Charging method for electric cars, and electric cars with interchangeable batteries

Abstract

The present invention discloses an entirely new system for charging the energy storage systems of electric cars. This method generally dispenses with charging the vehicle's own battery directly via a cable from an external power source, although this is possible in extremis. Instead, the segments making up the energy storage system of the novel electric cars are exchanged for e-fuelling. A battery management system ensures that the segments of the energy storage system are not discharged simultaneously while driving, but rather in each case just one or at most two are used in parallel. This staged discharge of the energy storage system means that, when needed, targeted exchange (or e-fuelling) of just these empty segments is possible. Accommodation of the energy storage system in the vehicle underbody enables both manual and automated e-fuelling. The battery segments are placed in the vehicle underbody in channels transversely to the direction of travel, meaning that they can be pushed in and out laterally. The number of segments to be exchanged during e-fuelling is determined by the driver and is displayed by light-emitting diodes placed in the lateral channel frame, which serve simultaneously as positioning aids for automated exchange. Lateral access to the battery segments enables straightforward, quick exchange thereof.

Description

[0001] Charging methods for electric cars and those with removable batteries

[0002] The present invention relates to a method for charging electric cars (hereinafter referred to as e-cars) and these e-cars with removable batteries.

[0003] The currently common method for charging electric cars involves connecting a charging support, connected by cable to an electric charging station, to the charging socket of the vehicle to be charged. After starting charging, you have to wait until the electric car's battery is fully charged. Charging takes approximately 6 hours, unless you choose the fast-charging option, where only 70-80% of the battery is charged, but in a shorter time, usually 30-60 minutes. This requires complex measuring and charging equipment housed in the charging station and charging supports. The following disadvantages can be identified with this system, among others: a- limited driving time with mandatory long breaks for battery charging b- difficulty in finding a battery station c- relatively low battery capacities; usually between 60 and 100 kWh and therefore short range d- rapid battery wear with frequent fast charging (30-60 minutes).) e- Driving at high speed (over 160 km / h) is not possible due to the enormous increase in energy requirements (third power of the speed) f- Required replacement of the battery after a maximum of 8 years, which is very expensive.

[0004] The state of the art includes:

[0005] - AU002008200543B8 “Light weight, Mass-producible, Combined Chassis, Battery Hüsing, Cooling System Structure forSolar Electric Vehicle” enables quick battery changes instead of “plug-in” charging.

[0006] - DE20 2018 003439 U1 “System for operating and changing accumulators in electrically powered motor vehicles” enables both e-fuelling from fuel pumps and e-fuelling by changing the battery

[0007] - US 2019 / 0118 782 A1 “Robotics for rotating energy cells in vehicles“ enables manual or robotic battery replacement in electric cars

[0008] - CN 1 12297 812 A “E-car and battery changing trolley suitable for the e-car” enables the change of the entire battery pack.

[0009] The present invention aims to design the electric car in such a way that recharging with energy is possible without an electrical connection between the charging station and the vehicle, while still being possible in emergencies. This partially or entirely avoids many of the aforementioned disadvantages.

[0010] The charging process for electric vehicles is based on an energy storage system that uses a segmented array of lithium batteries mounted on the vehicle's underbody. The individual segments, oriented perpendicular to the direction of travel, can be easily removed from the side. During EV charging, one segment with no battery charge is removed in turn and replaced with a segment with a full battery charge.

[0011] INCORPORATED BY REFERENCE (RULE 20.6) The battery management system of the electric vehicle is capable of determining which segments contain sufficient energy to meet the full vehicle requirements when driving; the aim is to ensure that only one segment of batteries is used at a time when driving, thus allowing a natural separation between battery segments with or without a full charge, which in turn opens up the possibility of only a certain selection of battery segments to be replaced, as determined by the driver, when necessary.

[0012] LED markings are used to indicate the positions of the battery segments to be replaced in the charging unit (human or automatic). The battery segments are secured against loss or theft by a double locking mechanism: one to release the segments for replacement, and the other, purely mechanical, to allow the segments to be removed.

[0013] The following advantages arise, among others:

[0014] - Ensuring fast charging with energy, which may be faster than filling up with petrol

[0015] - Electric cars built using this invention are sold with only one battery segment, which is sufficient to drive to the nearest charging station. This reduces the selling price to about half that of conventional electric cars.

[0016] - At every charging station for the electric cars according to the invention, the electric car receives full installation of all battery segments at no extra charge. In return, in addition to the energy costs, a proportional surcharge for the use of the borrowed battery segments must be paid for refueling. This eliminates any need for the driver to take care of the batteries.

[0017] - The arrangement of the battery segments allows for better utilization of the underbody of the electric car, enabling a much larger capacity for the energy source and thus also making it possible to increase the range and top speed of the electric car - 30 - 200% more than is usual today.

[0018] The present invention, in one embodiment, describes a method for charging and a suitable design of electric cars and their batteries.

[0019] The embodiment of the energy source according to the invention in the electric car is shown in the drawings and is explained in more detail below.

[0020] It shows

[0021] Fig. 1 - Schematic representation of electric cars with removable batteries

[0022] The method for charging electric cars 1 provided with a segmented arrangement 2 of lithium-ion battery segments 3, which are placed in the underbody of the vehicle transversely to the longitudinal axis, is based on the fact that the elongated

[0023] INCORPORATED BY REFERENCE (RULE 20.6) Battery segments 3 can be pushed in and out sideways to replace empty battery segments 3 with fully charged ones.

[0024] The battery segments 3 slide on four rollers 6 into corresponding channels 7 in such a way that, when these battery segments 3 are completely pushed in, the rollers 6 engage in suitable recesses and are firmly locked in all directions by pressure from above, generated by electromagnetic sliders 5 - not shown in the drawing.

[0025] The contacting of the respective battery segments 3 for the purpose of integration into the power supply of the electric car 1 is carried out by metal tongues 8, 9, which are located in a suitable socket 10 at the end of the sliding section in the channels 7.

[0026] When changing the battery, the hinged side flaps 12 must be folded up to allow access to the batteries.

[0027] The removal unit during refueling at the EV charging station—which may also be a human operator—inserts a pliers-shaped tool into two suitably shaped recesses 16, 17 located in the front panel of the battery segment 3 in order to move the battery segment 3 as needed. The removal unit is informed of which battery segment 3 is to be replaced by a lit LED 13 placed above the respective battery segment 3.

[0028] The electric car with removable batteries has a suitable number of channels 7 of equal size and configuration, which contain the battery segments 3 of the electric car. The turns of the channels 7 are rigidly connected to each other and form an extremely stable underbody 4 of the electric car 1, which protects the battery segments 3 from damage in the event of an accident. Lateral protection of the battery segments 3 is provided by the hinged side flaps 12. A mechanical lock 21—not shown in the drawing—keeps the side flaps 12 closed while driving.

[0029] Each channel 7 has at its inner end an elastic frame 22 which is precisely tailored to the dimensions of the battery segment 3, wherein each battery segment 3 has at its outer end a similar elastic frame 23, such that the two elastic frames 22, 23 prevent unwanted movements or even rattling of the batteries while driving.

[0030] In the ceiling of each channel 7, at least one electromagnetic slider 5 pushes the battery segment 3 downwards when it has reached its final position during insertion, signaled by a microswitch 19, whereby this is reversed when the car driver informs the battery management 24 when changing the battery from the dashboard 20.

[0031] A light-emitting diode 13 is placed in the side frame of the channel 7 above the respective battery segment 3, which lights up when the corresponding battery segment 3 is empty and needs to be replaced, whereby the driver can determine from the dashboard 20 which batteries should be replaced and which not.

[0032] INCORPORATED BY REFERENCE (RULE 20.6) On the outer front plate 18 of the respective battery segment 3 there are two suitably shaped recesses 16, 17 which can be used for handling the battery segment 3.

[0033] Each battery segment 3 has two insulated metal tongues 8, 9 at its inner end which enable the electrical connection of the segment. When the battery segment 3 is inserted in the channel 7, these tongues are inserted into the elastic elements of the corresponding socket 10 for the purpose of contacting and can be used for this purpose when the battery segment 3 is in the e-charging station during charging.

[0034] Typically, the battery segments 3 form two symmetrical rows around the vehicle's center channel 11, with the electrical connections routed through this center channel 11, allowing for relatively practical and easy handling of the battery segments 3. If the battery segments 3 are arranged in only one row and access to them is only possible from one side of the electric vehicle 1, the electrical connections are routed through a side channel (not shown), allowing for a more robust base plate 7.

[0035] Through the action of the battery management 24, the segments of the energy storage device are not discharged simultaneously while driving, but only one or a maximum of two are used in parallel, whereby this gradual discharge of the lithium-ion arrangement 2 means that a targeted exchange or e-fueling of certain empty segments is possible if necessary.

[0036] INCORPORATED BY REFERENCE (RULE 20.6)

Claims

Patent claims 1 . Method for charging electric cars (1 ) provided with a segmented arrangement (2) of lithium-ion battery segments (3) which are placed in the underbody of the vehicle transversely to the longitudinal axis, characterized in that a. the elongated battery segments (3) are pushed in and out laterally in order to replace empty battery segments (3) with fully charged ones b. the battery segments (3) slide on four rollers (6) into corresponding channels (7) in such a way that when these battery segments (3) are pushed in completely, the rollers (6) engage in suitable recesses and are firmly locked in all directions by contact pressure from above, generated by electromagnetic slides c. wherein the contacting of the respective battery segments (3) for the purpose of integration into the power supply of the electric car (1) is effected by metal tongues (8, 9), which are inserted into a suitable socket at the end of the sliding section in the channels (7).wherein hinged side flaps (12) are folded up when the battery is changed to allow access to the batteries e. wherein the removal unit when refueling at the e-charging station - in particular a human operator - inserts a pair of pliers-shaped tools into two suitably shaped recesses (16, 17) located on the front plate of the battery segment (3) in order to move the battery segment (3) as required; the removal unit is informed of which battery segment (3) is to be changed by a lit LED (13) placed above the respective battery segment (3).

2. Electric car with exchangeable batteries for enabling the charging method according to claim 1, which has a suitable number of channels (7) of the same size and equipment, which contain the battery segments (3) of the electric car, characterized in that a. The walls of the channels (7) are rigidly connected to one another and form an extremely stable underbody (4) of the electric car (1), which protects the battery segments (3) from damage in the event of an accident, while the lateral protection of the battery segments (3) is realized by the hinged side flaps (12), wherein a mechanical lock keeps the side flaps (12) closed during travel, b. Each channel (7) has an elastic frame at its inner end which is precisely tailored to the dimensions of the battery segment (3), wherein each battery segment (3) has an equally elastic frame at its outer end, such that the two INCORPORATED BY REFERENCE (RULE 20.6) elastic frames (22, 23) prevent unwanted movements or even rattling of the batteries while driving, c. Wherein in the ceiling of each channel (7) at least one electromagnetic slider (5) presses the battery segment (3) downwards when it has reached its end position during insertion, signaled by a microswitch, this being reversed when the driver informs the battery management (24) from the dashboard (20) when changing the battery, d. Wherein a light-emitting diode (13) is placed in the side frame of the channel (7) above each respective battery segment (3), which lights up when the corresponding battery segment (3) is empty and needs to be changed, whereby the driver can determine from the dashboard (20) which batteries should be changed and which not e.Wherein on the outer front plate (18) of the respective battery segment (3) there are two suitably shaped recesses (16, 17) which can be used for handling the battery segment (3). f. each battery segment (3) has two insulated metal tongues (8, 9) at its inner end which enable the electrical connection of the segment, whereby these, when the battery segment (3) is inserted in the channel (7), . for the purpose of contacting the elastic elements of the corresponding socket (10) and whereby when the battery segment (3) is in the e-charging station during charging they can be used for this purpose.

3. Electric car with exchangeable batteries according to claim 2, characterized in that the battery segments (3) generally form two symmetrical rows around the central channel (11) of the vehicle, with the electrical connections being guided through this central channel (11), which enables relatively handy and lightweight battery segments (3).

4. Electric car with removable batteries according to claim 2, characterized in that the battery segments (3) are placed in a row, while access to them is only possible from one side of the electric car (1), the electrical connections being led through a side channel, which enables a more robust base plate (4).

5. Electric car with exchangeable batteries according to claim 2, characterized in that by the action of the battery management (24) the segments of the energy storage device are not discharged simultaneously while driving, but only one or a maximum of two are used in parallel, whereby this gradual discharge of the lithium-ion arrangement (2) allows a targeted exchange or e-charging of only these empty segments if necessary. INCORPORATED BY REFERENCE (RULE 20.6)

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