Swappable modulated battery packs system for electrically driven vehicle

A system for swappable battery pack for electric vehicle is disclosed. Each battery pack units is comprising a battery compartment housing, a battery carrier rack which is slidable within the battery compartment housing via at least one linear actuator. The battery carrier rack also contains a plurality of modulated battery packs nested into its docking enclosures. In order to transfer or swap the modulated battery packs, the slidable battery carrier rack must projects out from its compartment in predetermined direction and distance and then the nested modulated battery packs can easily be detached from its docking enclosures.

FIELD OF THE INVENTION

The present invention relates to electrical vehicle battery packs. More particularly the arrangement of battery packs that are modulated and swappable.

BACKGROUND OF THE INVENTION

Architecturally, an electric vehicle battery pack is comprised of multi-battery modules, fuses, bus bars and safety circuitry system which are combined into one large battery enclosure. Combining all the parts in one package makes the battery pack very heavy. Due to the size and weight of the battery pack, the electric vehicle has limited range of travel. And in case of traveling a long distance journey, normally a diver has to stop at several charging stations to recharge the battery, and recharging the battery is time consuming for drivers and some don't have that much time to waste.

The idea of swappable large battery pack with a fresh battery pack was proposed many times before, and seems to solve the problem neatly. But it has not been done by auto industry for many reasons. One of the reasons is that battery pack is not standardized due to its shape and capacity among auto-industry. The second issue is the battery packs are heavy and usually weights around 500 lbs to 900 lbs and exchanging these batteries are huge tasks. The third problem is the high cost associated with maintaining a standing store of fresh packs at battery station.

However, this invention overcomes the shortcomings and solving some of the problems associated with large battery pack that exist today. The new vehicle's battery pack system replaces the huge battery pack with several battery pack arrangement units. Each units contains smaller modulated battery packs. The small size and weight of these modulated battery packs, allow driver to quickly exchange the depleted batteries with charged ones at battery exchange station with respect to charging the battery pack for few hours. Also it is easier to check these swappable battery packs for defective module and monitor each one of them either by an automated exchange/charging station or manually by auto technician.

The use of small modulated battery packs is an important factor for auto-industry to standardized EV battery. For example electronic devices uses standard batteries (e.g. AAA, AA, C, D batteries, etc.), the electric vehicle's battery packs can also be standardized for E-bike, E-scooters, and EV cars, EV buses and etc. Such standards will advances electric vehicle into next level for more practical use.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a system for electric vehicle's battery pack. This system provides multi battery pack units. Each unit comprising a battery compartment housing, a battery carrier rack which is slidable within the battery compartment housing via at least one linear actuator. The battery carrier rack also contains a plurality of modulated battery packs nested into its docking enclosures. In order to transfer or swap the modulated battery packs, the slidable battery carrier rack projects out from its compartment in predetermined direction and distance and then the nested modulated battery packs can easily be detached from its docking enclosures.

It is another object of this invention to add arrays of battery pack units as needed to provide extra mileage for the electric vehicle. The battery pack unit can be placed and located anywhere in the vehicle even on the roof with respect to direction of slidablities of battery carrier rack.

It is yet another object of this invention to secure modulated battery packs in proper position to its docking terminals due to vehicle vibrations and road bumps. Since the modulated battery packs are removable and transferable, it must be connected surely and securely to vehicle connector via guided tracks and spring-loaded rollers. Otherwise any loose connections would result in loss of power.

It is yet another object of this invention to show the method of swapping the modulated battery packs with regards to its arrangements from vehicle to an automated battery transfer/charge station and vice versa.

Further objects and advantages of this invention will become apparent from consideration of the drawings and descriptions that follow.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1-3are illustrating a series of battery pack arrangement units12a,12b,12c, which are positioned underneath an electric vehicle10. These battery pack units are flushed at the bottom of the vehicle10when assembled and it can be placed and orientated anywhere underneath the vehicle. Preferably, these battery pack units12a,12b,12c, are located near the rear end of the vehicle10. Each battery pack unit comprising a battery compartment housing14, a battery carrier rack22which carries a plurality of small modulated battery packs16. Each modulated battery pack16is placed into a docking enclosure24.

In order to extend out battery carrier rack22from its battery compartment housing which is affixed to vehicle, at least one motor20is activating the linear actuator18and the battery carrier slides out in linear direction. The battery compartment housing also shaped in a way to create rigid track14afor sliding battery carrier rack. If the motor20malfunction, the carrier can manually geared down from the bottom by using the actuator's shaft. Once the battery carrier rack is out of its compartment, the modulated battery packs can be accessed as seen inFIG. 4-5. When modulated battery packs are exposed, it can easily be swap or replaced by either automated battery transfer station or by a auto technician.

FIG. 6is also showing a sectional side view of one of the battery pack unit. Modulated battery pack16is shown in nested docking enclosure24and secured by top and side spring-loaded rollers34, in which the battery case positions itself with its indentations36. Battery electrical connections are done by blind mate connection to a receptacle30at the end of docking enclosure24. The battery pack plug in connector38and its terminal38amate with docking enclosures receptacle connector30and its terminals30awhen the battery pack is pushed in such that the battery pack will provide power to electric vehicle.

For placement of the battery pack16into the its docking enclosure24, a set of rollers32are provided at the bottom side of enclosure. Simply the battery pack16enters the open end26of the docking enclosure24and rolls into position with minimum applicable force. The docking enclosures24may also have an open end on both side or partially open on one end28. The open ends docking enclosure are for replacing & transferring the battery pack from both ends. In some cases the docking enclosure may need to have one open end and the other end is sealed, be closed the battery pack can be replaced from the open end only.

Referring toFIG. 7-11, modulated battery pack16optionally can be made of two main pieces which can fastened or snapped together. The battery pack may have a lower portion16amade of waterproof and fire retardant aluminum or stainless steel which contains all battery cells such as polymer Li-Ion cells, and the upper portion16bcontains blind mate plug in connectors38,38aat each ends, and monitoring circuitry42. The monitor circuitry is for balancing the amount of charge or discharge that battery cells required. It is best to monitor each battery pack per module. The two piece design of battery pack is also good practice for recycling all parts.

Each modulated battery pack size can be as small as E-bike's battery pack, which is approximately 11.9″ in length (L), 4.9″ in height (H), and 2.6″ in width (W). The battery pack may also include a charge status indicator44in front portion of battery case to monitor the energy level of the battery pack. An auto technician can visually check each battery packs before any testing or replacing.

FIG. 12is showing an alternative embodiment112aof the present invention to provide even more low profile battery pack unit. The modulated battery packs116are positioned and reoriented on its sides to save more space with respect to battery pack unit arrangement in vehicle. A rubber seal114around the bottom edge of battery carrier rack seals the battery compartment when the battery unit is in retracted position. The rubber seal114prevents any debris to enter into the battery compartment and when it is in seal position, it is flush with the bottom surface of vehicle.

Now referring toFIG. 13, a low profile battery transfer/charge station60showing in conjunction with vehicle's battery pack units12a,12b,12c. After vehicle's computer80send signals for data exchange with battery station computer transceiver82, the first battery pack unit12aposition itself in extended position and gets ready for transferring its depleted battery packs. At this time, battery station exchanging assembly unit68will adjust itself to the proper position with respect to X, Y and Z coordinates via related sensors and actuator. Once it is positioned to vehicle battery carrier rack22, an empty switchable battery magazine70will be deployed by station computer to be in front of vehicle's battery carrier rack as shown inFIG. 14.

InFIG. 15, a depleted battery is pushed away into the station magazine70by a linear actuator78. Once the depleted battery nested into station's magazine and its docking enclosure, it will be connected to battery station charging system and battery station start the charging process.

For delivery of charged battery packs from station to vehicle battery carrier rack, battery station deploy a battery magazine70with fully charged battery packs. As seen inFIG. 16, the fully charged battery pack pushed away from station magazine70into vehicle's battery carrier rack22via an actuator72. At this time the vehicle receives fully charged modulated battery packs. The battery carrier rack retracts into its compartment and electric vehicle waits for a new signal from station for of the next transfer process. Meanwhile, the station exchange assembly68, reposition itself for the next battery transfer.

FIG. 17-18illustrates a linear actuator with applicable suction force. Alternatively, this type of actuator can transfer the modulated battery packs via its pull or push force. The linear actuator72uses the suction force via a suction cup the applied to battery pack frontal face and then actuator can pull the battery pack from its position and displace it into station magazine70. Another advantage of applying the suction force is for better grip or control over the battery pack displacement process.

FIG. 19shows that vehicle battery pack16can be automatically get charged via a linear actuator84with plug in probe86. Vehicle battery pack unit may also have a main charging receptacle connector92,92ain the battery carrier rack for receiving automated plug in probe86as shown inFIG. 20. In some cases that battery packs doesn't need to be replaced and vehicle is parked, the battery packs can be charged automatically without any manual plug in. This automated charging device can be part of a battery station or it can be part of a separate plug in charging unit.

FIG. 20illustrate possible terminal connections between the modulated battery pack and its docking enclosure. In this configuration the battery pack94can be transfer at either end of its docking enclosure. The provided terminal contacts on the battery's top and side surface96makes proper connections with the enclosure terminal contacts98.

While this invention is susceptible of embodiments in many different forms, this specification and the accompanying drawings disclose only some specific forms as examples of the invention. The invention is not intended to be limited to the embodiments so described; however, the scope of the invention is pointed out in the appended claims.