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 4B-4B 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 5B-5B 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 5B-5B 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 12a, an opposite bottom support surface 12b, a support member opening 12c (FIGS. 3A and 3B) formed through and between the top support surface 12a and the bottom support surface 12b and a plurality of support member attachment holes 12d disposed outwardly relative to the support member opening 12c. 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 26a-26b are connected to the fuse connector 22 and circuit wires 28a-28d are connected to the circuit connector 24.
In FIGS. 3-7C, the battery part 14 has a main compartment 14a and a fuse assembly subcompartment 14b. The fuse assembly subcompartment 14b is disposed in the main compartment 14a. The disconnect part 16 has a shielding cover 16a that defines a disconnect part cavity 16b. 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, 5C and 6C, the circuit assembly 18 is disposed in the disconnect part cavity 16b and is also connected to the shielding cover 16a. The fuse assembly 20 is sized and adapted to be releasably received by the fuse assembly subcompartment 14b. The fuse connector 22 and the circuit connector 24 are connected to the battery part 14.
In FIGS. 4A, 4C, 5A, 5C, 6A and 6C, 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 14b 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 14b. Thereafter, the fuse assembly 20 can be detached from the fuse connector 22 and removed from the fuse assembly subcompartment 14b as shown in FIGS. 8A-8C
As shown in FIGS. 1, 3 and 4A-7C 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, 4A, 5A, 6A, 7A, 7B and 8B, the disconnect part 16 includes the shielding cover 16a that has a generally box-shaped configuration. The shielding cover 16a has a base wall 16a1, a front wall 16a2, a rear wall 16a3 and a pair of opposing side walls 16a4 that are connected to each other to define the disconnect part cavity 16b (FIGS. 3A and 3B) which, in turn, also has a generally box-shaped configuration. The disconnect part cavity 16b has a circuit assembly compartment 16c enclosed in the disconnect part cavity 16b as that shown in FIGS. 3A, 3B, 4C, 5C, 6C and 7C. 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 16a as shown in FIGS. 1 and 4A-7C. The U-shaped lever member 30 has a pair of arm members 30a and a cross-member 30b interconnecting the pair of arm members 30a. Respective ones of the pair of arm members 30a are pivotally connected to respective ones of the pair of opposing side walls 16a4. As discussed above, the lever member 30 is operative to move to and between lock position (as best illustrated in FIGS. 4A-C) and the release position (as illustrated in FIGS. 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 16a4 and arm members 30a as best shown in FIG. 1. In FIGS. 3A and 3B, each one of the pair of arm members 30a includes a free end arm portion 30a1 and each free end arm portion 30a1 having a pair of tabs 30a1a and 30a1b 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 30b forwardly of front wall 16a2 when the lever member 30 is in the lock position (FIGS. 4A-4C).
As best shown in FIG. 9, the front wall 16a2 includes a latch projection 38. The latch projection 38 extends from the front wall 16a2. Note that the cross-member 30b includes a living hinge piece 40 that has a latch hole 40a 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 40a. 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 40a. 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 30b is in the lock position, the cross-member 30b is positioned forwardly of the front wall 16a2 as shown in FIGS. 1, 4A and 4C. In the release position, the cross member 30b is positioned above the base wall 16a1 as shown in FIGS. 6A, 6B, 7A and 7B.
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 48a and a bottom mounting plate surface 48b that is disposed apart from the top mounting plate surface 48a. The top mounting plate surface 48a and the bottom mounting plate surface 48b define a mounting plate thickness 48c therebetween. The battery part body member 42 also includes an outer circumferential wall 50 that projects from the top mounting plate surface 48a to define the main compartment 14a and an inner circumferential wall 52 that is disposed apart from the outer circumferential wall 50 and inside the main compartment 14a to define the fuse assembly subcompartment 14b that is disposed in the main compartment 14a.
In FIG. 2, the fuse connector housing unit 44 is connected to the bottom mounting plate surface 48b of the mounting plate 48 and is in communication with the fuse assembly subcompartment 14b. The circuit connector housing unit 46 projects from the bottom mounting plate surface 48b of the mounting plate 48 and extends into and is in communication with the main compartment 14a.
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 50a and a pair of opposing long side walls 50b that interconnect the respective ones of the pair of opposing short side walls 50a. Each one of the pair of opposing long side walls 50b is longer than respective ones of the pair of opposing short side walls 50a.
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 50a. 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 48a 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, 4A, 5A, 6A and 10, each one of the plurality of caps 60 is integrally connected to the bottom mounting plate surface 48b. Also, in FIG. 10, each cap 60 has a cap hole 60a that extends partially into the cap 60. Again, with reference to FIG. 10, the cap hole 60a 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 14a. 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 14a. The circuit connector conduit 64 defines a circuit connector passageway 64a that extends to and between the main compartment 14a and exteriorly of the bottom mounting plate surface 48b. The circuit connector housing unit 46 is in communication with the circuit connector passageway 64a. The circuit connector housing unit 46 includes a circuit connector housing 46a, a circuit connector terminal position assurance device 46b and a circuit connector O-ring seal 46c. The circuit connector housing 46a first receives the circuit connector ring seal 46c and then the circuit connector housing 46a receives the circuit connector terminal position assurance device 46b. The circuit connector terminal position assurance device 46b retains the circuit connector ring seal 46c in the circuit connector housing 46a.
In FIGS. 3, 4A, 5A, 6A and 7A, the circuit connector housing 46a includes a circuit connector terminal arrangement 46a1, a pair of circuit connector internally-threaded tubes 46a2 connected to the circuit connector terminal arrangement 46a1 and a pair of circuit connector thumb screws 46a3. Respective ones of the circuit connector threaded tubes 46a2 rotatably receive respective ones of the pair of circuit connector thumb screws 46a3 for releasably connecting the circuit connector housing unit 46 to the bottom mounting plate surface 48b by threadably engaging mounting plate thumb screw holes 48d shown in FIG. 2.
As best shown in FIGS. 3, 7B and 8B, 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 20a that has a base section 20a1 forming a fuse-receiving compartment 20a2, a cover section 20a3, a pair of tube elements 20a4, a pair of thumb screws 20a5, a fuse 20a6 (FIGS. 3A and 3B) and a pair of busbars 20a7 electrically connected to the fuse 20a6. The cover section 20a3 is sized for removably covering the base section 20a1 in order to enclose the fuse-receiving compartment 20a2. The base section 20a1 has a first pair of opposing base section side walls 20a1a, a second pair of opposing base section side walls 20a1b that are connected to the first pair of opposing base section side walls 20a1a and a base section bottom wall 20a1c (FIGS. 3A and 3B) connected thereto. Respective ones of the tube elements 20a4 are integrally connected exteriorly to respective ones of the first pair of opposing base section side walls 20a1a. Respective ones of the pair of thumb screws 20a5 are rotatably disposed in respective ones of the tube elements 20a4. The fuse 20a6 is disposed in the fuse-receiving compartment 20a2 such that the busbars 20a7 extend from the fuse-receiving compartment 20a2, through busbar-receiving holes 20a8. The busbar-receiving holes 20a8 are formed through the bottom wall 20a1c to communicate exteriorly of the base section bottom wall 20a1c of the base section 20a1.
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 46c, 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, 5A, 6A and 7A, the fuse connector housing unit 44 is connected to the bottom mounting plate surface 48b of the mounting plate 48 and is in communication with the fuse assembly subcompartment 14b. Again, with reference to FIGS. 3 and 10, the fuse assembly O-ring seal 68 sized to surround and contact the base section 20a1 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 12c receives the outer circumferential wall 50 in a manner that the top mounting plate surface 48a and the bottom support surface 12b 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 12d, respective ones of the plurality of fasteners 74 extend through support member attachment holes 12d 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 14b 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 20a1a and the second pair of base section side walls 20a1b of the fuse assembly 20 and an inner circumferential surface 52a 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 44a. Each hollow terminal-receiving tube section 44a defines a terminal-receiving tube section opening 44b thereinto. Further, respective ones of the pair of hollow terminal-receiving tube sections 44a house respective ones of a pair of terminal-receiving tube section O-ring seals 44c. 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 44b.
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 16a 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.
Patent Grant
7704099
