Vehicle battery systems and methods

• US 8,453,773 B2
• Filed: 06/26/2009
• Issued: 06/04/2013
• Est. Priority Date: 06/27/2008
• Status: Active Grant

• Current Assignee: Proterra Operating Co., Inc.
• Original Assignee: Proterra AG
• Inventors: Hill, Dale, Walker, Michael, Onorato, Shaun, Morris, Donald, Misencik, Stephen, Winkel, John
• Primary Examiner(s): PHAN, HAU VAN
• Application Number:
  US12/459,074
• Publication Number:
  US 20100025132A1
• Time in Patent Office: 1,439 Days
• Field of Search: 180/68.5, 180/65.31, 180/65.1, 180/313, 180/65.29, 429/59, 429/129, 429/246, 429/60, 429/100, 320/116, 320/101, 320/109
• US Class Current: 180/65.29
• 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 2001/0438 Arrangement under the floor
• CPC Class Codes: B60K 6/20 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
• CPC Class Codes: B60L 2200/18 Buses
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2200/28 Trailers
• CPC Class Codes: B60L 2270/40 related to technical updates when adding new parts or software
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• 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: B60L 50/66 Arrangements of batteries
• CPC Class Codes: B60L 53/11 DC charging controlled by the charging station, e.g. mode 4
• CPC Class Codes: B60L 58/12 responding to state of charge [SoC]
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60R 16/04 Arrangement of batteries
• CPC Class Codes: B60W 10/24 including control of energy storage means
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• CPC Class Codes: B60Y 2200/1432 Low floor busses
• CPC Class Codes: B60Y 2200/15 : Fork lift trucks, Industrial trucks
• CPC Class Codes: B62D 29/00 : Superstructures, understructures, or sub-units thereof, characterised by the material thereof B62D33/044, B62D33/048 take precedence
• CPC Class Codes: B62D 29/02 : predominantly of wood
• CPC Class Codes: B62D 47/02 : for large numbers of passengers, e.g. omnibus
• CPC Class Codes: H01M 10/052 : Li-accumulators
• CPC Class Codes: H01M 10/42 : Methods or arrangements for servicing or maintenance of secondary cells or secondary half-cells H01M10/60 takes precedence
• CPC Class Codes: H01M 10/4207 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 2010/4271 : Battery management systems including electronic circuits, e.g. control of current or voltage to keep battery in healthy state, cell balancing
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 4/485 : of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy H01M4/505, H01M4/525 take precedence
• CPC Class Codes: H01M 50/209 : adapted for prismatic or rectangular cells H01M50/216 takes precedence
• CPC Class Codes: H01M 50/24 : adapted for protecting batteries from their environment, e.g. from corrosion thermal insulation H01M10/658
• 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 50/509 : characterised by the type of connection, e.g. mixed connections
• CPC Class Codes: H01M 50/516 : by welding, soldering or brazing
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02P 70/50 : Manufacturing or production processes characterised by the final manufactured product
• 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 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles

Abstract

The invention provides for a high occupancy or heavy-duty vehicle with a battery propulsion power source, which may include lithium titanate batteries. The vehicle may be all-battery or may be a hybrid, and may have a composite body. The vehicle battery system may be housed within the floor of the vehicle and may have different groupings and arrangements.

Claims

1. A heavy-duty vehicle comprising:

a battery power source, wherein the battery power source includes a plurality of battery packs and is housed within a battery-pack mounting floor structure of the heavy-duty vehicle such that individual battery packs are individually mounted into cavities within the battery-pack mounting floor structure,

wherein the battery-pack mounting floor structure of the heavy-duty vehicle is formed from a single molded piece or multiple molded pieces of at least one composite material,

wherein the battery power source is arranged with respect to the floor structure such that the heavy-duty vehicle has a low floor chassis with substantially no compromise in an interior seating layout of said heavy-duty vehicle.

2. The vehicle of claim 1 wherein the battery power source is a lithium titanate battery power source.

3. The vehicle of claim 1 wherein the heavy-duty vehicle is one of the following:

a transit bus, a school bus, a package delivery van, a shuttle bus, class 5-8 truck, or a tractor trailer.

4. The vehicle of claim 1 wherein the battery power source has a height of 6.75 inches or less.

5. The vehicle of claim 1 wherein an individual battery pack of the plurality of battery packs includes a watertight box made from stainless steel or a composite material that will not oxidize when exposed to an electric arc.

6. The vehicle of claim 1 wherein an individual battery pack of the plurality of battery packs includes dividers that provide isolation between the plurality of battery modules.

7. The vehicle of claim 1 wherein an individual battery pack of the plurality of battery packs has integrated cooling features.

8. A heavy-duty vehicle, comprising:

a battery power source, wherein the battery power source includes a plurality of battery packs and is housed within a battery-pack mounting floor structure of the heavy-duty vehicle such that individual battery packs are individually mounted into cavities within the battery-pack mounting floor structure,

wherein the battery-pack mounting floor structure of the heavy-duty vehicle is formed from a single molded piece or multiple molded pieces of at least one composite material,

wherein the battery power source is arranged with respect to the floor structure such that the heavy-duty vehicle has a low floor chassis with substantially no compromise in an interior seating layout of said heavy-duty vehicle, and

wherein the battery power source includes at least one battery assembly with a plurality of battery strings, wherein an individual battery string includes a plurality of battery packs, wherein an individual battery pack includes a plurality of battery modules, and wherein an individual battery module includes a plurality of cells.

9. The vehicle of claim 8 wherein said individual battery pack includes a watertight box made from stainless steel or a composite material that will not oxidize when exposed to an electric arc.

10. The vehicle of claim 8 wherein said individual battery pack includes dividers that provide isolation between the plurality of battery modules.

11. The vehicle of claim 8 wherein the individual battery pack and the individual battery module have integrated cooling features.

12. The vehicle of claim 8 further comprising a battery management system capable of disconnecting the battery string if a fault is detected.

13. The vehicle of claim 8 wherein the heavy-duty vehicle is capable of operating if the battery string is disconnected.

14. The vehicle of claim 8 wherein a floor of the heavy-duty vehicle is a level floor between axles of the vehicle.

15. The vehicle of claim 8 wherein the battery power source is a lithium titanate battery power source.

16. A heavy-duty vehicle comprising:

a battery power source, wherein the battery power source includes a plurality of battery packs and is housed within a battery-pack mounting floor structure of the heavy-duty vehicle such that individual battery packs are individually mounted into cavities within the battery-pack mounting floor structure,

wherein the battery-pack mounting floor structure of the heavy-duty vehicle is formed from a single molded piece or multiple molded pieces of at least one composite material,

wherein the battery power source is arranged with respect to the floor structure such that the heavy-duty vehicle has a low floor chassis with substantially no compromise in an interior seating layout of said heavy-duty vehicle,

wherein a floor of the heavy-duty vehicle is a level floor between axles of the vehicle.

17. The vehicle of claim 16 wherein an individual battery pack of the plurality of battery packs includes a watertight box made from stainless steel or a composite material that will not oxidize when exposed to an electric arc.

18. The vehicle of claim 16 wherein an individual battery pack of the plurality of battery packs includes dividers that provide isolation between the plurality of battery modules.

19. The vehicle of claim 16 wherein an individual battery pack of the plurality of battery packs has integrated cooling features.

20. The vehicle of claim 16 wherein the battery power source is a lithium titanate battery power source.