Patent Publication Number: US-2023150376-A1

Title: Vehicle Backup Battery

Description:
BACKGROUND 
     Technical Field 
     The present disclosure relates generally to batteries. More particularly the present disclosure relates to a backup battery for electric vehicles which is removably stored in a vehicle and which can provide backup power through direct connection or through a connection to the electric vehicle charge port. 
     Description of Related Art 
     Electric vehicles (“EVs”) are rapidly becoming ubiquitous and are predicted to rapidly replace internal combustion engine vehicles over the coming years. These vehicles utilize large battery packs to store energy and drive the motor or motors, rather than gasoline in a tank. 
     One problem with EVs is that in many instances they have a limited range, and charging stations are far less ubiquitous than gas stations, making it harder to easily find charging options when running low on charge. This can lead to running out of charge and a stuck vehicle. While this happens with gasoline vehicles sometimes, there is a greater concern with electric vehicles due to limited range and fewer charging option. 
     It is also more inconvenient when an EV runs out of charge than when an internal combustion vehicle runs out of fuel. When an internal combustion vehicle runs out of fuel, a small quantity of fuel can be delivered, poured into the tank, and the vehicle can be driven off. However, when an EV runs out of charge, one must bring a fuel based generator (gas, etc.) to generate electricity to charge the battery. This is both inconvenient and slow because one must wait for the battery to charge up enough to drive to a home or charge station. 
     Therefore, what is needed is a system which can more efficiently provide backup charge or supplemental charge to EVs. 
     SUMMARY 
     The subject matter of this application may involve, in some cases, interrelated products, alternative solutions to a particular problem, and/or a plurality of different uses of a single system or article. 
     In one aspect, an electric vehicle is provided. The electric vehicle has a frame, a body connected to the frame which defines an interior space for passengers and storage space, and a primary battery connected to at least one of the frame and the body. The primary battery is in electrical communication with at least one motor operable to rotate at least one of the plurality of wheels. The electric vehicle also has a charge port operable to receive an electrical connection to charge the primary battery. Further, the electric vehicle includes a backup battery removably connected to the electric vehicle, the backup battery having a charge capacity that is less than a charge capacity of the primary battery. The backup battery may have a case on an outside to define a body of the battery, as well as an electrical connector allowing an electronic communication of the backup battery with the electric vehicle. Further, a cord extends from the case, the cord allows for connection of the backup battery with a second different vehicle to charge a battery of the second different vehicle. The backup battery is removably connectable in the storage space. When the backup battery is in a connected position, the backup battery electrical connector engaged with a corresponding electrical connector in the vehicle storage space, the corresponding vehicle electrical connector in electronic communication with at least one of the primary battery and the at least one motor to cause a rotation of at least one of the plurality of wheels. A switch allows activation of the backup battery, and a vehicle computer operates to monitor a state of charge of both the primary battery and the backup battery, and can display this on a visual display of the vehicle. 
     In another aspect, a method of operation of an electric vehicle backup battery is provided. The method involves charging the backup battery using a wall outlet, the backup battery having a cord and plug for connection of the battery to the wall outlet. The method also includes positioning the backup battery into an electric vehicle, the step of positioning the backup battery comprising engaging an electrical connector of the backup battery with an electrical connector of the electric vehicle positioned within the electric vehicle. The backup battery may be removed from the vehicle. Further, the backup battery may be used for charging a second different electric vehicle by connecting a charging cord of the backup battery to a charge port of the second different electric vehicle. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    provides a flow chart of an embodiment of operation of the present disclosure. 
         FIG.  2    provides a provides a perspective view of an embodiment of a vehicle trunk or storage area having an embodiment of the backup battery of the present disclosure therein. 
         FIG.  3    provides a view of an embodiment of a backup battery of the present disclosure. 
         FIG.  4    provides a provides a perspective view of an embodiment of a vehicle trunk or storage area having an embodiment of the backup battery of the present disclosure therein. 
         FIG.  5    provides an embodiment of the present disclosure. 
         FIG.  6    provides a detail view of a connection of backup battery to vehicle of an embodiment of the present disclosure. 
         FIG.  7    provides a detail view of a connection of backup battery to vehicle of an embodiment of the present disclosure. 
         FIG.  8    provides an embodiment of the present disclosure in one mode of operation. 
         FIG.  9    provides a flow chart of another embodiment of operation of the present disclosure. 
         FIG.  10    provides a flow chart of yet another embodiment of operation of the present disclosure. 
         FIG.  11    provides a detail view of a connection of backup battery to vehicle of another embodiment of the present disclosure. 
         FIG.  12    provides a detail view of a connection of backup battery to vehicle of yet another embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention and does not represent the only forms in which the present disclosure may be constructed and/or utilized. The description sets forth the functions and the sequence of steps for constructing and operating the invention in connection with the illustrated embodiments. 
     Generally, the present disclosure concerns a backup battery system for electric vehicles (“EVs”). The system involves a battery pack operable to be removably secured in the vehicle, such that it can directly operate the vehicle it is in in a first operational mode, and having a secondary charging cord to provide electric power to another separate vehicle in a second operational mode. 
     An EV, as disclosed herein, typically has a vehicle frame, and a body connected to the frame which defines an interior space for passengers. The vehicle has a plurality of wheels, at least one of which can be rotated by at least one motor, with the motor(s) being powered by a primary battery which is connected to at least one of the frame and/or the body. The EV further has a charge port which is accessible from inside or outside the vehicle and which can receive an electrical connection to charge the primary battery. Further, the EV of this disclosure includes a backup battery which has a charge capacity that is less than a charge capacity of the primary battery. This backup battery is operable to provide an amount of charge which is sufficient to allow the vehicle to drive a limited amount of miles further to reach a charging source to recharge the primary battery in the event that the primary battery has run out of power. In various modes of operation, the backup battery may allow the vehicle to drive at a low speed using only minimal power to maximize range. Further, depending on embodiment, the backup battery may charge the primary battery which in turn may drive the vehicle, or the backup battery may directly drive the motors itself. 
     In one embodiment, a manually operated switch may be positioned in the vehicle or in a storage space such as a rear hatch or trunk of the vehicle which can activate the backup battery. In another embodiment, this switch may be actuated through an input into the EV&#39;s computerized control interface. In still another embodiment, the backup battery may automatically activate upon a decrease of the primary battery below a predetermined threshold. However, in many cases, a manually operated switch is preferred because it deters a driver from driving the primary battery too low on charge, it prevents accidental or frequent use by making the actuation more deliberate, and perhaps most importantly acts as a fail safe: if the primary battery is completely dead, the computerized actuation may not be possible because there will be no electricity to cause switch actuation. 
     The backup battery may be any type of battery capable of storing electricity. In one embodiment, the backup battery may be a lithium-ion battery due to its light weight and reliability. In another embodiment, the backup battery may be a lead acid battery due to its ability to hold a charge for a long time, reliability, and durability. Depending on the vehicle and vehicle needs, battery size and capacity may vary greatly. In most embodiments, the battery must be small enough that it can be removed from the vehicle by a person without injuring themselves, but also powerful enough to be able to drive the vehicle a sufficient distance. In various embodiments, the backup battery may be sized to provide between approximately 5, 10, 15, 20, and 25 miles of range. Of course, in other embodiments, range may be greater than this. Depending on the EV, this will result in a backup battery pack sized anywhere between 1.5-7.5 kwh, and in some embodiments up to 10 kwh. 
     In a particular embodiment, the EV may be operable-typically by a computer controller such as a chip- to charge the backup battery to 100% state of charge and hold it at 100% state of charge. In many cases, charging to 100% on certain batteries puts a strain on the battery and can lead to degradation over time. However, because the backup battery is a removable and replaceable, degradation is less of a concern and a maximum charge to allow emergency driving is a higher priority and therefore typically preferred. 
     In one embodiment, the backup battery may be charged preferentially to the primary battery when charging the vehicle. In other words, the EV computer may be operable to first charge the backup battery to predetermined state of charge (in many embodiments, 100% or close to it), and then once that is charged, the primary battery is charged. In another embodiment, the charge port charges the primary battery, and the primary battery in turn charges the backup battery. In yet another embodiment, the EV computer may be operable to monitor a state of charge of the backup battery and operable to cause the primary battery to charge the backup battery, even when not plugged in, if the backup battery drops below a certain state of charge, such as 90% or 95% for example. Of course, other embodiments of different charge configurations, such as partially charging both simultaneously, and the like, are also within the scope of this disclosure. 
     The backup battery is, in many embodiments, intended to be removable so that it can also be used to charge another vehicle. In one embodiment, the EV may be specifically designed with a well or port, or other storage space in the vehicle specifically sized and designed to receive the backup battery. This storage area for the backup battery may, in one embodiment, have an electrical connector which corresponds to an electrical connector on the backup battery. As such, when the battery pack is positioned in the storage space, it is automatically electrically connected to the vehicle. The electrical connectors may be electric contacts such as mating male and female plugs, metal strips, and the like. The male end of the plug can be on either the battery pack or vehicle, with the matching female plug on the other of the two. In some embodiments, the male side of the plug is retractable such that it only extends outwardly when the opposing plug is nearby. Structures such as magnets, springs, pistons, electric actuators, prongs, protrusions, levers, switches and the like may all be used to cause the male plug to extend from and retract to its retracted position. As such, the EV of the present disclosure is specifically designed to receive and engage with the backup battery of the present disclosure. 
     In certain embodiments, a well or other storage area in the vehicle for the backup battery pack may include a guide slot, channel, rail, or the like to aid in proper positioning of the backup battery to engage electrical contacts of the backup battery and vehicle. In a particular embodiment, the guide slot may have a catch or protrusion which can cause a retractable connector in either the backup battery pack or vehicle to engage and connect to a matching female connector on the other of the battery and vehicle. 
     In some embodiments, a cover, strap, or case, or similar structure can extend over the backup battery when attached to the vehicle to prevent it from being dislodged and to prevent accidental contacting or other interference with the backup battery by other items in the truck or vehicle storage area. 
     In one embodiment, the backup battery has a cord on its exterior or case. This cord is connected to the battery and has a plug on a distal end which allows it to directly connect to a charge port of a second, different EV. This configuration allows the backup battery to not only operate the EV in which it is installed, but it can also provide charge to a second EV through this cord by plugging into the second EV&#39;s charge port. 
     In a particular embodiment, the EV may further have an extending arm which can move or aid in moving the backup battery between an inside and outside of the vehicle. In a further embodiment, the extending arm may also move downward to the ground to lower the backup battery pack. In many cases, the backup battery is positioned somewhat deep inside the vehicle trunk or storage area/hatch. This makes it difficult to reach into the vehicle and while at an extended position of the arms, to lift up the somewhat heavy battery pack. Therefore, the extending arm allows for easier access by moving the battery pack to an edge of the vehicle trunk/storage space, out of it and away from the vehicle, or out of the vehicle and down to the ground, in varying embodiments. In particular embodiments, the arm may be a sliding or telescoping arm. Movement of the arm and battery pack may be aided by springs, pistons, a motor, and the like. Bearings, wheels, casters, greased surfaces, and low friction materials may all aid in the extending motions, such as telescoping and the like. 
     Turning now to  FIG.  1    a schematic chart of an embodiment of electrical communication of vehicle components is shown. In this view, a charge port is in electric direct communication with the primary battery as well as the backup battery. As such, charge can flow, selectively in some embodiments, directly to the primary and backup battery at the same time. The primary battery is also able to charge the backup battery in this embodiment, however the backup battery does not charge the primary battery. The primary battery is operable to provide power to the motor or motors of the EV, as well as providing electricity to the vehicle power interface (which includes vehicle computer, controls, climate control, and so forth). The backup battery, when activated by a switch, is also able to provide power to the motor or motors of the EV, as well as providing electricity to the vehicle power interface. As such, the backup battery is able to power the vehicle for a short period of time to allow it to travel to a nearby charging station or other electricity source. As can be envisioned, the backup battery has a capacity that is less-often significantly less, than the primary battery, and is used solely in emergency situations to allow the vehicle to “limp” to a charging station. 
     In many cases, performance ability such as top speed and acceleration rate are limited by the computer controller when using the backup battery so as to maximize range. For example, a top speed may be limited to 45, 50, or 55 mph in some embodiments. In additional embodiments, acceleration rate may be reduced to approximately 25%, 33%, 40%, 50%, 75% of maximum, depending on embodiment by, for example limiting a maximum electrical flow rate to the motor or motors. In still further embodiments, when using the backup battery, a vehicle having more than one motor may be operable to have the backup battery power only one of the multiple motors to conserve energy. 
       FIGS.  2  and  4    show an embodiment of an EV of the present disclosure having a well which is defined in the trunk of the vehicle to receive and store a removable backup battery pack. The well  22  is formed in the trunk  20  of the EV  1  and is sized to receive the backup battery pack (shown in  FIG.  4   ). Within the well  22  is a plug  21  which engages with a corresponding plug of the backup battery. As such, the backup battery can be removably positioned into the well  22  of the EV&#39;s trunk  20 , and can be securely held there during normal operation of the vehicle as well as when using the backup battery as an emergency backup source to reach a charging location. Further, a switch  23  within the trunk  20  is accessible to manually activate the backup battery and allow it to operate the vehicle, rather than relying on the primary battery. As noted above, the manual switch provides certain advantages in some cases that are not available with an electronically or computer controlled switch. 
       FIG.  3    provides a view of an embodiment of the removable backup battery pack. The backup battery  31  is enclosed in a case, and has a handle  33  allowing easy lifting and carrying. The backup battery, in this embodiment, is able to connect to a standard wall plug as a source of charging. Accordingly, cable stays  35  hold a cable  38  and plug  37 , shown here as a standard wall plug, in a wrapped position. The backup battery is also able to charge a second EV other than the one in which it is intended to be connected. In this embodiment, the backup battery has a cord  34  extending from the battery having a plug connector  36  operable to connect to an EV through its charge port, such as a J1772 plug and the like. The cord  34  can be held neatly in place using, in this embodiment, cable stays  35  to wrap the cord. An electrical connector  32  is positioned on a bottom of the battery  31  case and allows the backup battery to connect to the electric plug within the vehicle storage area, such as plug  21  shown in  FIG.  2   . This allows direct connection of the battery to the vehicle, without the need for a plug connection to the charge port of the EV. 
       FIG.  5    shows a view of an extending arm which allows the backup battery pack to slide, via the arm, between an engaged position within the vehicle and electrically connected to the EV, and an extended position outside of the vehicle and away from the vehicle body. The backup battery  31  is shown in solid lines in its engaged position having its electrical connector (not shown) engaged with the vehicle electrical connector  21 . The backup battery  31  is in the trunk of the EV in the engaged position, towards a rear corner of the trunk, to best prevent it interfering with cargo storage. Arm  51  is also shown in solid lines within the trunk. In broken lines, the arm  51  and backup battery  31  are shown in the extended position. Arm  51  may be any structure which can allow sliding or telescoping extension of the backup battery. In one embodiment, the arm  51  may be a telescoping arm which allows the telescoping components to extend outwardly with the backup battery  31  thereon. A pushing motion may then retract the arm telescoping components into each other. In a particular embodiment, this pushing motion may also load a spring, piston, elastic tensioner and the like so that the movement from engaged to extended position may be aided in a controlled manner. In another embodiment, the arm  51  may be formed as a track which allows the battery  31  to slide along it. In one embodiment, the backup batter  31  need not extend out or away from the vehicle in the extended position, it may just be movable to the edge of the trunk/vehicle storage area so that it is more easily accessible than if it were in the back of the trunk such that a user would have to extend his or her arms to reach in and lift at an uncomfortable angle. 
       FIG.  6    provides a detail cutaway view of an embodiment of the backup battery  31  engaging with the EV well/storage area. Here, battery pack  31  fits into a well  61  (which may be the same or different from well  22  shown in the previous figures) in the trunk of the EV. The backup battery  31  has a female plug electrical connector engagable with a male plug electrical connector of the EV. When engaged, the backup battery pack  31  pushes protrusion  32  downward which urges connector  21  upward into engagement with the female electrical connector in the backup battery  31  via pivoting arm  63 . Upon removing the backup battery  31  from its position in the well  61 , the connector  21  falls downward and disconnects, while protrusion  62  moves upward. In this embodiment, the well  61  and/or battery pack  31  may have a snap-fit arrangement that allows the two to engage securely, and also allows the battery pack  31  to be removed upon a sufficient application of force against the snap fit. 
       FIG.  7    provides a detail cutaway view of an embodiment of the backup battery  31  engaging with the EV well/storage area. Here, battery pack  31  fits into a well  61  in the trunk of the EV. The backup battery  31  has a male plug electrical connector  32  engagable with a female plug electrical connector  21  of the EV. In this embodiment, protrusion  62  is fixed to the well  61  and extends upwardly therefrom. The protrusion is sized to engage with a slot  71  in the backup battery pack  31 . A plunger  73  is slidable in the slot  71  and when the backup battery  31  is placed into he well  61 , its weight causes protrusion  62  to push plunger  73  upwardly. In turn, the upward motion by plunger  73  causes the male plug  32  out away from the backup battery  31  case via pivoting arm  72 , such that it can engage with plug  21  of the EV. 
       FIG.  8    provides a view of an embodiment of the backup battery being used to charge a second different EV from the EV it is installed in via a charging cable connected to the second EV&#39;s charge port. Here, the first EV  81  has the backup battery  31  engaged in its trunk or other storage area. A cord  34  of the backup battery  31  is connected to second EV  82  via a plug  36 , such as a J1772 plug or other connector, which is engaged with the charge port of the second EV  82 . 
       FIG.  9    provides a schematic chart of an embodiment of electrical communication of vehicle components is shown. In this view, a charge port is in electric direct communication with the backup battery, and then the primary battery in a chain. As such, charge flows first to the backup battery and, once the backup battery reaches a certain state of charge, to the primary battery. The primary battery is able to charge the backup battery in this embodiment, and also the backup battery may charge the primary battery. The primary battery is operable to provide power to the motor or motors of the EV, as well as providing electricity to the vehicle power interface (which includes vehicle computer, controls, climate control, and so forth). The backup battery, when activated by a switch, is also able to provide power to the motor or motors of the EV, as well as providing electricity to the vehicle power interface. As such, the backup battery is able to power the vehicle for a short period of time to allow it to travel to a nearby charging station or other electricity source. As can be envisioned, the backup battery has a capacity that is less, often significantly less, than the primary battery, and is used solely in emergency situations to allow the vehicle to “limp” to a charging station. 
       FIG.  10    provides a schematic chart of an embodiment of electrical communication of vehicle components is shown. In this view, a charge port is in electric direct communication with the primary battery, and then the backup battery in a chain. As such, charge flows first to the primary battery and, once the primary battery reaches a certain state of charge, to the backup battery. The primary battery is able to charge the backup battery in this embodiment, and also the backup battery may charge the primary battery. The primary battery is operable to provide power to the motor or motors of the EV, as well as providing electricity to the vehicle power interface (which includes vehicle computer, controls, climate control, and so forth). The backup battery, when activated by a switch, is operable to provide charge to the primary battery, which in turn can operate the vehicle once sufficiently charged by the backup battery. As such, the backup battery is able to provide power for the vehicle for a short period of time by charging the primary battery to allow it to travel to a nearby charging station or other electricity source. 
       FIG.  11    provides a detail cutaway view of an embodiment of the backup battery  31  engaging with the EV well/storage area. Here, backup battery  31  fits into the well  61  or similar storage space of the EV by sliding into it. The backup battery  31  has a male plug electrical connector  32  which is retractable and extendable from the battery case. The well  61  has guide slots or rails  112  to engage with the battery  31  and guide it into position. A tab  111  extends from one of the guide slots and engages with a catch  110  on the backup battery  31 . Movement of this catch  110  as the battery is guided into proper resting position at the bottom of the well  61  causes the male plug  32  to extend away from the backup battery to be able to engage with matching female plug  21  of the EV. 
       FIG.  12    provides a detail cutaway view of an embodiment of the backup battery  31  engaging with the EV well/storage area. Here, backup battery  31  fits into the well  61  or similar storage space of the EV by sliding into it. The backup battery  31  has a female plug electrical connector  32 , while the EV has a retractable male plug  21  which is retractable and extendable from the bottom of well  61 . The well  61  has guide channels or rails  112  to engage with the battery  31  and guide it into position. A movable tab  111  extends from one of the guide channels and engages with a catch  110  on the backup battery  31 . Movement of this tab  111  as the battery is guided into proper resting position at the bottom of the well  61  causes the male plug  21  to extend away from the well  61  towards the backup battery  31  to be able to engage with matching female plug  32  of the backup battery  31 . 
     While several variations of the present disclosure have been illustrated by way of example in preferred or particular embodiments, it is apparent that further embodiments could be developed within the spirit and scope of the present disclosure, or the inventive concept thereof. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present disclosure, and are inclusive, but not limited to the following appended claims as set forth.