Exchangeable electric vehicle battery receptacle, kiosk, and infrastructure

An exchangeable electric vehicle battery receptacle, kiosk is disclosed herein. The kiosk includes a receptacle, a bell crank and solenoid that lock a battery in the receptacle, and circuitry that dispenses the battery. The bell crank includes a first arm extending into the receptacle and a second arm coupled to an extension spring that is coupled to a fixed point on the kiosk. The battery includes a form factor dimensioned to fit at least partially around the first arm. The solenoid has an armature and is positioned adjacent to the second arm. The armature fixes the bell crank and fixes the extension spring in an extended state, thereby locking the battery in the receptacle slot. The circuitry retracts the armature into the solenoid. A retraction force on the second arm by the extension spring rotates the bell crank, at least partially dispensing the exchangeable battery from the receptacle slot.

TECHNICAL FIELD

The present invention relates to systems and methods that enable operators of electric vehicles (EV) to extend their range by utilizing exchangeable charging batteries.

BACKGROUND

Electric vehicles have been utilized for transportation purposes and recreational purposes for quite some time. Electric vehicles require a battery that powers an electric motor, and in turn propels the vehicle in the desired location. The drawback with electric vehicles is that the range provided by batteries is limited, and the infrastructure available to users of electric vehicles is substantially reduced compared to fossil fuel vehicles. For instance, fossil fuel vehicles that utilize gasoline and diesel to operate piston driven motors represent a majority of all vehicles utilized by people around the world. Consequently, fueling stations are commonplace and well distributed throughout areas of transportation, providing for easy refueling at any time. For this reason, fossil fuel vehicles are generally considered to have unlimited range, provided users refuel before their vehicles reach empty.

On the other hand, owners of electric vehicles must carefully plan their driving routes and trips around available recharging stations. For this reason, many electric vehicles on the road today are partially electric and partially fossil fuel burning. For those vehicles that are pure electric, owners usually rely on charging stations at their private residences, or specialty recharging stations. However specialty recharging stations are significantly few compared to fossil fuel stations. In fact, the scarcity of recharging stations in and around populated areas has caused owners of electric vehicles to coin the phrase range anxiety, to connote the possibility that their driving trips may be limited in range, or that the driver of the electric vehicle will be stranded without recharging options. It is this problem of range anxiety that prevents more than electric car enthusiasts from switching to pure electric cars, and abandoning their expensive fossil fuel powered vehicles.

SUMMARY OF THE INVENTION

An exchangeable electric vehicle battery receptacle, kiosk and infrastructure are disclosed herein. Embodiments generally include an exchangeable battery kiosk with a dual locking and releasing mechanism to secure an exchangeable battery and dispense the exchangeable battery. In one embodiment, a battery-exchange kiosk is disclosed. The kiosk includes at least one receptacle slot, a bell crank and solenoid that lock an exchangeable battery in the receptacle slot, and circuitry that dispenses the battery. The receptacle slot holds the exchangeable battery, which fits at least partially within the receptacle slot. The bell crank includes a first arm extending into the receptacle slot and a second arm coupled to an extension spring that is coupled to a fixed point on the kiosk. The exchangeable battery comprises a form factor dimensioned to fit at least partially around the first arm. The solenoid has an armature and is positioned adjacent to the second arm. The armature fixes the bell crank and fixes the extension spring in an extended state, thereby locking the exchangeable battery in the receptacle slot. The circuitry retracts the armature into the solenoid. A retraction force on the second arm by the extension spring rotates the bell crank, at least partially dispensing the exchangeable battery from the receptacle slot.

In another embodiment, an exchangeable battery is described. The exchangeable battery includes first and second form factors. The first form factor is dimensioned to at least partially fit within a receptacle slot of an exchangeable battery kiosk, where the receptacle slot includes similar features to that described above with regard to the kiosk, such as the bell crank with the first and second arms, the solenoid, and the circuitry. The second form factor is dimensioned to fit at least partially around the first arm. In yet another embodiment, an exchangeable battery housing in an electric vehicle is described. The housing includes features similar to those described above with regard to the kiosk, and is disposed in the electric vehicle.

DETAILED DESCRIPTION

A detailed description of the claimed invention is provided below by example, with reference to embodiments in the appended figures. Those of skill in the art will recognize that the components of the invention as described by example in the figures below could be arranged and designed in a wide variety of different configurations. Thus, the detailed description of the embodiments in the figures is merely representative of embodiments of the invention, and is not intended to limit the scope of the invention as claimed.

The descriptions of the various embodiments include, in some cases, references to elements described with regard to other embodiments. Such references are provided for convenience to the reader, and are not intended to limit the described elements to only the features described with regard to the other embodiments. Rather, each embodiment is distinct from each other embodiment.

Throughout the detailed description, various elements are described as “off-the-shelf.” As used herein, “off-the-shelf” means “pre-manufactured” and/or “pre-assembled.”

In some instances, features represented by numerical values, such as dimensions, quantities, and other properties that can be represented numerically, are stated as approximations. Unless otherwise stated, an approximate value means “correct to within 50% of the stated value.” Thus, a length of approximately 1 inch should be read “1 inch+/−0.5 inch.” Similarly, other values not presented as approximations have tolerances around the stated values understood by those skilled in the art. For example, a range of 1-10 should be read “1 to 10 with standard tolerances below 1 and above 10 known and/or understood in the art.”

FIG. 1depicts one embodiment of an exchangeable battery kiosk according to the claimed invention. Kiosk100includes receptacle slot101, exchangeable battery102, maintenance panel103, user interface104, and assist button105.

As depicted, each battery102includes charging indicator102aand charged indicator102b. Charging indicator102aindicates that battery102is currently charging and is not available for exchange. Charged indicator102bindicates that battery102is fully charged and is available for exchange. Maintenance panel103allows access to internal circuitry and controllers of kiosk100. In some embodiments, kiosk100includes processors, memory, and one or more network connectors, such as a CAT-5 network port or a wireless transceiver. In such embodiments, kiosk100communicates with a remote server information about the kiosk, such as identification of batteries exchanged, unauthorized access attempts, and/or battery and/or charging functioning. The circuitry, memory, and/or processors additionally control receiving and dispensing of batteries102.

In some embodiments, the circuitry, memory, and processors are implemented as a computer internal to kiosk100. The computer, in some such embodiments, associates a battery ID of a returned battery with a user enrolled in a battery exchange co-op. The computer dissociates the user from the returned battery and associates the user with a fully charged battery dispensed to the user. In some further embodiments, the computer communicates the association between the fully charged battery, with a corresponding battery ID, and the user, to a remote server.

Kiosk100is part of an exchangeable battery co-op, described further below with regard toFIG. 7. As depicted, kiosk100includes a plurality of receptacle slots101and a plurality of exchangeable batteries102. In some embodiments, one of the plurality of receptacle slots101is maintained as empty to receive a depleted exchangeable battery102from a user. Each of the other of the plurality of receptacle slots101holds an exchangeable battery. Kiosk100maintains the one empty receptacle slot101by dispensing a fully charged battery102to the user upon receiving the depleted battery102.

FIG. 2depicts a receptacle slot in an exchangeable battery kiosk according to the claimed invention. Kiosk200includes kiosk face201and receptacle slot202. Receptacle slot202is recessed into face201of kiosk200, and is defined by kiosk surfaces having edges201a-d. As depicted, face201is a vertical face of kiosk200. However, in other embodiments, face201is a horizontal face. In yet other embodiments, face201is a sloped face. Receptacle slot202includes open end202aand closed end202b. In some embodiments, open end202ais flush with face201. In other embodiments open end202ais slightly recessed into face201and includes filleting.

FIG. 3depicts an exchangeable battery according to the claimed invention. Battery300includes first form factor301, second form factor302, handle303, grip assist304, electrical contacts305, and identifier306. Exchangeable battery300is one of a plurality of exchangeable batteries in an exchangeable battery co-op. Battery300is any of a variety of rechargeable batteries, such as Lithium Ion batteries. Battery300has, in some embodiments, a specific density ranging from 100-265 Wh/kg. In other embodiments, battery300has a specific density ranging up to 500 Wh/kg or 710 Wh/kg. Additionally, battery300weighs an amount ranging from 5 to 20 lbs. In some embodiments, battery300weighs an amount ranging from 8 to 12 pounds. In yet other embodiments, battery300weighs approximately 10 pounds.

Weight is an important factor for exchangeable batteries, because users must be able to easily lift and move the batteries. 10 pounds has been found to be an optimal weight for exchangeable car batteries, because most adults are capable of easily moving 10 pounds, which is slightly more than a gallon of milk. The energy density of the battery, and the number of batteries included in a vehicle, vary, where higher energy density and more batteries equate to greater range. It has been found that users are discouraged when exchanging batteries if the user has to exchange more than 10 batteries. Thus, an optimal exchangeable battery set for an electric vehicle includes 10 10-pound batteries.

Handle303is disposed on top side300aof battery300, and is used to assist a user in carrying battery300from an electric vehicle to a battery kiosk. In embodiments where receptacles for battery300in the kiosk are on a horizontal or sloped face of the kiosk, and where a receptacle in a battery housing of the electric vehicle is also on a horizontal or sloped face of the housing, handle303is easily used by a user to transfer battery300between the electric vehicle and the kiosk. However, in embodiments where one or both of the housing and kiosk have the receptacles on vertical faces, it is additionally beneficial to have grip assist304. Unlike handle301, which passes completely through battery300and limits space available for cells, grip assist304is an indentation in battery300. Grip assist304aids a user in removing battery300from the receptacles as battery300is dispensed from the receptacles. For example, in one embodiment, the electric vehicle battery housing receptacle is on a horizontal face of the housing, and the kiosk receptacle is on a vertical face of the kiosk. In such an embodiment, a user uses handle303to lift battery300from the electric vehicle, and uses handle303and grip assist304to insert battery300into the kiosk. Similarly, when battery300is partially dispensed from the kiosk having vertical receptacles, grip assist304aids a user in removing battery300from the kiosk. In some embodiments, grip assist304is rubberized to increase a user's grip on battery300.

FIGS. 4A-Ddepict various views of an exchangeable battery and receptacle slot according to the claimed invention. Receptacle slot401holds exchangeable battery402. Receptacle slot401includes open end401aand closed end401b. Battery402includes first form factor402a, which is dimensioned to at least partially fit within receptacle slot401. Receptacle401further includes bell crank403, which has first arm403aextending into receptacle401and second arm403bcoupled to extension spring404. Extension spring404is additionally coupled to a fixed point on a battery kiosk or electric vehicle housing. Battery402includes second form factor402b, which is dimensioned to fit at least partially around first arm403a. Inserting battery402into receptacle401such that first arm403afits into second from factor402bcauses bell crank403to rotate around pivot point403c. Solenoid405includes armature405aextended outwards from solenoid405by a compression spring. Armature405ahas locking side405band pressing side405c. Solenoid405is positioned adjacent to second arm403bsuch that rotation of bell crank403caused by insertion of battery402into receptacle401causes second arm403bto slide across pressing side405c, pressing armature405ainto solenoid405and compressing the compression spring. Further insertion of battery402causes second arm403bto slide past armature405a. The compression spring forces armature405aout of solenoid405, and a retracting force of extension spring404on second arm403bforces second arm403bagainst locking side405bof armature405a. In this way, solenoid405and bell crank403lock battery402in receptacle401. In some embodiments, one or more of bell crank503and armature405aare comprised of steel to ensure security of battery402in receptacle401.

As described above, when a user inserts a depleted battery into a co-op kiosk, the kiosk dispenses a charged battery to the user. To dispense the battery, the kiosk further includes circuitry406, which communicates with battery ID reader407, electrical contacts408, and solenoid405. Upon insertion of the depleted battery, circuitry406recognizes that electricity of flowing to the depleted battery, charging the battery. Upon recognizing a depleted battery has been inserted, circuitry406identifies a solenoid associated with a receptacle holding a fully charged battery. Circuitry406activates solenoid405, retracting armature405ainto solenoid405. The retraction force on second arm403bby extension spring404rotates bell crank403about pivot point403c, forcing first arm403aagainst wall402cof second form factor402band sliding fully charged battery402at least partially out of receptacle401.

Battery ID reader407reads a battery ID (such as ID306inFIG. 3) of battery402. In some embodiments, battery ID reader407identifies battery402upon receiving a notification that batter402is locked into receptacle401. This prevents circuitry406from triggering the release of a fully charged battery before the depleted battery has been fully secured. Otherwise, in some cases, a user inserts a depleted battery only partially but retains the depleted battery and the charged battery.

FIGS. 5A-Bdepict a lift assist arm and exchangeable battery housing in an electric vehicle. As described above with regard toFIG. 3, battery weight can be a limiting factor for a battery exchange co-op. In some embodiments, therefore, kiosk501includes lift assist arm502. Lift assist arm couples to battery503and assists a user in moving the battery. For example, in one embodiment, lift assist arm includes hook502athat loops through a handle of battery503.

In some electric vehicle embodiments, it is beneficial to distribute weight forward of the front tires. Thus, as depicted inFIGS. 5A-B, battery housing504of electric vehicle505is disposed at least partially forward of front tires505aof electric vehicle505. Housing504includes at least one receptacle slot, such as those described above with regard toFIGS. 1-2 and 4, that holds battery503. In some such embodiments including housing504forward of front tires505a, it is necessary to position electric motor506behind front tires505ato accommodate housing504.

FIG. 6depicts an anti-theft design of an exchangeable battery receptacle slot. Receptacle slot601includes dimensions slightly larger than battery602. In order for battery602to be inserted into receptacle601, spaces603a-cmust be present; otherwise, it will be too difficult to insert battery602into receptacle601. Spaces603a-crange in size from fractionally larger than 0 mm each to 3 mm each. The sum of spaces603a-calong any single axis is referred to herein as tolerance. In the depicted embodiment, battery602dimensions are within a tolerance of one or more receptacle601dimensions.

One particular problem facing electric vehicle battery exchange systems is that electric vehicle batteries are expensive, and thus prime targets for theft. This is balanced against the need for simple, easily-maintained systems. Locking the batteries in an enclosed kiosk and dispensing them from the enclosed kiosk adds complexity and thus increases the need for maintenance and the potential for failures. The receptacle described above addresses this issue by using inexpensive parts that are easy to maintain and replace. However, having an open-air kiosk presents the potential for theft. One way to thwart potential theft is to have close tolerances of dimensions between the battery and the receptacle so that a thief cannot insert prying devices. However, this is balanced against the ease of inserting the battery into the receptacle; the closer the tolerances, the more precise a user has to be in inserting the battery. This can be particularly difficult with heavy batteries. An optimal tolerance that allows for simple inserting but thwarts theft ranges from more than 0 mm to 5 mm, and depends, in some embodiments, on environmental factors such as temperature fluxuations. In one embodiment, an optimal tolerance is 1 mm.

FIG. 7depicts an embodiment of an exchangeable electric vehicle battery co-op. User701purchases electric vehicle702from dealer703. Additionally, user701purchases batteries704from co-op705, thereby joining co-op705. A new and unused set of batteries704is introduced to co-op705as new user701joins co-op705. In some embodiments, membership in co-op705requires a monthly or annual fee. In other embodiments, membership in co-op705requires a periodic fee in addition to a use fee. In one alternative embodiment, user701purchases electric vehicle703, which comes with batteries704. Co-op705purchases user's701batteries by granting user701free membership and/or an amount of free use of co-op batteries. Once user701is a member of co-op705, user701can exchange batteries704at any co-op kiosk706.