Abstract:
This invention pertains to an economical method of easy conversion of any internal combustion fueled vehicle into a fuel saving plug-in hybrid electric vehicle (PHEV) by an add-on kit, without replacing the engine and with a minimal modification of the vehicle body. The converted vehicle substantially saves fuel as compared to the vehicle before this conversion.

Description:
CROSS REFERENCE TO RELATED DOCUMENTS 
       [0001]    The subject matter of the invention is described in the Disclosure Document of Joseph B. Kejha Ser. No. 600,693 filed on May 12, 2006, and entitled “Low Cost Conversion of any Vehicle into a Plug-in Hybrid Electric Vehicle.” 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention pertains to easy conversion of any existing vehicles with internal combustion-only engine into plug-in hybrid electric vehicles, without replacing the engine and with a minimal modification of the vehicle body, and thus substantially saving any fuel and reducing CO 2  emissions. 
         [0004]    2. Description of the Prior Art 
         [0005]    It is well known, that Plug-in Hybrid Electric Vehicle (PHEVs) are different from self-charging Hybrid Electric Vehicles (HEVs) by having additional batteries in parallel with a HEV battery, which additional batteries have to be recharged by plugging into electric grid and charging said extra batteries. The purpose of the Plug-in HEVs is to drive in electric-only mode for a certain limited distance, such as commuting to work, or driving in the near neighborhood, and thus saving more gasoline or other fuels than the self-charging HEVs, and conventional vehicles. For longer trips the internal combustion engine in combination with electric drive is used. Up to 80% of fuel can be thus saved, as compared to equivalent conventional vehicles, and all oil imports can be eliminated. 
         [0006]    The existing self-charging HEVs can drive in electric-only mode at 35 MPH speed, 5 miles or less, due to the small battery. The “Plug-ins” can drive up to 40 miles, (depending on the battery size), which makes them practical for electric-only commuting. 
         [0007]    Prior art Plug-in Hybrid Electric Vehicles (PHEVs) are made by modifying the existing HEVs by adding extra batteries and a charger into the trunk. 
         [0008]    Due to the cost of vehicle fuels rising, there is a need to make fast as many Plug-in HEVs as possible. 
         [0009]    The problem is that there is not enough of the existing HEVs made to the converted into the Plug-in HEVs (PHEVs), and thus substantially reduce oil consumption, cost and oil import. Making many new self-charging or plug-in HEVs takes long time and huge sums of money. The instant invention solved this problem, because by its add-on kit and its novel method of conversion, any existing internal combustion vehicle can be easily converted into a Plug-in Hybrid Electric Vehicle and thus substantially save fuel and cost, which is the primary object of this invention. 
         [0010]    Prior art self-charging HEVs, including internal combustion vehicles converted into self-charging HEVs, and HEVs converted into PHEVs employ a sophisticated communication system of sensors and controls between the electric and the internal combustion engine drive systems (=energy management). This invention provides much simpler system by having two totally independent drives in one vehicle; one driven by fuel, and the other driven by electricity. The driver then decides and selects which one to use. 
         [0011]    Prior art method of conversion of an internal combustion vehicle into a HEV or PHEV vehicle involves removing the existing drive system (including the engine) from the body of the vehicle and replace it with a new hybrid electric drive system having a smaller engine. This means virtually “gutting” and rebuilding the vehicle, including the body, which is impractical, time consuming and expensive. 
         [0012]    This invention does not suffer from prior art problems and provides a simpler lower cost conversion method, which results in improved vehicle efficiency and large fuel savings, and has many other advantages. 
       SUMMARY OF THE INVENTION 
       [0013]    It has now been found, that any existing internal combustion (IC) vehicle can be easily converted at a relatively low cost into a plug-in hybrid electric vehicle (PHEV) by replacing at least one, or all of its preferably non-driven wheels with a least one new wheel(s) containing electric motor(s), which may be also refered to as “wheel-motor(s),” and by adding at least one electric energy storage unit(s), such as a battery or a battery with a capacitor or ultracapacitor into the trunk or a storage place of the vehicle, and electrically connecting them by wires and/or cables through at least one electric control unit(s), mounted in any desirable place in the vehicle, including in the electric motor(s). A charger with a cable and plug should be also added into the vehicle and electrically connected to the energy storage unit(s). The axles and suspension supporting the new wheel(s) with electric motor(s) may be preferably reinforced, or replaced with similar, stronger parts. The battery should be larger than the battery in the self-charging hybrid electric vehicle, and must be rechargeable by connecting it to the outside electric grid (out of the PHEVs) and should provide the electric-only driving range of 20-60 miles at highway speeds 60-70 MPH, (unlike today&#39;s HEVs). This is substantially less range than an advanced full electric-only vehicle, but is sufficient to drive as a zero emission vehicle to work, or around the town, and thus save hydrocarbon fuels, or to extend the range of the internal combustion drive system. The existing internal combustion (IC) engine and its drive system stay intact. The electric and the internal combustion system should work preferably completely independently from each other, without communication between there, and the electric drive may be put in use by a selection switch, and by putting the internal combustion transmission into neutral, and by disconnecting the ignition. (No other communications or controls are needed). This independent work of each system of this invention is the major difference from the HEV vehicles. The operator decides which system to use for the specific purpose of driving. For example, commuting to work with the electric-only drive, and for a long trip will use the engine drive-only. The electric control unit(s) should be connected to the existing accelerator pedal, and brake pedals (or any other control) of the vehicle, preferably without any additional operator&#39;s input(s) (command(s), so that the operator can drive the vehicle electrically, preferably the same way as any other conventional vehicle before this conversion. 
         [0014]    The main purpose of the electric motor(s) in the wheel(s) is mostly to drive the vehicle in electric-only mode, and also they may assist brakes during breaking and absorb-fully or partly the deceleration energy of the vehicle and regenerate (recharge) thus the battery. Additionally, the electric motor(s) may help (assist) the internal combustion engine during heavy duty use, such as during an off-road driving, hill climbing and in the snow, on command only by the operator, equivalent to 4-wheel drive. During braking, the electric motor(s) in the wheels may become generator(s), since they may have both functions by design and are driven by the inertia of the vehicle through the friction with the road. If two or more motor(s) are used, then their controls must compensate for their different RPM during turns of the vehicle. This conversion should be custom designed to fit the selected vehicle as an add-on kit, or added-on option to new vehicles by their manufacturers. The kits should also include an installation of electric/hydraulic pump for hydraulic brakes and power steering, electric heater, defrosters, and the original low volt vehicle battery charging from the PHEV battery. 
         [0015]    Advantages of this PHEV conversion are: 1. Much simpler system than the system in prior art HEVs and PHEVs. 2. Four wheel (or more) drive in the snow, etc. 3. Easy engine start in cold weather, if low temperature operation ultracapacitors are used in the electric energy storage unit(s). 4. Vehicle also may start to drive in electric-only mode, and then by the vehicle inertia—crank the internal combustion engine to start. 
         [0016]    The principal object of this invention is to provide low cost and easy conversion of any internal combustion vehicle and into Plug-in Hybrid Electric Vehicle and thus save fuel. 
         [0017]    Another object of this invention is to provide vehicles, which lower CO2 emissions and eliminate oil imports. 
         [0018]    Other objects and advantages of the invention will be apparent from the description and claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         [0019]    The nature and characteristic features of the invention will be more readily understood from the following description taken in connection with the accompanying drawing forming part hereof in which: 
           [0020]      FIG. 1  is a diagrammatic, side elevational view of the front wheel drive vehicle, illustrating its components and preferred locations of the added electric drive components. 
           [0021]      FIG. 2  is a diagrammatic, top elevational, sectional view of the vehicle at the line  2 - 2  of  FIG. 1 , illustrating location of its components, including the electric drive system. 
           [0022]      FIG. 3  is a diagrammatic, side elevational view of the rear wheels drive vehicle, illustrating its components and preferred locations of the added electric drive components. 
           [0023]      FIG. 4  is a diagrammatic, top elevational, sectional view of the vehicle at the line  4 - 4  of  FIG. 3 , illustrating location of its components, including the electric drive system. 
           [0024]      FIG. 5  is a diagrammatic, side elevational view of the front wheel drive vehicle, illustrating its components and electric wheel-motor(s) mounted to driven axle(s) by the engine. 
           [0025]      FIG. 6  is a diagrammatic, side elevational view of two-wheeled vehicle, illustrating its components and preferred locations of its electric drive system. 
       
    
    
       [0026]    Like numerals refer to like parts throughout the several views and figures. 
         [0027]    It should, of course, be understood that the description and the drawings herein are merely illustrative, and it will be apparent that various modifications, combinations and changes can be made of the structures and the systems disclosed without departing from the spirit of the invention and from the scope of the appended claims. 
       DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0028]    When referring to the preferred embodiments, certain terminology will be utilized for the sake of clarity. Use of such terminology is intended to encompass not only the described embodiment, but also all technical equivalents which operate and function in substantially the same way to bring about the same results. 
         [0029]    Fuel saving hybrid electric vehicles (HEV&#39;s) employ propulsion system comprising a smaller internal combustion engine mechanically connected to an electric motor/generator, which is electrically connected to a battery through a control unit with sensors. This usually requires designing and building the vehicles “from scratch”, or requires an extensive modification and rebuilding of the existing vehicles. Both methods are time consuming and expensive. The HEVs are then converted into plug-in HEVs by adding a larger battery with a charger. The present invention employs a novel method of easy conversion of any internal combustion-only vehicle into plug-in hybrid electric vehicle (PHEV), which is fast, simple and low cost, and thus it can accelerate our effort to be free from the imported oil. 
         [0030]    The invention will be better understood when referring in more detail to the drawings of this patent and  FIGS. 1 and 2 , which is one embodiment of this invention illustrating as an example vehicle  1 A, comprising body  1  with a large standard internal combustion engine  2  driving front wheels  3  and  4 , which wheels are steered by steering system  11 , and the vehicle includes passenger seats  9 ,  10  and  15  and trunk  8  and rear non-driven wheels  5 A and  6 A, which wheels are replaced during the conversion with wheels having electric motors  5  and  6  therein. At least one wheel may be replaced in this manner. Additionally, electric energy storage units  7  such as a battery, and optionally ultracapacitor  7 A in parallel are added into the trunk  8 , and are connected with the electric motors  5  and  6  via cables  16  and  17 , through electric control units  16 A and  17 A. At least one electric energy storage unit is necessary and preferably the battery. The units  16 A and  17 A are electrically connected to command potentiometer  12  attached to gas pedal of the engine  2  by a well known link and lever (not shown). Additionally, at least one electric charger  13  with cable  13 A and plug  13 B are added into the trunk  8 , and the charger  13  is electrically connected to the battery  7  by cable  13 C. The charger  13  can be then connected to electric grid via plug  13 B. The cells of the battery  7  may be charged in parallel, as described in my prior U.S. Pat. No. 5,811,959. Only a small modification of the vehicle body by adding holes for the connecting cables and wires may be necessary. The energy storage unit(s)  7  and  7 A may be located in any desirable and available place in the vehicle, but the trunk space behind the rear seats is preferred. The ultracapacitor  7 A provides for long cycle life of the battery  7 , due to absorbing high electric peak loads. For example, a front wheel engine driven vehicle  1 A has the electric motors  5  and  6  in the rear wheels, and the energy storage unit, such as a large lithium-ion battery  7  for approximately 40 miles electric-only range with an ultracapacitor  7 A are in the trunk above the electric wheel-motors  5  and  6 , which helps to compensate as a counter-weight against the “unsprung weight” of these wheel-motors, resulting thus in a smoother ride. The axles and suspension supporting the new wheel(s) with the electric motors should be preferably reinforced or replaced with similar, stronger parts. The engine  2  is not replaced with a smaller engine. 
         [0031]    The control unit(s)  16 A and  17 A are commanded by the accelerator pedal (or any other controls) of the vehicle, preferably without any additional operator&#39;s input, so that the operator can drive the vehicle preferably the same way as any other conventional vehicle before this conversion. 
         [0032]    The purpose of the electric wheel-motors  5  and  6  is to drive the vehicle in electric-only mode for relatively short trips, such as commuting to work at highway speeds, or around the neighborhood slowly. This lowers the consumption of gasoline or any other fuel up to 80% and extends the driving range of the vehicle. During the electric-only driving, the engine  2  is disconnected from the front wheels  3  and  4  and should not be operating. Engine transmission should be in “neutral” position and the engine disconnect and shut-off may be done automatically by a selection switch  14  with interlock, which switch will also put the vehicle into electric-drive mode. Electric-reverse should be done by another switch  18 . No communications or controls are needed between the internal combustion (IC) engine  2  and the electric drive system. This independent work of each system makes the vehicle controls very simple and low cost. During braking, the electric motors  5  and  6  may become generators by design, to assist the brakes and absorb partly or fully the energy of braking, and store the energy in the energy storage units  7  and  7 A, to be ready for use for the next acceleration and driving of the vehicle. During braking, the electric motors in the wheels may become electric generators, since they may have both functions by design and are driven by the inertia of the vehicle. When the energy storage is full, it is disconnected from charge; by control unit(s)  16 A and  17 A. The electric motors  5  and  6  may also have an overdrive clutch to reduce the friction. In this case, the motors will not be also generators. Control units  16 A and  17 A also compensate for different RPM of the wheels  5  and  6  during turns of the vehicle, similarly as the differential gear box of engine driven wheels. The control units may be also included in the wheel-motor(s), instead being with the energy storage units. This provides for more trunk space. The internal combustion (IC) engine  2  is used for longer trips, preferably without the electric drive assistance. The operator decides and selects which drive system to use for specific purpose. Additionally, both systems together may be used for a heavy duty driving. For this, the selector switch  14  may have another position and will “unlock” the engine  2 . The vehicle  1 A also can not get “stuck” with a discharged battery  7  and can continue driving by using the engine  2 . The described conversion components should be custom designed to fit selected vehicle as a kit or as an added-on option to new vehicles by their manufacturers. 
         [0033]    The kits should also include an installation of electric/hydraulic pump for power brakes and power steering, electric heater, defrosters and low volt charging the engine start battery from the battery  7 . 
         [0034]    If a vehicle has rear wheels driven by the engine, such as vehicle  1 B shown in  FIGS. 3 and 4 , then the electric wheel-motors  5  and  6  may replace the front non-driven wheels, which is another embodiment of the invention. At least one wheel may be replaced in this manner. If a vehicle has four or more driven wheels by the engine, then at least one wheel may have its drive axel(s) disconnected and the wheel(s) replaced with the electric wheel-motors (not shown). Similarly, a three-wheeled vehicle&#39;s non-driven wheel(s) can be replaced with the electric wheel-motors (not shown). 
         [0035]    At least one electric wheel-motor  5  or  6  may also replace at least one driven wheel by the engine of the vehicle  1 C, as shown in  FIG. 5  as an example, which is another embodiment of the invention. Consequently, all or any wheel(s) of a vehicle (driven and/or non-driven by the engine) may be replaced with electric wheel-motor(s) (not shown). Then, in the electric mode, the engine may be disconnected by the clutch, put into neutral and shut-off. 
         [0036]    Similarly, another embodiment of the invention is two wheeled vehicle  1 D, having body  1 E with engine  2 D, as shown in  FIG. 6 . The vehicle  1 D has at least one wheel replaced with electric wheel-motor(s)  5  and/or  6 , and has electric energy storage unit(s)  7 ,  7 A with charger  13  added, and electrically connected as shown. 
         [0037]    It is apparent to any person skilled in the art, that the described conversion methods and kits can convert any internal combustion vehicle into a plug-in hybrid electric vehicle, and thus save up to 80% of fuel, which could eliminate all oil imports. 
         [0038]    It should, of course, be understood that the description and the drawings herein are merely illustrative and it will be apparent that various modifications, combinations and changes can be made of the structures and systems disclosed without departing from the spirit of the invention and from the scope of the appended claims. 
         [0039]    It will thus be seen, that a more economical and reliable conversion method of any internal combustion vehicle into plug-in hybrid electric vehicle (PHEV) has been provided, with which the objects of the invention are achieved.