Electric vehicle battery system

• US 8,517,132 B2
• Filed: 08/12/2011
• Issued: 08/27/2013
• Est. Priority Date: 09/19/2008
• Status: Expired due to Fees

• Current Assignee: Charge Peak Limited
• Original Assignee: Better Place GmbH
• Inventors: Heichal, Yoav, Agassi, Tal
• Primary Examiner(s): EBNER, KATY MEYER
• Application Number:
  US13/209,348
• Publication Number:
  US 20110297470A1
• Time in Patent Office: 746 Days
• Field of Search: 180/68.5, 429/100, 104/34
• US Class Current: 180/68.5
• 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 2001/0472 from below
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• 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 53/80 Exchanging energy storage elements, e.g. removable batteries
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/204 Racks, modules or packs for multiple batteries or multiple cells
• CPC Class Codes: H01M 50/242 adapted for protecting batteries against vibrations, collision impact or swelling
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• 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: 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 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10T 29/49815 : Disassembling

Abstract

The electric vehicle includes a battery pack that can be exchanged at a battery exchange station. At the battery exchange station, an at least partially spent battery pack is exchanged for an at least partially charged battery pack. A battery bay is configured to be disposed at an underside of the electric vehicle. The battery bay includes a frame which defines a cavity. The cavity is configured to at least partially receive the battery pack therein. The battery bay comprises at least one latch rotatably pivoted about an axis substantially parallel with a plane formed by the underside of the vehicle. The latch is configured to lift, retain the battery pack at least partially within the cavity.

Claims

1. A battery bay configured to be disposed at an underside of an at least partially electric vehicle, the battery bay comprising:

a frame defining a cavity configured to at least partially receive a battery pack therein from an underside of an at least partially electric vehicle;

at least three latches each being mounted on the frame for rotation with respect to the frame and being engageable with respective strikers of the battery pack to mechanically couple the battery pack from the underside of the vehicle, wherein said at least three latches are mounted for rotation towards engaged positions such that when engaged with the respective strikers they vertically lift and fasten the battery pack in the battery bay; and

at least one drive system coupled to the latches, the at least one drive system being configured for substantially simultaneously rotating all of the latches to substantially simultaneously engage with the respective strikers and vertically lift the battery pack from the underside of the vehicle, securing the battery pack at least partially into the cavity such that during Normal and Exceptional Operating Conditions of the electric vehicle, the battery pack does not substantially rock, rattle, or otherwise move.

2. The battery bay of claim 1, wherein the at least one drive system comprises a transmission assembly mechanically coupling the at least three latches.

3. The battery bay of claim 2, wherein the at least one drive system further comprises an electric motor.

4. The battery bay of claim 2, wherein the transmission assembly is configured to be driven by a rotation mechanism external to the vehicle.

5. The battery bay of claim 1, further comprising:

at least one compression spring mounted to the frame so as to generate a force between the frame and the battery pack in a direction substantially opposite to the lifting force when the battery pack is at least partially retained within the cavity.

6. The battery bay of claim 1, wherein one or more vibration dampers are disposed between the frame and the at least partially electric vehicle.

7. The battery bay of claim 1, wherein the battery bay further comprises:

a latch position indicator configured to determine whether one of the latches is in an engaged position.

8. The battery bay of claim 1, further including, for at least one of the latches:

a latch housing;

a first rotational member including a first pivot point and a second pivot point, wherein the first pivot point is permanently attached to a torque bar which rotates with respect to a first portion of the latch housing;

a coupler link rod including a first rod end and a second rod end, wherein the first rod end is pivotably coupled to the second pivot point of the first rotational member; and

the at least one latch including a third pivot point and a fourth pivot point, wherein the third pivot point is pivotably coupled to the second rod end of the coupler link rod and the fourth pivot point is pivotably coupled to a second portion of the latch housing.

9. The battery bay of claim 8, wherein a length of the coupler link rod is adjustable.

10. The battery bay of claim 9, wherein the geometric lock exists when the rotational member, coupler link rod, and the first, second, and third pivot points are all substantially along the same axis.

11. The battery bay of claim 8, wherein when the latch is in a locked position engaged with the respective striker of the battery pack, the rotational member, coupler link rod, and latch form a geometric lock.

12. The battery bay of claim 8, wherein the rotational member is a cam shaped input link.

13. The battery bay of claim 1, further comprising:

a mechanical lock which is configured to prevent at least one of the latches from rotating when engaged.

14. The battery bay of claim 13, wherein the mechanical lock is configured to be released with a key inserted along an axis substantially perpendicular to the plane formed by the underside of the vehicle.

15. The battery bay of claim 1, further comprising:

at least one electrically activated latch lock which is configured to prevent the latch from rotating when engaged.

16. The battery bay of claim 1, wherein said at least three latches comprise two latches rotatable in opposite directions towards the engagement positions with the respective strikers, and when engaged vertically lift the battery pack until the latches are in a geometric lock position thereof at which any movement of the battery pack is converted into compression or tensile forces on said pivot points without rotating any of said pivot points, thereby preventing the battery pack from being released from the battery bay.

17. A battery system for an electric vehicle, comprising:

a battery bay, for receiving a battery pack, located on an underside of the electric vehicle, said battery bay comprising;

a first latch at the underside of the electric vehicle, the first latch comprising a first hook configured to mechanically engage a first striker at a first end of the battery pack; and

a second latch at the underside of the electric vehicle, the second latch comprising a second hook configured to mechanically engage a second striker at a second end of the battery pack,

wherein the first latch and the second latch are configured for rotation in opposite directions to thereby engage with the respective strikers, and when engaged vertically lift the battery pack until the latches are in a geometric lock position at which any movement of the battery pack being held by the first and second latches is converted into compression or tensile forces on pivot points of the battery bay without rotating any of said pivot points, thereby locking the first and second strikers of the battery pack to the electric vehicle substantially simultaneously, and secure the battery pack at least partially into the battery bay such that during Normal and Exceptional Operating Conditions of the electric vehicle, the battery pack does not substantially rock, rattle, or otherwise move.

18. The battery bay of claim 17, wherein each of the first and second latches comprises:

a hook configured to engage the respective striker coupled with the battery pack, the latch being configured to retain the battery pack at least partially within a cavity of the battery bay;

a first rotational member including a first pivot point and a second pivot point, wherein the first rotational member is configured to rotate about the first pivot point;

a coupler link rod including a first rod end and a second rod end, wherein the first rod end is pivotably coupled to the second pivot point of the first rotational member, and

a third pivot point and a fourth pivot point, the third pivot point is pivotably coupled to the second rod end of the coupler link rod, and the latch is configured to rotate about the fourth pivot point.

19. The battery bay of claim 18, further comprising:

a worm gear coupled with the rotational member.

20. The battery bay of claim 19, further comprising:

a partial gear coupled with the worm gear.

21. The battery bay of claim 19, further comprising:

a motor coupled with the worm gear and configured to rotate the worm gear.

22. The battery bay of claim 21, wherein the first rotational member is configured to be rotated by the worm gear.