High-performance battery-swappable electric vehicle

Abstract

We provide high-performance, battery-swappable electric vehicles. [Solution] By moving the battery holder location of an electric vehicle from under the seat to under the hood (53) (10) or the rear luggage compartment (11), it is possible to replace the battery from above the vehicle. This top-up replacement method uses a standard forklift (91) that is widely used in loading and unloading sites. Compared to the conventional bottom replacement method, this method makes the vehicle structure less vulnerable, reduces the risk of salt damage, reduces the risk of vehicle fire, and significantly reduces investment costs. Furthermore, by making small improvements to the in-wheel motor unit used in this vehicle, it may be possible to drive it through underpasses and other flooded areas.

Description

[Technical Field]

[0001] This invention relates to a battery-swappable electric vehicle with a sturdy body structure that provides high off-road capability in the event of a flood. [Background technology]

[0002] Historically, electric vehicles were first sold in 1891, five years before internal combustion engine vehicles, and competed in the market with internal combustion engines and steam locomotives. However, in 1908, electric vehicles were driven out of the market with the completion of the mass production system for the Ford Model T internal combustion engine.

[0003] One of the reasons electric vehicles are now in the spotlight after a long period of dormancy is the energy security concerns regarding dependence on oil that arose following the oil shocks of the 1970s.

[0004] The subsequent spread and development of electric vehicles is due to the increase in the energy density of batteries, which are the power source that determines driving distance. The batteries used have gone from lead batteries, which have low energy density, to nickel-cadmium batteries, which have even higher energy density, and nickel-metal hydride batteries, and recently lithium-ion batteries, which have the highest energy density of all.

[0005] The advantages of a replaceable battery are: (1) When purchasing a new car, users can purchase only the vehicle body without the battery, which helps reduce initial costs. (2) There is no waiting time for charging. (3) It is assumed that a battery exchange station is located within the vehicle's driving range, which increases the sense of security when driving as the battery is less likely to run out. (4) Electric vehicle owners will no longer need to maintain their batteries. (5) There is no additional cost of replacing the battery due to deterioration.

[0006] Most electric vehicles have fixed battery installation methods, but if you look at the world of radio-controlled cars, which are ahead in electrification, you will see that almost all of them have replaceable batteries, so I think it is only a matter of time before actual electric vehicles also have replaceable batteries.

[0007] Now, the battery replacement method in electric vehicles currently in use is a minority compared to the method in which the battery pack is fixed to the vehicle body, and the design and manufacturing of battery replacement systems is mainly carried out by manufacturers with little experience in the automotive industry. Replacement battery packs in existing passenger cars are mainly installed under the seats, and when replacement is required, the entire vehicle is lifted on a special lift equipped with a positioning system that includes multiple expensive and precise image processing devices and sensors. The used battery pack is removed through a door on the bottom of the vehicle, a charged battery pack is then installed, the door is closed, and the vehicle is finally lowered to the ground on the lift, completing the work (see Figure 11). The conventional method of replacing the battery pack from the bottom of the vehicle will be referred to as the bottom replacement method, and the method proposed here will be referred to as the top replacement method. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Patent Publication No. 2022-046565 [Patent Document 2] Patent Publication No. 2023-523868 [Patent Document 3] Patent application No. 2023-528322 Publication Request for examination [Patent Document 4] Patent Publication No. 2023-522478 [Patent Document 5] Patent 6792891 Published Patent [Patent Document 6] Patent 6741323 Published Patent [Non-patent literature]

[0009] [Non-Patent Document 1] Nikkan Jidosha Shimbun "Replaceable Battery EVs Spreading in China" Online May 7, 2023 [Non-patent document 2] EV Native [Latest Information on New Chinese EVs] Battery Replacement in 3 Minutes Online June 1, 2023 [Non-patent document 3] Yomiuri Shimbun Online: "Complete in 2.5 minutes" Battery-swappable for commercial EVs Online November 4, 2023 [Non-patent document 4] Asahi Digital "Experiencing an EV exchange station on a major street in Guangzhou, China" Online November 14, 2023 Summary of the Invention [Problem to be solved by the invention]

[0010] In recent years, Western Japan has seen frequent saltwater flooding of roads in coastal areas due to "abiki" typhoons, and in snowy regions, large amounts of snow-melting agents are sprayed. In both cases, measures to prevent salt damage are strongly required for electric vehicles. If this is neglected, the risk of vehicle fires due to battery short circuits caused by salt seeping in from the underside of the vehicle increases, putting human lives at risk. In neighboring countries such as China and South Korea, electric vehicle fires due to battery short circuits have become a social problem, and as electric vehicles become more widespread in Japan, this issue could become a social problem that could put lives at risk and is not something that can be ignored.

[0011] Although battery-swappable electric vehicles are expected to become the mainstream battery mounting system for future electric vehicles, they are currently being produced by manufacturers with a short history in automobile manufacturing, and as a result, they have a fatal flaw in that the battery is swapped from the bottom, making it difficult to protect the body from salt damage. Typical electric vehicles require a sturdy structure for the bottom of the vehicle, as it is assumed that the bottom of the vehicle will scrape against rough or snowy roads.However, with the bottom replacement method, the battery must be replaced through the bottom of the vehicle, so a door for battery replacement must be installed on the bottom of the vehicle, which must be highly waterproof.This door must have a precise, sturdy structure that is completely waterproof, which increases manufacturing costs. In addition, with the assumption that the bottom of the vehicle will scrape against rough or snowy roads, sturdy opening and closing doors are required on the bottom of the vehicle, which leads to a rise in the manufacturing cost of the vehicle. Furthermore, when replacing the batteries, the electric vehicle must be lifted up and a dedicated, large-scale battery replacement station equipped with a positioning mechanism using numerous image processing devices and precision sensors is required, which increases the investment costs for the battery replacement station. We believe that the current bottom replacement method, which has these drawbacks, will inevitably fade out in the future.

[0012] Due to global warming in recent years, flooding accidents have become more frequent across the country, and cars are becoming stranded in underpasses and other areas. [Means for solving the problem]

[0013] Current battery-swappable electric vehicles have battery holders installed under the seats, and battery packs are mostly replaced from the bottom, but this invention uses a top-mounted battery replacement method in which the battery holder is installed under the front hood, in the rear trunk, or in both the front and rear of the vehicle.

[0014] The replacement batteries used in this device are different from the thin plate-shaped batteries that are conventionally installed under the seats, as they are designed to be installed in locations with ample space, which relaxes restrictions on the thickness of the battery pack and makes it possible to use a structurally sturdy rectangular battery.

[0015] The battery pack of this invention has a forklift insertion hole at the top of the pack (see Figure 1), and when replacing the battery, you insert the forks of a typical forklift into the hole to remove the used battery pack, and then install a charged battery pack.

[0016] The electric vehicle in this invention has high water resistance, and in order to realize further maneuverability on water, a high-pressure submersible pump is added to the in-wheel motor unit. To deal with flooding while traveling on water, drainage pumps are installed at the front and rear of the vehicle. (See Figure 3 56) [Effects of the Invention]

[0017] The battery holder of this invention has a simpler structure than conventional devices, making it less expensive to manufacture and easier to maintain.

[0018] The battery holder of this invention allows battery pack replacement to be done from above the vehicle, making the vehicle much more water-resistant than conventional devices that require replacement from below, and also significantly reducing the risk of fires caused by battery short circuits.

[0019] This device does not require an opening and closing door at the bottom of the car body, so the strength of the bottom of the car body is significantly higher than that of conventional exchange systems, and maintenance and manufacturing costs are significantly lower.

[0020] The battery pack of this invention is rectangular, so it is much more resistant to external forces than conventional thin plate-shaped battery packs, reducing the possibility of fire caused by damage to the battery pack in the event of an accident.

[0021] The rectangular battery pack of this invention makes it easier to incorporate a battery cooling system compared to conventional thin plate-shaped battery packs.

[0022] The rectangular battery pack of this invention is easier to handle than conventional thin plate-shaped battery packs.

[0023] The system of this invention eliminates the need for expensive, large-scale dedicated replacement equipment that lifts the vehicle body when replacing the battery pack, making it possible to keep the investment cost of battery replacement stations low.

[0024] This device makes it possible to realize electric vehicles with high maneuverability during floods. When an electric vehicle floats to the surface of the water in an underpass or other location during a flood and becomes unable to move, the high-pressure submersible pump mentioned above can be operated, allowing the vehicle to navigate on the water by the reaction of the discharged water.

[0025] Electric vehicles equipped with a battery holder under the hood at the front of the vehicle will have understeer characteristics, while those equipped in the trunk at the rear will have oversteer characteristics. Vehicles equipped with batteries at both the front and rear will have a natural, neutral steering without any quirks, and because the heavy battery is installed away from the center of gravity, steering is less susceptible to external disturbances, making it ideal for the average driver. [Brief explanation of the drawings]

[0026] [Figure 1] In this diagram of the battery pack of this invention, viewed diagonally from the front, the two recesses at the top are the fork insertion ports. [Figure 2] Three-view diagram of the battery pack: top view, front view, and side view. [Figure 3] The top diagram is a simplified diagram of the battery holder arrangement on the vehicle body, and the bottom diagram is a simplified diagram of the replacement battery pack being hung on the forks of a forklift and loaded into the front battery holder of an electric vehicle. [Figure 4] In the diagram of the radiator pod, the top image shows the radiator pod from the side. The second image shows the front view. The third image shows the movable cover fully open. The fourth image shows the movable cover fully closed. [Figure 5]The top image is a cross-section of the center interior of the battery holder when viewed from the front, and the second image is a cross-section of the frontmost part, which is lower than the center interior cross-section so that a fork can be inserted into the battery pack insertion opening. The third image is a cross-section of the battery holder when viewed from the side, with the lower part on the left being the front. In both images, the inner walls are curved to make it easier to insert the battery holder, and the top opening is wider than the bottom. [Figure 6] The top image is the front view of the battery holder, and the bottom is the side view. [Figure 7] This is a top view of the battery holder. [Figure 8] The diagram above is a simplified diagram of the state in which the battery holder's air intake and exhaust vent covers are open, allowing air to flow freely inside the device and cooling the battery pack. The diagram below is a simplified diagram of the state in which the battery holder cover is closed, the air intake and exhaust blocking gate is open, and air cooled by the air conditioner's condenser is circulated inside the device to cool the battery pack. [Figure 9] The top figure is a plan view of our in-wheel motor unit with a high-pressure submersible pump, the second is a front view, and the third is a side view seen from the inside. This device adds a high-pressure submersible pump to the in-wheel motor unit to make it amphibious, taking advantage of the high water resistance of electric vehicles. When a vehicle floats to the surface in an underpass or other location during a flood and becomes unable to drive, the high-pressure pump is activated, allowing the electric vehicle to navigate on water through the reaction of the drained water. The unit consists of a motor, a wheel hub connected via a reducer and clutch, and a high-pressure submersible pump connected via a reducer and a second clutch. For reference, Figure 10 shows an example of a power supply system integrated into an in-wheel motor unit. [Figure 10] Research was conducted at the University of Tokyo and this is manufactured by Toyo Denki Seizo. It is an example of a power supply system incorporated into an in-wheel motor unit, realizing a system in which the vehicle receives power from road surface coils installed on the road surface. [Figure 11]Tesla's battery swap system is a technically large system consisting of a mechanism to lift the electric vehicle, a mechanism to remove the replacement battery installed at the bottom of the vehicle, lower it and move it, and then a mechanism to move the charged battery, lift it up, and install it in the electric vehicle. [Explanation of symbols]

[0027] 1 battery pack 2 ventilation holes 3 outlets 10 Front Battery Holder 11 Rear battery holder 12 Air intake 13 Exhaust port 14 Air intake cover 15 Exhaust vent cover 16. Intake and exhaust shutoff gate 17 Blower fan 18 Evaporator 19 Intake trough 20 Exhaust gutter 32 Top Pod 33 Air intake (for oil cooler) 34 Air intake (battery air conditioner / condenser) 35 Air intake (cabin air conditioner condenser) 36 Oil cooler 37 Battery Air Conditioner Condenser 38 Cabin air conditioning condenser 51 Front wheel 52 rear wheel 53 Bonnet 54 Handle 55 Backdoor 56 Drainage pump 71 In-wheel motor unit 72 Motor 73 Reducer 74 First clutch 75 wheel hub 76 Second clutch 77 High-pressure submersible pump 78 Power transmission cover 79 Water inlet 80 Drain 91 Forklift 92 posts 93 Fork

Claims

1. The battery pack of this invention has an insertion port at the top of the battery pack so that it can be handled with a forklift, and the ceiling of the insertion port is slightly cut to make it easier to position the fork, and the corners of the sides and bottom of the battery pack are arched to make it easier to insert into the battery holder.

2. The battery holder for accommodating the battery pack of claim 1 has a sealed structure consisting of a holder body and a top cover, and the top cover has an opening and closing function. In some cases, the bonnet may also serve as the top cover due to the design. Furthermore, the inner wall of the holder is vertical on the bottom and arched on the upper wall, sloping outward, and the opening of the battery holder at the top is wider than the bottom of the holder. This means that even if the battery pack is set slightly out of position when it is inserted into the holder, the weight of the battery itself will automatically guide it into the designated position along the arched surface of the holder's inner wall. In addition, the height of the wall of the battery holder facing the battery pack insertion port in claim 1 is set to a height that allows the forks of a forklift to enter the insertion port.

3. The battery holder of claim 2 uses a bonnet as a substitute for the top cover.

4. The battery holder of claim 2 employs a completely sealed battery holder with a forced air cooling system, with movable covers installed on the intake and exhaust ports, and an intake and exhaust shutoff gate installed between the intake pipe and exhaust pipe. When the outside temperature is suitable for temperature control of the battery pack, outside air is circulated inside the battery holder to control the temperature of the battery pack. When the outside temperature is not suitable, the battery holder is isolated from the outside air and air conditioned by the air conditioner is circulated inside the battery holder to control the temperature of the battery pack.

5. The replacement battery holder of claim 2 is installed under the hood at the front of the vehicle.

6. The replacement battery holder for the upper battery replacement method of claim 2 is installed in the rear luggage compartment.

7. The replacement battery holder for the upper battery replacement method of claim 2 is installed in two locations: under the hood at the front of the vehicle and in the luggage compartment behind the rear seats.

8. A radiator pod is installed on the roof above the passenger compartment of an electric vehicle, and inside it is housed an oil cooler for cooling the motor, a battery, and a condenser for cooling the interior. Movable covers are installed at the front and rear of the radiator pod, and when the functions of the equipment inside the radiator pod are not being used, they can be closed to achieve the optimum aerodynamic characteristics of the vehicle.

9. This unit is an in-wheel motor that is used to power electric vehicles and is equipped with a high-pressure submersible pump. The unit of this invention consists of a motor and a reducer, a wheel hub connected to the power source via a first clutch, and a high-pressure underwater pump connected to the power source via a second clutch. When the vehicle of this invention is driven on land, power is transmitted to the wheel hub via the first clutch, and the vehicle moves on land using the tires. When the vehicle is driven on water, power is transmitted to the high-pressure underwater pump via the second clutch, and the reaction force of the water discharge enables the vehicle to navigate on water.

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