Vehicle battery system

Abstract

A vehicle battery system (1) for a vehicle (3), the system (1) comprising: a selectively removable battery (5), a battery support (11), and a pawl (15). The selectively removable battery (5) includes a plurality of battery cells (7). The battery support (11) at the vehicle (3) receives the selectively removable battery (5), wherein the battery support (11) includes a base structure (13) to support a weight of the selectively removable battery (5). The pawl (15) engages with a respective notch, wherein the pawl (15) in a first position (16) is configured to resist movement of the selectively removable battery (5) away from the base structure (13) along a first axis (21). Selective actuation of the pawl (15) to a second position (18) enables the selectively removable battery (5) to be moved away from the base structure (13).

Description

"Vehicle battery system"Technical Field

[0001] This disclosure relates to a vehicle battery system. This includes a system, support structure, removable battery, and method of coupling a battery to a vehicle.Background

[0002] The past decade has seen an increased demand for electric vehicles. As this area of technology continues to develop, it is necessary to provide the public with systems and products that satisfy changing transport requirements and demands.

[0003] Heavy vehicles, such as prime movers, are large machines that are complex and expensive to build and maintain. As a result, prime movers are often intended for long-term use. Accordingly, it may be desirable to convert existing internal combustion engine prime movers to electric drive or to install electric drives into traditionally internal combustion engine powered prime movers. In other words, rather than substituting existing heavy vehicles with entirely new (electric) models, conversion may be a more cost effective path forward. This allows a significant amount of the heavy vehicle to be re-used. Converted prime movers clearly have no use for large fuel tanks. However, they will require large batteries that provide sufficient power to enable travel over large distances.

[0004] To reduce downtime of an electric vehicle, one option is to have batteries that are removable. This enables a vehicle to swap a discharged battery for a charged battery so that that the vehicle can be back on the road.

[0005] In this description, reference to vehicles and prime movers includes trucks, semitrucks, tractor units, rigs, etc.

[0006] Throughout this specification the word "comprise", or variations such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0007] Any discussion of documents, acts, materials, devices, articles or the like which has been included in the present specification is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present disclosure as it existed before the priority date of each claim of this application.Summary

[0008] A vehicle battery system for a vehicle, the system comprising: a selectively removable battery including a plurality of battery cells; a battery support at the vehicle to receive the selectively removable battery, wherein the battery support includes a base structure to support a weight of the selectively removable battery; and a pawl to engage with a respective notch, wherein the pawl in a first position is configured to resist movement of the selectively removable battery away from the base structure along a first axis; and wherein selective actuation of the pawl to a second position enables the selectively removable battery to be moved away from the base structure.

[0009] In some examples of the vehicle battery system, wherein the pawl is biased from the second position towards the first position to enable the selectively removable battery to be received at the battery support by movement of the selectively removable battery in a first direction along the first axis towards the base structure, and wherein the selectively removable battery is configured to be selectively removed, from the battery support, by: (i) the selective actuation of the pawl against the bias to the second position and; (ii) movement of the selectively removable battery in a second direction along the first axis that is opposite the first direction.

[0010] In some examples of the vehicle battery system, wherein the pawl comprises at least one flap rotatable around a flap axis, wherein the flap axis is substantially perpendicular to the first axis.

[0011] In some examples, the vehicle battery system further comprises: a first electrical connection unit associated with the selectively removable battery; and a second electrical connection unit associated with the vehicle, wherein the first electrical connection unit and thesecond electrical connection unit are connectable to enable an electrical connection path from the plurality of battery cells to the vehicle, wherein at least one of the first electrical connection unit and the second electrical connection unit is movably mounted to enable movement along the first axis.

[0012] In some examples of the vehicle battery system, wherein the second electrical connection unit is movably mounted at the vehicle, and wherein the second electrical connection unit is biased in the second direction away from the base structure.

[0013] In some examples of the vehicle battery system, the first electrical connection unit and the second electrical connection unit form a connection system comprising: a socket assembly with at least one tapered socket wall; and a plug assembly with at least one plug wall, wherein the plug assembly is configured to be received in the socket assembly and the plug wall is configured to interface with the tapered socket wall to aid alignment of the plug assembly into the socket assembly.

[0014] In some examples of the vehicle battery system, the plug assembly is configured to be received in the socket assembly along a connector axis, wherein the connector axis is perpendicular to the first axis. To receive the selectively removable battery at the battery support comprises: movement of the selectively removable battery along the connector axis to enable the plug assembly to be received at the socket assembly; and subsequent movement of the selectively removable battery along the first axis towards the base structure to enable the pawl to engage with the respective notch.

[0015] In some examples of the vehicle battery system, wherein to selectively remove the selectively removable battery from the battery support comprises: selective actuation of the pawl to the second position; subsequent movement of the removable battery along the first axis away from the base structure; and subsequent movement of the selectively removable battery along the connector axis to separate the plug assembly from the socket assembly.

[0016] In some examples of the vehicle battery system, the selectively removable battery includes at least one aperture, wherein the at least one aperture is configured to receive asupport element to support a weight of the selectively removable battery during removal and / or insertion from the battery support.

[0017] In some examples of a vehicle battery system, the at least one aperture is configured to align with the pawl when the selectively removable battery is received at the battery support, and wherein the at least one aperture is further configured to enable the support elements to be inserted through the at least one aperture to selectively actuate the pawl to the second position.

[0018] A battery support structure to receive a selectively removable battery at a vehicle, the battery support structure comprising: a base support to support a weight, relative to a first axis, of the selectively removable battery; and a pawl to engage with a respective notch of the selectively removable battery, wherein the pawl in a first position is configured to resist movement of the selectively removable battery away from the base structure along the first axis; and wherein selective actuation of the pawl to a second position enables the selectively removable battery to be moved away from the base structure.

[0019] In some examples of the battery support, the pawl is biased from the second position towards the first position to enable the selectively removable battery to be received at the battery support by movement of the selectively removable battery in a first direction along the first axis towards the base structure, and wherein the selectively removable battery is configured to be selectively removed, from the battery support, by: the selective actuation of the pawl against the bias to the second position and; movement of the selectively removable battery in a second direction along the first axis that is opposite the first direction.

[0020] In some examples of the battery support, the height- adjustable electrical connection unit is configured to move along the first axis from a first position distal the base structure to a second position proximate the base structure.

[0021] In some examples, the battery support further comprises: a first stop face and a second stop face connected to distal edges of the base structure and existing substantially parallel to a plane defined between the first axis and the connector axis, and a barrier extending between the first and second edge faces and proximal the base support face.

[0022] A method comprising locking a selectively removable battery into a battery support in the vehicle battery system described above, the method comprising:(A) locating the selectively removable battery in a ready-to-insert position where first electrical connection unit of the selectively removable battery is distal to the second electrical connection unit at the vehicle, and the selectively removable battery is aligned along the connector axis to enable the selectively removable battery to be inserted, along the connector axis, to the intermediate unlocked position;(B) inserting the selectively removable battery, along the connector axis to an intermediate unlocked position where the selectively removable battery is distal from the base structure along the first axis, and wherein the first electrical connection unit of the selectively removable battery is connected to the second electrical connection unit associated with the vehicle (3);

[0023] (C) inserting the selectively removable battery, along the first axis, to a locked position when the selectively removable battery supported by the base structure and the pawl is in the first position to resist the selectively removable battery to be moved away from the base structure.

[0024] In some examples, the method further comprises removing the selectively removable battery from the battery support, and the method comprising the steps of:(D) inserting at least one support element into the at least one aperture of a selectively removable battery;(E) actuating the at least one pawl with the support element causing the pawl to move from a locked position to a second unlocked position thereby releasing the pawl from the notch;(F) moving the selectively removable battery along the first axis from a locked position to an intermediate unlocked position where the selectively removable battery is distal from the base structure;(G) moving the battery system along the connector axis from the intermediate position to a second position wherein the first electrical connection unit is distal to the second electrical connection unit.

[0025] In some examples, the method further comprises the step of: actuating the pawl with a support element causing the pawl to rotate about a flap axis from a first position to a second depressed position; and wherein when the selectively removable battery is in a position proximate the base support, rotating the pawl about the flap axis from the second depressed position to a locked position such that the pawl comes into contact with a notch thereby restricting movement of the selectively removable battery along the first height axis.

[0026] In some examples, the method further comprising the step of: while inserting the selectively removable battery along the first axis to a locked position , moving the movably mounted electrical connection unit along the first axis from a first position to a second position.

[0027] A selectively removable battery for a vehicle: a plurality of battery cells; a housing configured to house the plurality of battery cells; wherein the housing(s) further comprises at least one aperture extending from a first side to an opposite second side of the housing, and wherein the at least one aperture is configured to receive at least one tine of a forklift for insertion into and removal from the vehicle.

[0028] In some examples of the selectively removable battery, the housing further comprises at least one notch configured to engage with a pawl at the vehicle to lock the selectively removable battery, and wherein the at least one notch is proximal to an opening of the at least one aperture at the second side to enable the tine of the forklift to actuate the pawl to release the selectively removable battery.

[0029] In some examples, the selectively removable has an L-shaped cross section.

[0030] In some examples, the selectively removable battery further comprises: a plurality of layers; and an electrical connection unit, wherein one layer is a system management layer associated with the electrical connection unit, and wherein the system management layerhouses switchgear comprising a solenoid switch configured to output current when the system management layer is supplied with a specified input voltage from the vehicle.

[0031] In some examples, the selectively removable battery further comprising a cooling system wherein: at least one layer of the plurality of layers is provided with a fan configured to blow air between the battery cells; and the battery housing acts as a heat exchanger.

[0032] In some examples of the selectively removable battery, the electrical connection unit further includes a fluid coupling to transfer air to the battery housing air for thermal and / or moisture management, wherein the fluid coupling is co-located, or inside, the electrical connection unit.

[0033] In some examples of the vehicle battery system, the battery support further comprises at least one guide track to receive at least part of the selectively removable battery, wherein the at least one guide track guides, at least in part, the movement of the selectively removable battery in a direction along the connector axis.

[0034] In some examples of the vehicle battery system, the selectively removable battery further comprises at least one roller, wherein the roller is configured to be received in the at least one guide track.Brief Description of Drawings

[0035] Examples of the disclosure are described with reference to the following Figures:

[0036] Figs. 1A to 1C illustrates a side schematic sequence of a selectively removable battery inserted into a battery support of a vehicle;

[0037] Fig. 2 illustrates, in part, a battery support at the vehicle to receive the selectively removable battery;

[0038] Fig. 3 illustrates, in part, another view of the battery support including a base structure;

[0039] Fig. 4 illustrates a pawl to engage with the selectively removable battery to retain the selectively removable battery at the battery support;

[0040] Fig. 5 illustrates an alternative view of the pawl of figure 4;

[0041] Fig. 6 illustrates a side view of a selectively removable battery for a vehicle;

[0042] Fig. 7 illustrates a perspective view of the selectively removable battery;

[0043] Figs. 8A and 8B illustrates a sequence of an electrical connection unit that is movably mounted;

[0044] Figs. 9A to 9D shows a close up cross section sequence of the pawl engaging a notch of the selectively removable battery.

[0045] Figs. 10A to 10D shows an alternative cross-section of a sequence of inserting a selectively removable battery including tines of a forklift interacting with the pawl;

[0046] Figs. 11A and 11B illustrate a top view of a sequence of inserting the selectively removable battery into the battery support that correspond to Figs. 1A and IB;

[0047] Figs. 12A to 12C illustrates a side cross-section (along A-A in Fig. 11 A) and shows a sequence to connect the electrical connection units, where one of the electrical connection units are movably mounted.

[0048] Fig. 13 illustrates a schematic of an alternative battery support;

[0049] Figs. 14A to 14B illustrate a side cross-section (along B-B in Fig. 11 A) and shows a sequence of an alternative system wherein a pawl is associated with the selectively removable battery; and

[0050] Figs. 15A to 15B illustrate another example of an alternative battery support that uses guide tracks, where Fig. 15A shows a side schematic with the guide track partially sectioned, and Fig. 15B shows an end view of the battery supported by guide tracks.Description of Embodiments

[0051] Overview

[0052] An example of a vehicle battery system 1 for use with a vehicle 3 is illustrated by Fig. 1. The battery system 1 comprises a selectively removable battery 5 and a battery support structure 11 at an electric or hybrid electric vehicle 3.

[0053] The selectively removable battery 5 can be inserted and locked into the battery support structure 11. The battery support structure 11 comprising a base structure 13 that is configured to receive and support the weight of the selectively removable battery 5. The system further comprises a locking mechanism 60. In this example, the locking mechanism comprises a pawl 15 and a notch 17. The pawl 15 is configurable in a first position 16 to engage the notch 17 (as shown in Figs. 1C, 9D, and 10D), whereby the battery 5 is locked by resisting movement of the selectively removable battery along a first axis 21. In this example, the pawl 15 and notch resists movement of the battery upwards along the first axis 21 and the base structure 13 supports the weight. The pawl 15 is also configurable to a second position 18 (as shown in Figs. IB and 10C) so that the pawl 15 is clear of the notch 17 to enable the selectively removable battery 5 to be removed. In some examples the pawl 15 is biased toward one of the first or second positions 16, 18.

[0054] The selectively removable battery 5 includes a first electrical connection unit 9 that is connectable to a second electrical connection unit (associated with the vehicle 3) to enable an electrical connection path from battery cells 7 of the selectively removable battery 5 to the vehicle 3. One, or more, of the electrical connection units 9, 10 may be movably mounted to facilitate insertion and locking in the method described in further detail below.

[0055] The process and mechanism for inserting and locking the selectively removable battery 5 into the battery support 11 is configured to prevent the battery to be unintentionally disengaged. The selectively removable batteries 5 used in a prime mover are relatively heavy objects and therefore external operative machinery (such as a forklift) is required to move the selectively removable battery 5 - such as during insertion and removal. A simplified sequence of inserting the battery from a ready-to insert-position 100, to an intermediateunlocked position 110, and to the locked position 120 is illustrated in Figs. 1 A to 1C and 9A to 9D.

[0056] Each of the components of a non-limiting example of the system described herein will now be described in detail.

[0057] Vehicle

[0058] The vehicle battery system 1 comprises a vehicle 3 comprising at least one electric motor for propulsion. The vehicle 3 can include a heavy-duty towing vehicle configured to haul loads. In one example the vehicle 3 is an electric prime mover. In some examples, the vehicle 3 is provided with a tow hitch attached to the chassis. In some embodiments when in use, the vehicle comprises one or more trailers.

[0059] In some examples the vehicle 3 is a truck, a semi-truck, a tractor unit, rig, or articulated vehicle.

[0060] In some embodiments the vehicle 3 is a hybrid electric vehicle that comprises both an electric propulsion system and an internal combustion engine. In alternative embodiments the vehicle 3 comprises exclusively or primarily electric propulsion.

[0061] Battery support structure

[0062] The battery support structure 11 is configured to receive and lock a selectively removable battery 5 to a vehicle 3. Turning to the example of Fig. 13, the components of the battery support structure 11 include a base support 13, an electrical connection unit 10, a pawl 15, and a framework 75. The base support 13 is configured to support a selectively removable battery 5. The framework 75 is configured to constrain movement of the battery 5 in one or more axes. The battery support structure further comprises an opening 90 to enable the battery 5 to selectively pass through.

[0063] With reference to Figs. 2 and 13, the framework 75 of the battery support structure 11 comprises a first barrier 70. In some embodiments the framework 75 further comprises a second barrier 74. In this example, the first and second barrier 70, 74 inhibits side to sidemovement of the battery 5 when locked into the battery support structure 11. In some examples the battery support structure 11 further comprises at least one stop face 72, 73. In this example, the stop faces 72, 73 inhibits the battery 5 from moving forward and backwards during acceleration and deceleration of the vehicle 3.

[0064] In some examples the battery support structure 11 is part of a vehicle 3 chassis. In alternative embodiments the battery support structure 11 is configured to attach to a vehicle 3 chassis.

[0065] Base support

[0066] The base support 13 is configured to provide support for the selectively removable battery 5.

[0067] In some examples the base structure 13 provides a base surface comprising a continuous or semi-continuous sheet or shelf configured to support the weight of a selectively removable battery 5. In some embodiments the perimeter of the base structure 13 is defined by one or more beams 76 arranged in a truss. With reference to Fig. 3 extending between two edges of the quadrangle is at least one additional base beam or support beam 78. It is to be appreciated that the at least one support beam 78 can be configured in a variety of arrangements based on design specifications, such as expected mass of the battery, expected forces during operation, and mass considerations for the vehicle. In some examples the at least one support beam 78 is arranged to extend in a direction parallel to a base beam edge. In alternative examples the base structure 13 is provided with at least two support beams 78 configured such that one support beam bisects a second base beam (thereby forming a cross)

[0068] In some examples a plurality of base beams 78 extend between edges of the quadrangle at inverse angles at each edge (thereby forming a plurality of triangles in a Warren truss arrangement).

[0069] In some embodiments the base support 13 is made of steel.

[0070] Framework

[0071] The framework 75 of a battery support structure is configured to constrain lateral movement of a selectively removable battery 5. The framework 75 comprises at least a barrier 70 and an opening 90. In some examples the framework 75 further comprises a mounting face 68. In some examples, the framework 75 comprises at least one stop face 72.

[0072] Referring to Fig. 1C, the barrier 70 is configured to restrict movement of a selectively removable battery 5 when the selectively removable battery 5 is in a locked position 120. That is, to stop the selectively removable battery 5 from sliding out sideways from the vehicle 3. In this example, this restricts movement in a direction parallel to the connector axis 39.

[0073] Referring to Fig. 3, in some examples the barrier 70 is a continuous beam proximal the base support 13 extending in a direction parallel to a centreline of the vehicle 3. In alternative examples the barrier 70 comprises one or more teeth protruding from the base support 13. In yet other examples the barrier 70 is a gate or at least one non-rigid member such as a belt or chain configured to extend across an opening 90. In other examples, the barrier 70 can be a side panel.

[0074] In some embodiments the barrier 70 is a lip on the outer edge 86 of the base support 13 protruding above the base structure 13.

[0075] With reference to Figs. 1C and 2, in some embodiments the battery support structure 11 further comprises a second barrier 74. The second barrier 74 is configured to restrict movement of a selectively removable battery 5 along a connector axis 39 when the selectively removable battery 5 is in a locked position 120. This stops the battery 5 moving sideways too far towards the centreline (and / or or other side) of the vehicle 3.

[0076] In some embodiments the second barrier 74 is located proximal the inner edge 84 of the base support 13. In one embodiment the second barrier 74 comprises two teeth located at opposite corners on the inner edge 84. In some embodiments the second barrier 74 is a continuous beam extending along the inner edge 84 proximal the base support 13. In alternative examples, the second barrier 74 can be a panel.

[0077] With reference to Figs. 2, 3, and 13, in some embodiments the stop face 72 is a continuous or semi-continuous wall configured to constrain the movement of a selectively removable battery 5 (such as forces in the forward and rear direction as the vehicle accelerates and decelerates). In some embodiments the at least one stop face 72 extends from the base support 13 to a mounting face 68. In some embodiments the edge face 72 comprises one or more beams.

[0078] In some examples the framework 75 provides a first stop face 72 and a second stop face 73 (as best illustrated in Fig. 13). In one example, the first stop face is a front stop face 72 and the second stop face is an opposing (and substantially parallel) rear stop face 73. This is to constrain movement of the battery as the vehicle 3 accelerates and brakes. In other words, to stop the selectively removable battery 5 from sliding forwards and backwards.

[0079] Referring to Figs. 1 and 13, the opening 90 is a void that a selectively removable battery 5 passes through when it moves from a ready-to-insert position 100 to an intermediate unlocked position 110. With reference to Fig. 13, the opening 90 is a void above the barrier 70. In some examples, the opening 90 is substantially parallel the mounting face 68. In some examples, the sides of the opening 90 are defined by the first and second stop faces 72, 73.

[0080] Mounting face

[0081] With reference to Fig. 1, a mounting face 68 is a site at which the pawl 15 and second electrical connection unit 10 are mounted at the battery support structure 11. The mounting face 68 may include a panel surface. Turning now to Fig. 2, this shows an example of a mounting face 68 with two pawls 15 and an electrical connection unit 10.

[0082] Pawl

[0083] A depressible or rotatable detent acts as a pawl 15 to lock the battery 5. Referring to Figs. 4 and 5, in some embodiments the at least one pawl 15 comprises a substantially planar flap 25 hinged by a hinge member 20 that acts as a pin that extends along a flap axis 27. The movement of the pawl 15 is a rotation about the flap axis 27. The hinge member 20 is, at least in part, rotatably received in a bracket 20 (acting as a barrel or knuckle), that in turn is fixed to the battery support 11. This enables the pawl 15 to move (by rotation) between thefirst position 16 and the second position 18. In some examples the pawl 15 may move to other positions, such as third position 26 (as illustrated in Fig. 1A). This third position may extend beyond the first position 16 when movement of the pawl 15 is not constrained when the selectively removable battery 5 is removed.

[0084] The pawl 15 may also have a biasing means to bias the pawl 15 from the second position 18 to the first position 16. Examples of a biasing means may include a resilient element, spring, or other passive elastic or resilient materials as well as active biasing means such as pneumatic, hydraulic, and electromechanical devices. In the illustrated example, the biasing means is in the form of a resiliently deformable elastomeric bushing 24. The bushing24 has an external square-shaped cross-section that is received in a corresponding squareshaped bracket 22. The bushing 24 also has an internal square-shaped passage to receive a square-shaped profile of the hinge member 20. Thus rotation of the flap 25 of the pawl 15 causes rotation of the hinge member 20 that, in turn, causes deformation of the bushing 24. Since the bushing is resiliently deformable, the bushing 24, resists such forces to bias the flap25 back to the original state. The flap 25, and bushings 24 are configured so that the at rest state (i.e. with no, or little deformation of the bushing 24 is when the pawl is at the first position 16 and the second position 18 is when the bushing has been deformed.

[0085] That is, when the pawl 15 is moved from the first position 16 to the second position 18 the bushing 24 goes from a relatively uncompressed rest state to a compressed / deformed state.

[0086] In one embodiment the hinge member 20 has a square cross section and is positioned diagonally to the bracket 22 when the pawl 15 is in the first position 16 (as illustrated in Fig. 4). In this embodiment, when the hinge member is in the second position 18, this results in the hinge member being closer to an orthogonal relationship with the bracket 22.

[0087] In some examples the battery support structure 11 is provided with two pawls 15. However, it is to be appreciated that in other examples there could be a single pawl, or more that two pawls. In the illustrated example (such as in Fig. 5), the pawl 15 includes a flap 25 that extends (at one end at the right hand side of Fig. 5) to beyond the hinge mechanism. It isto be appreciated that the flap 25 can extend to the left hand side, to both sides, or not extend beyond the hinge mechanism.

[0088] In the above illustrated example, the flap axis 27 is substantially perpendicular to the first axis 21, and perpendicular to the connector axis 39 (that makes the flap axis 27 substantially parallel with a centreline of the vehicle). However, in alternative embodiments, the flap axis 27 extend in other directions, such as being substantially parallel with the first axis 21. This will result in flaps 25 that pivot around a substantially vertical axis. In further examples with multiple flaps, it is to be considered the multiple flaps can have different respective flap axes 27 and different respective directions 19, 23.

[0089] Electrical connection units

[0090] In some embodiments the vehicle battery system comprises a first electrical connection unit 9 associated with the selectively removable battery 5 and a second electrical connection unit 10 associated with the vehicle 3. At least one of the two electrical connection units 9, 10 are movable along the first axis 21 (which in the illustrated examples such as Fig. 12A to 12C is vertically up and down).

[0091] Figs. 2 and 8 illustrate the second electrical unit 10 at the vehicle 3. The second electrical connection unit 10 comprises a first element 34 movable relative to a second element 50. Located on the first element 34 is a plug assembly 35 with at least one plug wall 37. In some embodiments the plug assembly 35 includes a non-conducting tapered capsuleshaped prism with one or more electrical connector interfaces 32. In the illustrated example, this includes three connector interfaces 32 (in particular male DC GB / T connector interfaces).

[0092] The first electrical connection unit 9 (to be discussed in detail with the battery 5) includes a corresponding socket assembly 31 with socket walls 33. The socket may also have a plurality of electrical connector interfaces 36 (which in this example includes three female DC GB / T connector interfaces). The socket assembly 31 received the above mentioned plug assembly 35 to enable the electrical connection units 9, 10 to form a connection system 30 for energy to flow between the battery 5 and the vehicle 3.

[0093] It is advantageous for at least one electrical connection unit 9 or 10 to be provided with a tapered surfaces or walls 33, 37 to guide electrical plugs and sockets into contact. In some embodiments the wall 37 of the plug assembly 35 is tapered. In other examples, the socket wall 33 of the socket assembly 31 is tapered. In yet other examples, both the socket assembly 33 and the plug assembly 37 are tapered. It is to be appreciated that one of the walls 33, 37 may be straight whilst the other walls 33, 37 may be tapered.

[0094] With reference to Figs. 8 and 12, at least one of the electrical connection unit 9 or 10 is configured to move between a first position 800 and a second position 801. In some embodiments this movement is along the first axis 21 and the electrical connection unit 9 or 10 is biased upwards.

[0095] In the example of Figs. 8 and 12, the second electrical connection unit 10 is movably mounted to the mounting face 68 of the battery support structure 11. A mounting mechanism at the second electrical connection unit 10 enables relative movement between two substantially parallel elements 34, 50. This movable mounted electrical connection unit 10 enables the connection whilst permitting some movement of the battery 5 (such as vertical movement during insertion and removal as shown in Fig. 1).

[0096] With reference to Figs. 4 and 8, the second element 50 of the mounting mechanism comprises a first plate 51 and a second plate 52. The two plates 51, 52 are separated by distance D. In some embodiments, at least one guide rod 54 extends between the two plates 51, 52. The axis of the guide rod 54 is substantially parallel to the first axis 21. The at least one rod 54 is provided with a collar 55 movable along its axis 21. In some embodiments the collar 55 is attached to the first element 34 to support and constrain movement of the first element 34 along the first axis. In some embodiments the mounting mechanism further comprises biasing means, such as a spring 57 coiled around the at least one rod 54. The spring 57 is configured between the collar 55 and the second plate 52 to bias the first element 34 (and second electrical connection unit and plug assembly 35) towards in direction 19 towards the first position 800.

[0097] In some embodiments the vehicle battery system comprises a first electrical connection unit 9 associated with the removable battery 5. The first electrical connection unit9 is complementary to a second electrical connection unit 10 associated with an electric or hybrid vehicle 3. With reference to Figs. 7 and 12, the first electrical connection unit 9 comprises at least one socket assembly 31 with at least one tapered socket wall 33. The at least one plug assembly 35 of the second electrical connection unit 10 is configured to be received in the socket assembly 31 of the first electrical connection unit 9. The plug assembly 37 is configured to interface with a tapered socket wall 33 of the first electrical connection unit 9. An advantage of this is to aid alignment of the socket 31 and plug 35. Another advantage of the plug assembly 37 is that it provides at least partial protection of the connection point from water and debris.

[0098] Selectively removable battery

[0099] Some embodiments provide a selectively removable battery 5 comprising a plurality of battery cells 7, a housing 61, and at least one notch 17.

[0100] Figs. 6 and 7 illustrate an example of the selectively removable battery 5 wherein the plurality of battery cells 7 are configured to supply electric energy to a vehicle 3 via a first electrical connection unit 9. The selectively removable battery 5 comprises a housing 61 configured to house the plurality of battery cells 7. The housing 61 includes at least one locking feature, in the form of at least one notch 17 configured to engage with the pawl 15 to retain the battery at the battery support 11.

[0101] In some embodiments the battery comprises a plurality of layers 66. In some embodiments one layer is a system management layer 64 associated with the electrical connection unit 9 and contains switchgear 65. The other layer(s) contain a plurality of battery cells 7 that may be grouped on a layer by arrangement. These will be discussed in further details below.

[0102] Turning to the system management layer 64, this functions as a junction between the vehicle 3 and the battery cells. This can include communication components, electrical components (e.g. power convertors), battery management systems, temperature and other environmental management systems. The system management layer 64 may include switchgear 65 comprising a solenoid system configured to selectively switch output powerfrom the removable battery 5. In this example, the first electrical connection unit 9 is mounted to the system management layer 64.

[0103] In some embodiments the removable battery 5 is configured to require a specified input voltage in order to switch the solenoid system that, in turn, and enables electrical energy from the plurality of battery cells 7 to output from the selectively removable battery 5 to the vehicle 3. This serves as a safety feature to prevent unintentional power output from the removable battery 5, such as person touching the electrical connection unit 9 of a removed battery, or lose debris or moisture in and around the electrical connection unit. In one embodiment approximately 12 volts need to be supplied from the vehicle 3 to the selectively removable battery 5 in order for the removable battery 5 to supply output power to the vehicle 3.

[0104] In one embodiment the selectively removable battery 5 comprises two substantially parallel apertures or bores 41, which in this example are located on either side of the electrical connection unit 9 (see Figs. 7, 11, and 14A). These apertures 41 extend from a first side 62 to an opposite second side 63 of the housing 61 and are configured to receive tines 40 of a forklift or other external operative machinery. The two apertures 41 serve two purposes. The first is to enable lifting by a forklift. The second is to align the tines of the forklift with the two pawls 15 (as shown in Fig. 11A). In this particular example, the bores 41 extend along the depth of the system management layer 64, which is the top layer of the selectively removable battery 5.

[0105] With reference to Fig. 10, when the removable battery is positioned within a battery support structure, the two apertures 41 are substantially parallel to a connector axis 39. This facilitates the steps of inserting and removing the removable battery 5 and, in particular, how the tines 40 are passed in and out of the apertures / bores.

[0106] The selectively removable battery 5 is configured so that the at least one notch 15 is proximal of an opening of at least one of the apertures 41 on the second side 63. This enables the tine 40 of the forklift to actuate the pawl 15 to release the selectively removable battery 5.

[0107] In some embodiments the selectively removable battery 5 has an L-shaped cross section and is configured to maximise use of the available space on the vehicle 3. In alternative embodiments the selectively removable battery 5 takes a different shape to optimise for alternative vehicle spaces. For example, a rectangular prism, a trapezoidal prism, or having a T-shaped cross section. The shape of the battery is dependent on the vehicle 3.

[0108] In some embodiments the housing 61 is ribbed such that edges between the plurality of layers 66 define a series of substantially parallel protrusions. The protrusions extend along at least one face of the selectively removable battery 5. This increases the surface area of the battery thereby assisting with temperature control.

[0109] Temperature control

[0110] In some embodiments the selectively removable battery 5 comprises an air cooling system. The removable battery further comprises at least one fan configured to blow air in the space between battery cells 7. This can include a fan, or fan system for each layer. Each layer may be configured to include air flow passages between the battery cells 7 and a housing 61 of the layer. This is to create air circulation through the removable battery 5 thereby providing some degree of temperature control. The housing 61 of the removable battery 5 acts as a heat exchanger with the surrounding environment.

[0111] In some embodiments the removable battery 5 is supplied with dry air. This can facilitate removing moisture from within the air gaps inside the removable battery 5. In some examples, an air vent is provided between respective layers 66 and dry air is provided to one layer (such as a bottom layer). The dry air then permeates through the layers 66, such as via the air vents. Blowing dry air through the plurality of layers 66 in the battery 5 may be performed periodically, such as whilst the battery is charging at a charging station (i.e. outside of the vehicle). This can save energy and weight of a vehicle on board air drying system. Nonetheless, in some other examples the vehicle 3 may supply dry air to the battery for removing moisture. This may be useful in extreme operating conditions where the vehicle is operating in a high humidity environment. This is described further under the variations section

[0112] In one embodiment each of the plurality of battery cells 7 is a Lithium nickel manganese cobalt oxide (NMC) cell. In alternative embodiments the battery cells are lithium iron phosphate (LFP) batteries. It is to be appreciated that alternative battery cell composition and chemistry can be used.

[0113] Locking mechanism 60 and alternative features

[0114] The vehicle battery system 1 provides locking mechanism 60 to retain the battery 5 in the battery support 11 and vehicle 3.

[0115] As is described in above examples, the selectively removable battery 5 comprises at least one notch or channel or step 17 configured to receive the panel 15. When the selectively removable battery is located within the battery support 11 the panel 15 is in the first position 16. As a result of this the movement of the selectively removable battery 5 along the first axis 21 is constrained by contact between the panel 15 and the notch 17 (as best illustrated in Figs. 1C and 10D).

[0116] In alternative embodiments the locking mechanism 60 comprises at least one detent as a substitute for at least one pawl 15. In these embodiments the detent is biased away from the battery support structure 11. The detent is configured to be pushed thereby allowing the selectively removable battery 5 to be removed from the battery support structure 11. In alternative embodiments any pivoted or spring-loaded or magnetised or similarly depressible mechanism can serve as a substitute.

[0117] The notch 17 of the locking mechanism 60 can be broadly described as a dog in that it prevents or at least restricts movement of the pawl 15 thereby restricting movement of the removable battery 5. In some embodiments the physical engagement is between at least a pawl 15 and a notch 17.

[0118] Methods of locking and unlocking a removable battery

[0119] Methods of inserting and locking a selectively removable battery 5 into a battery support structure 11 as well as unlocking and removing a selectively removable battery 5from a battery support structure 11 will now be described. These will be discussed with reference to Figs. 1, 9, 10, 11, and 12.

[0120] Inserting and locking the batery

[0121] In some examples a method of locking a selectively removable battery 5 into a support structure 11 on a vehicle 3 involves the use of external operative machinery such as using tines of a forklift to support and move the battery. This is shown, in part, in the sequence in Fig. 10 that illustrates the tines 40 inserted through apertures 41 in the battery 5. For simplicity, only a portion of the battery 5 (in particular the system management layer 64) is shown in this sequence.

[0122] Figs. 9A, 10A, and 12A illustrate the same method step 100 at different cross sections of the top layer of the selectively removable battery 5 and the battery support structure 11. With reference to Fig. 10A, the selectively removable battery 5 comprises at least one aperture 41 configured to receive the tines 40 of a forklift (or functional equivalent). The tines 40 of the forklift are inserted through the at least one aperture 41 thereby enabling the forklift to lift the battery into a ready-to-insert position 100. At position 100, the first electrical connection unit 9 of the battery 5 is distal the second electrical connection unit 10 such that the two electrical connection units are aligned along a connector axis 39 as illustrated in 12A. Fig. 10A, depicts the tines 40 protruding from the second side 63 of the battery housing 61.

[0123] With reference to Figs. 9A and 9B, the method involves locating the selectively removable battery 5 into a ready-to-insert position 100 and moving the battery 5 in a direction 8 towards the second electrical connection unit 10 at an intermediate unlocked position 110. That is, inserting the battery 5 into the support structure 11. In some examples, the protruding forklift tine 41 engages at least one pawl 15 of the battery support structure 11 such the at least one pawl 15 is rotated to an unlocked position 18 (as shown in Figs. 10A, 10B and in Figs. 11A, 1 IB). At this step 110 of the method, the removable battery 5 is distal from the base structure 13 along a first axis 21. Simultaneously, the first electrical connection unit 9 makes contact with the second electrical connection unit 10 (as shown in 12B). Specifically, this includes inserting the plug assembly 34 into the socket assembly 31. The method furthercomprises the step 115 of moving the removable battery 5 along first axis 21 in direction 19 such that the selectively removable battery 5 makes contact with the base support 13 (as shown in a transition of the battery 5 downwards from Figs. IB to 1C, 9B to 9C, 10B to IOC, and 12B to 12C.

[0124] With reference to Fig. 10D, when the selectively removable battery is in contact with the base support 13 the forklift tine 40 is removed from aperture 41. As the forklift tine 40 is removed, the at least one pawl 15 is disengaged and rotates into a locked position 16 thereby coming into contact with notch 17. At this step, the selectively removable battery is in its locked position 120. During removal of the forklift tine 40, the barrier 70 stops movement of the battery from moving out of the void 90.

[0125] When the battery system 1 is in the locked position 120, the removable battery 5 is supported by the base structure 13. The removable battery 5 is sandwiched between the base structure 13 and the at least one pawl 15 thereby restricting its movement along the first axis 21. The combination of the pawl restricting movement along with the surfaces of the battery support structure 11 constrains movement of the removable battery 5 so that it is secured to the vehicle 3.

[0126] Unlocking

[0127] In some examples a method of unlocking a selectively removable battery 5 from a support structure 11 on a vehicle 3 also involves the use of external operative machinery such as a forklift.

[0128] With reference to a generally reversible sequence in Figs. 1A to 1C, the method starts at 120 where a selectively removable battery 5 is located inside a battery support structure 11. The selectively removable battery 5 is supported by a base support 13 and a first electrical unit 9 is connected to a second electrical connection unit 10. The at least one pawl 15 of the support structure 11 is in a locked position 16 and is in contact with (or at least proximal) the notch 17.

[0129] With reference to Fig. 10D, the method starts at 120 where the tines 40 of a forklift are inserted into an at least one aperture 41 of a selectively removable battery 5. At 115 inFig. IOC, the tines 40 actuate the at least one pawl 15 such that the pawl 15 is rotated from a locked position 16 to an unlocked second position 18.

[0130] The forklift then lifts the selectively removable battery along the first axis 21 in a direction 23 (at 110) such that the battery 5 is distal the base support 13 but still substantially inside the support structure 11 (see Fig. IB and 10C). The pawl 15 remains clear of the notch 17 due to the protruding tines 40. At this point the battery 5 is at the same location as the ready-to-insert position in the above locking method.

[0131] The forklift then moves the selectively removable battery 5 along the connector axis 39 such that the battery 5 is moved out of the support structure 11 via the opening 90 and with the two electrical connection units 9, 10 separated as illustrated in Figs. 1A and 12A.

[0132] Variations

[0133] Example application

[0134] In one example, an electric tractor unit of a semi-trailer truck 3 is provided with two vehicle battery systems 1 located on opposite sides of the centreline. The two vehicle battery systems 1 are mirror images and each is provided with a battery support structure 11 and a selectively removable battery 5. The vehicle battery support structure 11 and batteries are configured to replace fuel tanks of the vehicle 3. This can have particular application for converting an existing internal combustion vehicle 3 that typically has a diesel engine to an electric vehicle.

[0135] The battery support structure 11 has a general L-shaped profile and comprises a series of beams and surfaces welded to the chassis of the truck 3. The battery support structure is provided with a mounting face 68 located on the upper-inner portion. An electrical connection unit 10 is movably mounted thereon and is flanked by two pawls 15. The support structure 11 further comprises a base support 13 to support a selectively removable battery, a front and a rear stop face 72, 73 (to prevent forwards and backwards movement of the battery 5), an outer barrier 70 proximal to the base support 13 extending between the two stop faces (to prevent sidewards movement of the battery away from thecentreline), inner teeth 74 (to prevent sidewards movement of the battery 5 towards the centreline), and an opening 90 (for the support structure 11 to receive the battery).

[0136] Detents

[0137] In some examples the battery system 1 may have a locking system that includes one or more detents as a substitute for the pawl 15. In some examples, the detents are spring- loaded or elastically depressible surfaces, such as pins, arms, levers, etc.

[0138] Battery with pawl

[0139] In the above mentioned examples, the pawl 15 is mounted at the vehicle. In alternative examples, the pawl 15 is pivotally mounted at the selectively removable battery 5 and the notch 17 is located on the battery support structure 11. With reference to Fig. 14, the pawl 15 is actuated by a forklift tine 4 thereby disengaging the notch 17. That is, as the forklift tine 40 is inserted into aperture 41 the tine pushes a first portion of the pawl 15, causing a second portion to rotate out from under the notch 17. As can be appreciated, additional configurations of the pawl 15 and notch 17 could be used to lock the battery 5.

[0140] First electrical connection unit with height adjustment mechanism

[0141] In the above examples, especially Fig. 8A and 8B, the second electrical connection unit 10 is movable to enable the battery 5 to move vertically whilst connected. In some alternative examples, a height adjustment mechanism is located on the first electrical connection unit 9 on the selectively removable battery 5. In such examples, the second electrical connection unit 10 on the battery support structure 11 is at a fixed position. In such an example the electrical connection unit 9 at the battery is biased downwards. As the selectively removable battery 5 is moved downwards in the first direction 19 along the first axis 21 the electrical connection unit 9 movably mounted at the battery moves upwards whilst maintaining contact with the fixed second electrical connection unit 10 fixed to the battery support structure 11.

[0142] Front-loading

[0143] In alternative examples, the selectively removable battery may be inserted from other approaches to the vehicle. One example provides a front-loading vehicle battery system 1 wherein a selectively removable battery 5 is inserted at the front of a vehicle 3. A vehicle 3 comprises a receptacle or cavity proximal the front end thereof and is configured to receive a selectively removable battery 5. In this example the cavity provides battery support structure 11. That is, the cavity comprises: a base support 13, a barrier 70, at least one stop face 72, an opening 90, and a mounting face 68. The opening 90 may be selectively covered with a hinged surface to protect the battery from debris encountered from the vehicle travelling at high speeds.

[0144] Battery housing without apertures

[0145] In some examples the selectively removable battery 5 is T-shaped and can be broadly described as having a top or head portion and a body portion. The body portion of the battery 5 has a width sufficient to accommodate tines of operative machinery, such as a forklift. That is, the battery does not comprise any apertures and instead is shaped such that a forklift supports the battery 5 by its head with tines on either side of the battery’s body portion. The battery housing 61 comprises two ledges 17 located on opposite sides of the body portion in the void created under the head portion. The two ledges in this example are substitutes for the notch 17.

[0146] Guide tracks 211

[0147] In some examples, as illustrated in Figs. 15A and 15B, the battery support 11 further includes guide tracks 211 to assist insertion of the battery 5 through the opening 90 and into the void. In particular, the tracks can partially support and guide the battery during movement in direction 8. Advantageously, this can aid alignment of the first electrical connection unit 9 with the second electrical connection unit 10.

[0148] In some examples, the guide tracks 211 includes rails extending across the front and rear stop face 72, 73. The selectively removable battery 5 may have corresponding wheels, rollers 222, rails, bushings, or other elements to be received in the guide tracks 211. The use of wheels mounted at the removable battery 5 can assist in smooth insertion of the battery 5and part of the weight of the battery 5 may be supported by the guide tracks 211 during insertion in direction 8. The guide tracks 211 may have limited length or include cut outs 226 (or other discontinuity) so that after full insertion in direction 8, the removable battery 5 is allowed to drop downwards in direction 19.

[0149] In examples where rollers 222 are used, these may be mounted to the housing 61 of the battery 5. The rollers 222, are then keyed into a channel 224 formed by the guide tracks 211, so that the wheels are guided through the channel 224 This is illustrated in Fig. 15B.

[0150] The roller 222 and guide tracks 211 in alternative examples may be mounted in the opposite configuration. That is, having rollers (or other elements) mounted at the vehicle or battery support 11. The rollers are then received in guide tracks 211 at the battery housing 61.

[0151] External air supply for heating, cooling, and drying

[0152] In some examples, external air is supplied to the battery 5 for thermal management and / or moisture management. This can include supplying warm or hot air into the housing 61 to raise the temperature of the battery. In other examples, this can include providing ambient or cool air to aid cooling of the battery. It will be appreciated thermal management is used to enable the battery 5 to operate in, or close to, a desired operating range. This can include optimum temperatures for charging or discharging. Supply of air can also assist in moisture control inside the battery.

[0153] In some examples, an external air system supplies the air to the battery. This can include an air compressor and / or a dehumidifying systems, air conditioning, and / or heating system. The external air system may be mounted in the vehicle and / or at a battery charging station. For convenience, fluid couplings 311 between the battery and the external air system may be located within, at, or close to the first and second electrical connection units 9, 10. This can simplify alignment and save having a separate connector system to maintain. The fluid couplings 311 may include two couplings, one to inject air into the battery, and another to bleed air out of the battery.

[0154] Variation of plug and socket

[0155] Another variation of the plug assembly 35’ and socket assembly 31 will now be described. In this example, the sealing surfaces are flat and configured to be substantially perpendicular to direction 8. Thus during battery insertion the sealing surfaces are compressed together rather than being exposed to shear forces.

[0156] It is to be appreciated that other shapes could be used depending on the available space in the vehicle, and other design constraints.

[0157] It will be appreciated by persons skilled in the art that numerous variations and / or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

CLAIMS:

1. A vehicle battery system (1) for a vehicle (3), the system (1) comprising:- a selectively removable battery (5) including a plurality of battery cells (7);- a battery support (11) at the vehicle (3) to receive the selectively removable battery (5), wherein the battery support (11) includes a base structure (13) to support a weight of the selectively removable battery (5); and- a pawl (15) to engage with a respective notch (15), wherein the pawl (15) in a first position (16) is configured to resist movement of the selectively removable battery (5) away from the base structure (13) along a first axis (21), wherein selective actuation of the pawl (15) to a second position (18) enables the selectively removable battery (5) to be moved away from the base structure (13).

2. A vehicle battery system (1) according to claim 2, wherein the pawl (15) is biased from the second position (18) towards the first position (16) to enable the selectively removable battery (5) to be received at the battery support (11) by movement of the selectively removable battery (5) in a first direction (19) along the first axis (21) towards the base structure (13), and wherein the selectively removable battery (5) is configured to be selectively removed, from the battery support (11), by:- the selective actuation of the pawl (15) against the bias to the second position (18) and;- movement of the selectively removable battery in a second direction (23) along the first axis (21) that is opposite the first direction (19).

3. A vehicle battery system (1) according to either claim 1 or 2, wherein the pawl (15) comprises at least one flap (25) rotatable around a flap axis (27), wherein the flap axis (27) is substantially perpendicular to the first axis (21).

4. A vehicle battery system (1) according to any one of the preceding claims, further comprising:- a first electrical connection unit (9) associated with the selectively removable battery (5); and- a second electrical connection unit (10) associated with the vehicle (3), wherein the first electrical connection unit (9) and the second electrical connection unit (10) are connectable to enable an electrical connection path from the plurality of battery cells (7) to the vehicle (3), wherein at least one of the first electrical connection unit (9) and the second electrical connection unit (10) is movably mounted to enable movement along the first axis (21).

5. A vehicle battery system (1) according to claim 4, wherein the second electrical connection unit (10) is movably mounted at the vehicle (3), and wherein the second electrical connection unit (10) is biased in the second direction (23) away from the base structure (13).

6. A vehicle battery system (1) according to any one of claims 4 to 5, wherein the first electrical connection unit (9) and the second electrical connection unit (10) form a connection system (30) comprising:- a socket assembly (31) with at least one tapered socket wall (33); and- a plug assembly (35) with at least one plug wall (37);wherein the plug assembly (35) is configured to be received in the socket assembly (31) and the plug wall (37) is configured to interface with the tapered socket wall (33) to aid alignment of the plug assembly (35) into the socket assembly (31).

7. A vehicle battery system (1) according to claim 6 wherein the plug assembly (35) is configured to be received in the socket assembly (31) along a connector axis (39), wherein the connector axis (39) is perpendicular to the first axis (21), wherein to receive the selectively removable battery (5) at the battery support (11) comprises: movement of the selectively removable battery (5) along the connector axis (39) to enable the plug assembly (35) to be received at the socket assembly (31); and subsequent movement of the selectively removable battery (5) along the first axis (21) towards the base structure (13) to enable the pawl (15) to engage with the respective notch (17).

8. A vehicle battery system (1) according to claim 7, wherein to selectively remove the selectively removable battery (5) from the battery support (11) comprises:- selective actuation of the pawl (15) to the second position (18);- subsequent movement of the removable battery (5) along the first axis (21) away from the base structure (13); and- subsequent movement of the selectively removable battery (5) along the connector axis (39) to separate the plug assembly (35) from the socket assembly (31).

9. A vehicle battery system (1) according to any one of the preceding claims wherein the selectively removable battery (5) includes at least one aperture (41),wherein the at least one aperture (41) is configured to receive a support element (40) to support a weight of the selectively removable battery (5) during removal and / or insertion from the battery support (11).

10. A vehicle battery system (1) according to claim 9, wherein the at least one aperture (41) is configured to align with the pawl (15) when the selectively removable battery (5) is received at the battery support (11), and wherein the at least one aperture (41) is further configured to enable the support elements (40) to be inserted through the at least one aperture (41) to selectively actuate the pawl (15) to the second position (18).

11. A battery support structure (11) to receive a selectively removable battery (5) at a vehicle (3), the battery support structure (11) comprising:- a base support (13) to support a weight, relative to a first axis (21), of the selectively removable battery (5); and- a pawl (15) to engage with a respective notch (17) of the selectively removable battery (5), wherein the pawl (15) in a first position (16) is configured to resist movement of the selectively removable battery (5) away from the base structure (13) along the first axis (21); and wherein selective actuation of the pawl (15) to a second position (18) enables the selectively removable battery (5) to be moved away from the base structure (13).

12. A battery support (11) according to claim 11 wherein the pawl (15) is biased from the second position (18) towards the first position (16) to enable the selectively removable battery (5) to be received at the battery support (11) by movement of the selectively removable battery (5) in a first direction (19) along the first axis (21) towards the base structure (13), and wherein the selectively removable battery (5) is configured to be selectively removed, from the battery support (11), by:- the selective actuation of the pawl (15) against the bias to the second position (18) and;- movement of the selectively removable battery in a second direction (23) along the first axis (21) that is opposite the first direction (19).

13. A battery support (11) of claims 11 to 12 wherein the height- adjustable electrical connection unit (10) is configured to move along the first axis (21) from a first position (800) distal the base structure (13) to a second position (801) proximate the base structure (13).

14. A battery support (11) of claims 11 to 13 further comprising:- a first stop face (72) and a second stop face (73) connected to distal edges of the base structure (13) and existing substantially parallel to a plane defined between the first axis (21) and the connector axis (39), and a barrier (70) extending between the first and second edge faces and proximal the base support face.

15. A method comprising locking a selectively removable battery (5) into a battery support (11) in the vehicle battery system (1) according to claims 11 to 14 the method comprising:(A) locating the selectively removable battery in a ready-to-insert position (100) where first electrical connection unit (9) of the selectively removable battery (5) is distal to the second electrical connection unit (10) at the vehicle (3), and the selectively removable battery is aligned along the connector axis to enable the selectively removable battery (5) to be inserted, along the connector axis, to the intermediate unlocked position (110);(B) inserting the selectively removable battery (5), along the connector axis to an intermediate unlocked position (110) where the selectively removable battery (5) is distal from the base structure (13) along the first axis (21), and wherein the first electrical connection unit (9) of the selectively removable battery (5) is connected to the second electrical connection unit (10) associated with the vehicle (3);(C) inserting the selectively removable battery (5), along the first axis (21), to a locked position (120) when the selectively removable battery (5) supported by the base structure (13) and the pawl (15) is in the first position (16) to resist the selectively removable battery (5) to be moved away from the base structure.

16. A method according to claim 15 further comprising removing the selectively removable battery from the battery support, the method comprising:(D) inserting at least one support element (42) into the at least one aperture (41) of a selectively removable battery (5);(E) actuating the at least one pawl (15) with the support element (42) causing the pawl (15) to move from a locked position (16) to a second unlocked position (18) thereby releasing the pawl (15) from the notch (15);(F) moving the selectively removable battery (5) along the first axis (21) from a locked position (120) to an intermediate unlocked position (110) where the selectively removable battery (5) is distal from the base structure (13);(G) moving the battery system along the connector axis from the intermediate position (110) to a second position (100) wherein the first electrical connection unit (9) is distal to the second electrical connection unit (10).

17. A method of locking a selectively removable battery (5) into a battery support (11) according to claim 15 or 16 further comprising the step of: actuating the pawl (15) with a support element (40) causing the pawl (15) to rotate about a flap axis (27) from a first position (16) to a second depressed position (18); and wherein when the selectively removable battery (5) is in a position proximate the base support, rotating the pawl (15) about the flap axis (27) from the second depressed position (18) to a locked position (16) such that the pawl (15) comes into contact with a notch (15) thereby restricting movement of the selectively removable battery (5) along the first height axis (21).

18. A method of any of claims 15 to 17 further comprising the step of:(C3) while inserting the selectively removable battery (5) along the first axis (21) to a locked position (120), moving the movably mounted electrical connection unit along the first axis (21) from a first position (800) to a second position (801).

19. A selectively removable battery (5) for a vehicle (3) comprising:- a plurality of battery cells (7) ;- a housing (61) configured to house the plurality of battery cells (7); wherein the housing further comprises at least one aperture (41) extending from a first side (62) to an opposite second side (63) of the housing (61), and wherein the at least one aperture (41) is configured to receive at least one tine (40) of a forklift for insertion into and removal from the vehicle (3).

20. A selectively removable battery (5) according to claim 19: wherein the housing (61) further comprises at least one notch (15) configured to engage with a pawl (15) at the vehicle (3) to lock the selectively removable battery (5), and wherein the at least one notch (15) is proximal to an opening of the at least one aperture (41) at the second side (63) to enable the tine (40) of the forklift to actuate the pawl (15) to release the selectively removable battery (5).

21. A selectively removable battery (5) according to claim 20 wherein the selectively removable battery (5) is further has an L-shaped cross section.

22. A selectively removable battery (5) according to any of claims 19 to 21 wherein the selectively removable battery (5) further comprises:- a plurality of layers (66); and- an electrical connection unit (9); wherein one layer is a system management layer (64) associated with the electrical connection unit (9), and wherein the system management layer (64) houses switchgear (65) comprising a solenoid switch configured to output current when the system management layer (64) is supplied with a specified input voltage from the vehicle (3).

23. A selectively removable battery (5) of claim 22 further comprising a cooling system wherein:- at least one layer of the plurality of layers is provided with a fan configured to blow air between the battery cells (7); and- the battery housing (61) acts as a heat exchanger.

24. A selectively removable battery (5) according to either claim 22 or 23, wherein the electrical connection unit (9) further includes a fluid coupling (311) to transfer air to the battery housing (61) air for thermal and / or moisture management, wherein the fluid coupling (311) is co-located, or inside, the electrical connection unit (9).

25. A vehicle battery system (1) according to either claim 7 and 8, wherein the battery support (11) further comprises at least one guide track (211) to receive at least part of the selectively removable battery (5), wherein the at least one guide track (211) guides, at least in part, the movement of the selectively removable battery (5) in a direction (8) along the connector axis (39).

26. A vehicle battery system (1) according to claim 25, wherein the selectively removable battery (5) further comprises at least one roller (222), wherein the roller (222) is configured to be received in the at least one guide track (211).

Images