System for electrically connecting batteries to electric vehicles

The connection system is designed to facilitate electrical and data connections between the battery and the electric vehicle. The connectors are designed with alignment mechanisms to account for initial misalignment of the battery and vehicle while still ensuring positive contact between them. The alignment mechanisms also introduce compliance into the system to ensure that the mechanical components of the system are not placed under unwanted loads or stresses. The connection system houses data connectors carrying communication signals as well as power connectors carrying high voltage electricity. The data connectors are shielded to prevent interference caused by proximity to the high voltage elements. The connection system uses no mechanical latching or locking mechanisms.

TECHNICAL FIELD

The disclosed embodiments relate generally to electric vehicles with removable battery packs. In particular, the disclosed embodiments relate to connector mechanisms for establishing electrical and data connections between a removable battery pack and an electric vehicle.

BACKGROUND

The vehicle (e.g., cars, trucks, planes, boats, motorcycles, autonomous vehicles, robots, forklift trucks etc.) is an integral part of the modern economy. Unfortunately, fossil fuels, like oil which is typically used to power such vehicles, have numerous drawbacks including: a dependence on limited foreign sources of fossil fuels; these foreign sources are often in volatile geographic locations; and such fuels produce pollution and climate change. One way to address these problems is to increase the fuel economy of these vehicles. Recently, gasoline-electric hybrid vehicles have been introduced, which consume substantially less fuel than their traditional internal combustion counterparts, i.e., they have better fuel economy. However, gasoline-electric hybrid vehicles do not eliminate the need for fossil fuels, as they still require an internal combustion engine in addition to the electric motor.

Another way to address this problem is to use renewable resource fuels such as bio-fuels. Bio-fuels, however, are currently expensive and years away from widespread commercial use.

Yet another way to address these problems is to use clean technologies, such as electric motors powered by fuel cells or batteries. However, many of these clean technologies are not yet practical. For example, fuel cell vehicles are still under development and are expensive. Batteries are costly and may add as much as 40% to the cost of a vehicle. Similarly, rechargeable battery technology has not advanced to the point where mass-produced and cost effective batteries can power electric vehicles for long distances. Present battery technology does not provide an energy density comparable to gasoline. Therefore, even on a typical fully charged electric vehicle battery, the electric vehicle may only be able to travel about 40 miles before needing to be recharged, i.e., for a given vehicle storage, the electric vehicles travel range is limited. Furthermore, batteries can take many hours to recharge. For example, batteries may need to be recharged overnight. As the charging time of a typical electric vehicle battery can last numerous hours and recharging may not be an option on a long journey, a viable “quick refuel” system and method for battery powered electric vehicles would be highly desirable.

The existing art utilizes permanent batteries that can be re-charged. However, in some embodiments described herein removable batteries are utilized. In these embodiments forming an electrical connection where there is an initial misalignment between the battery and the vehicle can be challenging. In the batteries described herein, both power connections and data connections are encompassed in the same electrical connection system. The high voltage power connection creates electromagnetic interference with the data connection if the connections are in close proximity. The data connection and power connection can be moved far apart from each other such that they do not interfere. However, moving these connectors away from each other requires creating two separate connection assemblies, which adds cost and complexity to the system.

Accordingly, it would be highly desirable to provide a system for addressing the above described drawbacks.

SUMMARY

In order to overcome the above described drawbacks, a network of charge spots and battery exchange stations are deployed to provide the EV (electric vehicle) user with the ability to keep his or her vehicle charged and available for use at all times. Some embodiments provide a system and method to quickly exchange, a spent depleted (or substantially discharged) battery pack for a fully charged (or substantially fully charged) battery pack at a battery exchange station. The quick exchange is performed in a period of time significantly less than that required to recharge a battery. Thus, the long battery recharge time may no longer be relevant to a user of an electric vehicle who is traveling beyond the range of the battery.

Furthermore, the cost of the electric vehicle can be substantially reduced because the battery of the electric vehicle can be separated from the initial cost of the vehicle. For example, the battery can be owned by a party other than the user of the vehicle, such as a financial institution or a service provider. These concepts are explained in more detail in U.S. patent application Ser. No. 12/234,591, filed Sep. 19, 2008, entitled Electronic Vehicle Network, incorporated herein by reference. Thus, the batteries may be treated as components of the electric recharge grid (ERG) infrastructure to be monetized over a long period of time, and not a part of the vehicle purchased by the consumer.

The following provides a detailed description of a system and method for swapping-out or replacing battery packs in electric vehicles. Some embodiments provide a description of the quick exchangeable battery packs attached to the vehicle.

Some embodiments provide a battery bay configured to be disposed at an underside of an at least partially electric vehicle. The battery bay includes a frame that defines a cavity configured to at least partially receive a battery pack therein. In some embodiments, the frame of the battery bay forms part of the structure of the vehicle body and is not a separate component. The battery bay also includes at least one latch mechanism rotatably pivoted about an axis substantially parallel with a plane formed by an underside of the vehicle (and/or the surface on which the vehicle is configured to travel, e.g., the road). The latch mechanism is configured to retain the battery pack at least partially within the cavity. In some embodiments, an additional latch is rotatably pivoted about an additional axis substantially parallel to and distinct from the first axis. In some embodiments, the axis and the additional axis are substantially perpendicular to a length of the vehicle.

In some embodiments, a transmission assembly is mechanically coupled to the latch and the additional latch, the transmission assembly is configured to simultaneously rotate the latch and the additional latch in rotational directions opposite to one another. In some embodiments, an electric motor is mechanically coupled to the frame for driving the transmission assembly. In some embodiments, the transmission assembly is configured to be driven by a rotation mechanism external to the vehicle.

Some embodiments provide a method of removing a battery pack from an underside of an at least partially electric vehicle. The method includes rotating a latch mechanism mechanically coupled to a vehicle so as to disengage contact between the latch and a battery pack disposed at an underside of at least partially electric vehicle. The battery pack is then translated away from the underside of the vehicle. In some embodiments, the method of removal involves, prior to the rotating, mechanically disengaging a first lock mechanism. In some embodiments, the method of removal involves, prior to the rotating, electronically disengaging a second lock mechanism. In some embodiments, the method of removal involves occurs in less than one minute.

Some embodiments provide another method of coupling a battery pack to an electric vehicle. The method of coupling includes substantially simultaneously engaging a first latch located at a front end of the underside of the electric vehicle with a first striker located at a front end of a battery pack and a second latch located at a back end of the underside of the electric vehicle with a second striker located at a back end of a battery pack. Then, the battery pack is substantially simultaneously locked into the electric vehicle by rotating the first and second latches into their respective physical lock positions. In some embodiments, the method of coupling further comprises substantially simultaneously vertically lifting the battery pack into the electric vehicle by rotating the first and second latches in opposite directions, which engages with and raises the battery pack.

Some embodiments provide a battery system that includes a battery bay for receiving a battery pack. The battery bay is located at an underside of the electric vehicle. The battery bay includes a first latch configured to mechanically couple a front end of the battery pack to a front end of the underside of the electric vehicle, and a second latch configured to mechanically couple a back end of the battery pack to a back end of the underside of the electric vehicle. The first latch and the second latch mechanically couple the battery pack to the underside of the electric vehicle by engaging, vertically lifting, and locking the front and back ends of the battery pack to the electric vehicle substantially simultaneously.

Some embodiments provide a battery system that includes a battery pack configured to be mechanically coupled to an underside of an electric vehicle, a first latch configured to mechanically couple a proximate end of the battery pack to a proximate end of the underside of the electric vehicle, and a second latch configured to mechanically couple a distal end of the battery pack to a distal end of the underside of the electric vehicle. The first latch and the second latch mechanically couple the battery pack to the underside of the electric vehicle substantially simultaneously.

In some embodiments, the battery bay includes a latch that is attached to the frame at a first side of the cavity. The battery bay also includes at least one additional latch attached to the frame at a second side of the cavity opposite the first side of the cavity. The additional latch is rotatably pivoted about another axis substantially parallel with the plane formed by the underside of the vehicle. The additional latch is configured to retain the battery pack at least partially within the cavity.

In some embodiments, the battery bay's latch has a proximate end which rotates about the axis and a distal end remote from the proximate end that is configured to engage a bar shaped striker on the battery pack. In some embodiments, the distal end of the latch has a hook shape.

In some embodiments, the frame is formed integrally with a frame of the vehicle. In some embodiments, the frame is a separate unit configured to attach to the at least partially electric vehicle. In some embodiments, the frame is located between a front axle and a rear axle of the partially electric vehicle. In some embodiments, the frame defines a substantially rectangular shaped opening, having two long sides and two short sides. In some embodiments, the frame defines an opening having five, six, or more sides defining any shape configured to receive a corresponding battery pack. In some embodiments, the long sides extend along axes substantially parallel (or near parallel) with an axis extending from the front to the back of the vehicle. In some embodiments, the frame defines a substantially cuboid shaped cavity for at least partially receiving the battery pack therein.

In some embodiments, the battery bay has one or more vibration dampers that are disposed between the frame and the at least partially electric vehicle.

In some embodiments, the latch and the additional latch substantially simultaneously rotate in opposite directions about their respective axes. In some embodiments, the battery pack is engaged and locked into the at least partially electric vehicle when the latches substantially simultaneously rotate towards one another. In some embodiments, the battery pack is disengaged and unlocked from the at least partially electric vehicle when the latches substantially simultaneously rotate away from one another.

In some embodiments, the latch and the additional latch are configured to mechanically decouple the battery pack from the underside of the at least partially electric vehicle substantially simultaneously.

In some embodiments, the latch (or latch mechanism) is part of a four bar linkage mechanism. In some embodiments, the four bar linkage mechanism includes: a latch housing, a input link including a first pivot point and a second pivot point, wherein the first pivot point is pivotably coupled to a proximate end of the latch housing; a latch including a third pivot point and a fourth pivot point; and a coupler link rod including a first rod end and a second rod end. The fourth pivot point is pivotably coupled to a distal end of the latch housing. The first rod end is pivotably coupled to the second pivot point of the input link. The second rod end is also pivotably coupled to the third pivot point of the latch.

In some embodiments, the coupler link rod includes an adjustment bolt configured to adjust a length of the coupler link rod. In some embodiments, when the input link is in a first position, the latch is configured to mechanically decouple from a striker of the battery pack. In some embodiments, when the input link is in a second position, the latch is in an engaged position configured to mechanically couple to a striker of the battery pack and the input link, the coupler link rod, and the hook are in a geometric lock configuration. In some embodiments, the latch is configured to raise the battery pack along an axis substantially perpendicular to the plane formed by the underside of the vehicle.

In some embodiments, the battery bay further comprises a battery pack, which comprises: at least one rechargeable battery cell that stores electrical energy, and a housing at least partially enclosing the at least one rechargeable battery cell. The housing further comprises at least one striker having a bar shape, that is configured to engage with the latch.

In some embodiments, the housing of the battery pack has a height substantially less than its length, wherein a portion of the housing includes a heat exchange mechanism that has at least a portion thereof exposed to ambient air at the underside of the vehicle when the battery pack is attached to the vehicle. In some embodiments, the battery pack, when attached to the vehicle, at least partially protrudes below the plane of the underside of the electric vehicle. In some embodiments, a portion of the housing includes a heat exchange mechanism that has at least a portion thereof exposed to ambient air at the underside of the vehicle, when the battery pack is attached to the vehicle. In some embodiments, the heat exchange mechanism is selected from at least one of: a heat sink; a heat exchanger; a cold plate; and a combination of the aforementioned mechanisms. In some embodiments, the heat exchange mechanism is a cooling mechanism that includes a duct running through the housing. In some embodiments, the cooling duct includes a plurality of fins. In some embodiments, the cooling duct includes a scooped inlet. In some embodiments, the scooped inlet contains a filter to prevent debris from entering the cooling duct.

In some embodiments, the battery bay further includes a battery pack. The battery pack includes a housing configured to substantially fill a cavity in a battery bay of the vehicle. The housing includes: a first side wall; a second side wall opposing the first side wall; at least one first striker disposed at the first side wall having a bar shape wherein the central axis of the first striker is parallel to the first side wall; at least one second striker disposed at the second side wall having a bar shape wherein the central axis of the second striker is parallel to the second side wall; and at least one battery cell that stores electrical energy. The battery cell is at least partially enclosed within the housing. In some embodiments the bar shaped strikers have some anti-friction attachments such as roller bearings or low friction surface treatments.

In some embodiments, the frame of the battery bay further includes at least one alignment socket configured to mate with at least one alignment pin on the battery pack.

In some embodiments, the frame of the battery bay further includes at least one compression spring coupled to the battery bay, wherein the at least one compression spring is configured to generate a force between the battery bay and the battery pack when the battery pack is held at least partially within the cavity.

In some embodiments, the transmission assembly further includes: a plurality of latches mechanically coupled to a first torque bar. The first torque bar is configured to actuate the latches. Additional latches are mechanically coupled to a second torque bar. The second torque bar is configured to actuate the additional latches. Furthermore, the first torque bar and the second torque bar are configured to substantially simultaneously rotate in opposite directions. In some embodiments, the first torque bar is located at a side of the battery bay nearest to a front end of the vehicle. The second torque bar is located at a side of the battery bay nearest to a back end of the vehicle.

In some embodiments, the transmission assembly further includes a first gear shaft coupled to a first torque bar via a first worm gear set, and a second gear shaft coupled to a second torque bar via a second worm gear set. The first gear shaft and the second gear shaft substantially simultaneously rotate in opposite directions causing the first torque bar and the second torque bar to substantially simultaneously rotate in opposite directions via the first worm gear set and second worm gear set. In some embodiments, the first gear shaft comprises two shafts joined by a universal joint. In some embodiments the design may include left and right worm gear set, a design which does not require the gear shafts to rotate in opposite directions.

In some embodiments, the transmission assembly further includes a miter gear set coupled to the first gear shaft and a second gear shaft. The miter gear set is configured to synchronously rotate the first and second gear shafts in opposite directions.

In some embodiments, the transmission assembly further includes a drive motor coupled to the miter gear set via a gear ratio set. The drive motor is configured to rotate the first and second gear shafts in opposite directions via the gear ratio set and the miter gear set.

In some embodiments, the transmission assembly further includes a drive socket located at an underside of the electric vehicle. The socket is coupled to the central gear of the miter gear set. Rotation of the socket actuates the miter gear set. In some embodiments, the drive socket has a non-standard shape for receiving a socket wrench having a head corresponding to the non-standard shape.

In some embodiments, the transmission assembly further includes a miter gear lock configured to prevent the miter gear set from rotating. In some embodiments, the miter gear lock is configured to be released with a key. In some embodiments, the key physically unlocks the miter gear lock. In some embodiments, miter gear lock is spring loaded.

In some embodiments, the battery bay further includes one or more latch locks, which when engaged, are configured to prevent the at least one latch from rotating. In some embodiments, the latch lock further includes a lock synchronization bar coupled to the one or more latch locks and a lock actuator coupled to the lock synchronization bar. The lock synchronization bar is configured to actuate the one or more latch locks. The lock actuator is configured to actuate the lock synchronization bar. In some embodiments, the one or more latch locks are lock bolts. In some embodiments, the lock actuator is coupled to an electric motor configured to actuate the lock synchronization bar via the lock actuator. In some embodiments, the lock synchronization bar is configured to rotate the one or more latch locks in a first direction so that the one or more latch locks become engaged, and wherein the lock synchronization bar is configured to rotate the one or more latch locks in a second direction so that the one or more latch locks become disengaged.

In some embodiments, the battery bay further comprises one or more latch locks, which when engaged, are configured to prevent the at least one latch from rotating. The one or more latch locks are configured to disengage only when the miter gear lock has been released.

In some embodiments, the battery bay further comprises a latch position indicator configured to determine an engaged position and a disengaged position of the latch.

In some embodiments the latches are synchronized electronically without the presence of mechanical coupling. An individual latch unit, containing internal electric motor and transmission performs the latching operation. A control unit is utilized to synchronize and control the operation of all latches.

The engaging (coupling) and disengaging (uncoupling) of a removable battery pack may happen many times over the lifecycle of the at least partially electric vehicle. In some embodiments, the battery pack and vehicle should withstand up to 3000 cycles of engaging and disengaging. In some embodiments, the components should withstand up to 5000 cycles. Once coupled or engaged, a high electrical voltage and current may be transmitted between the battery pack and the vehicle for the battery pack to power the electric vehicle. In some embodiments, the battery pack also contains circuitry to communicate data to the vehicle. Such “smart” batteries provide information to the vehicle's computer systems regarding battery charge, battery health, remaining range, or other pertinent information. In these embodiments, a data signal path is also formed between the battery pack and the vehicle in each engagement. In order for the power connection and the data connection to be formed, the power and data contacts on the battery pack and the electrical and data contacts on the vehicle must be properly aligned with one another. For example, the small data and power pins and sockets should be precisely aligned to form appropriate electrical connections. Furthermore, the data and power connectors must remain in contact with each other and withstand rigorous factors caused by daily driving such as vertical and horizontal shock and vibration, impact etc.

This connection system described herein provides for a quick connect/disconnect system that compensates for misalignments that may occur between the battery-side connector and the vehicle-side connector during the removal and replacement of the battery. These embodiments provide structural flexibility for the coupling portions of the battery and vehicle to be moved into proper alignment through alignment mechanisms such as pin and socket alignment mechanisms. These embodiments also provide one or more misalignment relief mechanisms. Specifically, at least one connector in connection system includes a coupler designed to allow movement between a fixed mounting portion directly attached to the battery or vehicle respectively and a free coupling portion containing the data and power interfaces of the connector. In some embodiments, the allowed movement there between is horizontal, or substantially parallel to the X-Z plane of the underside of the vehicle. In some embodiments, the allowed movement is also vertical. In some embodiments, the coupler includes a spring which in addition to aiding in compensating for misalignments also provides vertical force to keep the electrical and data components connected to one another. Some of these embodiments also employ data and power sockets with conductive mesh sleeves capable of remaining in electrical contact with their corresponding data and power pins despite the vibration and jarring of daily driving and are further capable of withstanding the 3000 or more engagement cycles.

In some embodiments, the data connection between the battery pack and the vehicle are both located in the same electrical connection system having precise alignment capabilities. In other words, a single battery side connector component contains both data and power interfaces, and a single vehicle side connector component also contains both data and power interfaces. One advantage of providing a data connection and a power connection in the same electrical connection system is that one electrical connection system can be used to align both power and data interfaces simultaneously. However, data communication conductors are susceptible to electromagnetic interference caused by proximity to high voltage or high current conductors. Sometimes electromagnetic interference can be overcome by maintaining a substantial distance between any high voltage or high current conductor and any data or signal conductors. However, given the desire to minimize the number of connection points requiring precise alignment between the vehicle and the battery, in some embodiments, it is beneficial to include both power and data interfaces on the same connector system components. In these embodiments, it is impractical to maintain adequate distances between the data and the power conductors to overcome electromagnetic interference. Instead, a shielding mechanism is provided in order to allow the use of a single connector for both data and power while preventing undesirable electromagnetic effects caused by the data conductor's proximity to power conductors. In embodiments of an electrical connection system that have both electrical connectors and data connectors on the same connector components, the electrical connection system also has shielding mechanisms that shield data interfaces from electromagnetic interference caused by high voltage electrical interfaces located near one another in the connection system. In some embodiments, the data connectors and the electrical connectors are within one inch of each other. In other embodiments the electrical and data connections are located on separate connection systems each having separate alignment mechanisms like those of the electrical connection system described below.

Another noteworthy element of the embodiments described herein is the lack of any latching mechanisms on the electrical connection system itself. These embodiments do not require additional clamping or latching mechanisms to ensure positive contact between the power and data interfaces. Instead, the components of the electrical connection system embodiments are held in contact with one another through the latch mechanisms in the battery bay. Because the alignment mechanisms employed in the connection system embodiments compensate for initial misalignments between the battery pack and the vehicle, battery packs can be quickly removed and inserted into the vehicle's battery bay without additional concern for latching or aligning a complicated electrical connector. Additionally, the latching mechanism secures the battery with adequate force to maintain the connection between the vehicle-side and battery-side connectors. By reducing the steps and complexity of the battery swapping process, electric vehicles are more convenient for everyday use.

Some embodiments provide an electrical connection system for a battery of an at least partially electric vehicle. The electrical connection system utilizes a shielding mechanism with the vehicle-side connector and the battery-side connector as follows. The vehicle-side connector is configured to permanently attach to an underside of an at least partially electric vehicle. The battery-side connector is configured to permanently attach to a battery pack. The battery-side connector is configured to mate to the vehicle-side connector. The battery-side connector and the vehicle-side connector also are configured to removably couple to each other, along an axis substantially perpendicular to the underside of the at least partially electric vehicle. Each electrical connector includes a high voltage interface for transmitting high voltage electricity between the electrical connectors and a data interface for transmitting data between the electrical connectors. The electrical connection system also includes a shielding mechanism to counteract electromagnetic effects caused by the high voltage connection elements. In some embodiments, the shielding mechanisms separate the data interface from the high voltage interface to counteract electromagnetic effects caused by the high voltage connection elements. In some embodiments, the shielding mechanism comprises a housing that substantially covers the data interface. In some embodiments, the housing is L-shaped.

In some embodiments, the electrical connection system further comprises a sealing mechanism positioned between the first and second electrical connectors for preventing environmental contamination when the first and second electrical connectors are coupled.

In some embodiments, the high voltage interface includes conductive pins; and sockets for receiving the conductive pins. Furthermore, the sockets are made of a conductive mesh sleeve for forming an electrical connection with the conductive pins. Similarly, in some embodiments, the data interface also has pins and sockets where the sockets are made of a conductive mesh sleeve. In other embodiments the data interface comprises a fiber optic interface.

In some embodiments, the high voltage electricity is between about 100 and 1000 VDC. In other embodiments, the high voltage electricity is between about 200 and 800 VDC. In yet other embodiments, the high voltage electricity is between about 350 and 450 VDC.

Some embodiments provide an electrical connection system for a battery of an at least partially electric vehicle. The electrical connection system utilizes a coupling mechanism for compensating for misalignment between the vehicle-side connector and the battery-side connector as follows. The electrical connection system includes a first electrical connector, a second electrical connector, and a coupler for compensating for misalignment between the first and second electrical connectors. The first electrical connector is configured to mount to an underside of an at least partially electric vehicle. It includes a first coupling portion for mating with a second coupling portion of a second electrical connector. The second electrical connector is configured to mount to a battery and comprises a second coupling portion for mating with the first coupling portion of the first electrical connector. Located there between is coupler for compensating for misalignment between the first and second electrical connectors. The first and second coupling portions include a high voltage interface for transmitting high voltage electricity and a data interface for transmitting data between the first and second coupling portions. In some embodiments, the coupling portion is on the vehicle side connector. In other embodiments the coupling portion is on the battery side connector.

In some embodiments, the connection system for a battery of an at least partially electric vehicle includes one or more coupling portions for compensating for misalignment between the vehicle-side connector and the battery-side connector as follows. A first electrical connector is configured to mount to an underside of an at least partially electric vehicle. The first electrical connector includes a first coupling portion for mating with a second coupling portion of a second electrical connector, a first mounting portion for attaching the first electrical connector to the at least partially electric vehicle, and a first coupler for attaching the first coupling portion to the first mounting portion. The first coupler allows relative motion between the first coupling portion and the first mounting portion. A second electrical connector is configured to mount to a battery. The second electrical connector includes a second coupling portion for mating with the first coupling portion of the first electrical connector. The first coupler compensates for misalignment between the first and second electrical connectors. The first and second coupling portions include a high voltage interface for transmitting high voltage electricity and a data interface for transmitting data between the first and second coupling portions. In some embodiments, the second electrical connector also includes a second mounting portion for attaching the second electrical connector to the battery and a second coupler for attaching the second coupling portion to the second mounting portion. The second coupler allows for relative motion between the second coupling portion and the second mounting portion. The second coupler also compensates for misalignment between the first and second electrical connectors.

In some embodiments, the first coupler is configured to allow the first coupling portion to move in vertical and horizontal planes with respect to the first mounting portion. In some embodiments, the first coupler is made of a hole in the first coupling portion and a bolt rigidly attached to the first mounting portion and extending through the hole in the first coupling portion, where the bolt has a smaller diameter than the hole. In some embodiments, the first coupler further includes a coil spring positioned between the first coupling portion and the first mounting portion. In some embodiments, the bolt extends through the center of the coil spring.

In some embodiments, the first coupling portion of the electrical connection system of claim includes a pin and a socket. The pin and socket are configured to ensure lateral alignment between the first and second coupling portions. In some embodiments, the inside surface of the socket is a channel having an oval cross section. The channel has an inside surface larger than the pin to allow for space between a portion of the inside surface of the channel and a portion of the outside surface of the pin.

The above described embodiments address one or more previously mentioned drawbacks. For example, misalignment between the electrical interface components of a battery and its corresponding bay in an electric vehicle are compensated for by the alignment and misalignment compensation mechanisms described. Furthermore, electromagnetic interference caused by high voltage power connections is overcome or alleviated by various shielding mechanisms. In some embodiments, both misalignment and electromagnetic interference are addressed using a combination of the above described features making a robust battery exchanging system capable of withstanding may exchange cycles.

DESCRIPTION OF EMBODIMENTS

FIG. 1illustrates an electric vehicle network100, according to some embodiments. The electric vehicle network100includes a vehicle102and a battery pack104configured to be removably mounted to the vehicle102. In some embodiments, the battery pack104includes any device capable of storing electric energy such as batteries (e.g., lithium ion batteries, lead-acid batteries, nickel-metal hydride batteries, etc.), capacitors, reaction cells (e.g., Zn-air cell), etc. In some embodiments, the battery pack104comprises a plurality of individual batteries or battery cells/chemical modules. In some embodiments, the battery pack104also comprises cooling mechanisms, as well as mechanical and electrical connectors for connecting to the vehicle102or to the various elements of the battery exchange station134. These mechanical and electrical connectors will be described in further detail below.

In some embodiments, the vehicle102includes an electric motor103that drives one or more wheels of the vehicle. In these embodiments, the electric motor103receives energy from the battery pack104(shown separate from the vehicle for the ease of explanation). The battery pack104of the vehicle102may be charged at a home130of a user110or at one or more charge stations132. For example, a charge station132may be located in a shopping center parking lot. Furthermore, in some embodiments, the battery pack104of the vehicle102can be exchanged for a charged battery pack at one or more battery exchange stations134. Thus, if a user is traveling a distance beyond the range of a single charge of the battery of the vehicle, the spent (or partially spent) battery can be exchanged for a charged battery so that the user can continue with his/her travels without waiting for the battery to be recharged. The battery exchange stations134are service stations where a user can exchange spent (or partially spent) battery packs104of the vehicle102for charged battery packs104. The charge stations132provide energy to charge the battery pack104while it is coupled to the vehicle102. These components of the network100are connected to related power and data networks, as explained in more detail in U.S. patent application Ser. No. 12/234,591, filed Sep. 19, 2008, entitled Electronic Vehicle Network, the disclosure of which is incorporated herein by reference.

FIGS. 2A-2Bare side and bottom views of an at least partially electric vehicle102. The vehicle102includes a removable battery pack104(sometimes herein referred to just as a battery) attached to the vehicle102at its underside. In some embodiments, the battery pack104is substantially flat and runs along at least a portion of the length of the vehicle102; i.e., along the longitudinal X-axis of the vehicle. In some embodiments, the battery104may protrude below the plane204of the underside of the vehicle102, i.e., protruding in the negative Y-axis direction. Protruding from the underside of the vehicle is helpful for air cooling the battery pack104, as the protruding battery pack is exposed to ambient air flow. In embodiments with air scoops, discussed below in relation toFIG. 6, at least the air scoop intake will be exposed to ambient air at the underside of the vehicle102to receive air flow when the vehicle102is moving forward. In some embodiments where the battery pack is retrofitted to a vehicle, i.e., after-market, the battery pack may protrude from the bottom of the vehicle.

When the battery104, or portions thereof, protrude from below the plane of the underside204of the vehicle102, it may, however, be unsightly. Therefore, in some embodiments, cosmetic fairings202are attached to the vehicle to hide the battery pack104. In some embodiments, the cosmetic fairings202also produce a smooth outline and reduce drag. These cosmetic fairings202may be mounted on any or all of the front, sides, and rear of the vehicle.

FIGS. 3A and 3Bare underside perspective views of the electric vehicle102and battery pack104ofFIG. 1.FIG. 3Ashows the battery pack104mounted in a battery bay108.FIG. 3Bshows the battery pack104removed from the battery bay108. The battery bay108includes a frame118that defines the outline of a cavity302disposed at the underside of the vehicle102. The cavity302is configured to at least partially receive the battery pack104therein. In some embodiments, the bay frame118has a substantially rectangular shape, for at least partially receiving a substantially cuboid or rectangular parallelepiped battery pack104therein. In some embodiments, the frame118has two long sides along at least part of the length of the vehicle102(parallel to the X-axis) and two shorter sides along at least part of the width of the vehicle (parallel to the Z-axis) as shown. In some embodiments, the long sides of the frame118extend along axes substantially parallel with an axis extending from the front to the back of the vehicle102(parallel to the X-axis). In some embodiments, the battery bay108is located under the vehicle floor boards, between the rear and front axles of the vehicle102.

In some embodiments, the cavity302into which the battery bay108is inserted uses existing volumes which are normally occupied by the fuel tank and muffler in a traditional gasoline or hybrid vehicle. In such a manner, the storage and/or passenger volume is not substantially impacted by the addition of the battery pack104. In some embodiments, the vehicle body floor structure is shaped as a basin to accommodate the battery pack. The location of the battery bay108at or near the bottom of the vehicle lowers the vehicle's center of mass or gravity, when the battery pack104is coupled to the vehicle, which improves the cornering, road-holding, and performance of the vehicle. In some embodiments, the battery bay108is located within zones of the vehicle that are designed to not buckle during front or rear collisions to protect the battery pack104.

In some embodiments, the battery bay108is a self-contained unit. In some embodiments, the battery bay structural connections to the vehicle frame (or unibody) are made through flexible vibration dampers (not shown). This allows the battery bay108to not interfere with the natural bending and torsion deflection of the vehicle frame. In some embodiments, the connections to the vehicle frame are made using removable fasteners such as bolts. In other embodiments the battery bay104is substantially permanently mounted to the vehicle by welding or other means.

The battery bay108is designed to withstand the load factors required by an original equipment manufacturer, national safety standards, or international safety standards. In some embodiments, the battery bay108is designed to withstand the following load factors:Normal Operating Conditions: +/−1.5 G Fxand Fz, and +/−4 G Fy, which may be substantially continuously oscillating at 1-100 Hz, where Fx, Fy, and Fzare the forces in the X, Y, and Z directions respectively. In some embodiments, at this condition substantially no plastic deformation of the battery bay108will occur.Exceptional Operating Conditions: +/−12 G Fxand Fz, and +/−8 G Fy, which are not substantially continuously oscillating. In some embodiments, at these conditions substantially no plastic deformation of the battery bay108will occur.Crash Conditions: +/−30 G in Fxand Fz, and +/−20 G Fy.

In some embodiments, during Normal and Exceptional Operating Conditions, the battery pack104does not substantially rock, rattle, or otherwise move.

In some embodiments, the mechanical connection between the battery bay108and the vehicle frame is provided during the assembly of the vehicle102. In other words, the battery bay108is a separate unit configured to attach to the at least partially electric vehicle102. In some embodiments, the separate unit style battery bay108is retrofitted to a hybrid or internal combustion engine vehicle either before or after market. In other embodiments, the design of the battery bay108is formed integrally with a frame of the vehicle102.

FIG. 4is a perspective view of an embodiment of the battery pack104. In some embodiments, the battery pack104has a height (h or H) substantially less than its length (L). In some embodiments, the battery104has a first portion401being substantially long and flat and a second portion402being shorter and thicker than the first portion, i.e., the first portion401has a height (h) significantly less than the height (H) of the second portion402. In some embodiments, the second portion402has a greater height (H) as it is configured to fit under or behind the rear passenger seats or in a portion of the trunk, and as such does not significantly impact the passenger space inside the electric vehicle. In some embodiments, the volume of the battery pack104is 200 to 300 liters. In some embodiments, the weight of the battery pack104is 200-300 kg.

In some embodiments, the battery pack104is an at least partially sealed enclosure which is built to substantially enclose and absorb an explosion of battery cells/chemical modules (502,FIG. 5) within the battery pack. The sealed enclosure of the battery pack104is made of materials that are able to substantially withstand damage caused by dust, dirt, mud, water, ice, and the impact of small rigid objects. Suitable materials include some plastics, carbon fibers, metals, or polymers, etc. In some embodiments, an external cover on the battery pack104protects and insulates the internal components of the battery from harsh environmental conditions and penetration of moisture or fuel vapors.

In some embodiments, a battery management system (BMS)406in the battery pack104manages the charging and the discharging cycles of the battery pack. The BMS406communicates with the vehicle onboard computer to report on the battery's state of charge and to alert of any hazardous operating conditions. In some embodiments, during charging, the BMS406communicates with the battery charge station132. In some embodiments, the BMS406can communicate with the vehicle onboard computer via a 9-pin connector. The number of pins in the connector varies depending on the connector design. In some embodiments, the BMS406is able to arm and disarm the electric power connector between the battery pack104and the vehicle102by cutting the current to the connector using a switching device located in the battery pack104. In some embodiments, the BMS406handles substantially all aspects of battery safety issues during charging, operation and storage.

FIG. 5is a perspective view of the battery pack104with the battery pack chemical modules502that receive, store, and discharge electric energy. The modules502are housed within a battery pack housing504. These chemical modules502are sometimes referred to herein as rechargeable battery cells502. In some embodiments, a plurality of chemical modules502are disposed within the battery pack104. In other embodiments, at least one chemical module502is used. In most embodiments, each chemical module502is rechargeable but there may be instances where a one time use emergency battery could be used. The chemical modules502are re-charged as a group at either a charge station132or at a charging portion of a battery exchange station134, based on parameters set and controlled by the BMS.

FIG. 6is a perspective view of an embodiment wherein the battery pack104includes a cooling system which dissipates heat from the battery pack104. In some embodiments, a portion of the battery pack's housing504includes a heat exchange mechanism with at least a portion thereof exposed to ambient air at the underside of the vehicle102when the battery pack104is attached to the vehicle. In some embodiments, the heat is conducted from the modules502to a heat exchanger or heat sink at the bottom section of the battery pack. In some embodiments, the cooling system includes-openings404in the external cover, which fluidly communicate with one or more cooling ducts602that direct ram air flow past the battery to further dissipate heat generated by the battery. In some embodiments, the cooling ducts602run the entire length of the battery pack104while in other embodiments the ducts take any appropriate path to best cool the modules502. In some embodiments, the cooling ducts602direct air through heat exchangers which dissipate heat from the battery pack modules. In some embodiments, the cooling ducts602also include cooling fins604therein. In some embodiments, air cooling is accomplished by electric fans. In some embodiments, the inlet404comprises a scoop606for directing ram air through the ducts602while the vehicle is in motion. In some embodiments, the scoop606contains a mesh cover608for preventing debris from entering the cooling ducts602.

FIG. 7is a perspective view of the battery pack104and battery bay frame as viewed from the underside of the battery pack. In some embodiments, the battery pack104includes another cooling system made up of dimples or cavities702. The dimples/cavities702are located in the bottom surface of the battery pack104, which runs along the bottom of the vehicle, to be exposed to air passing over them when the vehicle102is in motion. Even when the vehicle is stopped, heat generated by the battery is dissipated due to its large surface area and shaded location on the underside of the vehicle. The dimples/cavities702increase the overall surface area of the bottom of the battery pack, which further helps to cool the modules502. In some embodiments, the increased surface area is sufficient for cooling, and ducts and/or heat exchangers are not necessary. In some embodiments, this increased surface area is used in conjunction with one or more of the previously described cooling mechanisms (such as the cooling ducts with fins described inFIG. 6, or the heat sink and heat exchanger also described above.)

In some embodiments, battery pack cooling systems, such as those described above in relation toFIGS. 6 and 7, are capable of dissipating a majority of the heat generated during full power operation and/or during the charging process. In some embodiments, the cooling systems are capable of dissipating 3 KW of heat. The exact amount of heat emitted from the battery varies from one design to another. In some embodiments, the heat from the cooling systems described above is substantially emitted to the environment rather than to other parts of the vehicle102.

FIG. 7also shows an embodiment with a plurality of pilot holes704on the underside of the battery pack104. These pilot holes704mate with locating pins on an exchange device platform discussed in application No. 61/166,239 (filed Apr. 2, 2009, entitled Battery Exchange Station and incorporated herein) to help properly align the exchange device platform with the battery pack104. In some embodiments, one pilot hole is present. In other embodiments, two or more pilot holes are present. The embodiment ofFIG. 7shows pilot holes on either side of every striker on the battery. In some embodiments, the pilot holes704exist in the frame of the battery bay rather than the battery, and function substantially the same, i.e., to facilitate proper alignment of the exchange platform during a battery exchange operation.

FIG. 8is a perspective view of another embodiment a battery pack806. The battery pack806has a first portion401being substantially long and flat; a second portion402being shorter and thicker than the first portion; and a third portion403of the battery pack104being long and thin and running substantially the length of the first portion401with a height larger than the first portion401but smaller than or equal to the height of the second portion402. The third portion403of the battery104protrudes in the Y-direction from the first portion401along a central axis in the X-direction formed between the driver and passenger seats, as shown. Still other embodiments (not shown) have a substantially cuboid shape, without two differently shaped portions. Other embodiments may have more complex shapes. For example, some embodiments are taller than they are wide. Embodiments of this general shape are sometimes located behind a passenger space, rather than underneath it.

In some embodiments, the battery pack104includes one or more pins802to align the battery104with the battery bay108of the vehicle102. The pins802may also be used to prevent the battery pack from being inserted in the battery bay108in the wrong direction. For example, the pins at the battery and corresponding openings in the battery bay may be keyed to one another.

In some embodiments, the battery pack housing504further comprises bar shaped strikers1924, which are firmly attached to the battery pack housing and configured to carry the entire weight of the battery pack104, i.e., the battery pack can be suspended from the strikers1924when they are engaged with latches1920(FIG. 19A) on the battery bay108. All versions of the battery pack104also contain an electrical connector804(discussed below in relation toFIG. 9), for quickly and safely connecting and disconnecting the battery pack104to and from the vehicle102. In some embodiments the electrical connector804is located on the third portion403of the battery104, but in other embodiments, it may be located anywhere on the pack.

FIG. 9is a detailed perspective view of the electrical connection system900. This figure shows both the battery electrical connector804as well as the corresponding battery bay electrical connector902which mate together to form the electrical connection system900. The battery electrical connector804is attached to the battery pack104by means of a base unit916. Similar attachment mechanisms are used to attach the battery bay electrical connector902to the frame118of the battery bay108or to the electric vehicle102directly. In some embodiments, the electrical interface between the battery bay108and the battery pack104(i.e. the connection between the bay electrical connector902and the battery pack electrical connector804) allows for quick connect/disconnection between the pack and the bay or vehicle.

Both connectors also include electric shields904to shield the electro-magnetic forces of the connections from interfering with the chemical modules/battery cells502. The electric shield may be grounded. In some embodiments, the electric shield904also comprises an O-ring913to prevent moisture and debris from fouling the electrical connectors and causing electrical shorts and/or fires. The alignment between the bay electrical connector902and the battery pack electrical connector804is facilitated by one or more tapered alignment pins912and corresponding alignment receptacles or sockets914. In some embodiments, the alignment pins912are on the battery pack electrical connector804while the alignment sockets/receptacles914are on the bay electrical connector902. In other embodiments, the arrangement is transposed. In some embodiments, the pins912are keyed to one another to prevent inappropriate mating of the electrical connectors.

In some embodiments, the electric connections between the battery bay108and the battery pack104have two separate groups of connectors. The first group of connectors is for power (approximately 400 VDC, 200 Amp) to and from the battery pack104. The second group of connectors910is for data communications (5-12V, low current.) In some embodiments, the connector has 9 pins. In other embodiments the connector will have more or fewer pins than 9.

In some embodiments, the first group of connectors includes a first pair of connectors906for power to the battery pack104from a charging mechanism. In some embodiments, the charging mechanism is a stand alone charging station132that connects to the vehicle102and charges the battery pack104while it is still coupled to the vehicle (as shown inFIG. 1). In some embodiments, the charging mechanism is incorporated into a portion of the battery exchange station (134,FIG. 1), where the depleted/discharged battery pack104that has been removed from a vehicle102is charged again before being inserted into a vehicle. In some embodiments, the first group of connectors also includes a second pair of connectors908to provide power from the battery pack104to the electric motor103.

In some embodiments, the battery electrical connector804as well as the corresponding battery bay electrical connector902mate together as a result of the translation of the battery pack104into the battery bay108. Both the battery electrical connector804as well as the corresponding battery bay electrical connector902have some flotation, i.e., they can travel a few millimeters to the left and right. The male connector (battery bay electrical connector902in this embodiment) has alignment pins912which penetrate into sockets914in the female connector (the battery electrical connector804in this embodiment). The connection between the pins912and the sockets914and this aligns the two parts of the electrical connection system900during the translation of the battery pack104to its final position in the battery bay108. The flotation of the two parts of the electrical connection system900allows some misalignments (due to production and assembly tolerances) of the two connector parts.

In some embodiments, the electrical connectors906,908, and910in the electrical connection system900align and connect themselves automatically only after the mechanical connections (i.e., the locking of the battery pack104into the battery bay108by means of the latch mechanisms1016,1018in the transmission assembly1000, described inFIGS. 10 and 19) have been established.

FIG. 10is a perspective top side view of one embodiment of the battery pack104connected to the battery bay108. In this embodiment the battery pack104and battery bay108are substantially cuboid/rectangular parallelepiped in shape. This embodiment includes a battery electrical connector1022being on one side of the first portion401.

In some embodiments, the battery bay108includes a battery bay transmission assembly1000. The transmission assembly1000is a grouping of gears, rotating shafts, and associated parts that transmit power from a drive motor1310or alternatively from an external/manual rotation source (such as the wrench received within a drive socket1308shown inFIG. 13). The latch mechanisms1016,1018as will be explained in detail below with regard toFIG. 19.

In some embodiments, the transmission assembly1000includes a first gear set1002(such as a miter gear set) which drives a first gear shaft1004and a second gear shaft1006in opposite directions. The rotational force about the Y-axis by the drive motor1310or manual rotation is translated by the first gear set1002into equal and opposite rotational forces of the gear shafts1004,1006about the X-axis. The first gear shaft1004is attached to a second gear set1008(such as a first worm gear set). The second gear shaft1006is attached to a third gear set1010(such as a second worm gear set). The second and third gear sets1008,1010, which are discussed in more detail below with respect toFIG. 12, connect each gear shaft1004,1006to respective torque bars1012,1014which permits the power flow to turn a corner around the battery bay. In other words, the rotational force of the gear shaft1004about the X-axis is translated by the gear set1008into a rotational force of torque bar1012about the Z1-axis, while at the same time the rotational force of gear shaft1006about the X-axis (in an equal and opposite direction to that of gear shaft1004) is translated by gear set1010into a rotational force of torque bar1014about the Z2-axis (in an equal an opposite direction to the rotation of torque bar1012.) By this means, the transmission assembly1000drives the torque bars1012,1014to substantially simultaneously rotate in equal but opposite directions.

In some embodiments, the torque bars1012,1014and gear shafts1004,1006are at right angles to one another respectively. In some embodiments, the torque bars1012,1014and gear shafts1004,1006form an obtuse angle with each other, and in further embodiments they form an acute angle with one another. In this embodiment second gear set1008connects the first gear shaft1004to the first torque bar1012, and the third gear set1010connects the second gear shaft1006to the second torque bar1014. As such, in some embodiments, the first gear shaft1004and the second gear shaft1006substantially simultaneously rotate in opposite directions causing the first torque bar1012and the second torque bar1014to substantially simultaneously rotate in opposite directions via the second gear set1008and third gear set1010.

The embodiment shown inFIG. 10shows two latch mechanisms1016,1018attached to each torque bar1012,1014. These latches1016,1018hold the battery pack104at least partially inside the battery bay108during normal operation of the vehicle.

Some embodiments include one or more first latches1016coupled to the first torque bar1012and one or more second/additional latches1018coupled to the second torque bar1014. The first torque bar1012is configured to actuate the first latch mechanism(s)1016, whereas the second torque bar1014is configured to actuate the second latch mechanism(s)1018. When more than one of the first latches1016or second latches1018are attached to each torque bar1012,1014the torque bar ensures that the plurality of latches actuated and thus rotating substantially simultaneously with each other.

At least one latch lock mechanism1020prevents the latches1016,1018from releasing the battery104from the battery bay108until the lock is disengaged as described in more detail in relation toFIG. 20. In some embodiments, only one latch lock mechanism1020is used, while in other embodiments at least one latch lock mechanism1020is attached to each torque bar1012,1014. In some embodiments, the latch lock1020is electronically activated, while in other embodiments it is mechanically activated.

In some embodiments, the first torque bar1012is located at a side of the battery bay108nearest to the front end of the vehicle102, and the second torque bar1014is located at a side of the battery bay108nearest to the rear of the vehicle, or the arrangement may be transposed. The gear sets and mechanisms of the transmission assembly may be located anywhere so long as the torque bars1012,1014are driven in opposite directions simultaneously at the same angular velocity to actuate the latch mechanisms1016,1018.

FIG. 11is a perspective view of another embodiment of a battery bay108. This embodiment also includes a first gear set1002(such as miter gear set) that drives a first gear shaft1004and a second gear shaft1006in opposite directions. In this embodiment, however, the battery bay's frame is not rectangular in shape. Instead, along one side of the battery bay108, the second gear shaft1006is made up of three portions, a first gear shaft link1102connected by a first universal joint1104to a second gear shaft link1106, and a third gear shaft link1108connected by a second universal joint1110to a third gear shaft link1112. In this manner the first gear shaft1006is bent to accommodate for other components of the electric vehicle102. As such, the battery bay108cavity has a smaller volume than it would have were the first gear shaft1006a single straight component extending from the first gear set1002.

FIG. 11also shows a lock synchronization bar1112in the transmission assembly1000which is located near each torque bar1012(FIG. 10),1014. Each lock synchronization bar1112is attached to a latch lock mechanism1020to keep its respective latch mechanisms1016,1018from releasing, as will be explained in detail below with respect toFIG. 20.FIG. 11also shows springs1806in the latch mechanisms1016,1018which are located on either side of the latch1920as explained in more detail inFIG. 18.

It should be noted that while various forms of shafts and gear sets have been described above, in other embodiments the driving torque can be transmitted to the latches by using other types of drive components such as belts, pulleys, sprockets drive chains.

FIG. 12shows one embodiment of the second and third gear sets1008,1010. In some embodiments the gear sets1008,1010are each made up of a helical gear1202and a spur gear1204. In some embodiments, the helical gear1202is a worm gear. In operation, the rotation of the helical gear1202, which is connected to the gear shafts1004,1006, rotates the corresponding torque bar1012,1014by means of interlocking teeth on the helical gears1210and spur gear1204. The precise number and configuration of teeth on the helical gear1210and the spur gear1204varies depending on the particular electric vehicle102. For example, in some embodiments the helical gear1202is significantly longer and has more threading, while in some embodiments, the spur gear1204gear has more teeth, or forms a complete circle. In other embodiments the diameter of the helical gear1202is larger than the proportions shown inFIG. 12. In normal operation, the helical gear1202turns the spur gear1204in one direction to engage the latch mechanisms1016,1018by which the battery104is lifted and locked into the battery bay108, and the helical gear1202turns the spur gear1204in the opposite direction to disengage the latch mechanisms1016,1018and allow the battery104to be removed from the battery bay108.

FIG. 13shows a detailed view of one embodiment of the first gear set1002. In some embodiments, the first gear set1002is a miter gear set. In some embodiments, the miter gear set1002comprises three helical bevel gears; including a central gear1302coupled to a first outer gear1304and a second outer gear1306. As the central gear1302rotates it drives the first outer gear1304in a first rotational direction and the second outer gear1306in a second rotational direction opposite of the first rotational direction. The first outer gear1304drives the first gear shaft1004, while the second outer gear1306drives the second gear shaft1006. As such, the rotation of the central gear1302drives the first gear shaft1004in a first rotational direction by means of the first outer gear1304while simultaneously/synchronously driving the second gear shaft1006in a second rotational direction by means of the second outer gear1306. In some embodiments, the first gear set1002, specifically the central gear1302is driven by the rotation of a drive socket1308located at the underside of the electric vehicle102. To turn the gear1308, the shaft is mechanically rotated, such as by an Allen or socket wrench1314configured to mate with the drive socket1308. In some embodiments, the female drive socket1308has an unusual or non-standard shape such that it can only receive a particular shaped Allen or socket wrench1314made to mate with the non-standard shaped drive socket1308.

In some embodiments, the transmission assembly1000is driven by an electric drive motor1310through the drive motor gear ratio set1312. The gear ratio set1312drives the first gear set1302, which drives the first gear shaft1004and the second gear shaft1006simultaneously in opposite directions to eventually simultaneously actuate the latch mechanisms1016,1018as described above with relation toFIG. 10. In some embodiments, the drive motor1310is used in most circumstances to rotate the shafts1004,1006, while the drive socket1308is only used for manual override situations. In some embodiments, the drive socket1308is the preferred means for driving the first gear set1002.

As shown inFIGS. 23A and 23B, in some embodiments, the transmission assembly1000encompasses a second gear set1008which is a right worm gear set and third gear set1010which is a left worm gear set. When right gear set1008and the left worm gear set1010are used in the transmission assembly1000, the first gear shaft1004and the second gear shaft1006need not be driven to rotate in opposite directions about the X-axis. Instead, the torque bar1012is driven about the Z1-axis and torque bar1014is driven about the Z2-axis (in an equal an opposite direction to the rotation of torque bar1012) by means of the opposite threading on the right and left worm gears (1008,1010). In other words, the pitch of the threading on the right worm gear1008is opposite to the pitch of the threading on the left worm gear1010. As such, the first gear set1002need not be a miter gear set as shown inFIG. 13, but is instead a simpler gear set shown inFIG. 23B. In other words, because the right and left worm gears1008,1010translate the motion of the first gear set1008in directions opposite from one another due to their opposing thread pitch, the shafts1004,1006can rotate the same direction, and a complex miter gear set is not needed at the point of actuation of the shafts1004,1006.

FIG. 14shows a bottom perspective view of another embodiment of the drive socket1308as viewed from the underside of the at least partially electric vehicle102. In some embodiments, the drive socket1308is accessible through a hole in the battery pack housing1400. In other embodiments, the drive socket1308is accessible at the side of the cavity302in the battery bay108. In some embodiments, the first gear set1002is driven by the socket wrench1314only after a key1602has been inserted into a key hole1402and unlocks the first gear set1002as described inFIG. 17. Like the drive socket1308, in this embodiment, the key hole1402is also located at the underside of the electric vehicle102and requires a hole in the battery housing1400. In other embodiments, the key hole1402is in the battery bay108.

FIG. 15is a perspective view of one embodiment of a first gear lock1502(which in some embodiments is the miter gear lock). In this embodiment, when a key is inserted into the key hole1402, as depicted by the arrow in the figure, the first gear lock1502rotates upward and disengages from a small gear on the shaft1004and thus is unlocked. Then, the first gear set1002can then perform its function of rotating the central gear1302, which drives the first gear shaft1004in a first rotational direction by means of the first outer gear1304while simultaneously driving the second gear shaft1006in a second rotational direction (opposite the first rotational direction) by means of the second outer gear1306. When the key is removed the first gear lock1502rotates downward and engages the small gear on the shaft1004and thus locks it. In the embodiment shown inFIG. 15, the electric drive motor1310of the transmission assembly1000is located above the first gear set1002, and as such does not require a drive motor gear set1312as described inFIG. 13.

FIG. 16is a perspective view of a second embodiment of the gear lock1600. In this figure the key1602is shown outside of the key hole1402. In some embodiments, the key hole1402is located close to the drive socket1308. In some embodiments, the key1602has a specific and unconventional shape for mechanically releasing the second embodiment of the gear lock1600, explained in more detail below, while avoiding other components of the first gear set1002.

FIG. 17is a detailed view of the key1602inserted into the key hole1402and releasing the first gear lock1502. InFIG. 17, the first gear lock1502is positioned in-between the motor1310and the gear set1312. In some embodiments, the key1602unlocks the first gear lock1502by pushing a locking latch1702with a locking tooth1704away from a locking gear1706. In some embodiments, the locking latch1702is designed to be biased into its locked position, i.e., mated with the locking gear106, as soon as the key1602is removed. In some embodiments, a spring1708is attached to the locking latch1702to provide the biasing force, while in other embodiments gravity or other mechanisms for biasing the locking latch1702may be used. In some embodiments, the key1062remains in the inserted position throughout the battery exchange process. In other embodiments the key1602is only required to originally unlock the first gear lock1502, but is not required to remain in place throughout the battery exchange process.

In all of the embodiments of the key1602and first gear lock1502, like those shown inFIGS. 15-17, the first gear set1002is kept from rotating until the key1602unlocks the gear lock1502. As such, the shafts1004,1006, torque bars1012,1014, and their corresponding latch mechanisms1016,1018will not turn unless the gear lock1502has been unlocked. Furthermore, in some embodiments, a latch lock mechanism1020(described in relation toFIG. 20) must also be unlocked before the process to actuate the latch mechanisms1016,1018can begin. In some embodiments, the latch lock mechanism and the gear lock1502are independent of one another, and are individually/independently released before the transmission assembly1000can be actuated. In some embodiments, the latch lock mechanism1020is electrically actuated, and the gear lock1502is mechanically activated or vice versa. Activating the two different locks by two separate mechanisms (mechanical and electrical) prevents unauthorized or inadvertent removal of the battery pack104from the vehicle102. Furthermore, in some embodiments, all of the locks are equipped with indicators which indicate possible failure before, during, or after the battery exchange process.

An actuator located on board the vehicle102actuates one or both of the above described locks. In some embodiments, the actuator is operated by a single 5V 15 mA digital signal, which is sent from an onboard computer system on the vehicle. In some embodiments, the actuator is protected against excessive power flow by indicators. In some embodiments, other types of mechanical or electro-mechanical actuators may be used to remove the safety locks.

FIG. 18shows a battery bay108with several alignment sockets/holes1802configured to receive tapered alignment pins802disposed on the battery104. This figure shows an embodiment with two alignment sockets1802and alignment pins802, but in some embodiments, only one alignment socket1802and pin802are used. In some embodiments, the aligned pins802and the alignment holes have keyed shapes different from one another to prevent backwards or incorrect alignment of the battery pack104with the battery bay108. In some embodiments, at least one compression spring1806is mounted to the battery bay108. The compression springs1806are configured to generate a force between the frame118battery bay108and the battery pack104when the battery pack104is held and locked at least partially within the cavity302of the battery bay108. Thus, the springs1806absorb vertical motion (Y-axis motion) of the battery pack104and bay108during driving or other operations. Also, the compression springs1806help maintain the latches1920in contact with the strikers1924on the battery locked position, and also help expel the battery104from the battery bay108when the locks are unlocked.FIG. 18shows compression springs1806on either side of each latch1920. Matching compression springs1806on either side of the latches balance each other such that the resulting force on the battery is substantially in a vertical (Y-axis) direction only. Other embodiments use greater or fewer compression springs1806. In some embodiments, other types of flexible mechanical parts are used to preload the latches. For example, rubber seals are used instead of the springs1806.

FIG. 18shows an embodiment having three strikers1924. The strikers inFIG. 18are not bar shaped, as they are shown in other figures, but instead are rounded cut away portions in the frame118of the battery pack104itself. Other embodiments employ non-bar shaped strikers as well. In some embodiments, the strikers have different forms. In some embodiments, the strikers contain low friction solutions. Examples of low friction solutions include but are not limited to roller bearings or low friction coatings, as shown inFIG. 19A, element1930.

FIG. 19Ashows one embodiment of a latch mechanism1016,1018used by the battery bay transmission assembly1000. In this embodiment, the latch mechanism1016,1018is a four bar linkage mechanism. The latch mechanism1016,1018comprises a latch housing1902which is rigidly attached to the frame of the battery bay. It also comprises a cam shaped input link1904rigidly coupled to a respective torque bar at first a pivot point1906such that the input link1904rotates/pivots together with a torque bar1012,1014around the first pivot point1906with respect to the stationary latch housing1902. The end of the input link1904remote from the torque bar is rotatably coupled at second pivot point1908to a first rod end1912of a coupler link rod1910. The coupler link rod1910has a second rod end1914remote from the first rod end1912that is pivotably coupled to a latch1920at a third pivot point1918. In some embodiments, the coupler link rod1910is a turnbuckle which includes an adjustment bolt1916configured to adjust the length of the coupler link rod1910. The latch1920has a fourth pivot point1922pivotably connected to another portion of the latch housing1902. The latch1920pivots about an axis, running through the center of the fourth pivot point1922. In some embodiments, the axis about which the latch pivots at the fourth pivot point1922is parallel but distinct from to the axis about which the torque bar1012,1014rotates at the first pivot point1906. The latch is substantially “V” or hook shaped with the third pivot point1918at the apex of the “V.” The fourth pivot point1922is at an end of the “V” remote from the apex (this end shall be called herein the latch's proximate end1926). The other end of the “V,” is also remote from the apex of the “V” (this other end shall be called the latch's distal end1928). The distal end1928of the latch is configured to engage the bar shaped striker1924on the battery pack104. In some embodiments, the distal end1928of the latch1920has a hook shape, as shown inFIG. 19A, which is configured to cradle the striker1924when engaged with the striker (as shown inFIG. 19C). The hook shaped distal end1928is also useful in engaging and lifting the battery pack104, at least partially, into the cavity of the battery bay108(FIG. 3) when engaging/receiving the battery. The striker1924may have a low friction element such as a roller bearings or low friction coating1930.

As shown inFIG. 19A, when the input link1904is in a released position, the latch1920is configured to mechanically disengage from a corresponding striker1924on the battery pack104. In other words, when the input link1904is in a released position, the latch1920does not contact the striker1924. The input link1904is driven/rotated, by means of the torque bar1012,1014connected to it.

FIG. 19Bshows an intermediate position where the input link1904has rotated such that the latch1920begins to engage the striker1924on the battery pack104and begins lifting the battery pack104, at least slightly into the cavity of the battery bay108(FIG. 3).

As shown inFIG. 19C, when the input link1904is in a fully engaged position, striker1924is cradled in the hook shaped distal end1928of the latch1920, and the input link1904and coupler link rod1910are in a geometric lock configuration. The geometric lock is the position in which the input link1904and the coupler link rod1910are in vertical alignment with one another with the coupler link rod1901in its fully extended position. In other words, the input link1904, coupler link rod1901, and first1906, second1908, and third1918pivot points are all substantially along the same axis. As such, any movement of the battery pack104is converted into compression or tensile forces along the single axis to the stationary latch housing1902without rotating any of the pivot points. Because the input link1904and coupler link rod1910are in a geometric lock they prevent the battery104from being released from the battery bay108, such as while the vehicle102is driving. Furthermore, in the geometric lock position, only minimal loads are transferred from the battery pack104to the drive components of the vehicle102.

In some embodiments, (a) releasing and (b) engaging are done as follows. The (a) releasing a battery pack104from the battery bay108is performed by means of the transmission assembly1000by rotating the latch(s)1920on the battery bay108to disengage the striker(s)1924on the battery pack104, and (b) engaging a new battery pack104in the battery bay108is done by means of the transmission assembly1000rotating the latch(s)1920on the battery bay108to engage, lift, and lock the striker(s)1924on the battery pack104. In some embodiments, the (a) releasing occurs in less than one minute. In some embodiments, the (b) engaging happened in less than one minute. In some embodiments, both the (a) releasing of the first battery pack104from the battery bay108and the (b) engaging of a second battery pack104in the battery bay108occur in less than one minute.

In some embodiments, a latch position indicator is utilized to measure whether the latch1920is in an engaged or disengaged position. In some embodiments, the latch position indicator communicates the position of the latch1920to a computer system in the electric vehicle102. In some embodiments, other indicators are used throughout the battery pack104and battery bay108to verify the workings of any or all of the following elements: the first gear lock1502, the latch lock mechanism1020, the latch mechanism1016,1018, the miter gear set1002, the torque bars1010,1012, the gear shafts1004,1006, the electrical connector804, and the position of the battery pack104inside the battery bay108. In some embodiments, the indicators include switches, Hall sensors, and/or micro-switches. In some embodiments, the alignment devices (such as alignment pins802and latch mechanisms1016,1018) and position indicators allow the battery pack104to be precisely monitored and positioned inside the battery bay108in six different degrees of freedom (3 degrees of translation and 3 degrees of rotation.)

In some embodiments, the battery bay have some or all of the following internal electric indications: a) proper/improper connection of the electrical connectors between the battery bay and the battery pack; b) open/close indication on each of the individual latches which fasten the battery pack to the battery bay; c) open/close indication on each of the safety lock devices; d) existence/non existence of the unique key like device which is mentioned in section14; e) in-position/out-of-position of battery pack inside the battery bay in at least three different locations around the battery pack; f) excessive/in-excessive temperature measurement in two different locations within the battery bay. (Excessive temperature may be a temperature above 90° C.); and g) excessive/in-excessive power limits in the quick release actuator.

FIG. 20is a detailed view of the latch lock mechanism1020. When the latch mechanism1016,1018is in its lock configuration, with the latch1920engaging the striker1924, the latch lock mechanism1020will also be engaged. The latch lock mechanism1020is configured to prevent the latch mechanism1016,1018from rotating when engaged. In some embodiments, the latch lock mechanism1020comprises a toothed cantilevered lock arm (2002) (also called a lock bolt) configured to engage a corresponding tooth2010on the latch1920. As such, the toothed cantilevered lock arm2002is configured to prevent the latch1920from rotating when engaged. The toothed cantilevered lock arm2002is coupled to a lock synchronization bar2004, which is configured to disengage the toothed cantilevered lock arm2002when rotated. The lock synchronization bar2004is also coupled to a lock actuator2006, which is configured to rotate the synchronization bar2004. In some embodiments, the lock actuator2006includes an electric motor2008that rotates the lock synchronization bar2004via a gear set or any other suitable mechanism. In some embodiments, the electric motor2008is activated by an electric lock or unlock signal. In other embodiments, latch lock mechanism is mechanically activated. In some embodiments, both electrical and mechanical activation is provided, the mechanical activation being useful if any electronic malfunctions occur. In some embodiments, the latch lock mechanism1020is configured to disengage only after the gear lock1502(shown inFIG. 15) has been released.

The lock synchronization bar2004is configured to rotate one or more latch locks2002in a first direction so that the one or more latch locks1920engage with the latch1920. The lock synchronization bar2004is also configured to rotate the one or more latch locks2002in a second, opposite, direction to disengage the latch locks2002from the latch1920. As such, after the latch locks have been rotated in a second direction, to unlock the latch1920, the latch is allowed to disengage the striker1924by means of the torque bar1012,1014rotation through the four bar linkage latch mechanism1016,1018described above.

By means of the mechanisms described above, the miter gear set1002, driven by the electric drive motor1310, causes the latches1016,1018to rotate opposite one another. When the latches1016,1018on either side of the battery bay108rotate away from each other, they release the corresponding strikers1924on the battery104.

FIG. 21is a flow diagram of a process for releasing a battery pack from a battery bay. In some embodiments, the release process happens as follows. A first latch mechanism, the miter gear lock1502, is which physically released (2102). In some embodiments, the physical release happens by means of a key1602inserted into the key hole1402(2104). A second latch mechanism, the latch lock mechanism1020, releases the one or more latches1016,1018(2106). In some embodiments, the latch lock unlocks when an electric motor2008, activated by an electronic unlock signal, actuates the lock actuator2006which rotates the latch lock2002and disengage its tooth from the tooth of the latch1920by rotating the lock synchronization bar2004(2108). Once both the miter gear lock and the latch lock have been released, the battery104is released from the battery bay108as follows. The drive motor1310actuates a transmission assembly (2110). In some embodiments, the transmission assembly is actuated as follows, the drive motor1310rotates the miter gear set, which rotates the gear shafts, which rotate the worm gears, which rotate the torque bars (2112). Specifically, the drive motor rotates the central gear1302of the miter gear set1002by means of a gear ratio set1312. As the central gear1302rotates it drives the first outer gear1304in a first rotational direction and the second outer gear1306in a second rotational direction opposite of the first rotational direction. The first outer gear1304drives the first gear shaft1004in a first rotational direction, while the second outer gear1306drives the second gear shaft1006in a second rotational direction. The first gear shaft1004rotates the first torque bar1012by means of the first worm gear set1008. The second gear shaft1006rotates the second torque bar1014in a direction opposite that of the first torque bar1012by means of the second worm gear set1010. The rotation of the first torque bar1012then causes at least one latch1920to rotate and disengage a striker1924on the battery104(2114). Specifically, the first torque bar1012, being coupled to the input link1904, rotates the input link1904, which actuates the coupler link rod1910such that the latch1920disengages the striker1924. In some embodiments, substantially simultaneously, the rotation of the second torque bar1014causes the latch mechanism1018coupled to the second torque bar1014to rotate in a direction opposite that of the latch mechanism1016coupled to the first torque bar1012. As such, latches on either side of the battery bay108rotate away from one another to release their respective strikers1924. (2116) Then the battery pack is translated vertically downward away from the underside of the vehicle. In some embodiments, the battery pack is translated by means of first being lowered onto a platform under the battery and then being further lowered by means of the platform lowering.

FIG. 22is a flow diagram of a process for engaging a battery pack to a battery bay. To engage a battery104at least partially within the battery bay108involves substantially the same process described above only in reverse. Specifically, the drive motor1310actuates a transmission assembly (2202). In some embodiments, the transmission assembly is actuated as follows, the drive motor1310rotates the miter gear set, which rotates the gear shafts, which rotate the worm gears, which rotate the torque bars (2204). Specifically, the drive motor1310rotates the central gear1302of the miter gear set1002in the opposite direction as that used for disengaging a battery104by means of a gear ratio set1312. As the central gear1302rotates, it drives the first outer gear1304one rotational direction and the second outer gear1306in the opposite direction. The first outer gear1304drives the first gear shaft1004in one direction, while the second outer gear1306drives the second gear shaft1006in the opposite direction. The first gear shaft1004rotates the first torque bar1012by means of the first worm gear set1008. The second gear shaft1006rotates the second torque bar1014in a direction opposite that of the first torque bar1012by means of the second worm gear set1010. The rotation of the first torque bar1012then causes at least one first latch1920to rotate and engage a striker1924on the battery104(2206). Specifically, the first torque bar1012, being coupled to the input link1904, rotates the input link1904, which actuates the coupler link rod1910such that the latch1920engages the striker1924. In some embodiments, the first latch is located at the front end of the underside of the vehicle. In some embodiments, substantially simultaneously a second latch located at the back end of the electronic vehicle is also rotated in the same manner (2208).

Once the strikers are engage, they then vertically lift the battery at least partially into the battery bay of the electronic vehicle (2210). The lifting happens as follows, substantially simultaneously, the rotation of the second torque bar1014causes the latch mechanism1018coupled to the second torque bar1014to rotate in a direction opposite that of the latch mechanism1016coupled to the first torque bar1012. As such, latches on either side of the battery bay108rotate towards one another to engage their respective strikers1924substantially simultaneously and lift them. Then the battery is secured into the battery bay108(2212). Specifically, the latches1920hook onto the strikers1924and lift the battery until the latches are in their geometric lock (dead center) positions. Once the battery104is engaged, the first lock mechanism is engaged. (2214) Specifically, once the four bar mechanism of the latches1016,1018are in their geometric lock positions, the key1602is removed from the key hole1401and the locking latch1702with a locking tooth1704engages with the locking gear1706(2216). Also, the second lock mechanism is electrically engaged (2218). Specifically, the an electric motor2008, activated by an electronic unlock signal, actuates the lock actuator2006which rotates the latch lock2002and engages its tooth with the tooth of the latch1920by rotating the lock synchronization bar2004(2220).

In some embodiments, the battery bay108is configured to be disposed at the underside of the at least partially electric vehicle102such that the releasing and engaging mechanisms described can release an at least partially spent battery104and have it replaced by an at least partially charged battery104underneath the vehicle102.

As described above, in reference toFIGS. 21 and 22, in some embodiments, the first latch mechanism1016and the second latch mechanism1018substantially simultaneously rotate in opposite directions about their respective axes. In some embodiments, the at least two latches rotate towards one another to engage, lift, and lock the battery104at least partially within the cavity of the battery bay108. In some embodiments, the at least two latches then rotate away from each other to disengage the battery104. Similarly, the battery pack104is disengaged and unlocked from the at least partially electric vehicle102when the latches1920of the first latch mechanism1016and the second latch mechanism1018substantially simultaneously rotate away from one another.

FIGS. 24A-31illustrate various embodiments of an electrical connection system that provide additional detail to what was described above with relation toFIG. 9.FIG. 9illustrated one embodiment of an electrical connection system900comprising a battery electrical connector804connected to the battery pack104that was configured to mate with a battery bay electrical connector902connected to the electric vehicle102.FIGS. 24A-30Billustrates an electrical connection system2400. These embodiments utilize the term vehicle-side connector2402to describe other embodiments of the element referred to as the battery bay electrical connector902inFIG. 9, and utilize the term battery-side connector2452to describe other embodiments of the element referred to as the battery electrical connector804inFIG. 9. It should be noted that in some instances these embodiments include additional components. For example, the shielding mechanism2902described in relation toFIGS. 30 and 31is an additional element that performs a different shielding function than the electric shields904described in relation toFIG. 9. Furthermore, the power connectors906and908and data connectors910ofFIG. 9(which included the cables and connection interfaces) are described in greater detail with relation toFIGS. 24A-27and are thus referred to by new names and numbers.

FIG. 24Ais a top perspective view of an electrical connection system2400, including a vehicle-side connector2402and a battery-side connector2452.FIG. 24Bis a bottom perspective view of the vehicle-side connector2402. The battery-side connector2452is attached to the battery pack104and electrically connects the battery pack104to the vehicle102by mating with the vehicle-side connector2402. In some embodiments, the battery-side connector2452has mechanisms for compensating for misalignment as described in detail below. Similarly, the vehicle-side connector2402is attached to the vehicle102and electrically connects the vehicle102to the battery pack104by mating with the battery-side connector2452. In some embodiments, the vehicle-side connector2402has mechanisms for compensating for misalignment as described in detail below. It should be noted that while the components described in relation to the figures below are described as being “battery-side” or “vehicle-side,” these components could be swapped. In other words, all comments described as “battery-side” in embodiments illustrated below, could be mounted to the “vehicle” in an alternative embodiment, and vice versa. As shown inFIG. 24A, the battery-side connector2452comprises a battery-side mounting portion2454and a battery-side coupling portion2456. The battery-side coupling portion2456includes one or more alignment sockets2470. In some embodiments, one or more bolts2462, which are surrounded by sleeves2464, secure the battery-side coupling portion2456to the battery-side mounting portion2454. In some embodiments, the battery-side coupling portion2456and the battery-side mounting portion2454are rigidly secured to one another, such that both components are fixed with respect to the battery pack. In other embodiments, the battery-side connector2452also comprises a battery-side coupler2458(shown and described in detail with respect toFIG. 27) which allows for relative motion between the battery-side coupling portion2456and the battery-side mounting portion2454. This relative motion between the components relieves potential misalignment between the battery-side connector2452and the vehicle-side connector2402.

The battery-side coupling portion2456houses a battery-side power interface2466with one or more power sockets2486and a battery-side data interface2468with one or more data sockets2488. In some embodiments, the battery-side coupling portion2456also includes a sealing mechanism2472surrounding a portion of the battery-side coupling portion2456including the battery side power interface2466and the battery-side data interface2468and which assists in protecting these components from dirt and debris.

As shown inFIG. 24A, the vehicle-side connector2402has a vehicle-side mounting portion2404, a vehicle-side coupling portion2406, and a vehicle-side coupler2408. The vehicle-side coupling portion2406is connected to the vehicle-side mounting portion2404via the vehicle-side coupler2408. The vehicle-side coupler2408is designed to allow relative motion between the vehicle-side coupling portion2406and the vehicle-side mounting portion2404to relieve potential misalignment between the battery-side connector2452and the vehicle-side connector2402and to absorb relative motion between the battery and vehicle. The vehicle-side connector2402also has one or more alignment pins2420.

FIG. 24Bis a bottom perspective view of the vehicle-side connector2402. As shown inFIG. 24B, the vehicle-side coupling portion2406houses a vehicle-side power interface2416with one or more power pins2476and a vehicle-side data interface2418with one or more data pins2478. The vehicle-side coupling portion2406connects to the battery-side coupling portion2456(FIG. 24A) to electrically connect the battery pack104to the vehicle102. The vehicle-side coupler2408comprises one or more bolts2412and coil springs2414. In some embodiments, the vehicle-side coupler2408uses a combination of bolts2412and the coil springs2414to allow relative motion between the vehicle-side coupling portion2406and the vehicle-side mounting portion2404, as described in further detail below in relation toFIG. 26.

In some embodiments, the vehicle-side mounting portion2404, used to mount the vehicle-side connector2402to the vehicle102is shaped to conform to the specific contours of the underside of the vehicle102. In some embodiments, the vehicle-side mounting portion2404is attached directly to the underside of a vehicle, while in other embodiments the vehicle-side mounting portion2404is attached to any portion of the vehicle that facilitates the coupling between the vehicle-side connector2402and a battery-side connector2452of the connection system2400. The vehicle-side mounting portion2402is any suitable plate, bracket, or other mounting mechanism that is configured to attach to the vehicle102. In some further embodiments, the vehicle-side mounting portion2404forms a part of the vehicle102. Similarly, the battery-side mounting portion2454is configured to attach to or form a part of the battery104in a similar manner as described above for the vehicle-side mounting portion2404.

FIG. 24Aalso shows the sealing mechanism2472surrounding a portion of the battery-side coupling portion2456. When the vehicle-side connector2402and the battery-side connector1452are coupled together, the sealing mechanism2472is disposed between two proximate surfaces of the vehicle-side coupling portion2406and the battery-side coupling portion2456. The sealing mechanism2472is designed to prevent the ingress of environmental contaminants to the area between the coupling portions that contains the power2416,2466and data interfaces2418,2468. Because of the extreme environments in which vehicles often operate, the sealing mechanism2472is designed to protect the most sensitive elements of the connector from contaminants such as water, dust, dirt, soot, chemicals, etc. In some embodiments, the sealing mechanism2472is a rubber O-ring. In some embodiments, the coupling portions2406and2456utilize more than one sealing mechanism. In some embodiments, the connection system2400employs additional types or combinations of sealing mechanisms including other types of gaskets or scraping mechanisms designed to clean away foreign contaminants.

As shown inFIG. 24A, one or more tapered alignment pins2420are mounted to the vehicle-side coupling portion2406. The tapered alignment pins2420are perpendicular to the surface of the vehicle-side coupling portion2406(the X-Z plane ofFIG. 3A) and parallel to the axis along which the coupling portions2406and2456are connected together (the Y-axis ofFIG. 3A). The one or more alignment sockets2470mounted to the battery-side coupling portion2456are configured to receive the tapered alignment pin2420. In some embodiments, the inside edges of the openings in the alignment sockets2470are chamfered in order to reduce friction and provide a smoother contact interface between the alignment pins2420and the alignment sockets2470. The alignment pins2420and alignment sockets2470are mounted such that when the alignment pins2420are in the alignment sockets2470, the coupling portions2406and2456and their respective power interfaces2416,2466and data2418,2468interfaces are aligned.FIG. 26illustrates the alignment pins2420in further detail.

In some embodiments, the one or more alignment sockets2470each have a substantially cylindrical shaped cross-section. In some embodiments, one of the alignment sockets2470has an oval shaped cross-section rather than a cylindrical shaped cross-section. In this embodiment, the oval shaped alignment socket2470is mounted such that the long dimension of the oval is parallel to a line formed between two tapered alignment pins2420. Thus, the extra space between the alignment pin2420and the inside walls of the alignment socket channel accommodates alignment pins2420that may not be exactly parallel. This reduces possible mechanical stresses on the alignment pins2420and alignment sockets2470.

The alignment pins2420and alignment sockets2470are more robust and durable than the connection elements that are utilized in the power interfaces2416,2466and data2418,2468interfaces. By employing an alignment mechanism such as the illustrated alignment pins2420and alignment sockets2470, the lateral and bending loads that might otherwise be imparted to the electrical interfaces due to misalignments between the battery104and the vehicle102can be borne by structural components rather than the more fragile electrical and data components.

As shown inFIG. 24A, the vehicle-side coupling portion2406houses the vehicle-side power interface2416and the vehicle-side data interface2418. Likewise, the battery-side coupling portion2456houses a battery-side power interface2466and a battery-side data interface2468. The vehicle-side power interface2416, when coupled to the battery-side power interface2466, transmits high voltage and current electrical energy between the battery104and the vehicle102. In order to provide adequate propulsion, electric vehicles may require up to 1000 volts and up to 1000 amps of direct current electricity. In some embodiments, the vehicle requires up to 400 volts and 200 amps of direct current electricity. In some embodiments, the high voltage electricity is between about 100 and 1000 VDC. In other embodiments, the high voltage electricity is between about 200 and 800 VDC. In yet other embodiments, the high voltage electricity is between about 300 and 700 VDC. In still other embodiments, the high voltage electricity is between about 350 and 450 VDC. The particular voltage and current capacities of the vehicle-side power interfaces2416,2466will vary depending on the particular energy needs of the application. For instance, high performance vehicles may require a higher voltage or current carrying capacity than standard vehicles.

The vehicle-side power interface2416of the vehicle coupling portion2406uses conductive pins that are received by the power interface2466in the battery-side coupling portion2456. In some embodiments, the vehicle-side power interface2416comprises two conductive power pins2476. In other embodiments the vehicle-side power interface2416comprises four or more conductive power pins2476. The inside surface of the battery side power interface2466is conductive in order to facilitate the transmission of electricity between the battery104and the vehicle102. In some embodiments, the battery-side power interface2466employs power sockets2486that utilize a conductive mesh sleeve to make electrical contact with the power pins2476, as described with reference toFIG. 28. In some embodiments, the battery-side power interface2466includes as many power sockets2486as there are power pins2476.

In some embodiments, the vehicle-side data interface2418contains seventeen conductive data pins2478. In some embodiments, the vehicle-side data interface2418has nine, fifteen, or twenty data pins2478. In some embodiments, the battery-side data interface2468will utilize as many data sockets2488as there are data pins2478in the data interface2418. In some embodiments, the vehicle-side data interface2418employs data sockets2488that utilize a conductive mesh sleeve to make electrical contact with the data pins2478, as described with reference toFIG. 28. The data interfaces2418and2468transmit data between the battery104and the vehicle102using electronic communication signals. Many electronic communication signals can be supported over the data interfaces2418and2468, including but not limited to Ethernet, Universal Serial Bus, RS-232 or any other electrical signal. Furthermore, the data interfaces2418and2468can support many communication protocols, including but not limited to TCP/IP, CAN-bus (Controller Area Network), or other proprietary protocols. In some embodiments, the data interfaces2418and2468are optical connectors. In such embodiments, the data interfaces2418and2468do not require conductive pins or sockets in order to transmit data between the battery104and the vehicle102.

FIG. 25is an elevation view of the vehicle-side connector2402and the battery-side connector2452. Line26-26inFIG. 25defines the sectional views shown inFIGS. 26 and 27.

FIG. 26is a sectional view of the vehicle-side connector2402along axis26-26shown inFIG. 25.FIG. 26shows a more detailed view of the vehicle-side coupling portion2406of this embodiment. In some embodiments, the vehicle-side coupler2408comprises bolts2412that are attached to the vehicle-side mounting portion2404and the vehicle-side coupling portion2406, and are surrounded by the coil springs2414. The bolts2412pass through holes2602in the vehicle-side coupling portion2406that are larger than the diameter of the shafts of the bolts2412. The coil springs2414are positioned between the vehicle-side mounting portion2404and the vehicle-side coupling portion2406. The coil springs2414are flexible and provide a resilient force between the vehicle-side mounting portion2404and the vehicle-side coupling portion2406. This resilience provides a centering force between the vehicle-side coupling portion2406and the vehicle-side mounting portion2404to keep the vehicle-side coupling portion2406in a neutral position when the connectors2402,2452are not coupled together. Additionally, the resilient structure of the coil springs2414allows the vehicle-side coupling portion2406to move both vertically and horizontally to aid in the alignment of the vehicle-side and battery-side coupling portions,2406and2456. The coil springs2414also absorb vertical and horizontal shock and vibration when the vehicle102is driven. The bolt and spring style vehicle-side coupler2408provides sufficient free play in the horizontal plan (the X-Z plane defined inFIG. 3A) to allow the vehicle-side connector2402and the battery-side coupler2452to align given the general geometrical tolerances of the complete battery bay assembly. In other words, if the total accuracy of the battery bay system is high, less free play in the vehicle-side coupler2408is required. For example, a free play of +/−3 mm will be enough. For lower accuracy battery bay systems, will require more free play. In some embodiments, the bolt and spring style vehicle-side coupler2408allows +/−6 mm movement in a plane that is substantially parallel to the vehicle102(the X-Z plane defined inFIG. 3A). In some embodiments, the bolt and spring style vehicle-side coupler2408allows for +/−6 mm movement along a vertical axis (the Y-axis defined inFIG. 3A.)

In some embodiments, the coil springs2414do not surround the bolts2412, but are positioned elsewhere between the vehicle-side coupling portion2406and the vehicle-side mounting portion2404. In some embodiments, the vehicle-side coupler2408utilizes a resilient mechanism other than coil springs, including but not limited to leaf springs, elastomer springs, or torsion springs. In some embodiments, the vehicle-side coupler2408utilizes more or fewer coil springs and bolts. Those skilled in the art will recognize that a variety of springs and configurations may be used.

FIG. 26shows the tapered alignment pin2420and its mounting mechanism in greater detail. In some embodiments, the one or more tapered alignment pins2420are rigidly fixed to the vehicle-side coupling portion2406. In other embodiments, the one or more tapered alignment pins2420are attached as shown inFIG. 26, so as to allow relative motion between the alignment pins2420and the vehicle-side coupling portion2406. In some embodiments, the vehicle side coupler2408comprises the floating pin mechanism as well as the bolt and spring mechanism described above. The mount for the alignment pin2420uses a hollow flanged sleeve2604with an “I-shaped” cross-section between the pin2420and the vehicle-side coupling portion2406. In some embodiments, the flanged sleeve2604is made up of two sleeves, each having a single flange or shoulder, to facilitate assembly. The shoulders, or flanges, of the flanged sleeve2604rest on the surface of the vehicle-side coupling portion2406, and are wider than the opening of the hole2608in the vehicle-side coupling portion2406. The flanges thus keep the tapered alignment pins2420captive to the surface of the coupling portion2406in the vertical direction. The outside cylindrical surface of the flanged sleeve2604is smaller than the inside diameter of the hole2608, leaving free space2606between the two surfaces. The free space2606allows the alignment pin to have some lateral play or to “float” in the plane defined by the surface of the vehicle-side coupling portion2406to which the alignment pin2420is mounted. In some embodiments, the floating pin style vehicle-side coupler2408allows +/−1 mm movement in a plane that is substantially parallel to the vehicle102(the X-Z plane defined inFIG. 3A).

FIG. 27is a sectional view of the battery-side connector2452along axis26-26shown inFIG. 25. The battery-side connector2452including the battery-side mounting portion2454, a battery-side coupling portion2456, and a battery-side coupler2458is shown. The bolts2462, which form a part of the battery-side coupler2458, secure the battery-side coupling portion2456to the battery-side mounting portion2454. In some embodiments, the shafts of the bolts2462are surrounded by flanged sleeves2464. The flanged sleeves2464have two shoulders, or flanges, creating a hollow “I-shaped” cross-section. In some embodiments, the flanged sleeves2464are made up of two sleeves (as shown), each having a single flange or shoulder, to facilitate assembly. The shoulders of the flanged sleeves2464have a diameter larger than the opening in the battery-side coupling portion2456in which the sleeves2464sit. The shoulders of the sleeves contact the top and bottom surface of the battery-side coupling portion2456, thus keeping the battery-side coupling portion2456captive to the battery-side mounting portion2454(in the vertical direction).

The outer cylindrical surfaces of the sleeves2464have a diameter smaller than the openings in the battery-side coupling portion2456. This configuration leaves space2702between the wall of the hole in the battery-side coupling portion2456and the cylindrical surface of the sleeve2464. The space2702allows the battery-side coupling portion2456to move laterally relative to the battery-side mounting portion2454. In some embodiments, the space2702permits the battery-side coupling portion2456to slide or “float” freely in one plane. In some embodiments, the sliding sleeve style battery-side coupler2458allows +/−1 mm movement in a plane that is substantially parallel to the vehicle102(the X-Z plane defined inFIG. 3A). In other embodiments, planar motion will change based on the particular mounting location of the connection system2400and its elements.

FIG. 28shows an example of a mesh sleeve2800utilized by either the power sockets2486, the data sockets2488, or both power and data sockets in the battery-side coupling portion interface2456. The conductive surface of the mesh sleeve is made up of a number of conductive wires2802positioned between two rings2804. The wires2802are attached to the rings2804diagonally with respect to the axis formed by the center of the rings2804. This configuration of wires2802and rings2804together form a semi-spiral shaped conductive mesh sleeve2800. The semi-spiral configuration disposes the sleeve2800with a narrowing bias, creating a gradual decrease in the internal diameter of the sleeve2800with the middle internal diameter2806being the smallest. A corresponding pin (such as a power pin2476or a data pin2478from the vehicle-side coupling portion2406) has a diameter smaller than the rings2804, but larger than the middle internal diameter2806. Thus, as the pin is inserted into the sleeve2800, the portion of the wires2802near the middle internal diameter2806must deform to accommodate the larger diameter of the pin. This process ensures that the conductive wires2802are held firmly against the surface of the pin. The mesh sleeve2800is designed such that the wires2802bend only slightly, within their elastic deformation range. The configuration of the wires2802is such that they resist plastic deformation when a pin of the appropriate size is inserted. The mesh sleeve2800and the pins are therefore able to withstand many contact cycles without damage to themselves or degradation of the electrical connections. In some embodiments, the pins and sockets can withstand 3000 or more connection cycles.

FIG. 29is an exploded view of the vehicle-side coupling portion2406and shows a shielding mechanism2902. The shielding mechanism2902separates and isolates data conductors from power conductors in the connection system. AlthoughFIG. 29only depicts the vehicle-side coupling portion2406, a similar shielding mechanism is employed in the battery-side coupling portion2456. The shielding mechanism2902is particularly designed to prevent electromagnetic or other electrical interference from degrading the signals carried by the data conductors and interfaces2418. As mentioned, electric vehicles require high voltage and current electricity, which can disrupt nearby electrical communication signals. Due to the desire to employ data and power connections on the same connector2400, such interference must be prevented.

FIG. 30is a perspective view of the shielding mechanism2902included in the vehicle-side connector2402and the battery-side connector2452.FIG. 31includes planar views of all sides of the shielding mechanism2902ofFIG. 30. The shielding mechanism2902surrounds the data conductors910and the data interfaces2418,2468. The shielding mechanism2902is made of a metal, preferably a conductive metal material which is designed to counteract the electromagnetic field produced by the power conductors and power interfaces2416,2466. The wall thickness of the shielding mechanism2902depends on the strength of the electromagnetic field and the location of the shield relative to the field. In some embodiments, the wall thickness is between 0.1 mm and 5 mm depending on the electro-magnetic interference generated by the power conductors. The general dimensions of the shielding mechanism2902are such that there is sufficient room for the data wires to be encased. In some embodiments, the shielding mechanism2902is “L” shaped, or elbow shaped. In some embodiments, the specific dimensions of the L-shaped shielding mechanism are dependant upon the constraints and frequencies of the electro-magnetic interference generated by the power conductors. When designed with the dimensions discussed above, the material of the shielding mechanism2902establishes an internal electromagnetic force that substantially counteracts the external field generated by the nearby high voltage conductors. This counteracting field is created simply by the interaction of the specially designed shield wall and the nature of the material. It does not require additional power or grounding systems in order to function properly. This is especially beneficial given the desire to employ as simple and robust a connection system as possible.

The foregoing description, for purpose of explanation, has been described with reference to specific embodiments. However, the illustrative discussions above are not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. For example, the above described embodiments are described in relation to an at least partially electric vehicle, but the mechanisms described herein could be used in any at least partially electric machine employing a removable battery. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.