  FIGS. 3 and 10 , the fuse assembly O-ring seal  68  sized to surround and contact the base section  20   a   1  of the fuse assembly  20  and the mounting plate O-ring seal  70  is sized to be received in part by the endless grove  56 . The support member opening  12   c  receives the outer circumferential wall  50  in a manner that the top mounting plate surface  48   a  and the bottom support surface  12   b  are facially opposed to one another with the mounting plate O-ring  70  disposed therebetween. With the plurality of mounting plate holes  58  in registration with respective ones of the plurality of support member attachment holes  12   d,  respective ones of the plurality of fasteners  74  extend through support member attachment holes  12   d  and into respective ones of the plurality of mounting plate holes  58  to secure the battery part  14  to the support member  12 . Additionally, the fuse assembly  20  is disposed in the fuse assembly subcompartment  14   b  and is releasably connected to the battery part  14  with the fuse assembly O-ring seal  68  being in simultaneous contact with the first pair of base section side walls  20   a   1   a  and the second pair of base section side walls  20   a   1   b  of the fuse assembly  20  and an inner circumferential surface  52   a  of the inner circumferential wall  52 . And, when the disconnect part  16  is releasably connected to the battery part  14 , the circuit assembly O-ring seal  66  is disposed between and in contact with the circuit assembly  18  and the circuit connector conduit  64 . 
     Furthermore, the fuse connector housing unit  44  includes a pair of hollow terminal-receiving tube sections  44   a.  Each hollow terminal-receiving tube section  44   a  defines a terminal-receiving tube section opening  44   b  thereinto. Further, respective ones of the pair of hollow terminal-receiving tube sections  44   a  house respective ones of a pair of terminal-receiving tube section O-ring seals  44   c.  Respective ones of the pair of terminal-receiving tube sections on O-ring seals are disposed adjacent to respective ones of the terminal-receiving tube section openings  44   b.    
     One of ordinary skill in the art would appreciate that the manual disconnect system  10  of the present invention can be employed with vehicles such as automobiles, trucks, boats and the like. Further, a skilled artisan would appreciate that the disconnect part  16  can be disposed in the passenger compartment of the vehicle while the battery part  14  is disposed exteriorly of the passenger compartment of the vehicle. Because of the construction of the manual disconnect system  10  as described by way of example above, undesirable fluids, fumes or other possible dangerous byproducts that might be generated exteriorly of the passenger compartment are prevented from entering into the passenger compartment through the manual disconnect system  10  based, at least in part, on the seals as described above. Furthermore, the present invention is particularly useful in high-current applications because the disengagement of the shielding cover  16   a  is capable of disabling a high-current connection. Also, no tools are required to remove the disconnect part  16  from the battery part  14  nor are any small parts such as nuts, bolts and screws needed to removably retain the battery part  14  and the disconnect part  16  together. 
     The present invention, may, however, be embodied in various different forms and should not be construed as limited to the exemplary embodiments set forth herein; rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete and will fully convey the scope of the present invention to those skilled in the art.