Uninterruptible battery power for electric motor vehicle

• US 8,987,935 B2
• Filed: 12/30/2011
• Issued: 03/24/2015
• Est. Priority Date: 12/30/2011
• Status: Active Grant

• Current Assignee: Starvolt Inc.
• Original Assignee: Allen King
• Inventors: King, Allen
• Primary Examiner(s): Barnie, Rexford
• Assistant Examiner(s): Kessie, Daniel
• Application Number:
  US13/341,275
• Publication Number:
  US 20130169038A1
• Time in Patent Office: 1,180 Days
• Field of Search: 307/10.1
• US Class Current: 307/10.1
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: H02J 7/0029 with safety or protection devices or circuits
• CPC Class Codes: H02J 7/00308 Overvoltage protection
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

An apparatus, system, and method are disclosed for assuring uninterruptible battery power for a typical electric motor vehicle powered by an array of series-connected member batteries. Such assurance results from a provision of an electrically-operated bypass switch configured to form a closed electrical bypass circuit path across a faulty first member battery upon activation, thus keeping the vehicle powered up. In one embodiment, the bypass switch is a double-pole multi-contact selector switch connected to each member battery and complimented by a pole-connect switch. For an atypical electric motor vehicle, such as with a multiple battery array parallel configuration, a backup battery may be provided and connected with the faulty battery array in series to displace the bypassed member battery, thus maintaining equal voltage outputs from the battery arrays.

Claims

1. An apparatus comprising:

an electrically operated bypass switch configured to form a closed electrical bypass circuit path across a first member battery of a battery array of N series-connected member batteries responsive to activation, wherein N is a positive integer greater than one, said bypass switch comprising;

a double-pole N-contact selector switch, said selector switch configured to have no electrical connection between the two poles and, while normally deactivated, have neither pole electrically connected to any of the associated N contacts, the first set of N contacts configured to be individually electrically connected to positive terminals of said member batteries, and, likewise, the second set of N contacts configured to be individually electrically connected to negative terminals of said member batteries, and responsive to activation, the activated selector switch configured to make the first pole selectively electrically connectable to any of said first set of N contacts thereof and the second pole selectively electrically connectable to any of said second set of N contacts thereof;

a normally-open single-pole single-throw pole-connect switch, said pole-connect switch configured to be electrically connected across said two poles of said selector switch and, responsive to activation, the activated pole-connect switch configured to electrically connect said two poles together; and

wherein said activated bypass switch is configured to have said two poles of said selector switch electrically connected to the contacts thereof that are electrically connected to the positive terminal and negative terminal, respectively, of said first member battery and have said pole-connect switch electrically connect said two poles of said selector switch together; and

a switch activator module configured to activate said bypass switch in response to detection of a failure in said first member battery.

2. The apparatus of claim 1, wherein said bypass switch is replaceable by N electrically-operated normally-open single-pole single-throw switches, each said switch configured to be independently electrically connected across the positive terminal and the negative terminal of one and only one said member battery, and responsive to activation, configured to form a closed electrical bypass circuit path across said member battery.

3. The apparatus of claim 1, wherein if said battery array is connected with one or more like battery arrays in parallel, the apparatus further comprises a) a like bypass switch associated with each said additional battery array, said bypass switch configured to form a closed electrical bypass circuit path across a first member battery thereof responsive to activation, b) a backup battery, and c) an electrically-operated backup switch associated with each battery array participating in the parallel connection, the backup battery configured with electric and electronic characteristics of member batteries, and each said backup switch, while normally deactivated, configured to have said backup battery electrically bypassed by said associated battery array, and responsive to activation, the activated backup switch configured to electrically connect said backup battery in series with said associated battery array.

4. The apparatus of claim 3, wherein the switch activator module is configured to activate both said bypass switch and said backup switch associated with any said battery array in response to detection of a failure in the first member battery thereof, whereby an equal voltage output from each said battery array required for a parallel connection is attained.

5. The apparatus of claim 1, wherein each said member battery is selected from the group consisting of member battery, member fuel cell, and member ultracapacitor, and said battery array is accordingly selected from the group consisting of battery array, fuel cell array, and ultracapacitor array.

6. The apparatus of claim 3, wherein said backup battery is selected from the group consisting of backup battery, backup fuel cell, and backup ultracapacitor.

7. The apparatus of claim 1, wherein the process for accessing the terminals of said first member battery through said activated selector switch is selected from the group consisting of sequential and direct.

8. A system comprising:

an electric motor vehicle operating unit;

an electric motor vehicle operation controller, coupled to the electric motor vehicle operating unit; and

a battery enclosure with battery cooling means, coupled to the electric motor vehicle operation controller, the battery enclosure comprising;

at least one battery array of N series-connected member batteries supplying power to the electric motor vehicle, wherein N is a positive integer greater than one;

an uninterruptible power adapter (“

UPA”

), coupled to said at least one battery array, the UPA comprising;

at least one electrically-operated bypass switch each configured to form a closed electrical bypass circuit path across a first member battery of an associated battery array responsive to activation, each of said at least one bypass switch comprising;

a double-pole N-contact selector switch, said selector switch configured to have no electrical connection between the two poles and, while normally deactivated, have neither pole electrically connected to any of the associated N contacts, the first set of N contacts configured to be individually electrically connected to positive terminals of said member batteries, and, likewise, the second set of N contacts configured to be individually electrically connected to negative terminals of said member batteries, and responsive to activation, the activated selector switch configured to make the first pole selectively electrically connectable to any of said first set of N contacts thereof and the second pole selectively electrically connectable to any of said second set of N contacts thereof;

a normally-open single-pole single-throw pole-connect switch, said pole-connect switch configured to be electrically connected across said two poles of said selector switch and, responsive to activation, the activated pole-connect switch configured to electrically connect said two poles together; and

wherein said activated bypass switch is configured to have said two poles of said selector switch electrically connected to the contacts thereof that are electrically connected to the positive terminal and negative terminal, respectively, of said first member battery and have said pole-connect switch electrically connect said two poles of said selector switch together;

a switch activator module configured to activate any of said at least one bypass switch in response to detection of a failure in said first member battery of the associated battery array; and

a plurality of electric conductors with connection means configured to electrically interconnect said components; and

a central battery controller, interfacing with said member batteries of each said at least one battery array and the UPA, configured to provide battery operation and charge control and communication.

9. The system of claim 8, wherein each of said at least one bypass switch is replaceable by N electrically-operated normally-open single-pole single-throw switches, each said switch configured to be independently electrically connected across the positive terminal and the negative terminal of one and only one member battery of the associated battery array, and responsive to activation, configured to form a closed electrical bypass circuit path across said member battery.

10. The system of claim 8, wherein if said at least one battery array is connected with one or more like battery arrays in parallel, the UPA further comprises a) a like bypass switch associated with each said additional battery array, said bypass switch configured to form a closed electrical bypass circuit path across a first member battery thereof responsive to activation, b) a backup battery, and c) an electrically-operated backup switch associated with each battery array participating in the parallel connection, the backup battery configured with electric and electronic characteristics of member batteries, and each said backup switch, while normally deactivated, configured to have said backup battery electrically bypassed by said associated battery array, and responsive to activation, the activated backup switch configured to electrically connect said backup battery in series with said associated battery array.

11. The system of claim 10, wherein the switch activator module is configured to activate both said bypass switch and said backup switch associated with any said battery array in response to detection of a failure in the first member battery thereof, whereby an equal voltage output from each said battery array required for a parallel connection is attained.

12. The system of claim 8, wherein the process for accessing the terminals of said first member battery through said activated selector switch is selected from the group consisting of sequential and direct.

13. A method for assuring uninterruptible battery power for an electric motor vehicle powered by a battery array of N series-connected member batteries, wherein N is a positive integer greater than one, comprising:

providing an electrically-operated bypass switch configured to form a closed electrical bypass circuit path across a first member battery of said battery array responsive to activation, said bypass switch comprising;

a double-pole N-contact selector switch, said selector switch configured to have no electrical connection between the two poles and, while normally deactivated, have neither pole electrically connected to any of the associated N contacts, the first set of N contacts configured to be individually electrically connected to positive terminals of said member batteries, and, likewise, the second set of N contacts configured to be individually electrically connected to negative terminals of said member batteries, and responsive to activation, the activated selector switch configured to make the first pole selectively electrically connectable to any of said first set of N contacts thereof and the second pole selectively electrically connectable to any of said second set of N contacts thereof;

a normally-open single-pole single-throw pole-connect switch, said pole-connect switch configured to be electrically connected across said two poles of said selector switch and, responsive to activation, the activated pole-connect switch configured to electrically connect said two poles together; and

wherein said activated bypass switch is configured to have said two poles of said selector switch electrically connected to the contacts thereof that are electrically connected to the positive terminal and negative terminal, respectively, of said first member battery and have said pole-connect switch electrically connect said two poles of said selector switch together;

connecting said bypass switch to each said member battery electrically;

powering the electric motor vehicle for operation;

maintaining communication between said member batteries and a central battery controller of the electric motor vehicle; and

activating said bypass switch in response to detection of a failure in said first member battery, whereby a closed electrical bypass circuit path is formed across said first member battery.

14. The method of claim 13, wherein said bypass switch is replaceable by N electrically-operated normally-open single-pole single-throw switches, each said switch configured to be independently electrically connected across the positive terminal and the negative terminal of one and only one said member battery, and responsive to activation, configured to form a closed electrical bypass circuit path across said member battery.

15. The method of claim 13, wherein if said battery array is connected with one or more like battery arrays in parallel, the method further comprises providing a) a like bypass switch associated with each said additional battery array, said bypass switch configured to form a closed electrical bypass circuit path across a first member battery thereof responsive to activation, b) a backup battery, and c) an electrically-operated backup switch associated with each battery array participating in the parallel connection, the backup battery configured with electric and electronic characteristics of member batteries, and each said backup switch, while normally deactivated, configured to have said backup battery electrically bypassed by said associated battery array, and responsive to activation, the activated backup switch configured to electrically connect the backup battery in series with said associated battery array.

16. The method of claim 15, further comprising connecting each said additional bypass switch to said associated battery array electrically, connecting each said backup switch to said associated battery array electrically, and activating said backup switch associated with any said battery array in response to detection of a failure in the first member battery thereof, whereby an equal voltage output from each said battery array required for a parallel connection is attained.

17. The method of claim 13, wherein said member battery is selected from the group consisting of member battery, member fuel cell, and member ultracapacitor, and said battery array is accordingly selected from the group consisting of battery array, fuel cell array, and ultracapacitor array.

18. The method of claim 15, wherein said backup battery is selected from the group consisting of backup battery, backup fuel cell, and backup ultracapacitor.

19. The method of claim 13, wherein the process for accessing the terminals of said first member battery through said activated selector switch is selected from the group consisting of sequential and direct.