Patent Description:
<CIT> relates to a battery connector assist unit comprises a base having means to secure a battery connector first part thereto and a slidable member interconnected to the base with the slidable member having a slide base having an upper surface and a lower surface. The lower surface is adjacent to the base. The slidable member also has a pair of smooth-sided cantilevered beams extending therefrom for temporarily retaining a battery connector second part and for transmitting force from the slidable member to the connector. The slidable member has a handle member easily accessible to assist in moving the connector parts into and out of mating relationship. The base has a slot therein and the slidable member has means to engage the slot. A cover plate is provided.

<CIT> concerns a high voltage diagnostic connector includes a housing holding a positive terminal, a negative terminal and a ground terminal with a cover removably coupled to the housing. An HVIL assembly is in the housing having a HVIL contacts and an HVIL shunt. An HVIL switch is held by the housing including a shunt actuator operably coupled to the HVIL shunt to position the HVIL shunt in an un-shunted position to open an HVIL circuit when in the primary position and in a shunted position to close the HVIL circuit when in the secondary position. The shunt actuator is movable between the primary position and the secondary position when testing the positive terminal, the negative terminal and the ground terminal with the testing device during diagnostic testing of the high voltage diagnostic connector.

Presently, cables that connect UPSs to external battery packs (XBPs) are connected to connectors provided on the UPS (UPS connectors). An exemplary cable and connector do not have a quick-disconnect mechanism to enable the cable and thus the XBP to be quickly disconnected from the UPS. The connector is typically screwed into the chassis of the UPS, thus taking time to connect and disconnect the cable and the XBP from the UPS.

Further, presently there is no mechanism associated with such cables and connectors to ensure there is no high voltage on UPS connectors during the connection and disconnection process. A user runs the risk of unwanted electrical discharge when connecting and disconnecting the cable used to connect the XBP to the UPS. Circuit breakers can be employed to protect the user, but circuit breakers take up space and provide additional cost.

As mentioned, many power devices, including UPSs, employ extra XBPs that are connected to the UPSs by connectors, such as Anderson connectors, to transfer power and signal from the UPSs to and from the XBPs to extend the run time of the UPSs. There are different types of power pole connectors that are used. These connectors are used at either a rear or a front side of the product so that they are easily accessible to the user to engage the connections. In addition, no other connector available in the market are configured to deliver max voltage (<NUM> volts (V)) and current.

When using a number of XBPs that are connected to the UPS, disconnection of a circuit breaker device is also another concern, which will lead to additional wiring complexity. With existing connectors, a connector is secured to the chassis by using overmolded cables that are attached using screws. <FIG> illustrate an example of an overmolded plug <NUM>. A tool, such as a screwdriver, is required to install and remove a set screw to secure the cable thereby hindering the ability to provide a quick disconnect connector. To meet UL requirements, an additional device, such as a circuit breaker, may be needed to meet manual disconnect requirements. When a remote battery cabinet that is located away from the UPS, a circuit breaker is provided to protect the building wiring, in addition to protecting the person working on the UPS. When providing a full or complete rack, there is no building wiring involved so the rack should include a disconnect device to connect to the external battery. When the unit is under consideration for being serviced, and where a group of units having individual supply connections is interconnected in such a way that it is possible for hazardous voltage or energy levels are transmitted between units, a disconnect device may be provided to disconnect hazardous parts likely to be contacted.

Some challenges of this environment include using a typical screw to secure the connector in a conventional design, which makes the design restricted for service personnel only. In this instance, a manually operated switch or additional circuit breaker is required to meet manual disconnect requirements. One aspect is to make the disconnect safe by the user. To add circuit breakers, existing schemes may have restriction of space and cost limitation. To avoid disconnect device, these parts should be guarded and marked with appropriate warning labels.

In one industry standard, a manual disconnect is applicable, without a screw to secure the connector. A cover not requiring a tool to open the cover is required. One option is a thumb screw. If a thumb screw is used, the limitation of quarter turn is realized, which may not possible and may not be acceptable as manual disconnect is a key requirement. The connector should be interrupt rated, if the agency accepts the same as disconnecting device. Available connectors in the market, such as Anderson connectors, have been evaluated at <NUM> V as per UL <NUM> or can be classified as a connector with breaking capacity (CBC) as per IEC <NUM>, which are specially designed to be engaged or disengaged in normal use when live or under load. The same connector will not meet interrupt requirement of higher voltage e.g., <NUM> V dc, as the connector does meet <NUM> cycle tests as per UL <NUM> standard due to high energy associated during make or break. The same connector, which is not deemed to be engaged or disengaged in normal use when live or under load, is known as a connector without breaking capacity (COC). Thus, there is need for a CBC connector with interrupt rating as per application which is not available in the market for greater than <NUM> V.

Mechanical disconnect mechanisms can have challenge in meeting <NUM> cycles. The connector should be able to meet overload test and resistance to arc test for <NUM> cycles. The test is not applicable as in UL <NUM> as the contact is interlocked with an integral switch. When a contact device is interlocked with an integral switch or other means, such as having the circuit opened before a mating contact is inserted or withdrawn, need not be subjected to this test. Thus, there is need of disconnection requirement mechanically and electrically. Interlocking the mechanical disconnect with electrical circuit so that circuit is opened when mating connector is inserted or withdrawn.

Additionally, lithium ion battery standard UL <NUM> requires battery systems with hazardous voltage circuits, including outputs of <NUM> V or greater, shall be provided with a manual disconnect device or be provided with installation instructions for the disconnect device to be provided during installation of the system. The disconnect device should be located as near as possible to the battery system terminals and shall be rated for the application including disconnect under load. The manual disconnect shall not require the use of a special tool or equipment to be operated.

According to the invention a quick disconnect connector assembly that includes a plug and a receptacle is provided.

The plug includes a plug body, a slide that is slidably received within a space formed in the plug body, and a connector that is secured to the plug body. The receptacle includes a plate, a contact switch housed within an enclosure that is secured to the plate, and a mating connector secured to the plate. The plug includes a pair of latches that are secured to the plug body and configured to be engaged by the slide as the slide moves laterally. The latches are configured to releasably engage the plate of the receptacle within an opening provided in the plate to secure plug to the receptacle. The top latch engages a top edge of the opening and the bottom latch engages a bottom edge of the opening. Each latch is pivotally secured to the plug body. The slide includes an end that engages the contact switch to position the contact switch in an ON position, which enables electrical connection between the connector and the mating connector. The plug includes at least one compression spring, which is coupled to the slide by an arm that extends through the center of the compression spring. The other end of the at least one compression spring engages a wall formed within the plug body. The at least one compression spring is configured to bias the slide to an extended position to enable the end of the slide to engage the contact switch. Concurrently, the slide is configured to move the latch to an outboard or engaged position in which latch members associated with the latch are moved away from one another to engage the inner side of the plate. The slide has a pull to enable an operator to move the slide away from the contact switch thereby disconnecting power between the connector and mating connector. The at least one compression spring is configured to rotate the latches toward the slide when the slide compresses the compression spring.

Another aspect of the present disclosure is directed to a cable connector comprising a slide coupled to a spring to bias the slide from a retracted position to an extended position and at least one latch coupled to the slide. The slide, when in the extended position, is configured to rotate the at least one latch to secure the at least one latch, and when in the retracted position, is configured to rotate the at least one latch in an opposite direction to release the at least one latch. The slide is configured to engage a contact switch when securing the at least one latch.

Embodiments of the cable connector further may include configuring the at least one latch to be secured to a plug and configuring the at least one latch to be engaged by the slide as the slide moves laterally with respect to the plug. The at least one latch may include a pair of latches each configured to releasably engage a plate of a receptacle within an opening provided in the plate to secure the plug to the receptacle. A top latch of the pair of latches may engage a top edge of the opening of the plate and a bottom latch of the pair of latches may engage a bottom edge of the opening of the plate. Each latch may be pivotally secured to the plug by a pin, with the top latch being configured to rotate about the pin and the bottom latch being configured to rotate in an opposite direction than the top latch when the slide is in the extended position to secure the top latch and the bottom latch. The slide may include an end that engages the contact switch to position the contact switch in an ON position, which enables electrical connection between a connector and a mating connector. The spring may be a compression spring, which is coupled to the slide. An end of the compression spring may engage a wall formed within a plug. The compression spring may be configured to bias the slide to the extended position to enable an end of the slide to engage the contact switch. The slide may be configured to move the at least one latch to an outboard or engaged position in which the at least one latch is moved to engage an inner side of a plate. The slide may be configured to rotate the at least one latch to an inboard or disengaged position when the slide compresses the spring when being moved to the retracted position. The slide may have a pull to enable an operator to move the slide to the retracted position away from the contact switch to disconnect power between a connector and a mating connector.

Yet another aspect of the present disclosure is directed to a connector assembly configured to connect and disconnect a connector from a mating connector. In one embodiment, the connector assembly comprises a plug including a plug body, a slide that is slidably coupled to the plug body, and a connector that is secured to the plug body and a receptacle including a plate, a mating connector secured to the plate, and a contact switch housed within an enclosure that is secured to the mating connector. The slide is configured to engage the contact switch when securing the connector to mating connector.

Embodiments of the connector assembly further may include at least one latch that is coupled to the plug body and configured to be engaged by the slide as the slide moves laterally. The at least one latch may include a pair of latches each configured to releasably engage the plate of the receptacle within an opening provided in the plate to secure plug to the receptacle. A top latch of the pair of latches may engage a top edge of the opening and the bottom latch of the pair of latches engages a bottom edge of the opening. Each latch may be pivotally secured to the plug body by a pin. The slide may be configured to be biased by a spring to an extended position to rotate the top latch and a bottom latch to secure the plug to the receptacle. The slide may be configured to move against the bias of the spring to a retracted position to rotate the top latch and the bottom latch in an opposite direction to release the plug from the receptacle. The slide may include an end that engages the contact switch to position the contact switch in an ON position, which enables electrical connection between the connector and the mating connector. The plug may include at least one compression spring, which is coupled to the slide. An end of the at least one compression spring may engage a wall formed within the plug body. The at least one compression spring may be configured to bias the slide to an extended position to enable an end of the slide to engage the contact switch. The slide has a pull to enable an operator to move the slide away from the contact switch to disconnecting power between the connector and the mating connector.

Another aspect of the present disclosure is directed to a method of connecting and disconnecting a connector and a mating connector. In one embodiment, the method comprises biasing a slide from a retracted position to an extended position. The slide, when in the extended position, is configured to rotate at least one latch to secure the at least one latch. The slide, when moved to the retracted position, is configured to rotate the at least one latch in an opposite direction to release the at least one latch. The slide further is configured to engage a contact switch when securing the at least one latch.

Embodiments of the method further may include a pair of latches each configured to releasably engage a plate of a receptacle within an opening provided in the plate to secure a plug to the receptacle. The method further may include engaging a top latch of the pair of latches with a top edge of the opening of the plate and engaging a bottom latch of the pair of latches with a bottom edge of the opening of the plate. The method further may include pivotally securing each latch to the plug by a pin, with the top latch being configured to rotate about the pin and the bottom latch being configured to rotate in an opposite direction than the top latch to secure the top latch and the bottom latch when the slide is the extended position. The method further may include engaging an end of the slide to the contact switch to position the contact switch in an ON position, which enables electrical connection between the connector and the mating connector.

Yet another aspect of the present disclosure is directed to a method of connecting and disconnecting a connector and a mating connector. In one embodiment, the method comprises: when inserting a connector associated with a plug into a mating connector associated with a receptacle, engaging a slide, which is coupled to the plug, with a contact switch that is housed within an enclosure coupled to the receptable; and releasably securing the plug to the receptacle.

Embodiments of the method further may include providing at least one latch that is coupled to the plug body and configured to be engaged by the slide as the slide moves laterally with respect to the plug body. The at least one latch may include a pair of latches each configured to releasably engage a plate of the receptacle within an opening provided in the plate to secure plug to the receptacle. Each latch may be pivotally secured to the plug by a pin. The method further may include biasing the slide toward the contact switch. Biasing the slide may include providing at least one spring, which is coupled to the slide. The at least one spring may be configured to bias the slide to an extended position to enable an end of the slide to engage the contact switch. The method further may include moving the slide away from the contact switch to disconnecting power between the connector and the mating connector.

This disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following descriptions or illustrated by the drawings. Also, the phraseology and terminology used herein is for description purposes and should not be regarded as limiting. The use of "including," "comprising," "having," "containing," "involving," and variations herein, are meant to be open-ended, i.e. "including but not limited to.

Embodiments of an integrated quick disconnect connector for external lithium ion battery connection include a connector that is designed to meet standard requirement, such as a SBS75-type connector provided by Anderson Power Products. The disconnect connector is configured to break the voltage or current at the terminals of connector prior to disconnecting the disconnect connector. As described above, prior to the disconnect connector disclosed herein, breaking the voltage was achieved by using circuit breakers in series to battery voltage supply connection. This is readily available solution, but circuit breakers are bulky in size and need a space inside the unit or external battery packs.

The disconnect connector disclosed herein addresses all the above needs described above. Specifically, the disconnect connector avoids usage of bulky and huge circuit breakers in the system. The integrated connector provides a safe disconnect by the user. The integrated switch provided in the disconnect connector meets requirements of existing power switches or circuit breakers with optimized cost and no additional space. The quick disconnect mechanism can be provided as an add-on to an Anderson connector to achieve voltage breaking with minimum interrupt current without use of any tool.

In some embodiments, power connection occurs when the cable is inserted into a mating Anderson connector and at the same time cable should be retained in locked position.

In some embodiments, the need to either guard or mark the connector with warning labels is eliminated. Further, the need to have thumbscrews is eliminated.

Referring now to the drawings, and more particularly to <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, <FIG>, a quick disconnect connector assembly is generally indicated at <NUM>. As shown, the connector <NUM> includes a plug generally indicated at <NUM> and a receptacle generally indicated at <NUM>. The plug <NUM> includes a plug body <NUM>, a slide <NUM> that is slidably received within a space <NUM> formed in a side of the plug body <NUM>, and a connector <NUM> that is secured to the plug body <NUM>.

The receptacle <NUM> includes a plate <NUM>, a contact switch <NUM> housed within an enclosure <NUM>, and a mating connector <NUM> secured to the plate <NUM>. As shown, the enclosure <NUM> is secured to the mating connector <NUM> on a side of the mating connector by screw fasteners. In one embodiment, the connector <NUM> and the mating connector <NUM> includes a SBS75-type connector and mating connector. However, as noted below, the quick disconnect assembly <NUM> can be used with a variety of connectors used for power connections. As shown, when connected, the connector <NUM> is configured to enter an enlarged opening <NUM> formed in the plate to be received within the mating connector <NUM>.

The plug <NUM> includes a pair of latches, each indicated at <NUM>, that are secured to the plug body <NUM>. As shown, each latch <NUM> is secured to the plug body <NUM> by a pin <NUM> that enables the latch to rotate or pivot with respect to the pin body. The latches <NUM> are configured to be engaged by the slide <NUM> as the slide moves laterally within the space <NUM>. The latches <NUM> are configured to releasably engage the plate <NUM> of the receptacle <NUM> within an opening <NUM> provided in the plate <NUM> to secure plug <NUM> to the receptacle <NUM>. As shown, the top latch <NUM> engages a top edge of the opening <NUM> of the plate <NUM> and the bottom latch <NUM> engages a bottom edge of the opening <NUM> of the plate <NUM>. In this position, each latch <NUM> engages the plate <NUM> to secure the latch against the plate, with the slide <NUM> providing a force against each latch since the slide is biased to an extended position, which will be described in greater detail below.

<FIG> illustrate the plug <NUM> received within the receptacle <NUM>, with the connector <NUM> received within the mating connector <NUM> and the slide <NUM> engaging the contact switch <NUM>, which will be described in greater detail below. <FIG> illustrates an enlarged view of the enclosure <NUM>, with the slide <NUM> extending into the enclosure to engage the contact switch <NUM>.

Referring to <FIG>, the plug <NUM> is secured to the receptacle <NUM>, with the latches <NUM> secured to the plate <NUM> of the receptacle. As shown, the slide <NUM> includes an end <NUM> that engages the contact switch <NUM> to position the contact switch in an ON position. This in turn enables electrical connection between the connector <NUM> and the mating connector <NUM>. Thus, it should be observed that the connector <NUM> and mating connector <NUM> cannot provide power from a device, e.g., a battery, to the UPS. As shown, the plug <NUM> include a pair of compression springs, each indicated at <NUM>. Each compression spring <NUM> is coupled to the slide <NUM> by an arm <NUM> that extends through the center of the compression spring. The other end of each compression spring <NUM> engages a wall <NUM> formed within the plug body <NUM>.

The compression springs <NUM> bias the slide <NUM> to the extended position to enable the end <NUM> of the slide to engage the contact switch <NUM> when securing the connector <NUM> to the mating connector <NUM>. The slide <NUM> is configured to move the latches <NUM> to an outboard or engaged position in which latch members associated with the plug <NUM> are moved away from one another to engage the inner side of the plate <NUM>. In this position, the latches <NUM> are secured to the plate <NUM> in that the latches prevent the plug <NUM> from being removed from the receptacle <NUM>. The slide <NUM> has a pull <NUM> to enable an operator to move the slide <NUM> away from the contact switch <NUM> against the bias of the springs <NUM> thereby disconnecting power between the connector <NUM> and mating connector <NUM>.

Referring to <FIG>, and to <FIG>, the slide <NUM> is shown to be pulled against the bias of the springs <NUM> so that the end <NUM> of the slide disengages the contact switch <NUM>. As shown in <FIG>, when an operator grasps the pull <NUM> to move the slide against the bias of the springs <NUM>, the slide is configured to move the latches <NUM> inboard so that the latches disengage the plate <NUM> of the receptacle <NUM> to enable the plug <NUM> to be disconnected from the receptacle. In this position, the connector <NUM> of the plug <NUM> is able to disconnect the mating connector <NUM> of the receptacle <NUM> to fully remove the plug from the receptacle. <FIG> show the plug <NUM> completely removed from the receptacle <NUM> with the slide <NUM> being moved to its biased extended position by the springs <NUM>. In this position, the slide is configured to move the latches <NUM> outboard.

Thus, the operation of the disconnect connector assembly <NUM> is as follows. During installation, an operator manipulates the plug <NUM> so that when the plug approaches the receptacle <NUM> with the connector <NUM> aligned with the mating connector <NUM> and the slide <NUM> aligned with the enclosure <NUM> that houses the contact switch <NUM>. The operator then inserts the connector <NUM> into the mating connector <NUM>. Simultaneously, the end <NUM> of the slide <NUM> enters the opening of the plate <NUM> so that the end is proximate with the contact switch <NUM>. Only when the connector <NUM> is fully received within the mating connector <NUM> can the end <NUM> of the slide <NUM> engage the contact switch <NUM> to provide power between the connector and mating connector and thus the XBP to the UPS.

During removal, the operator grasps the pull <NUM>, e.g., a tether, provided on an opposite end of the slide <NUM> to move the slide within the space <NUM> against the bias of the compression springs <NUM>. This movement causes the end of the slide <NUM> to disengage the contact switch <NUM> to disconnect power between the connector <NUM> and the mating connector <NUM>. This movement further causes the latches <NUM> to be moved inboard with respect to one another so that the connector <NUM> can be removed from the mating connector <NUM> in a safe, efficient manner.

Referring <FIG>, when the slide <NUM> is in the extended position under the bias of the springs <NUM>, portions of the slide, each indicated at <NUM>, engage respective latches <NUM> to rotate the latches about their respective pins <NUM> in an outboard direction. Specifically, in the shown embodiment, the top latch <NUM> is rotated clockwise and the bottom latch <NUM> is rotated counterclockwise. Referring to <FIG>, when the slide <NUM> is moved against the bias of the springs <NUM> by pulling the pull <NUM>, portions of the slide, each indicated at <NUM>, engage respective latches <NUM> to rotate the latches about their respective pins <NUM> in an inboard position. Specifically, in the shown embodiment, the top latch <NUM> is rotated counterclockwise and the bottom latch <NUM> is rotated clockwise.

<FIG> illustrate connectors on which the plug and receptacle of the present disclosure can be applied. As shown, the quick disconnect connector can be used with an SBS175-type connector (<FIG>), a PP45-type connector (<FIG>), and an SBS75-type connector (<FIG>).

Referring to <FIG>, an electrical schematic of the UPS and XBPs is generally indicated at <NUM>. As shown, there is a UPS <NUM> and two XBP battery modules <NUM>, <NUM>. A mating connector <NUM> of the UPS <NUM> is connected to a connector <NUM> of the XBP battery module <NUM>. An interlock switch <NUM> is provided between the connector <NUM> and a mating connector <NUM> of the XBP battery module <NUM>. The mating connector <NUM> of the XBP battery module <NUM> is connected to a connector <NUM> of the XBP battery module <NUM>. As with XBP battery module <NUM>, the XBP battery module <NUM> includes an interlock switch <NUM> provided between the connector <NUM> and a mating connector <NUM>.

For the XBP battery module <NUM> (XBP1) to operate normally, REM_OFF should be connected to a battery return (RTN). During the disconnect operation, REM_OFF is first disconnected from RTN using an interlock switch, which turns off the power supply for the battery module. At this point, VBATT and IBATT return to zero. Subsequently, the plug is removed from the receptacle to complete the disconnect operation.

The functionality and benefits associated with the quick disconnect connector of embodiments of the present disclosure are as follows:.

In some embodiments, a quick disconnect connector has an enhanced rating from a "COC rated connector" to a "Connector with Breaking Capacity" by meeting interrupt requirement at higher application voltage to eliminate restriction of non-availability which would have forced to use circuit breakers thereby leading to cost escalation and increased space requirements.

In some embodiments, a quick disconnect connector is configured to perform a lengthy reliability test as per UL <NUM>, and is exempted as there is integral switch to connect and disconnect the connector.

In some embodiments, a quick disconnect connector complies with mechanical construction requirement of standard UL <NUM> Clause <NUM>. Manual disconnect connectors do not require the use of a special tool.

Overall, user safe disconnect scheme complies with the requirement of lithium ion enabled UPS standard UL <NUM> as well as component requirement of UL <NUM> for battery and connector requirement of UL <NUM> and IEC <NUM>.

In some embodiments, a tool-less quick connect/disconnect mechanism is employed.

In some embodiments, connector engagement/disengagement, locking/unlocking, and connector energize/de-energize happens at the same time with just one push or pull, respectively, of the slide.

In some embodiments, the quick disconnect connector can be deployed in products where there are space constraints.

In some embodiments, the quick disconnect connector has a unique connect/disconnect mechanism to ensure customer safety for lithium ion-enabled UPSs.

In some embodiments, the quick disconnect connector provides a comprehensive system to manage conflicts between UPS and lithium ion battery standards with respect to manual disconnect mechanisms.

In some embodiments, the quick disconnect connector eliminates lengthy reliability testing during product design cycle leading to better time to market.

In some embodiments, the quick disconnect connector eliminates the need for multiple circuit breakers in the extended battery connected systems leading to optimal cost reduction.

In some embodiments, the quick disconnect connector is configured to release latches by pulling a tether.

In some embodiments, the quick disconnect connector, when the cable engages the connector, the ALU latch deflects against the rear panel cut and becomes locked, which secures the whole cable assembly.

In some embodiments, the quick disconnect connector meets industry standards, including clause <NUM>. <NUM>(c) of Standard UL <NUM>-5th edition.

Claim 1:
A cable connector comprising:
a slide (<NUM>) coupled to a spring (<NUM>) to bias the slide from a retracted position to an extended position; characterized in that the cable connector further comprises:
at least one latch (<NUM>) coupled to the slide,
wherein the slide, when in the extended position, is configured to rotate the at least one latch (<NUM>) to secure the at least one latch, and when in the retracted position, is configured to rotate the at least one latch in an opposite direction to release the at least one latch, and
wherein the slide (<NUM>) is configured to engage a contact switch (<NUM>) when securing the at least one latch.