Apparatus and system for placing and managing battery pack for powering all-electric commercial vehicle

Abstract

An apparatus and system for installing, monitoring and managing one or more battery packs attached to or integrated in a housing of a commercial vehicle, such as a semitrailer, for the purpose of providing battery power to an all-electric commercial vehicle. One or more removable battery packs of various sizes may be mounted in one or more housings in an assembly that is mounted on a frame of a commercial vehicle, or included therein as a structural part of its frame. Electrical connections on the installed battery packs connect the individual battery packs to each other and to an electric motor of the commercial vehicle. A computer system allows monitoring and management of each installed battery pack. Accordingly, a commercial vehicle may be provided with an appropriate supply of battery power for an expected journey without purchasing or consignment of excess batteries, thereby avoiding excessive weight during journey.

Description

Background Art

[0001] This application claims the benefit of the filing date of U.S. Provisional Patent Application Serial No. 63 / 358,074, filed on July 1, 2022, for “Apparatus and Systems for Placement and Management of Battery Packs for Powering All-Electric Semi-Trailers and Other Commercial Trucks,” the entire disclosure of which is incorporated herein by reference.

[0002] The present disclosure relates to battery-powered transport vehicles, and in particular to devices and systems for locating batteries on commercial vehicles, including but not limited to tractor-trailers (i.e., eighteen-wheelers), dump trucks, cement mixers, flatbed trucks, tank trucks, refrigerated trucks, refrigerated trailers, garbage trucks, vans, freight containers, freight vehicles, box trucks, trailers, etc. (collectively referred to herein as commercial vehicles), whose batteries can be easily and effectively removed and replaced.

[0003] For example, the long-haul trucking industry relies heavily on a specific type of commercial vehicle that includes a tractor-trailer combination, commonly referred to as a semi-trailer or semi-tractor trailer. These semi-trailers typically include a tractor (the power unit, sometimes called a cab) and a trailer that includes the cargo (the load) being transported, which is pulled by the tractor. Currently, these semi-trailers run almost entirely on diesel fuel.

[0004] There are several advantages to running on diesel fuel, including the fact that diesel fuel is readily available at nearly any gas station and truck stop across the country. Diesel-powered trucks can be refueled quickly. They also typically carry 150 gallons or more of diesel fuel, allowing them to travel 800 miles or more on a single refuel.

[0005] Current all-electric semi-trailers and other all-electric commercial vehicles have difficulty reaping the benefits of diesel fuel. That is, in locations where diesel fuel is plentiful, all-electric commercial vehicles require dedicated charging stations to “refuel.” The charging stations required for battery-powered all-electric semi-trailers are currently scarce, and installing sufficient numbers of charging units to address this problem would require a significant capital investment. Where charging stations are available, the time required to charge a commercial vehicle’s electric batteries is also significantly longer than it takes to refuel a truck with diesel fuel. Additionally, while a diesel-powered semi-trailer can easily carry enough fuel for a long cross-country trip, the range of an all-electric semi-trailer is currently limited by the number of batteries built into its tractor. The efficiency with which batteries can power all-electric semi-trailers, and therefore the range of these vehicles, is affected by environmental conditions and driver habits.

[0006] In current use, all-electric semi-trailers have multiple individual batteries contained in one large battery pack. For example, Tesla's "Long Range" battery pack reportedly includes 828 individual 4680 battery cells, each weighing approximately 1,200 pounds (544.31 kg). It has also been reported that in order to power its semi-tractors to achieve a claimed range of 500 miles (804.67 km), Tesla combines as many as ten (10) battery packs with a total weight of 12,000 pounds (5443.11 kg). Currently, these multiple battery packs are installed in the body of the tractor as an integral part of manufacturing. The battery packs are reportedly installed under the floor of the semi-tractor cab, roughly between the front axle and the leading rear axle. The maximum number of miles that an all-electric tractor-trailer can travel is limited by the size and number of battery packs installed in the tractor.

[0007] While the maximum range of an all-electric semi-trailer is limited by the number of battery packs installed in the tractor, the number of battery packs that can be installed in the cab of a semi-tractor is limited by the overall weight imposed on the tractor-trailer. In the United States, the gross vehicle weight (GVW) of a Class 8 semi-trailer (18-wheeler) is limited to 80,000 pounds (36,287.39 kg), although for an all-electric semi-trailer, this weight limit is increased to 82,000 pounds (37,194.57 kg). This maximum weight limit includes the tractor, trailer, fuel, people on board, auxiliary tools and equipment, and load. In other words, all items transported by the semi-trailer must not exceed the GVW limit. Therefore, the weight of the batteries currently in use actually reduces the amount of load and other items that can be transported by the all-electric semi-trailer. In other words, when the battery capacity of the all-electric semi-trailer currently in use exceeds that required for a specific trip, the weight of these excess battery capacities will inevitably reduce the amount of load that can be loaded in that trip.

[0008] Another problem that all-electric semi-trailers face is that the amount of battery power carried by the tractor cannot be customized in current use. Compared to diesel semi-trailers (where the amount of diesel fuel carried can be easily adjusted by simply refueling with less fuel, thereby saving weight), all-electric semi-tractors are built with a set number of batteries. As a result, all-electric semi-tractor manufacturers must build different truck models with different but unchangeable battery sizes to achieve different ranges. For example, Tesla offers two different versions of its all-electric semi-tractor: one with an estimated range of 300 miles (563.27km) and the other with an estimated range of 500 miles (804.67km). If an owner / operator's regular routes require a range of 350 miles (563.27km), then the owner / operator must purchase the 500-mile (804.67km) model with the larger battery, and is therefore forced to carry more battery weight than necessary and pay for almost twice the required battery capacity. Alternatively, if an all-electric semi-trailer were to operate on a 350-mile (563.27km) route using a smaller battery configuration, it would need to stop mid-route to recharge the battery, increasing delivery time and associated labor costs, and over time reducing the maximum number of loads that could be delivered.

[0009] While all-electric semi-trailer manufacturers make claims about the range their electric semi-trailers are capable of, these range estimates are highly questionable. The range of electric vehicles is highly susceptible to changing environmental conditions and varying driver habits. Current fixed battery manufacturing designs and their maximum battery capacities do not allow the owner / operator to adjust to these changing conditions.

[0010] For example, in real-world testing situations, electric vehicles can lose 10% or more of their actual driving range when operating in cold weather conditions of 20°F (-6.7℃). If the driver also uses the vehicle's interior climate control (heater) in such cold conditions, the loss in driving range can be as high as 40%. This means that in cold weather, the estimated 500-mile (804.67km) range of an all-electric semi-trailer may drop to 300 miles (482.80km) or less, and the 350-mile (563.27km) range of an all-electric semi-trailer may drop to 180 miles (289.68km) or less. These range reductions, like the weather, are unpredictable, making it unlikely that transportation companies will switch to an all-electric semi-trailer fleet. The risk of those all-electric vehicles being stranded on the road in inclement weather conditions, unable to deliver their loads, is simply too great. Exacerbating the loss of cold weather range is that cold weather also triples the time it takes to charge an all-electric semi-trailer's battery.

[0011] At the other extreme, operating an all-electric vehicle in extremely hot conditions can cause accelerated battery degradation. Charging the battery in hot conditions can also cause physical damage to the battery, causing it to work less efficiently, which can significantly reduce the available battery charge and, therefore, the range. In other words, both cold and hot weather conditions can have a negative impact on battery performance and can significantly reduce the actual range of an all-electric semi-trailer. Other environmental conditions can also have a negative impact on the range of an all-electric semi-trailer. For example, headwinds can significantly reduce range, as can worn or underinflated tires, heavy loads, and uphill routes.

[0012] In current use, the driver's personal habits also have a large impact on the range of electric semi-trailers. Drivers who habitually accelerate or drive hard will achieve significantly less mileage on the batteries of an all-electric semi-trailer than drivers who accelerate smoothly or drive slowly. It is estimated that driving an electric vehicle at 75 miles per hour (MPH) (120.70km / h (KPH)) compared to 65MPH (104.61KPH) will reduce the expected range by 15% or more. It is reasonable to expect that the range loss of an all-electric semi-trailer may be significantly greater. To put it bluntly, a driver carrying a heavy load and driving hard on an uphill route in bad weather is likely to achieve only a fraction of the manufacturer's estimated range. These factors make relying on all-electric semi-trailers for nationwide freight transportation a high-risk proposition for transportation companies. These high risks are not currently willing to be taken by transportation companies.

[0013] Furthermore, in current use, the requirement that the battery is an integral part of the semi-tractor body means that damaged, defective or exhausted batteries cannot be easily repaired or replaced. In current use, repairing or replacing damaged, defective or exhausted batteries requires the entire all-electric semi-tractor to be sent to a repair shop where it is disassembled to remove and repair or replace the damaged, defective or exhausted battery pack. This requires a lot of time and effort, resulting in expensive repair costs and long periods of downtime. Summary of the invention

[0014] According to the present disclosure, battery packs no longer have to be installed as part of the manufacture of an all-electric commercial vehicle. The present disclosure relates to an assembly that 1) is integrated into the structure of a commercial vehicle or trailer frame; or 2) is fixed to the frame of a commercial vehicle or trailer, wherein the assembly allows the battery pack to be removed and replaced. The assembly forms at least one housing that securely secures one or more battery packs for delivering battery power to the electric motor of the all-electric commercial vehicle. Typically, the assembly includes a mounting system, a removable cover, and one or more housings that provide space for securely securing the one or more battery packs to the commercial vehicle or trailer. One or more battery packs can be inserted into each of the housings. Multiple assemblies, and therefore multiple housings and battery packs, can be attached to a commercial vehicle or trailer.

[0015] According to the present disclosure, the shape and size of the components of the present disclosure can be adjusted according to the requirements of the specific application or the commercial vehicle or trailer to which the component is attached. Although the present disclosure shows an embodiment in which the component is rectangular, other embodiments can include various sizes of various shapes, including but not limited to circular, oval, square, hexagonal and other component shapes. Similarly, according to the requirements of the specific application or the commercial vehicle or trailer to which the component is attached, the housing (one or more) of the component can be various sizes and shapes to accommodate the safe placement of battery packs of different sizes and shapes.

[0016] When the battery packs are fixed in the assembly, each battery pack is connected to all other battery packs in the assembly and all other battery packs in other assemblies on the commercial vehicle or trailer through a central wiring harness. This connection allows the computer-driven integrated power management system to continuously monitor the health and charge of each installed battery pack. This connection also enables the collective charge of the battery packs in each assembly to be transmitted to the motor of the commercial vehicle through a coupler or other connection device (connection currency), that is, it can be connected to the wiring harness of the commercial vehicle and then connected to its motor. When the battery packs are fixed in the assembly, each battery pack is connected to all other battery packs in the assembly and all other battery packs in other assemblies on the commercial vehicle or trailer through a dedicated wiring harness, which allows the battery packs in each assembly to be charged through a coupler or other connection device that can be connected to an external charging device. Each individual battery pack in the assembly can also be quickly removed and replaced. When the battery pack is removed from the assembly, it is stored on a dedicated assembly / housing rack where it can be monitored, maintained and charged. When the battery pack is fixed in the assembly, whether it is attached to the commercial vehicle or placed on a dedicated assembly / housing rack, it can be cooled or heated as needed to improve its performance.

[0017] Because each battery pack can be removed individually, a damaged, defective or exhausted battery pack can be quickly and easily replaced without having to move the commercial vehicle to a repair shop and dismantle the commercial vehicle. This will allow the battery pack to be removed and replaced wherever a replacement battery pack is available.

[0018] Attaching varying numbers of components to, for example, a semi-trailer enables the owner / operator to calculate the number of battery packs required for a trip, using a power management system or other means, and to carry only the required number of battery packs, thereby reducing battery weight and increasing load weight. The ability to easily carry multiple combinations of battery packs allows all-electric semi-trailer manufacturers to build their tractors with minimal battery range, thereby reducing manufacturing weight and costs, while enabling the owner or operator to purchase and carry only the number of battery packs required to meet their specific use. This advantageous flexibility is achieved by simply adding or removing battery packs from the components. As a result, the owner or operator only needs to invest in the number of battery packs (and carry their weight) that approximates the distance, weight, and load requirements. And, by strategically storing replacement batteries along the route, the owner or operator can ensure that there are fully charged battery packs to deal with any unexpected route conditions or battery failures, thereby eliminating most, if not all, of the risks of operating an all-electric commercial vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Other features and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings, in which:

[0020] Figure 1 A side view of a representative current all-electric semi-tractor is shown.

[0021] Figure 2 A perspective view of a representative battery pack is shown.

[0022] Figure 3 A side view of a representative current all-electric semi-tractor is shown with the location of the battery pack on the semi-tractor generally indicated.

[0023] Figure 4 Shown is a perspective side view of a representative 53 foot (16.15 m) trailer for use with a semi-trailer.

[0024] Figure 5 A top plan view of a representative 53 foot (16.15 m) trailer frame is shown, showing representative structural end members, structural side members, a central main structural member extending to each end member and equidistant between the structural side members, and vertical structural cross members extending from each side of the central main structural member to the structural side members.

[0025] Figure 6A front view of an exemplary assembly is shown having a top, a bottom, two sides, a rear, an open front (covered during operation), and an internal divider forming two housings for securely securing the battery pack, with two side structures extending upward for attaching the assembly to a trailer frame from below.

[0026] Figure 7 A side view of a representative 53 foot (16.15 m) trailer frame is shown with panels on the ends and sides forming walls, a roof, and a floor attached to the top of the frame to form an enclosed box accessible by doors inserted into the rear and / or sides of the box, and further showing the voids formed between the vertical structural frame members of the frame.

[0027] Figure 8 It shows that Figure 6 An exemplary assembly is shown, wherein the assembly is positioned underneath a portion of a trailer frame, wherein a trailer bed is positioned on top of the trailer frame and vertical cross members of the frame, and wherein an extended side of the assembly is designed to attach to the vertical cross members of the trailer frame.

[0028] Fig. 9 A front view of an exemplary assembly forming two shells is shown, and how the assembly is mounted to the vertical cross member of the frame by bolts passing through the vertical cross member of the frame and the extended side of the assembly, and further showing the vibration damping generated between the extended side of the assembly and the vertical cross member of the frame.

[0029] Fig.10 Shown is an enlarged view of the extended side of the assembly, which is attached by bolts passing through the side of the assembly, the vibration damping product and the vertical cross member of the frame.

[0030] Fig.11 A side view of a representative trailer is shown having three assemblies attached to the bottom of a vertical cross member of the trailer frame, wherein each assembly forms two housings for securing a battery pack, and illustrating exemplary placement of a box comprising a power management system.

[0031] Fig.12 A front view of an assembly forming two housing cavities for securing at least one battery pack is shown, an exemplary position of one possible iteration of an internal mounting for securely securing at least one battery pack in the housing, and an enlarged front view of an exemplary internal housing mounting in which a male connector for securely attaching the battery pack is inserted into a female hole in the housing.

[0032] Fig.13 Shows Fig.12 0026] An illustration of a side view of one embodiment of an internal housing mount showing a front threaded female receptacle and a rear male bolt for securing a battery pack within the housing.

[0033] Fig.14 A side view of an exemplary trailer is shown having two assemblies mounted adjacent to each other beneath the frame of the trailer, each assembly having two housings for carrying battery packs and wherein each assembly does not extend below the lowest point of a retracted front trailer frame, and an exemplary placement of a box comprising a power management system.

[0034] Fig.15 shows a rear view of two battery packs secured in an assembly, wherein each battery pack has 1) an electrical connector for attaching the battery pack to a central wiring harness and 2) an additional electrical connector for attaching the battery pack to a wiring harness dedicated to recharging the battery pack;

[0035] Fig.16 A top plan view of a trailer frame is shown according to one embodiment of the present invention, showing the electrical wiring from the connector on the battery pack, which connects to the main wiring harness, which connects to the coupler or other connection at the front of the trailer to connect the battery pack in the assembly fixed to the trailer to the electric motor on the tractor and the box including the power management system.

[0036] Fig.17 A top plan view of a trailer frame is shown showing one embodiment of electrical wiring from a connector attached to a battery pack, the connector connecting to a wiring harness for recharging the battery pack, the wiring harness connecting to a coupler or other connector at the rear of the trailer to connect the assembly and the battery pack retained therein to an external recharging device, and also showing an exemplary placement of a case including a power management system according to one embodiment of the present invention.

[0037] Fig.18 An exemplary trailer is shown having a coupler or other connector on the front of the trailer for connecting the trailer battery power to the semi-tractor motor and a coupler or other connector on the rear of the trailer for connecting a battery pack secured in the trailer to an external charging source, and exemplary placement of a box including a power management system according to another embodiment of the present invention.

[0038] Fig.19 A side view of an exemplary height adjustable dolly for attaching to a battery pack and inserting or removing a battery pack from an assembly is shown in accordance with one embodiment of the present invention.

[0039] Fig. 20A front view of a battery pack rack having an assembly forming a housing cavity for storing, monitoring and recharging multiple battery packs when the multiple battery packs are not installed in the assembly is shown in accordance with one embodiment of the present invention.

[0040] Fig.21 A top plan view of a representative trailer frame is shown illustrating exemplary mounting of multiple components beneath the trailer floor and between vertical cross members of the trailer frame, and also illustrating exemplary placement of a box including a power management system according to yet another embodiment of the present invention.

[0041] Fig. 22 Shows Fig.21 A side view of a trailer with components mounted below the trailer floor and between vertical cross members of the frame, and illustrating exemplary placement of a box including a power management system according to one embodiment of the present disclosure.

[0042] Fig.23 Shown is a front view of one embodiment of an assembly and a removable protective cover that can be locked in place to protect a battery pack from the elements in an assembly mounted on an all-electric commercial vehicle or trailer. DETAILED DESCRIPTION

[0043] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Embodiments of the present disclosure are provided to more completely explain the present disclosure to those of ordinary skill in the art. The following embodiments may be modified or altered in various other forms. The scope of the present disclosure is not limited to the following embodiments. These embodiments are provided to make the present disclosure clearer and more thorough, and are provided to convey the spirit of the present disclosure to those skilled in the art.

[0044] For the sake of convenience and clarity, the size of the details in the drawings may be exaggerated and / or inconsistent with the correct relationship with other details. In the drawings, the same reference numerals refer to the same elements. The term "and / or" used in this article includes any of the mentioned items and all combinations of one or more of them. The term "connected" used in this article refers not only to the case where, for example, member A and member B are directly connected, but also to the case where member A and member B are indirectly connected through an intermediate member C inserted between member A and member B.

[0045] The terms used herein describe representative embodiments and are not intended to limit the present disclosure. As used herein, singular forms may include plural forms. When used, the terms "include" and / or "comprise" indicate the presence of the mentioned shapes, quantities, steps, actions, components, elements and / or groups thereof, but do not exclude the presence or addition of one or more other shapes, quantities, steps, actions, components, elements and / or groups.

[0046] Obviously, the terms "first", "second" and the like are used in this article to describe various components, parts, regions, layers and / or parts, but these components, parts, regions, layers and / or parts are not limited by these terms. These terms are only used to distinguish a component, component, region, layer or part from another component, component, region, layer or part. Therefore, without departing from the teaching of the present disclosure, the first component, component, region, layer or part described below may refer to the second component, component, region, layer or part. Spatial related terms such as "below", "below", "lower", "above" and "upper" can be used to facilitate understanding that an element or feature is different from an element or feature shown in the figure, or to indicate the relationship between one or more elements or features shown in the figure and other elements or features shown in the figure. These spatially related terms are to facilitate understanding of the present disclosure according to various process conditions or conditions of use of the present disclosure, and are not intended to limit the present disclosure.

[0047] In addition, any suitable hardware, firmware (e.g., dedicated semiconductors), software, applications, wireless devices, or suitable combinations of software, applications, wireless devices, firmware, and / or hardware may be used to implement the power management system and other related devices or components according to the present disclosure. For example, various components and other related devices or components of the power management system according to the present disclosure may be formed on a single integrated circuit chip or formed on each separate integrated circuit chip, or may be remotely accommodated and connected to the components of the present disclosure via a wireless connection. Various components of the power management system may be implemented on a flexible printed circuit film, or may be formed on a tape carrier package, a printed circuit board, or on the same substrate as the power management system. Various components of the power management system may be processes or threads executed in one or more processors in one or more computing devices, and may execute computer program instructions and interact with other components to perform various functions mentioned herein. Computer program instructions are stored in a memory, which may be executed in a computing device using a standard memory device such as a random access memory, or may be accessed on a remotely located storage device and accessed via a wireless connection. Computer program instructions may also be stored in other non-temporary computer-readable media, such as a CD-ROM, a flash drive, and the like. Those skilled in the art to which the present disclosure relates should understand that the functionality of various computing devices may be combined or integrated into a single computing device, or that the functionality of a particular computing device may be distributed among one or more other computing devices without departing from the exemplary embodiments of the present disclosure.

[0048] Those skilled in the art will appreciate that, in accordance with the present disclosure, the shape and size of the components of the present disclosure may be adjusted according to the requirements of a particular application or commercial vehicle or trailer to which the component is attached. Although the present disclosure shows an embodiment in which the component is rectangular, other embodiments may include various sizes of various shapes, including but not limited to circular, oval, square, hexagonal, and other component shapes. Similarly, the housing (one or more) formed within the component may be of various sizes and shapes to accommodate the secure placement of battery packs of various sizes and shapes, depending on the requirements of a particular application or commercial vehicle or trailer to which the component is attached.

[0049] Those skilled in the art will appreciate that by varying the size and shape of the components, the housing formed therein may be adapted to securely hold battery packs from a variety of manufacturers.

[0050] Those skilled in the art will appreciate that for any commercial vehicle or trailer, multiple assemblies and housings may be employed to enable multiple battery packs to be carried on the commercial vehicle or trailer.

[0051] Those skilled in the art will appreciate that when multiple battery packs are carried in one or more assemblies of a commercial vehicle or trailer, each battery pack may be individually removed and replaced without removing any other battery pack included in the same or another assembly.

[0052] Those skilled in the art will appreciate that the housing including the power management system may be placed elsewhere on the trailer, or may be placed on the semi-tractor or other commercial vehicle, or may be distributed between the trailer and the semi-tractor or commercial vehicle. In those applications where the assembly is attached to a commercial vehicle that is not towing a trailer, the power management system may be placed within the assembly, attached to the assembly, attached elsewhere on the commercial vehicle, or distributed between one or more locations within the assembly, attached to the assembly, or elsewhere on the commercial vehicle.

[0053] Figure 1 is a representative drawing showing the design of an all-electric semi-tractor. Current all-electric semi-tractors are generally configured with a set battery pack when manufactured, which determines the maximum mileage range of the vehicle.

[0054] Electric semi-tractors, e.g. Figure 1 As shown, the battery is typically installed inside the tractor as part of the manufacturing process, with the battery typically located under the floor of the driver's cabin between the front and rear axles.

[0055] Figure 2A representative battery pack 10 according to a current embodiment of the present disclosure is shown. The battery pack 10 includes a plurality (200 or more) of individual cells that are combined and held in a single closed sealed housing. Each battery pack has connectors 12 required to connect the battery energy to the vehicle's electric motor, charging station, and power management system. Current all-electric commercial vehicles are typically configured with multiple battery packs 10 in a semi-tractor to provide power to the electric motor.

[0056] Figure 3 A representative all-electric semi-tractor is shown having a plurality of battery packs 10 mounted beneath the driver's cabin floor between the front axle and the leading rear axle.

[0057] like Figure 4 As shown, a typical semi-trailer 20 has a box 22 with a floor 24 built on a frame 28, the frame 28 having a coupler 30 for connecting a semi-tractor, the semi-tractor having wheels 32 for transportation and brackets 34 for securing the ends of the trailer when the trailer is not connected to the tractor.

[0058] like Figure 5 As shown, according to one embodiment of the present disclosure, a representative trailer frame 28 has a center frame member 40 connected to end frame members 42, wherein a plurality of support frame members 44 are attached perpendicular to the center frame member 40 and extend and attach to frame rail structures 48 on both sides of the trailer frame 28, and the frame rail structures together with the end frame members 42 form the trailer frame 28.

[0059] like Figure 6 As shown, according to one embodiment of the present disclosure, when viewed from the front, the assembly 50 includes a top 52, side portions 54, an open accessible front portion 58 that is covered during operation, and a rear portion 60, a floor 62, and one or more internal partitions 64, the entire assembly forming a frame 68 having cavities (hereinafter referred to as "shells") 70, each of which will securely accommodate one or more battery packs 10. The side portions 54 of the assembly 50 extend beyond the top 52 of the shell to form a bracket 72, whereby the assembly can be attached to the vertical frame member 44 to securely fix the assembly under the trailer frame 28. In this embodiment of the present disclosure, when the assembly is installed on the trailer, the top 52 of the assembly 50 (which in this embodiment also forms the top of one shell 70) creates a gap 74 between the top 52 of the assembly 50, the vertical frame member 44 of the trailer, and the floor 24 of the trailer. The void 74 forms a sealed (ie, waterproof or weatherproof) space suitable for securing electrical wiring, monitoring equipment, and components of the battery pack 10 mounted in the housing 70 .

[0060] Figure 7The trailer 20 is depicted from the side with the trailer skin 76 removed from above the vertical frame members 44, thereby exposing the ends of the vertical frame members 44. Figure 7 As shown, the trailer bed 24 and the vertical frame members 44 form a void 74 , with the top of the assembly 50 forming the bottom of the void 74 .

[0061] like Figure 8 As shown, according to one embodiment of the present disclosure, the assembly 50 is mounted or "hung" to the bottom of the trailer frame 28 by attaching the assembly 50 via bolts or other mechanisms through the extended side brackets 72 and vertical cross members 44 of the frame so that the assembly 50 is located below the bottom of the trailer frame 28, thereby creating a gap 74 between the trailer bed 24, the vertical cross members 44 and the top 52 of the assembly.

[0062] like Fig. 9 As shown, according to one embodiment of the present disclosure, the assembly 50 forming two shells 70 is attached to the bottom of the vertical frame member 44 of the trailer by bolts 80 secured by self-locking washers and nuts 84 via extended side brackets 72 of the assembly and vibration damping material 82, thereby creating a gap or cavity 74 between the top 52 of the shell and the bottom of the trailer bed 24.

[0063] like Fig.10 As shown, according to one embodiment of the present disclosure, threaded bolts 80 are inserted through the vertical trailer frame member 44, the vibration damping material 82, the assembly extension side bracket 72, and then secured with self-locking washers and nuts 84. Typically, multiple threaded bolts are used to mount the assembly 50 under the vertical frame member 44 of the semi-trailer 20. Multiple assemblies 50 can be mounted under multiple vertical frame members 44, thereby allowing multiple battery packs to be secured in multiple housings 70.

[0064] like Fig.11 As shown, according to one embodiment of the present disclosure, the exemplary trailer 20 has three assemblies 50, each assembly 50 includes two housings 70 mounted below the trailer frame 28, each housing 70 being capable of securing at least one battery pack 10. Also shown is a box 50A for housing a power management system.

[0065] like Fig.12 As shown, according to one embodiment of the present disclosure, each housing 70 in the assembly 50 includes a mounting member 90 inside to securely fix each battery pack 10 in place within the housing 70. Each of these mounting members 90 may, for example, include a threaded female socket 92, into which a bolt 94 passing through the battery pack 10 is inserted and tightened until the battery pack 10 is securely fastened.

[0066] like Fig.13As shown, according to one embodiment of the present disclosure, the rear portion 98 of the exemplary internal mount 90 has a male pin or bolt 100, and the battery pack 10 has a female socket that is pushed onto the pin or bolt 100 until the battery pack 10 is secured in place. The front portion of the internal bracket 90 has a threaded female socket 92, wherein the battery pack 10 is mounted flush with the internal bracket 90, and into which a threaded bolt 94 is inserted until the battery pack 10 is secured in the housing 70.

[0067] like Fig.14 As shown, according to one embodiment, when the assembly 50 is installed under the trailer 20, the assembly 50 is attached to the bottom of the vertical cross member 44 of the frame between the wheels 32 of the trailer 20 and the trailer front frame 34. One or more assemblies 50 generally do not extend further under the trailer's frame 28 than the bottom of the trailer's retracted front frame 34. In this embodiment, each assembly 50 forms two housings 70, each of which can hold a battery pack 10. A box 50A for housing a power management system is also shown.

[0068] Fig.15 The rear portion of two battery packs 10 are shown secured in the assembly 50, each within the housing 70. Each battery pack 10 has an electrical connector 110 for connecting to an electrical harness 112, thereby enabling the battery pack 10 to be connected to an external charging device, and an electrical harness 118 for connecting to a main electrical harness to deliver battery energy to the battery pack 10. Figure 1 The electric motor of the all-electric semi-tractor is provided with a separate electrical connector 114. Each of these respective connectors 110, 114 can be connected to wiring connectors from other battery packs 10 secured in other housings 70 within other components 50 mounted on the trailer 20. In this way, all battery packs 10 can be recharged simultaneously, and energy from all battery packs 10 will be used simultaneously. Figure 1 Alternatively, battery management software included in the box 50A can be used, and in conjunction with trip planning, one or more specific battery packs 10 can be discharged faster or slower than other battery packs, thereby improving efficiency by symbolically removing depleted battery packs 10 from the system or replacing depleted battery packs 10 with newly charged battery packs 10.

[0069] like Fig.16As shown, according to one embodiment of the present disclosure, viewing the trailer frame 28 from the top down, each assembly 50 is attached to the bottom of the vertical frame member 44, thereby creating a gap 74 above the assembly 50 and between the vertical frame members 44. The battery packs 10 housed in the assembly 50 are connected to the main harness 120 via the connector 114 at the rear of the battery pack 10. Typically, all battery packs 10 are connected to the main harness 120, which in this example is fixed within the center frame member 40 of the trailer. The main harness 20 is connected to a coupler or other type of connector 122 at the front of the trailer 20 and is connected to the box 50A at the front of the trailer 20 that includes the power management system. The coupler provides a connection from the main harness 120 of the trailer to the harness of the semi-tractor, thereby providing power from all battery packs 10 of the trailer 20 to the electric motor of the semi-tractor.

[0070] Fig.17 A top view of a trailer frame according to one embodiment of the present disclosure is shown, wherein a box 50A includes a power management system located in a different position. As shown, each assembly 50 is attached to the bottom of the vertical frame member 44, thereby creating a gap 74 above the assembly 50 and between the vertical frame members 44. The battery packs 10 fixed in the housing 70 in each assembly 50 are connected to the main charging harness 130 via the connector 110 in the rear of each battery pack 10. Typically, all battery packs 10 are electrically connected at the charging harness 130, which in this example is maintained within the center frame member 40. The charging harness 130 is connected to a coupler or other connector 132 at the rear of the trailer 20. The coupler provides a connection from the trailer charging harness 130 to an external charging unit. This allows all battery packs 10 fixed in all assemblies 50 to be recharged simultaneously, for example, when the trailer is loaded or unloaded, or when the trailer is idle.

[0071] like Fig.18 As shown, a typical trailer 20 has an electrical wiring connection that connects to the main harness, such as a coupler 122 located at a different position in this example; a box 50A located at the front of the trailer to connect the power of the main harness 122 of the trailer 20 to the semi-tractor and power management system; and a charging harness coupler 132 at the rear of the trailer 20 to connect the main charging harness 130 to the battery pack 10 fixed in the assembly 50 and the housing 70.

[0072] According to one embodiment of the present disclosure, Fig.19A representative height adjustable dolly 140 is shown, which is on wheels 148 and has a table 142, a task specific screw drive 144, a motor 142A for advancing and retracting the screw drive, and a removable motto 144A for connecting the internal mounts 100, 92 of the battery pack 10. Once connected, the battery pack 10 can be securely inserted or removed from the assembly 50. The dolly 140 with the screw drive 144 makes it easy, quick and safe to insert or remove the battery pack.

[0073] like Fig. 20 As shown, according to one embodiment of the present disclosure, a representative battery pack rack 150 includes a frame 152 for securing the assembly 50 in a plurality of cavities 154, in which the battery packs 10, when not secured in the assembly 50 of the trailer 20, can be secured and stored by female sockets 158. When each battery pack 10 is in the battery pack rack, each battery pack 10 can be monitored, charged, and maintained via a wire coupler or connector 160 attached to each battery pack 10.

[0074] Fig.21 A trailer frame 28 is shown viewed from the top down according to one embodiment of the present disclosure. During original trailer manufacture, the battery pack may be incorporated into the structure of the trailer, such as by removing certain vertical frame members 44, creating greater spacing 170, 172 between the vertical frame members 44, and integrating the assembly 50 into the frame 28 within these new spaces 170, 172. Thus, the assembly 50 and inserted battery pack 10 are placed under the trailer bed 24, but typically as part of the frame structure rather than being located below the frame 28.

[0075] like Fig. 22 As shown, according to one embodiment of the present disclosure, during original manufacturing, the assembly 50 is installed as an integral part of the trailer 20 frame 28 structure, wherein the battery pack 10 is mounted in the housing 70 and fixed below the trailer floor 24, while providing structural strength to the trailer frame 28 and thus becoming an integral part of the trailer frame 28.

[0076] like Fig.23 As shown, according to one embodiment of the present disclosure, the housing 70 of each component 50 (regardless of whether Fig. 22 As shown, it is mounted as part of the structure of the frame or as Fig.11The assembly 50 (shown mounted below the vehicle frame) is covered by a removable, tight fitting cover 180 that can be mounted over the exposed front portion 58 of the assembly 50. The cover 180 in this embodiment is equipped with a lock 182 that securely secures the cover 180 to the assembly 50, thereby protecting the assembly 50, the housing 70, and the installed battery pack 10 from the elements. The inside of the cover 180 and the assembly 50 may have a manufactured channel 184 that can be securely configured on the assembly 50. The cover 180 is secured in place by a locking mechanism 182 on the cover that is attached to the locking mechanism on the assembly 50 and covers the manufactured channel 184 to securely lock the cover in place.

[0077] As mentioned above, diesel semi-trailers currently enjoy significant advantages over electric semi-trailers. The present disclosure addresses these advantages and enables electric semi-trailers to not only effectively compete with diesel trucks, but in many cases surpass them. Due to the characteristics of electric motors, electric vehicles have greater torque, greater acceleration and power, and greater towing capacity. The present disclosure provides a practical design that takes advantage of these advantages while overcoming the inherent deficiencies of electric vehicles.

[0078] First, for example, moving the battery to the trailer can significantly increase the maximum battery power that can be carried, thereby increasing the potential mileage range. Second, under the design of the present disclosure, it is relatively simple to add or reduce the batteries contained in the components on the exemplary trailer, so that a single semi-trailer design can be used for a variety of mileage and load requirements and different environmental conditions. This means that manufacturers do not need to manufacture multiple versions of electric commercial vehicles with different battery capacities. Instead, 1 vehicle can simply handle various possible mileage and load requirements by adding or reducing power on the trailer (or in the cab if the cab is provided with multiple components for fixing battery packs). For the same reason, proper battery management helps to adjust to cope with various extreme weather. In extremely cold or hot weather, the owner or operator can simply insert additional battery packs into the housing to increase the range. Each component can also be adjusted to allow the battery packs installed in the housing to be heated or cooled as needed to offset the efficiency reduction caused by the weather. Importantly, the owner or operator can monitor the health and power of each battery pack and make adjustments or replacements to ensure the safe completion of the journey.

[0079] Third, by making the batteries accessible and easily removed and replaced, damaged, defective or exhausted batteries no longer require expensive and time-consuming repairs. Instead, damaged, defective or exhausted battery packs can be simply and quickly replaced by removing the old battery pack and replacing it with a fully functional replacement battery pack. Fourth, increasing the range of the truck by simply adding a battery pack in the shell will reduce the problems caused by the lack of charging stations. An all-electric semi-trailer constructed in accordance with the present disclosure is typically capable of traveling eight hundred miles or more, thereby reducing the number of charging required during a cross-country trip and, therefore, reducing the number of charging stations required. In addition, exhausted batteries can be simply and quickly replaced with fully charged batteries, eliminating a lot of downtime wasted waiting for the battery to be charged. Downtime typically includes waiting in line to obtain a suitable charger.

[0080] The significant advantage of the present disclosure is that fully charged, undamaged battery packs can be stored in convenient locations across the country, allowing long-distance truck drivers to stop and quickly replenish batteries when they reach their maximum available mileage. For example, locations such as truck stops currently located along interstate highways can store battery packs in positions in the rack to allow the battery packs to be monitored, recharged and maintained, ensuring that undamaged, fully charged battery packs are always available to replace damaged or exhausted battery packs carried on the semi-trailer. When a semi-trailer with a damaged or exhausted battery pack arrives at the truck stop, it is usually a relatively simple matter to remove the damaged or exhausted battery pack and install the undamaged, fully charged replacement battery pack into the assembly. The turnaround time for replacing a battery pack is expected to be a few minutes, which is much shorter than the time required to fully charge the battery pack on the semi-trailer.

[0081] The potential to store battery packs across the country could lead to an entire battery pack rental / leasing business, whereby companies purchase large quantities of battery packs and store them in racks until they are needed to replace depleted or damaged battery packs on a semi-trailer. Once needed, the battery packs would be replaced by the leasing company, which is responsible for tracking the logistics of the battery packs, billing for the replacement of the battery packs, and the use of the replacement battery packs. These battery pack leasing companies can effectively "front" the capital cost of purchasing the battery packs and be responsible for the maintenance and charging of their battery pack inventory. By assuming the capital cost of purchasing the battery packs, battery pack leasing companies can significantly reduce the upfront cost of purchasing an all-electric tractor-trailer or other commercial vehicle by purchasing the battery packs and leasing the battery packs to commercial vehicles.

[0082] The racks that hold the batteries can serve a secondary purpose when the batteries are not installed in the trailer. For facilities that do not yet utilize solar energy due to cost reasons, the battery racks can be used as an external power reserve for the power generated by the solar installation, replacing the existing battery storage unit. Connecting the batteries in the rack to the solar generator has multiple purposes, including using solar energy to charge and maintain the power of the batteries fixed in the rack. At the same time, when the sun goes down or is blocked by clouds, the accumulated stored energy can power the facility, making it possible to operate the truck stop 24 hours a day using solar energy alone.

[0083] Alternatively, in those cases where the truck driver intends to make an extended stop at a truck stop facility (e.g., where the driver intends to eat, sleep, bathe, or relax), the battery secured within the assembly may be recharged by connecting to a Direct Current Rapid Charger (“DCRC”). The use of DCRC stations (or similar charging stations) in these circumstances would incentivize truck stop operators to invest in installing charging stations. These DCRC networks could also provide charging to the public driving electric vehicles to charge their vehicles. These DCRC networks could be owned by truck stops, or could be owned by third-party companies that install the chargers and charge for their use. Charging stations located at truck stops or other convenient locations could be set up for on-site billing (i.e., credit and debit cards) or direct customer billing (i.e., charging fees are automatically charged directly to the truck driver's company).

[0084] The battery pack, whether installed in an assembly on a commercial vehicle or kept in a charging rack, can be monitored at all times. This continuous monitoring will enable the owner or operator of the commercial vehicle to always know the charge status of the battery pack and monitor the efficiency and health of the battery pack. This monitoring will allow the owner or operator to receive early notification when problems may arise and take action before the problem becomes serious, such as removing the battery pack from service and replacing it. The monitoring can include battery efficiency, battery temperature, charge level, discharge rate, etc., and thus identify defective batteries at an early stage.

[0085] The disclosed apparatus will also allow for the addition of equipment to the trailer to charge the battery pack while the semi-trailer is in operation. For example, a wind-driven fan that powers a small turbine could be added to the trailer to provide a continuous charge to the battery pack. Likewise, solar panels on the trailer roof could charge the battery pack during the day. Charging through the vehicle's braking system is also a possibility. Each of these possible on-the-road recharging methods has the potential to further extend the range of commercial vehicles.

[0086] As needed, the battery packs secured in the housing can be cooled or heated in situ as required to ensure optimal operation. While such cooling and heating consumes battery power, the ability to carry more than the battery power allows for cooling and heating without reducing the useful range of the commercial vehicle. Likewise, the present system and apparatus will allow shippers to transport their freight in a temperature controlled environment, as the additional battery power required to power the refrigerated trailer can be simply and quickly added to the trailer.

[0087] In current use, transportation companies that operate as full-load carriers, such as Swift Transportation, typically own and operate two to three times as many trailers as semi-tractors. Therefore, a company with one thousand semi-tractors can also own three thousand trailers. The service life of these trailers is significantly longer than that of semi-tractors. Having more trailers than semi-tractors allows companies to park trailers at customers' docks for loading and unloading operations without having to leave semi-tractors on site. Since there are many more trailers than tractors used to tow them, it is important that trailers can be interchangeable. The present disclosure allows existing trailer fleets to be modified to carry components and therefore battery packs. It will be feasible to transform existing trailer fleets because the present disclosure installs components on semi-trailers, a process that can be completed on almost any trailer. By transforming existing trailers, transportation companies will avoid the substantial additional capital costs of purchasing new trailers for their electric fleets, making the adoption of all-electric semi-trailers less capital intensive and therefore enabling faster advancement.

[0088] Similar to battery packs, a large number of new and modified trailers could be owned by leasing companies, which would lease these trailers to trucking companies. These leasing companies would handle the logistics of tracking the trailers, maintaining them, and billing for their use. Using leasing companies would reduce the initial capital costs of transitioning to an electric fleet, making the transition quicker. There are already several active trailer leasing companies in the market. These companies will likely expand their operations into the electric vehicle market.

[0089] Local laws in some jurisdictions allow semi-trailers consisting of two, and sometimes even three, trailers to be towed by a single semi-tractor. Where permitted, these trailer configurations allow the semi-trailer to carry additional weight beyond the standard 80,000 lb (36,287.39 kg) gross vehicle weight (GVW). These additional trailers can sometimes haul loads in excess of 100,000 lb (45,359.24 kg) GVW. While a typical single trailer length is 53 feet (16.15 m), trailer lengths vary widely, ranging from 24 feet (7.32 m) to 53 feet (16.15 m). In cases where multiple trailers are allowed to be towed by a tractor, each trailer can have its own set of assemblies and battery packs secured in the housing of the assemblies. In these cases, the battery packs from each trailer can be connected to the battery packs on the other trailers being towed so that the combined battery power of all trailers can be used to power the semi-tractor's electric motor. These additional trailer combinations can also enjoy the other benefits of the battery pack being fixed to the trailer assembly.

[0090] Many large companies receive deliveries from semi-trailers on an almost daily basis. For example, large retail stores receive deliveries from central distribution centers to their warehouses each night. For such customers, it would be advantageous to have charging stations at their locations so that trailers that are unloaded to load or unload deliveries can charge their battery packs while parked. This viable charging would allow the owner or operator of a commercial vehicle to minimize the number of battery packs required in the vehicles that make deliveries to a specific store each night, a significant advantage over operators who purchase semi-tractor trucks with fixed battery packs.

[0091] Those skilled in the art will appreciate that there are various battery pack mounting designs and configurations to meet the functional requirements of various commercial vehicle configurations used in the industry. Although the present invention describes specific embodiments related to the long-haul semi-trailer industry, those skilled in the art will recognize that various modifications and changes can be made by those skilled in the art without departing from the spirit and scope of the present invention. The present invention may be implemented in other specific forms without departing from its structure, method or other essential characteristics, which have been extensively described and claimed herein. The described embodiments are to be considered in all respects only as illustrative and not restrictive.

Claims

1. A trailer for use with an all-electric commercial vehicle for transporting goods, the commercial vehicle having at least one electric motor for driving the vehicle, the electric motor being connected to a wiring harness, the trailer comprising: a frame having a center frame member, side frame members, end frame members, and a plurality of structural struts extending between the side frame members and the center frame member and between the end frame members to provide structural frame support for the trailer; an assembly secured to the trailer, the assembly having a top, a bottom, a first side, a second side, and a rear, the top, bottom, sides, and rear forming at least one housing in which a battery pack is removably mounted; a cover of the assembly to protect the battery pack when the battery pack is installed in the assembly; as well as A battery pack has electrical connectors for connecting the mounted battery pack to the wiring harness to provide power from the battery pack to the at least one electric motor through the wiring harness.

2. The trailer of claim 1, wherein the electrical connector and the wiring harness allow communication between the mounted battery pack and any other battery packs mounted on the trailer.

3. The trailer of claim 1, wherein the electrical connection allows for charging of the battery pack.

4. The trailer of claim 1 , wherein the electrical connector and the wiring harness allow for communication between the battery pack and a power management system that monitors at least one of: Battery pack energy capacity; Battery pack charge status: Approximate range of the battery pack; Battery pack charging requirements; Battery pack efficiency; an overall estimated range of the installed battery packs; and an overall estimated state of charge of the installed battery packs.

5. The trailer of claim 1 , wherein the electrical connector and the wiring harness allow for communication between the battery pack and a power management system that manages at least one of: The available energy capacity of the battery pack; The available power status of the battery pack; Approximate range available from the battery pack; Battery pack charging; Battery pack efficiency; The total estimated available estimated range of the installed battery pack; the overall estimated available state of charge of the installed battery packs; The total estimated approximate range available from the installed battery pack; the overall estimated charge of the installed battery pack; the overall efficiency of the installed battery pack; as well as A driver input to the at least one electric motor of the commercial vehicle.

6. The trailer of claim 1, wherein a power management system uses information collected about the battery pack to determine an expected range of the battery pack installed in the housing when the battery pack is powering the at least one electric motor during driving the vehicle.

7. An assembly connected to an electric commercial vehicle for transporting goods, the commercial vehicle being designed to be driven by at least one electric motor, the assembly comprising: a top portion, a bottom portion, two first side portions, and a rear portion that together form a housing in which a battery pack can be removably mounted; as well as An electrical connector on the assembly is used to connect the battery pack to the electric motor when the battery pack is installed in the assembly.

8. The assembly of claim 7, further comprising a wiring harness for electrically connecting the mounted battery pack to the at least one electric motor.

9. The assembly of claim 7, further comprising a cover for the assembly to protect the battery pack when the battery pack is installed in the assembly.

10. An assembly connected to an electric commercial vehicle, the assembly comprising an electrical socket for facilitating communication between an electric motor of the commercial vehicle and a removable battery pack mounted in the assembly.

11. A system for providing a power supply to a commercial vehicle for at least one electric motor on the commercial vehicle, the system comprising: a plurality of assemblies into which a plurality of battery packs are mounted, each assembly including at least one connector for electrical wiring to provide electrical communication between the mounted battery pack and the at least one electric motor; A power management system for monitoring at least one of the following characteristics of the battery pack installed in at least one assembly: Battery pack energy capacity; Battery pack charge status: Approximate range of the battery pack; Battery pack charging requirements; Battery pack efficiency; the overall estimated range of the installed battery pack; and the overall estimated state of charge of the installed battery pack; The power management system is also used to manage at least one of the following characteristics of the battery pack installed in the at least one component: The available energy capacity of the battery pack; The available power status of the battery pack; Approximate range available from the battery pack; Battery pack charging; Battery pack efficiency; the total estimated available range of at least one installed battery pack; an overall estimated available state of charge of at least one installed battery pack; The total estimated available approximate range of the installed battery pack; the overall estimated charge of the installed battery pack; the overall efficiency of the installed battery pack; and driver input to the at least one electric motor of the commercial vehicle; and calculating a minimum number of battery packs required to provide sufficient charge to the at least one electric motor to enable the commercial vehicle to complete a predetermined trip along a predetermined route while the commercial vehicle is carrying a predetermined load by taking into account at least one of the following: the approximate charge held by each available battery pack; the age and condition of each available battery pack; the estimated distance of the intended trip; the weight of the load to be transported on the trip; the altitude gain or loss involved in the scheduled trip; the approximate temperature along the route of the scheduled trip; the forecast of weather conditions along the route of the scheduled trip; the planned stops along the scheduled route of the scheduled trip; the charging equipment available along the scheduled route of the scheduled trip; information regarding the availability of replacement battery packs along a predetermined route of the predetermined trip; and expected driver inputs during said predetermined trip; as well as The calculated minimum number of battery packs is installed on the assembly before the predetermined trip.

12. A storage system for securing a plurality of battery packs, the battery packs having internal mountings and electrical connections formed thereon, the system comprising: a storage rack having a plurality of cavities formed by top, bottom, side and intermediate frame members, each cavity being designed to receive a battery pack of a predetermined size, each cavity further comprising an electrical interface for monitoring and charging the battery pack via the electrical connector on the battery pack; as well as A movable cart includes a table top and a task-specific screw drive designed to attach the cart to the internal mountings on the battery pack to allow the battery pack to be inserted or removed from the storage rack and to secure the battery pack to the cart for transporting the battery pack to and from the storage rack.

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