Patent Description:
A secondary battery refers to a battery capable of charging/discharging, unlike a primary battery incapable of charging, and is used as a power source of an electric vehicle (EV) or a hybrid vehicle (HEV) as well as a small high-tech electronic device such as a mobile phone, a PDA, a laptop computer, etc..

At present, it is impossible to obtain sufficient output enough to drive an EV with one secondary battery (cell). In order to apply a secondary battery as an energy source of the EV, for example, a battery module in which a plurality of lithium ion battery cells are connected in series and/or in parallel needs to be configured, and a battery pack including a battery management system (BMS) which connects the battery modules in series and functionally maintains the battery modules, a cooling system, a battery disconnection unit (BDU), an electric wiring cable, etc. is configured.

Meanwhile, a high-voltage battery pack mounted on an EV or a HEV usually includes a power disconnection device so as to prevent safety accidents that may occur in production, assembly, repair, and transportation. The power disconnection device is a device configured to allow an operator to physically disconnect the battery power of the EV, and is commonly used by various names such as manual service disconnect (MSD), safety plug, service plug, disconnect switch, etc. in the art.

As an example, a power disconnection device according to the related art includes a socket <NUM> fixedly mounted on one side of a battery pack and a plug <NUM> detachably attached to the socket <NUM> as shown in <FIG>. The socket <NUM> includes an HV (±) terminal (not shown) connected to a high voltage line of the battery pack, and the plug <NUM> includes a connector (not shown) connecting the HV (±) terminal. When the plug <NUM> is removed from the socket <NUM>, connection of the HV (±) terminal of the socket <NUM> is cut off, and thus the power of the battery pack may be disconnected.

When the plug is removed, a spark is generated at the HV (±) terminal due to a high voltage, which may cause a safety problem. In general, the power disconnection device further includes a high voltage interlock loop (HVIL) pin. In the case of a power disconnection device including the HVIL pin, when the plug is removed, an interlock loop pin on the plug side and an interlock loop pin on the socket side are first separated from each other, and then a terminal connector on the plug side and the HV (±) terminal of the socketare configured to be separable from each other. When the interlock loop pins are separated from each other, flow of a large current of the battery pack is blocked, and thus no spark is generated when the terminal connector on the plug side and the HV (±) terminal of the socket are separated from each other.

However, such a power disconnection device of the related art has disadvantages in that there is inconvenience of having to detach and attach the plug and socket every time, and the manufacturing cost is also high because the plug and socket are separately manufactured and then assembled. <CIT> relates to a service plug that includes a lever, a cover which supports the lever movably between one side and another side, a housing which is provided to be connectable to and separable from the cover as the lever is moved, the cover being separated from the housing by moving the lever from a full locking position to a partial locking position, heavy current terminals which open the power supply circuit by being disconnected from the power supply circuit in a separating process of the cover, a detection terminal which is switched from an ON-state to an OFF-state in the separating process of the cover, and a stopper which comes into contact with restricting walls provided on the cover to stop a movement of the lever from the full locking position toward the partial locking position until the heavy current terminals are disconnected from the power supply circuit after the detection terminal is switched from the ON-state to the OFF-state in the separating process of the cover.

The present disclosure is designed to solve the problems of the related art, and therefore the present disclosure is directed to providing a power disconnection device that improves ease of use by changing a power disconnection method to a switch method, and a battery pack including the same.

In one aspect of the present disclosure, there is provided a power disconnection device according to claim <NUM>.

The first moving contact bar may include a push bar configured to rise or fall during the seesaw operation and connected to other end portion of the first moving contact bar so as to pressurize the second switch module upon falling, and the second switch module may be configured to interlock with the first switch module by receiving pressure of the push bar.

The push bar may be formed of an insulating material.

The second switch module may include a support disposed vertically; a second moving contact bar having one end portion of the support as an axis and configured to perform the seesaw operation by pressing of the push bar; and a pair of high voltage connection pins provided on an opposite side to a side of the second moving contact bar which is pressed by the push bar, with respect to the support, and configured to extend in a downward direction from the second moving contact bar, and the first high voltage terminal and the second high voltage terminal may be disposed on lower portions of the pair of high voltage connection pins, and may be in contact or non-contact with the pair of high voltage connection pins by the seesaw operation of the second moving contact bar.

The pair of high voltage connection pins may be hinge-coupled to the second moving contact bar.

The second moving contact bar may include an insulating portion formed of an insulating material and a conductive portion formed of an electrically conductive material, and the insulating portion may be formed to extend to a position where the insulating portion is contactable with the push bar, and the conductive portion may be connected to the pair of high voltage connection pins.

The second switch module may further include an elastic member configured to elastically support the insulating portion on a lower portion of the insulating portion.

The second switch module may further include a pin guide tube member provided in the form of a tubular body guiding upward and downward linear movement of the pair of high voltage connecting pins between the conductive portion and the first high voltage terminal and the second high voltage terminal.

Each of the first high voltage terminal and the second high voltage terminal may include a socket portion formed so that the corresponding high voltage connection pin is insertable, and a fastening portion extending from the socket portion and exposed to an outside of the housing.

In another aspect of the present disclosure, there is provided a battery pack including the power disconnection device described above.

According to an aspect of the present disclosure, the power disconnection device capable of disconnecting power safely and conveniently by using the switch method may be provided.

That is, the power disconnection device according to the present disclosure is configured to sequentially disconnect the interlock terminal and the high voltage terminal by operating the switch lever on/off with the force of a finger, and thus the user may safely and easily disconnect the power of the battery pack.

The effects of the present disclosure will be more clearly understood by the following examples of the present disclosure. It will also be readily apparent that the present disclosure can be realized by the means and combinations thereof indicated in the claims of the present disclosure.

A power disconnection device <NUM> to be described below is collectively referred to by various names such as manual service disconnect (MSD), safety plug, service plug, disconnect switch, etc. in the art, and, for example, as a component included in a battery pack <NUM> for an electric vehicle, generally refers to a device used by a user to manually disconnect the power of the high voltage battery pack <NUM> in an emergency.

<FIG> is a diagram illustrating a battery pack on which a power disconnection device according to an embodiment of the present disclosure is mounted, <FIG> is a perspective view of the power disconnection device according to an embodiment of the present disclosure, and <FIG> is a diagram schematically illustrating an internal configuration in an on state of the power disconnection device according to an embodiment of the present disclosure.

Referring to these figures, the power disconnection device <NUM> according to an embodiment of the present disclosure includes a housing <NUM> forming an exterior, a first interlock terminal <NUM>, a second interlock terminal <NUM>, a first high voltage terminal <NUM>, a second high voltage terminal <NUM>, a switch lever <NUM>, a first switch module <NUM>, and a second switch module <NUM> that are provided inside the housing <NUM>.

In the case of an electric vehicle, because the battery pack <NUM> is usually mounted on a underside of the vehicle body, a cover is provided to hide the battery pack <NUM> under the vehicle seat. The power disconnection device <NUM> is installed on an upper portion of a pack case <NUM> of the battery pack <NUM> so that the power disconnection device <NUM> may be immediately visible when the cover is opened.

The housing <NUM> of the power disconnection device <NUM> may include a box-shaped body portion <NUM> for accommodating and protecting components, and a plate-shaped flange portion <NUM> provided on a lower portion of the body portion <NUM>. The pack case <NUM> includes through holes in an upper surface. An electric wire, a flexible bus bar (or a high voltage cable), etc. are pulled out from the inside of the battery pack <NUM> through the through holes and connected to terminals of the power disconnection device <NUM>. In addition, the power disconnection device <NUM> may be installed on the upper portion of the pack case <NUM> by covering the through holes with the flange portion <NUM> of the housing <NUM> and fastening the flange portion <NUM> with bolts.

As will be described below in detail, the power disconnection device <NUM> according to the present disclosure is configured to disconnect the power of the switch-type high-voltage battery pack <NUM>, and thus the power disconnection device <NUM> is much superior in user convenience to the detachable type power disconnection device <NUM> of the related art.

For example, in the detachable type power disconnection device <NUM> of the related art, in order to disconnect the power of the battery pack <NUM>, first, an interlock pin needs to be released by pulling a lever, and a plug needs to be removed from a socket. However, the power disconnection device <NUM> according to the present disclosure only needs to flip the switch lever <NUM> to an OFF position with the force of a finger.

Hereinafter, the main configuration and operation of the power disconnection device <NUM> will be described in detail.

The first interlock terminal <NUM> and the second interlock terminal <NUM> are terminals connected to an interlock circuit of the battery pack <NUM>. Here, the interlock circuit refers to a circuit that notifies an abnormal situation that occurs when a device deviates from a normal state, and stops the device immediately to protect the user's safety. The interlock circuit of the battery pack <NUM> may be configured to include a control unit (e.g., a battery management system (BMS)) that detects a connection state between the first interlock terminal <NUM> and the second interlock terminal <NUM> and a power relay device controlled by the control unit. For example, when the connection between the first interlock terminal <NUM> and the second interlock terminal <NUM> is cut off, it is regarded as out of the normal state and the BMS turns off the power relay device to block the flow of large current of the battery pack <NUM>. The configuration of such an interlock circuit is widely known in the art, and thus a detailed description thereof is omitted.

The first high voltage terminal <NUM> and the second high voltage terminal <NUM> are terminals connected to a high voltage line of the battery pack <NUM>. For example, battery modules are usually connected in series inside the battery pack <NUM>, wherein a cable between two of the battery modules is cut off, one end of the cable is connected to the first high voltage terminal <NUM>, and the other end of the cable is connected to the second high voltage terminal <NUM>. Accordingly, when the connection between the first high voltage terminal <NUM> and the second high voltage terminal <NUM> is cut off inside the power disconnection device <NUM>, the power of the battery pack <NUM> is disconnected.

At this time, if the connection between the first high voltage terminal <NUM> and the second high voltage terminal <NUM> is cut off while a large current is flowing, a strong spark is generated, which may cause danger to the operator, and the power disconnection device <NUM> may be damaged by a fire. Therefore, when the power of the high voltage battery pack <NUM> is disconnected, before the connection between the first high voltage terminal <NUM> and the second high voltage terminal <NUM> is cut off for safety, the interlock circuit is cut off so that it is necessary to send a control signal from the BMS, turn off the power relay, and block the flow of large current in advance.

To this end, like the existing detachable type power disconnection device, even the switch-type power disconnection device <NUM> needs to be configured such that the connection between the first interlock terminal <NUM> and the interlock second terminal <NUM> is cut off, and then at a time difference, the connection between the first high voltage terminal <NUM> and the second high voltage terminal <NUM> is cut off.

As a means for implementing such an operation mechanism, the power disconnection device <NUM> according to the present disclosure includes a first switch module <NUM> operating by the switch lever <NUM> and a second switch module <NUM> interlocking with the first switch module <NUM>.

The switch lever <NUM> includes a handle <NUM> exposed to the outside of the housing <NUM> and a rod portion <NUM> formed by extending from the handle <NUM> to a predetermined position inside the housing <NUM>, and may be provided to be rotatable in front and reverse directions within a predetermined angle range with respect to a support point. For example, as shown in <FIG>, the switch lever <NUM> may be provided such that the handle <NUM> of the switch lever <NUM> may be tilted to the left or right at a predetermined angle.

The first switch module <NUM> may be in contact with the first interlock terminal <NUM> and the second interlock terminal <NUM>, upon an off operation of the switch lever <NUM>, may operate by the switch lever <NUM> and provided to be separated from any one of the first interlock terminal <NUM> and the second interlock terminal <NUM>.

Specifically, the first switch module <NUM> according to the present embodiment may be configured to include a first moving contact bar <NUM>, springs S1 and S2, and a push bar <NUM>, and the first interlock terminal <NUM> and the second interlock terminal <NUM> may be configured in the form of metal rods disposed on a lower portion of the first moving contact bar <NUM> and extending side by side in a vertical direction. Then, wires L1 and L2 are respectively connected to a lower end of the first interlock terminal <NUM> and a lower end of the second interlock terminal <NUM>. The wires L1 and L2 may be used to connect the first interlock terminal <NUM> and the second interlock terminal <NUM> to the interlock circuit of the battery pack <NUM>.

The first moving contact bar <NUM> is a bar-shaped conductor made of a metal material, and may be configured such that approximately a central portion is hinged to one end portion of the first interlock terminal <NUM> to be rotatable with respect to one end of the first interlock terminal <NUM> as an axis. In addition, the first moving contact bar <NUM> may further include a protrusion 41b having inclined surfaces on a left side and a right side to secure a smooth contact distance when the switch lever <NUM> rotates.

The spring includes the first spring S1 and the second spring S2. The first spring S1 and the second spring S2 may be disposed below the right side and the left side of the first moving contact bar <NUM> with respect to the first interlock terminal <NUM>. The two springs limit a rotation radius of the first moving contact bar <NUM> and provide force against a pressurization force of the switch lever <NUM>. For this reason, a predetermined force needs to be applied to tilt the switch lever <NUM>.

For example, it may be preferable to place a cover on the switch lever <NUM> in order to prevent unintentional movement of the switch lever <NUM> due to an external impact or an operator's mistake, or set the force required to tilt the switch lever <NUM> to <NUM> kgf to <NUM> kgf by using a spring having a relatively great elastic modulus. That is, it is preferable to prevent the switch lever <NUM> from moving with a force less than or equal to at least <NUM> kgf.

As for the switch lever <NUM>, when the handle <NUM> is tilted to an on position, the rod portion <NUM> pressurizes the right side of the first moving contact bar <NUM>, and when the handle <NUM> is tilted to an off position, the rod portion <NUM> pressurizes the left side of the first moving contact bar <NUM>. Accordingly, according to the on/off positions of the switch lever <NUM>, the first moving contact bar <NUM> performs a seesaw operation with respect to one end portion of the first interlock terminal <NUM> as the axis.

The second interlock terminal <NUM> is disposed at a position where one end portion is contactable with one end portion 41a of the first moving contact bar <NUM> when the switch lever <NUM> is in the on position as shown in <FIG>. When the second interlock terminal <NUM> is in contact with the first moving contact bar <NUM> that is a conductor, the second interlock terminal <NUM> may conduct electricity with the first interlock terminal <NUM>.

When the handle <NUM> of the switch lever <NUM> in the on position is tilted to the right, the first moving contact bar <NUM> performs the seesaw operation and the one end portion 41a of the first moving contact bar <NUM> rises and is separated from the second interlock terminal <NUM>. In this case, an electrical connection between the first interlock terminal <NUM> and the second interlock terminal <NUM> is cut off, and accordingly, the interlock circuit is in an unconnected state.

The push bar <NUM> is a rod-shaped member formed by extending in a lower direction from the other end portion of the first moving contact bar <NUM> and may be hinged to the other end portion of the first moving contact bar <NUM>. Such a push bar <NUM> is configured to rise or fall during the seesaw operation of the first moving contact bar <NUM>, and pressurize the second switch module <NUM> upon falling. Even when the push bar <NUM> is in contact with the second switch module <NUM>, the push bar <NUM> may be made of an insulating material so that current does not flow between the first switch module <NUM> and the second switch module <NUM>.

The second switch module <NUM> may interlock with the first switch module <NUM> by receiving pressure when the push bar <NUM> falls, may be in contact with the first high voltage terminal <NUM> and the second high voltage terminal <NUM> and separated from any one of the first interlock terminal <NUM> and the second interlock terminal <NUM>, and then may be configured to be separated from the first interlock terminal <NUM> and the second interlock terminal <NUM>.

Specifically, the second switch module <NUM> according to the present embodiment includes a support <NUM>, a second moving contact bar <NUM>, a pair of high voltage connection pins 52a and 52b, a third spring S3, and a pin guide pipe member <NUM>.

The support <NUM> is a bar-shaped member vertically disposed inside the housing <NUM>, supports the second moving contact bar <NUM>, and has one end portion serving as a rotation axis of the second moving contact bar <NUM>.

The second moving contact bar <NUM> is disposed in a direction crossing the support <NUM>, and has approximately a central portion hinged to one end portion of the support <NUM>. Accordingly, similarly to the first moving contact bar <NUM>, the second moving contact bar <NUM> may also rotate with respect to one end portion of the support <NUM> as an axis.

In addition, the second moving contact bar <NUM> may be formed of two types of materials. That is, the second moving contact bar <NUM> includes an insulating portion 51a formed of an insulating material and a conductive portion 51b formed of an electrically conductive material. As shown in <FIG>, a right side of the second moving contact bar <NUM> may be formed as the insulating portion 51a and a left side of the second moving contact bar <NUM> may be formed as the conductive portion 51b. The insulating portion 51a may extend to a position where the insulating portion 51a is contactable with the push bar <NUM>, and a lower portion thereof may be supported by a third spring S3. Here, the third spring S3 may be replaced with another type of elastic member having an elastic restoring force. The conductive portion 51b may extend in a direction opposite to the insulating portion 51a by a length of the insulating portion 51a for balance.

The pair of high voltage connection pins 52a and 52b may be hinged to the conductive portion 51b and may be provided to extend in a downward direction crossing the conductive portion 51b.

The pin guide tube member <NUM> is a member in the form of a tubular body through which the high voltage connection pins 52a and 52b pass, and serves to guide upward and downward linear movement of the pair of high voltage connection pins 52a and 52b between conductive portion 51b and the first high voltage terminal <NUM> and the second high voltage terminal <NUM>.

The first high voltage terminal <NUM> and the second high voltage terminal <NUM> of the present embodiment respectively include socket portions 23a and 24a formed so that the respectively corresponding high voltage connection pins 52a and 52b may be inserted, and fastening portions 23b and 24b extending from the socket portions 23a and 24a and exposed to the outside of the housing <NUM>. For example, the fastening portion 23b of the first high voltage terminal <NUM> and a negative electrode terminal (not shown) of a battery module are connected to each other by a flexible bus bar, and the fastening portion 24b of the second high voltage terminal <NUM> and a positive electrode terminal (not shown) of another battery module may be connected to each other by another flexible bus bar.

The above-described second switch module <NUM> may be configured such that the second moving contact bar <NUM> is horizontally supported by the third spring S3, and the pair of high voltage connection pins 52a and 52b are in contact with the first high voltage terminal <NUM> and the second high voltage terminal <NUM>, respectively, when the switch lever <NUM> is in the on state. Also, when the switch lever <NUM> is in the off state, as the third spring S3 is compressed by pressing of the push bar <NUM>, the insulating portion 51a falls and the conductive portion 51b rises. At this time, the pair of high voltage connection pins 52a and 52b may be in non-contact with the first high voltage terminal <NUM> and the second high voltage terminal <NUM>.

Next, an example of use of the power disconnection device <NUM> having the configuration described above will be described with reference to <FIG>.

The power disconnection device <NUM> of the battery pack <NUM> is normally in an on state. At this time, referring to <FIG>, the switch lever <NUM> pressurizes the right side of the first moving contact bar <NUM> so that the one end portion 41a of the first moving contact bar <NUM> moves down the rotation axis and comes into contact with the second interlock terminal <NUM>, and the other end portion of the first moving contact bar <NUM> rises above the rotation axis, and thus, the push bar <NUM> and the second switch module <NUM> are in a non-contact state. Accordingly, the first interlock terminal <NUM> and the second interlock terminal <NUM> are in a state capable of conducting electricity with each other by means of the first moving contact bar <NUM>, and the first high voltage terminal <NUM> and the second high voltage terminal <NUM> are in the state capable of conducting electricity with each other by means of the second moving contact bar <NUM>.

That is, when the switch lever <NUM> is in the on position, both the interlock circuit and the high voltage line are connected, and thus the power of the battery pack <NUM> is supplied to the load of the electric vehicle (In <FIG>, HVIL <NUM> corresponds to the first interlock terminal <NUM>, HVIL <NUM> corresponds to the second interlock terminal <NUM>, HV+ corresponds to the first high voltage terminal <NUM>, and HV- corresponds to the second high voltage terminal <NUM>).

When the power of the battery pack <NUM> is disconnected, the switch lever <NUM> is tilted to the off position. At this time, the switch lever <NUM> is tilted in two steps. For example, as shown in <FIG>, the switch lever <NUM> is tilted and erected vertically and then at predetermined time interval, as shown in <FIG>, the switch lever <NUM> is fully tilted to the off position. Here, a step of tilting and erecting the switch lever <NUM> vertically is a first step, and a step of fully tilting the switch lever <NUM> to the off position is a second step.

Referring to <FIG>, in the first step, the switch lever <NUM> pressurizes a rotation axis portion of the first moving contact bar <NUM>. Therefore, the one end portion 41a of the first moving contact bar <NUM> rises to the height of the rotation axis and is separated from the second interlock terminal <NUM>, and the other end portion of the first moving contact bar <NUM> falls to the height of the rotation axis. At this time, the push bar <NUM> may fall to a position close to or simply in contact with an upper surface of the second moving contact bar <NUM>.

Accordingly, the first interlock terminal <NUM> and the second interlock terminal <NUM> are in a state incapable of conducting electricity with each other, and a power supply disconnection signal is transmitted to the BMS. Even when the power relay is turned off according to the control signal of the BMS and the first high voltage terminal <NUM> and the second high voltage terminal <NUM> are connected, the flow of large current is cut off.

Referring to <FIG>, in the second step, the switch lever <NUM> pressurizes the left side of the first moving contact bar <NUM>. Therefore, one end portion of the first moving contact bar <NUM> further rises above the rotation axis, and the other end portion of the first moving contact bar <NUM> further falls below the rotation axis. At this time, the insulating portion 51a of the second moving contact bar <NUM> is pressed by the push bar <NUM> and falls below the rotation axis, and the conductive portion 51b of the second moving contact bar <NUM> of the opposite side rises above rotation axis so that the pair of high voltage connection pins 52a and 52b are separated from the first high voltage terminal <NUM> and the second high voltage terminal <NUM>.

Therefore, when the switch lever <NUM> is tilted to the off position, even the first high voltage terminal <NUM> and the second high voltage terminal 24are in the state incapable of conducting electricity with each other, and thus the power of the battery pack <NUM> may be physically disconnected.

As described above, when the power disconnection device <NUM> according to the present disclosure is used, the operator may disconnect the power of the battery pack <NUM> more conveniently and safely than the detachable type power disconnection device <NUM> of the related art and perform a necessary operation.

Meanwhile, a battery pack according to the present disclosure may be configured to include the power disconnection device described above, a plurality of battery modules connected in series with the power disconnection device, a cooling system for managing the temperature of the battery modules, various devices (not shown) for controlling charging and discharging of the battery modules, such as BMS, current sensor, fuse, and a pack case for storing and installing the components.

The battery pack may be applied to a vehicle such as an electric vehicle or a hybrid vehicle. That is, in the present disclosure, the battery pack may be used as a driving energy source of an electric vehicle.

Claim 1:
A power disconnection device (<NUM>) for manually disconnecting power of a battery pack (<NUM>), the power disconnection device (<NUM>) comprising:
a housing (<NUM>);
a first interlock terminal (<NUM>) and a second interlock terminal (<NUM>) provided in the housing (<NUM>) and connectable to an interlock circuit of the battery pack, and a first high voltage terminal (<NUM>) and a second high voltage terminal (<NUM>) connectable to a high voltage line of the battery pack (<NUM>);
a switch lever (<NUM>) disposed over inner and outer portions of the housing (<NUM>);
a first switch module (<NUM>) in contact with the first interlock terminal (<NUM>) and the second interlock terminal (<NUM>), and, upon an off operation of the switch lever (<NUM>), configured to operate by the switch lever (<NUM>) to be separated from any one of the first interlock terminal (<NUM>) and the second interlock terminal (<NUM>);
wherein the first switch (<NUM>) module comprises a first moving contact bar (<NUM>) rotatably coupled to one end portion of the first interlock terminal (<NUM>) and provided to perform a seesaw operation with respect to the one end portion of the first interlock terminal (<NUM>) as an axis according to on/off positions of the switch lever (<NUM>),
wherein the second interlock terminal (<NUM>) is disposed at a position where one end portion is contactable with one end portion of the first moving contact bar (<NUM>); and
a second switch module (<NUM>) configured to interlock with the first switch module(<NUM>) and be in contact with the first high voltage terminal (<NUM>) and the second high voltage terminal(<NUM>),
wherein the second switch module (<NUM>) is configured to operate to be separated from the first high voltage terminal (<NUM>) and the second high voltage terminal (<NUM>) by interlocking with the first switch module (<NUM>) when the first switch module (<NUM>) is separated from any one of the first interlock terminal (<NUM>) and the second interlock terminal (<NUM>) by the switch lever (<NUM>).