Very low emission hybrid electric vehicle incorporating an integrated propulsion system including a hydrogen powered internal combustion engine and a high power Ni-MH battery pack

• US 20030157045A1
• Filed: 12/05/2002
• Published: 08/21/2003
• Est. Priority Date: 01/31/1997
• Status: Active Grant

• Current Assignee: ChevronTexaco Technology Ventures LLC (Chevron Corp.)
• Original Assignee: ChevronTexaco Technology Ventures LLC (Chevron Corp.)
• Inventors: Stempel, Robert C., Ovshinsky, Stanford R.
• Granted Patent: US 6,759,034 B2
• Time in Patent Office: Days
• US Class Current: 424/69
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 2001/005 the electric storage means
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/10 Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: F02B 43/10 Engines or plants characterised by use of other specific gases, e.g. acetylene, oxyhydrogen
• CPC Class Codes: F02G 1/00 Hot gas positive-displacement engine plants
• CPC Class Codes: H01M 10/345 Gastight metal hydride accumulators
• CPC Class Codes: H01M 10/44 Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/443 in response to temperature
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/647 : Prismatic or flat cells, e.g. pouch cells
• CPC Class Codes: H01M 10/651 : characterised by parameters specified by a numeric value or mathematical formula, e.g. ratios, sizes or concentrations
• CPC Class Codes: H01M 10/653 : characterised by electrically insulating or thermally conductive materials
• CPC Class Codes: H01M 10/6557 : arranged between the cells
• CPC Class Codes: H01M 10/6563 : with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/6567 : Liquids
• CPC Class Codes: H01M 4/24 : Electrodes for alkaline accumulators
• CPC Class Codes: H01M 4/242 : Hydrogen storage electrodes
• CPC Class Codes: H01M 4/383 : Hydrogen absorbing alloys
• CPC Class Codes: H01M 4/625 : Carbon or graphite
• CPC Class Codes: H01M 4/626 : Metals
• CPC Class Codes: H01M 4/661 : Metal or alloys, e.g. alloy coatings H01M4/669 take precedence
• CPC Class Codes: H01M 4/667 : in the form of layers, e.g. coatings
• CPC Class Codes: H01M 4/80 : Porous plates, e.g. sintered carriers
• CPC Class Codes: H01M 4/801 : Sintered carriers
• CPC Class Codes: H01M 4/803 : of only powdered material
• CPC Class Codes: H01M 4/805 : of powdered and fibrous material
• CPC Class Codes: H01M 4/808 : Foamed, spongy materials
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/227 : Organic material
• CPC Class Codes: H01M 50/249 : specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/417 : Polyolefins
• CPC Class Codes: H01M 50/423 : Polyamide resins
• CPC Class Codes: H01M 50/534 : characterised by the material of the leads or tabs
• CPC Class Codes: H01M 50/536 : characterised by the method of fixing the leads to the electrodes, e.g. by welding
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/30 : Use of alternative fuels, e.g. biofuels
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/905 : Combustion engine
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

A very low emission hybrid electric vehicle incorporating an integrated propulsion system which includes a hydrogen powered internal combustion engine, a metal hydride hydrogen storage unit, an electric motor, high specific power, high energy density nickel-metal hydride (NiMH) batteries, and preferably a regenerative braking system. The nickel-metal hydride battery module preferably has a peak power density in relation to energy density as defined by:

P >1,420−16 E,

where P is greater than 600 Watts/kilogram, where P is the peak power density as measured in Watts/kilogram and E is the energy density as measured in Watt-hours/kilogram.

Claims

1. A very low emission hybrid electric vehicle drive system comprising:

a hydrogen powered internal combustion engine;

a hydrogen storage unit for storing hydrogen to be supplied to said hydrogen powered internal combustion engine;

an electric motor; and

at least one nickel-metal hydride battery module for providing electric power to said electric motor.

2. The drive system of claim 1, wherein said at least one battery module has an internal resistance effective to provide a peak power density in relation to an energy density as defined by:

P>

1,375−

15E, with p greater than 600 watts/kilogram, where p is the peak power density as measured in watts/kilogram and E is the energy density as measured in watt-hours/kilogram;

3. The drive system of claim 1, further including means for connecting and disconnecting said combustion engine and said electric motor in driving relationship to said electric vehicle.

4. The drive system of claim 3, further including control means for operating said at least one battery module in a charge depleting mode.

5. The drive system of claim 3, further including control means for operating said at least one battery module in a charge sustaining mode.

6. The drive system of claim 2, wherein said peak energy density is at least 70 Wh/Kg.

7. The drive system of claim 1, further comprising a cooling system for cooling said at least one nickel metal hydride battery module.

8. The drive system of claim 2, wherein said peak power density is greater than 700 Watts/kilogram.

9. The drive system of claim 2, wherein said peak power density is at least 1000 Watts/kilogram.

10. The drive system of claim 1, wherein said at least one battery module includes negative electrodes having porous metal substates formed substantially of copper.

11. The drive system of claim 1, wherein said hydrogen storage unit comprises a metal hydride hydrogen storage unit including a hydrogen storage material.

12. The drive system of claim 11, wherein said hydrogen storage material includes AB₂ or AB₅ type hydrogen storage alloys.

13. The drive system of claim 12, wherein said AB₂ or AB₅ type hydrogen storage alloy is selected from the group consisting of rare earth-nickel alloys, titanium-manganese alloys, titanium-zirconium alloys, titanium-iron alloys, or magnesium alloys.

14. The drive system of claim 13, wherein said hydrogen storage alloy is a powder characterized in that said alloy powder has:

a) a hydrogen storage capacity of at least 6 weight %;

b) absorption kinetics such that the alloy powder absorbs 80% of it'"'"'s total capacity within 5 minutes at 300°

C.; and

c) a particle size range of between 30 and 70 microns.

15. The drive system of claim 14, wherein said alloy includes at least 90 weight % magnesium.

16. The drive system of claim 15, wherein said alloy further includes 0.5-2.5 weight % nickel.

17. The drive system of claim 16, wherein said alloy further includes 1.0-4.0 weight % Misch metal.

18. The drive system of claim 17, wherein said Misch metal comprises predominantly Ce, La and Pr.

19. The drive system of claim 18, wherein said alloy further includes one or more from the group consisting of 3-7 weight % Al, 0.1-1.5 weight % Y, and 0.3-1.5 weight % Si.

20. The drive system of claim 13, wherein said alloy is a non-pyrophoric alloy which comprises 0.5-10 at. % Zr, 29-35 at. % Ti, 10-15 at. % V, 13-20 at. % Cr, 32-38 at. % Mn, 1.5-3.0 at. % Fe, and 0.05-0.5 at. % Al.

21. The drive system of claim 20, wherein said alloy comprises Zr₁ Ti₃₃ V_12.54 Cr₁₅ Mn₃₆ Fe_2.25 Al_0.21.

22. The drive system of claim 20, wherein said alloy comprises Zr_1.5 Ti_32.5 V_12.54 Cr₁₅ Mn₃₆ Fe_2.25 Al_0.21.

23. The drive system of claim 20, wherein said alloy further comprises 1-10 at. % total of at least one element selected from the group consisting of Ba, Co, Cu, Cs, K, Li, Mm, Mo, Na, Nb, Ni, Rb, Ta, Tl, and W.

24. The drive system of claim 1, further comprising:

a regenerative braking system providing charging current for said nickel-metal hydride batteries.

25. The drive system of claim 2, wherein each of said nickel-metal hydride batteries have at least one negative electrode, said negative electrode including a porous metal substrate comprising a material selected from the group consisting of copper, copper alloy, nickel coated with copper, and nickel coated with copper alloy.

26. The drive system of claim 20, wherein said negative electrode includes an electrode tab, said electrode tab welded to said porous metal substrate.

27. The drive system of claim 26, where said negative electrode comprises Ovonic alloys.

28. The drive system of claim 27, where said Ovonic alloys comprise the composition:

(Base Alloy)_aCo_bMn_cAl_dFe_eLa_fMo_g

wherein Base Alloy represents a disordered multicomponent alloy having at least one structure selected from the group consisting of amorphous, microcrystalline, polycrystalline, and any combination of these structures;

b is 0 to 7.5 atomic percent;

c is 0 to 8.5 atomic percent;

d is 0 to 2.5 atomic percent;

e is 0 to 6 atomic percent;

f is 0 to 4.5 atomic percent;

g is 0 to 6.5 atomic percent;

b+c+d+e+f+g>

0; and

a+b+c+d+e+f+g=100 atomic percent.

29. The drive system of claim 2, wherein each of said nickel-metal hydride batteries includes at least one positive electrode, said positive electrode comprising an active material comprising a disordered y-phase positive electrode material.

30. The drive system of claim 29, wherein said active material further comprises an additive chosen from the group consisting of nickel particles, nickel fibers, graphite particles, nickel plated graphite particles, nickel plated copper particles, nickel plated copper fibers, nickel flakes, and nickel plated copper flakes.

31. The drive system of claim 2, wherein said nickel metal hydride batteries are low pressure nickel metal hydride electrochemical cells comprising:

a negative electrode comprising a metal hydride active material;

a positive electrode comprising a nickel hydroxide active material; and

a reduced thickness separator positioned around said negative electrode and around said positive electrode, said separator comprising a material selected from the group consisting of nylon, and grafted polyethylene.

32. The drive system of claim 31, wherein said negative electrode or the surface of said reduced thickness separator facing said negative electrode has a uniform distribution of hydrophobic material.

33. The drive system of claim 32, where said hydrophobic material comprises a 1% aqueous solution of polytetrafluoroethylene.

34. The drive system of claim 2, further comprising a fluid cooled battery-pack system, said system comprising:

a battery-pack case including at least one coolant inlet means and at least one coolant outlet means, said at least one battery module disposed within said case such that said module is spacedly disposed from said case and from any other module disposed within said case to form coolant flow channels along at least one surface of said module, the width of said coolant flow channels sized to provide maximum heat transfer from said module to said coolant; and

at least one coolant transport means, said coolant transport means causing said coolant to enter said coolant inlet means of said case, to flow through said coolant flow channels and to exit said coolant outlet means of said case.

35. The drive system of claim 34, where said coolant transport means includes a forced-air blower.

36. The drive system of claim 34, where said coolant flows perpendicular to the longest dimension of said coolant flow channels.

37. The drive system of claim 34, where said coolant flows parallel to the longest dimension of said coolant flow channels.

38. The drive system of claim 34, where said coolant flow channels are designed to impede the flow of coolant flowing therethrough by no more tnat about 5 to 30% in flow volume.

39. The drive system of claim 34, where the width of said coolant flow channels is between 0.3 and 12 mm.

40. The drive system of claim 34, where said system maintains the temperature of said battery modules below 65°

C.

41. The drive system of claim 34, where said system maintains the temperature difference between battery modules below 8°

C.