# US 2014/0193990 A1 · Manual service disconnects for battery systems > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0193990 A1 - Document ID: US20140193990A1 - Status: Published application - Kind: A1 - Application number: 13/738,741 - Filed: 2013-01-10 - Published: 2014-07-10 - Earliest claimed: 2013-01-10 - Assignees: Tyco Electronics Corporation - Applicants: Tyco Electronics Corporation - Inventors: Weiping Zhao; James Aric Boyer - Web page: https://patentgrep.com/patent/US20140193990A1 ## CPC - H01R 13/6335: {comprising a handle} - H01R 13/648: Protective earth or shield arrangements on coupling devices {, e.g. anti-static shielding} (coaxially arranged shields H01R24/38) - H01R 13/688: with housing part adapted for accessing the fuse - H01R 13/703: operated by engagement or disengagement of coupling parts, {e.g. dual-continuity coupling part}(H01R13/71 takes precedence) - H01R 13/713: the switch being a safety switch - H01M 10/4207: {for several batteries or cells simultaneously or sequentially} - H01M 2200/103: Fuse - H01R 13/62938: {Pivoting lever comprising own camming means} - H01R 13/66: Structural association with built-in electrical component (coupling devices having concentrically or coaxially-arranged contacts H01R24/38) - H01R 13/684: the fuse being removable - H01R 2201/26: for vehicles - Y02E 60/10: Energy storage using batteries - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A manual service disconnect for a battery system includes a disconnect header having a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a control device terminal connector within the receptacle. A disconnect plug is removably coupled to the disconnect header. The disconnect plug has a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector. A current power control device is received in the receptacle and is electrically connected to the control device terminal connector. The current power control device is exposed for servicing when the disconnect plug is removed from the disconnect header and the current power control device is inaccessible when the disconnect plug is coupled to the disconnect header. ## Claims ### Claim 1 A manual service disconnect for a battery system, the manual service disconnect comprising: a disconnect header configured to be mounted proximate to a battery pack, the disconnect header comprising a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a control device terminal connector within the receptacle; a disconnect plug removably coupled to the disconnect header, the disconnect plug having a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector, respectively; and a current power control device received in the receptacle, the current power control device being electrically connected to the control device terminal connector, the current power control device being exposed for servicing when the disconnect plug is removed from the disconnect header, the current power control device being inaccessible when the disconnect plug is coupled to the disconnect header. ### Claim 2 (depends on 1) The manual service disconnect of claim 1, wherein a space is defined in the receptacle between the HVIL connector and the high current terminal connector, the current power control device being positioned in the space. ### Claim 3 (depends on 1) The manual service disconnect of claim 1, wherein the housing includes an open top, the disconnect plug being plugged into the housing to close the open top, the current power control device being covered by the disconnect plug. ### Claim 4 (depends on 1) The manual service disconnect of claim 1, wherein the disconnect header includes a base configured to be mounted directly to the battery pack, and wherein the high current terminal connector, the high voltage interlock connector and the control device terminal connector extend into the battery pack through the base. ### Claim 5 (depends on 1) The manual service disconnect of claim 1, wherein the disconnect header includes a base having a top and a bottom, the housing extending from the top, the bottom being configured to be mounted directly to the battery pack, and wherein the high current terminal connector, the HVIL connector and the control device terminal connector extend from the base below the bottom. ### Claim 6 (depends on 1) The manual service disconnect of claim 1, wherein the current power control device is configured to be disconnected from the control device terminal connector and removed from the disconnect header when the disconnect plug is removed from the disconnect header and after the HVIL shunt terminal and high current fuse are disconnected from the HVIL connector and the high current terminal connector, respectively. ### Claim 7 (depends on 1) The manual service disconnect of claim 1, wherein the high current terminal connector includes a pair of high current terminals, the high current fuse includes a pair of contacts electrically connected to the high current terminals when the disconnect plug is coupled to the disconnect header, the high current fuse defining a fused electrical path between the contacts. ### Claim 8 (depends on 1) The manual service disconnect of claim 1, wherein the HVIL connector includes a pair of HVIL terminals, the HVIL shunt terminal creating a shunt electrical path between the HVIL terminals when the disconnect plug is coupled to the disconnect header. ### Claim 9 (depends on 1) The manual service disconnect of claim 1, wherein the control device terminal connector includes a pair of low current terminals, the current power control device comprising a serviceable fuse, the serviceable fuse electrically connecting the low current terminals when the disconnect plug is coupled to the disconnect header, the serviceable fuse defining a fused electrical path between the low current terminals. ### Claim 10 (depends on 1) The manual service disconnect of claim 1, further comprising a second control device terminal connector and a second current power control device in the disconnect header, the HVIL connector being positioned between the current power control device and the second current power control device. ### Claim 11 (depends on 10) The manual service disconnect of claim 10, wherein the disconnect plug includes a HVIL shroud surrounding the HVIL shunt terminal, the HVIL shroud being positioned between the current power control device and the second current power control device when the disconnect plug is coupled to the disconnect header. ### Claim 12 (depends on 1) The manual service disconnect of claim 1, wherein the current power control device comprises a relay received in the receptacle, the relay being exposed when the disconnect plug is removed from the disconnect header, the relay being inaccessible when the disconnect plug is coupled to the disconnect header. ### Claim 13 A manual service disconnect for a battery system, the manual service disconnect comprising: a disconnect header configured to be mounted proximate to a battery pack, the disconnect header comprising a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a control device terminal connector within the receptacle; a disconnect plug removably coupled to the disconnect header, the disconnect plug having a high current fuse electrically connected to the high current terminal connector when the disconnect plug is coupled to the disconnect header and unmated from the high current terminal connector when the disconnect plug is removed from the disconnect header, the high current fuse forming part of a high current circuit controlling power to the battery pack, the disconnect plug having a HVIL shunt terminal electrically connected to the HVIL connector when the disconnect plug is coupled to the disconnect header and unmated from the HVIL connector when the disconnect plug is removed from the disconnect header, the HVIL shunt terminal controlling power supply on the high current circuit; and a current power control device received in the receptacle, the current power control device being electrically connected to the control device terminal connector, the current power control device being exposed for servicing when the disconnect plug is removed from the disconnect header, the current power control device being inaccessible when the disconnect plug is coupled to the disconnect header. ### Claim 14 (depends on 13) The manual service disconnect of claim 13, wherein a space is defined in the receptacle between the HVIL connector and the high current terminal connector, the current power control device being positioned in the space. ### Claim 15 (depends on 13) The manual service disconnect of claim 13, wherein the housing includes an open top, the disconnect plug being plugged into the housing to close the open top, the current power control device being covered by the disconnect plug. ### Claim 16 (depends on 13) The manual service disconnect of claim 13, wherein the disconnect header includes a base having a top and a bottom, the housing extending from the top, the bottom being configured to be mounted directly to the battery pack, and wherein the high current terminal connector, the HVIL connector and the control device terminal connector extend from the base below the bottom. ### Claim 17 (depends on 13) The manual service disconnect of claim 13, wherein the current power control device is configured to be disconnected from the control device terminal connector and removed from the disconnect header when the disconnect plug is removed from the disconnect header and after the HVIL shunt terminal and high current fuse are disconnected from the HVIL connector and the high current terminal connector, respectively. ### Claim 18 A battery system comprising: a battery pack having a plurality of battery cells in an outer casing; a battery distribution unit controlling power distribution to the battery cells; and a manual service disconnect comprising: a disconnect header coupled to the outer casing of the battery pack, the disconnect header comprising a housing defining a receptacle, a high current terminal connector within the receptacle, a high voltage interlock (HVIL) connector within the receptacle and a control device terminal connector within the receptacle, the high current terminal connector, HVIL connector and control device terminal connector being electrically connected to the battery distribution unit; a disconnect plug removably coupled to the disconnect header, the disconnect plug having a high current fuse electrically connected to the high current terminal connector and a HVIL shunt terminal electrically connected to the HVIL connector; and a current power control device received in the receptacle, the current power control device being electrically connected to the control device terminal connector, the current power control device being exposed for servicing when the disconnect plug is removed from the disconnect header, the current power control device being inaccessible when the disconnect plug is coupled to the disconnect header. ### Claim 19 (depends on 18) The battery system of claim 18, wherein a space is defined in the receptacle between the HVIL connector and the high current terminal connector, the current power control device being positioned in the space. ### Claim 20 (depends on 18) The battery system of claim 18, wherein the disconnect header includes a base having a top and a bottom, the housing extending from the top, the bottom being mounted directly to the battery pack, and wherein the high current terminal connector, the HVIL connector and the control device terminal connector extend from the base below the bottom into the outer casing of the battery pack.