Hybrid power supply apparatus for battery replacement applications

• US 20040245031A1
• Filed: 10/14/2003
• Published: 12/09/2004
• Est. Priority Date: 02/16/2001
• Status: Active Grant

• Current Assignee: Plug Power Inc.
• Original Assignee: Cellex Power Products, Inc. (Plug Power Inc.)
• Inventors: Kratschmar, Kenneth W., Corless, Adrian J., Reid, Christopher E.J., Leboe, David, Lawrence, Carolyn
• Granted Patent: US 7,207,405 B2
• Time in Patent Office: Days
• US Class Current: 180/65.1
• 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 2001/0455 Removal or replacement of the energy storages
• CPC Class Codes: B60L 2200/42 Fork lift trucks
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 50/72 Constructional details of fuel cells specially adapted for electric vehicles
• CPC Class Codes: B60L 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: B60L 58/33 by cooling
• CPC Class Codes: B60L 58/34 by heating
• CPC Class Codes: B60L 58/40 for controlling a combination of batteries and fuel cells
• CPC Class Codes: B60Y 2200/15 Fork lift trucks, Industrial trucks
• CPC Class Codes: B66F 9/07572 Propulsion arrangements
• CPC Class Codes: B66F 9/07595 Cooling arrangements for device or operator
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/6563 with forced flow, e.g. by blowers
• CPC Class Codes: H01M 10/6565 with recirculation or U-turn in the flow path, i.e. back and forth
• CPC Class Codes: H01M 10/66 Heat-exchange relationships between the cells and other systems, e.g. central heating systems or fuel cells
• CPC Class Codes: H01M 16/006 : of fuel cells with rechargeable batteries
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/242 : adapted for protecting batteries against vibrations, collision impact or swelling
• 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 50/267 : having means for adapting to batteries or cells of different types or different sizes
• CPC Class Codes: H01M 50/296 : characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 8/00 : Fuel cells; Manufacture thereof
• CPC Class Codes: H01M 8/04014 : Heat exchange using gaseous fluids; Heat exchange by combustion of reactants
• CPC Class Codes: H01M 8/04373 : of auxiliary devices, e.g. reformers, compressors, burners
• CPC Class Codes: H01M 8/04417 : of the coolant
• CPC Class Codes: H01M 8/04567 : of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04597 : of auxiliary devices, e.g. batteries, capacitors
• CPC Class Codes: H01M 8/04701 : Temperature
• CPC Class Codes: H01M 8/04768 : of the coolant
• CPC Class Codes: H01M 8/0491 : of fuel cell stacks
• CPC Class Codes: H01M 8/0612 : from carbon-containing material
• CPC Class Codes: H01M 8/2475 : Enclosures, casings or containers of fuel cell stacks
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02E 60/50 : Fuel cells
• CPC Class Codes: Y02P 90/60 : Electric or hybrid propulsion means for production processes
• 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 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

This application relates to a hybrid power supply apparatus comprising a fuel cell and an energy storage device for use in off-road electric vehicles, such as lift trucks. The apparatus is a substitute for conventional lead acid batteries and is sized to fit within a conventional lift truck battery receptacle tray. The fuel cell and fuel processor systems are designed to meet the average load requirements of the vehicle, while the batteries and power control hardware are capable of responding to very high instantaneous load demands. The invention has a similar electrical interface as conventional battery systems and does not require vehicle modification. The apparatus is air-cooled to ensure that the hybrid power components operate within a preferred temperature range and to maintain the external surfaces of the apparatus and exhaust gases within safe temperature limits. Apart from vehicular applications, low power hybrid fuel cell products as exemplified by the present invention may also find application in uninterruptable power supply systems, recreational power, off-grid power generation and other analogous applications.

Claims

1-28. -28. (Cancelled)

29. A removable power source for use in a host machine that operates on electrical power, the host machine having a peak power demand, comprising:

a housing;

a battery disposed within said housing, said battery sized to supply the peak power demand of the host machine;

an electrical power generator disposed within said housing and sized to supply less than the peak power demand of the host machine; and

a power control module disposed within said housing and coupled to said battery and said electrical power generator and arranged to supply power to the host machine from either said battery or said generator.

31. The power source of claim 29, wherein said electrical power generator further comprises a fuel cell.

32. The power source of claim 29, wherein said housing is sized to fit in a compartment for holding a battery of said machine.

33. The power source of claim 32, wherein said housing is removable from the compartment for holding a battery.

30. (Cancelled)

34-37. -37. (Cancelled)

38. A method of replacing a battery in an electric powered machine with a rapidly renewable power source, comprising:

uncoupling the battery from the machine;

removing the battery from the battery compartment of the machine;

placing a rapidly renewable power source in the battery compartment; and

coupling the rapidly renewable power source to the machine.

39. A method for converting a battery-powered machine to a hybrid powered machine comprising the steps:

uncoupling the battery from the machine;

removing the battery from the machine;

placing a hybrid power source in the battery compartment of the machine; and

coupling the hybrid power source to the machine.

40. An electric vehicle having a peak power requirement, comprising:

a power source electrically coupled to the electric vehicle, said power source comprising;

a housing,

a battery disposed within said housing, said battery sized to supply the peak power requirement of the host machine,

a power control module disposed within said housing and coupled to said battery, and

an electrical power generator disposed within said housing and coupled to said power control module, said electrical power generator sized to supply less than the peak power requirement of the electric vehicle.

41. The electric vehicle of claim 40 wherein said electric vehicle is a forklift further comprising

a lifting mechanism coupled to said electric vehicle.

42. The vehicle disclosed in claim 40 wherein said vehicle is a work platform further comprising a scissor type lifting mechanism coupled to said chassis.

43. The electric vehicle of claim 40, wherein said housing is removable as a unit.

44-45. -45. (Cancelled)

46. A modular hybrid power source configured to convert to hybrid operation a host machine that is not configured for hybrid operation, the host machine designed and built to operate on electrical power supplied by a removable battery contained in a battery compartment, the host machine having a peak power demand, comprising:

a housing sized to fit within the battery compartment;

an electrical power generator disposed within said housing and sized to supply less than the peak power demand of the host machine;

a battery disposed within said housing, said battery sized to supply at least that portion of the peak power demand of the host machine not supplied by the electrical power generator;

a power control module disposed within said housing and coupled to said battery and said electrical power generator and arranged to supply power to the host machine from either said battery or from both said battery and said generator, and

a remotely mounted operator interface module connected to the power control module.

52. The power source as claimed in claim 46, wherein said interface module is configured to provide information to an operator about said electrical power generator.

48. An electric vehicle designed and built to operate on electrical power supplied by a removable battery contained in a battery compartment, the electric vehicle having a peak power requirement, comprising:

a modular hybrid power source electrically coupled to the electric vehicle, said power source configured to convert to hybrid operation a host machine that is not configured for hybrid operation, said power source comprising;

a housing sized to fit within the battery compartment;

an electrical power generator disposed within said housing and sized to supply less than the peak power requirement of the electric vehicle;

a battery disposed within said housing, said battery sized to supply at least that portion of the peak power requirement of the electric vehicle not supplied by the electrical power generator;

a power control module disposed within said housing and coupled to said battery, to said electrical power generator and to said electric vehicle, said power control module configured to supply power to the electric vehicle from either said battery or from both said battery and said generator, and

a remotely mounted operator interface module connected to the power control module.

49. The electric vehicle of claim 48 wherein said electric vehicle is a forklift further comprising a lifting mechanism coupled to said electric vehicle.

50. The electric vehicle of claim 48 wherein said electric vehicle is a work platform further comprising a lifting mechanism coupled to said electric vehicle.

51. The electric vehicle of claim 48, wherein said housing is removable as a unit.