A swappable battery and a battery swapping system for ev's and other applications

Abstract

A portable and convenient swappable battery and a battery swapping system are disclosed. The proposed battery (called UNiBat) is relatively robust and simple in design, with many features and capabilities, and it is practical and flexible for use in many applications, thus having the Potential to be standardised, be used in a large scale, and be adopted in EV's manufacturing, energy storage and other sectors. The proposed battery swapping system could be entirely embedded on the EV or any application in general since it has a simple design, and its swapping operation could work basically without any added external mechanism at the swapping station or even anywhere.

Description

[0001] A SWAPPABLE BATTERY AND A BATTERY SWAPPING SYSTEM FOR EV's AND OTHER APPLICATIONS

[0002] Field of the Invention:

[0003] This proposed invention relates to energy storage batteries used to power electrical vehicles and other applications. More particularly, it relates to swappable batteries.

[0004] Background of the Invention:

[0005] The classical design of EV's with fixed battery packs comes with many disadvantages. One of them is the non-standardised battery pack across all EV's leading to higher car production cost and higher maintenance cost in repairing or replacing the battery pack. Also, for recharging those vehicles, a big number of charging stations is needed, and building these infrastructure needs a lot of resources and comes at a high cost. And no mater how big the charging station is (the number of charging points), its charging capacity is limited by the maximum electrical power it can withdraw from the local electrical grid. Even with increasing charging capacity by adding energy storage to the charging station, it is still limited by the available electrical power from the grid at that location, and yet by increasing its cost (the energy storage units are expansive).

[0006] And given the relatively long time it takes to fully charge an EV even with a super charger, recharging an EV is somehow inconvenient especially when in high demand (too many vehicles at the same station), for long distance drivers and for taxi and delivery fleet, etc.

[0007] Another drawback of the superchargers especially when using them often is the reducing of lifespan of the Li-ion batteries of the EV's. It is also known that the classical EV's equipped with fixed battery packs are much more expensive compared to conventional internal combustion engines vehicles due primarily to the cost of the fixed battery pack, and even if their routine maintenance cost is less expensive, the battery capacity is degrading overtime and the cost of replacing the battery pack after warranty is very high for the owner.

[0008] A proposed technology for mitigating the drawbacks of the fixed battery packs consist of the swappable battery systems. There were some solutions for swappable battery systems that are developed in the recent years but none of them was adopted broadly by the EV's manufacturing companies like Tesla or widely used in mobile or stationary applications. Among the reasons are the degree of complexity of such proposed systems, the economical feasibility, the convenience, the safety, and the non standardisation of both the swappable batteries and the swapping systems. Among the examples of those systems, the ones developed by companies like Ample and Aulton.

[0009] This emphasis the need to find a better solution for a battery swapping system and a swappable battery that mitigate those issues.

[0010] Summary of the Invention:

[0011] The proposed battery swapping system with its proposed portable universal use battery (UNiBat) will redesign the charging of EV's by bringing more charging capacity and flexibility for the charging stations and by speeding up the EV’s recharging process and giving more convenience and flexibility for the end user.

[0012] The proposed battery (UNiBat) is designed such a way to facilitate its loading, unloading, transportation and handling during the replacement and recharging procedures. As well it offers many operational and safety features thanks to its power converter and its battery management system (BMS) leading to more convenience and safety when used or recharged.

[0013] The proposed battery swapping system could be entirely embedded on the EV or any application in general since it has a simple design, and its swapping operation could work with minimal or without any external mechanism at the swapping station or even anywhere.

[0014] For the EV owner, the proposed battery and battery swapping system will remove the burden of replacing a degraded battery pack or repairing a malfunctioning one, in fact with swappable batteries, there is no battery degradation or functionality issues, thus less maintenance of the EV is needed.

[0015] At the swapping stations, the proposed battery and battery swapping system will bring recharging flexibility in a way that the batteries could be recharged locally, otherwise if there is not enough power from the local grid they will be brought to be recharged in another location and the recharged batteries will be brought back to be reloaded into the station, and this could be done by special trucks like conventional fuel. Furthermore, it is not even necessarily for the batteries to be recharged at all locally at the swapping station thus removing the load demand on the local electrical grid and reducing the charging cost since there is less needed distributed electrical infrastructure.

[0016] Economically, the proposed battery and the battery swapping system can be standardised, and mass produced given their simple design and easy assembly, leading to reduce their cost considerably for the end user.

[0017] In the other hand, EV manufacturing will be redesigned as well, so the new cars will be made without integrated battery packs. This will speed up car production and will help the creation of new EV manufacturing companies and all of this will lead to cheaper EV's in the market.

[0018] Also, with the proposed battery swapping system, the electrical vehicles will be featured with modulable autonomy, given that the battery system can work with only a few loaded batteries or possibly even one battery, this will bring flexibility of using only a needed number of batteries and a possibility of adding more batteries in the future as needed, this will reduce even further the front cost of EV ownership for some users.

[0019] Also, there is even more flexibility with many options of using the batteries as needed, for the end user, with the possibility of buying, renting, or paying per use... etc.

[0020] To make the proposed solution more convenient for the EV user, the EV with the proposed battery system could always be recharged at home in a conventional way by plugging with level 1 or level 2 charger.

[0021] Regarding the stationary applications, the proposed universal battery and the battery swapping system will bring considerable benefits over the classical fueling or recharging methods especially for energy demanding applications as machinery in remote construction sites for example. There is also a possibility for this battery given its convenience and safety to be used for energy storage for any application with its power converter output that could be configured to deliver DC or AC current depending on the need.

[0022] - In one aspect of the invention, a convenient, portable, and universal swappable battery for storing and delivering electrical energy is proposed. The battery comprises an elongated body with two ends and at least one head attached to one end. The body and heads of the battery can be in any shape, but preferably cylindrical for making it more convenient to handle and to swap.

[0023] Each head is made in overall of electrically insulating and mechanically resistant material and is provided with a passageway that is used for electrical mating with a plug member for at least one head, allowing the battery to deliver its power. Depending on the applications, the passageways with the plug members are used also for holding the battery firmly and secure in place.

[0024] The battery body comprises several modules stacked together along the body longitudinal axis and are electrically connected in parallel via electrical buses or via any electrical conductors that run in the center of the battery along its longitudinal axis. Each module is a grouping of Li-ion cells or any electrical energy storage cells connected in parallel together and to the electrical buses or electrical conductors. The holding body of each module is made preferably of cork, a material that is highly fire resistant, fire retardant, shock tolerant, vibration absorbent; and liquid / gas proof and yet verry light weighted.

[0025] - In another aspect of the invention, the body of the proposed battery is provided with a heat sink envelope that is made of high temperature coefficient transfer material for heat exchange from the battery to cool it down when in operation. The material is preferably aluminium alloy, and the outer surface of the envelope is preferably slotted all around longitudinally along the length of the body to facilitate such heat transfer. In this case, the heads are preferably provided with aeration openings to facilitate cooling air circulating along the body envelope of the battery.

[0026] - In another aspect of the invention, the heat sink envelope is reinforced with steel rods going along its length to enhance its strength, the said steel rods extremities could be threaded and used to fasten the said heads to the said envelope by using appropriate hardware.

[0027] - In another aspect of the invention, each one of the said battery modules is provided with a heat dissipater plate that is wrapped around some or all the cells and including the module holding body to allow for the heat transfer from the cells to the heat sink envelope. Preferably, two types of cells are put in the modules; low heat reaction cells in the middle of the module and high heat reaction cells at the periphery of the module and wrapped in the heat exchanger plate including the module holding body.

[0028] - In another aspect of the invention, the battery is equipped with a battery management system to protect the battery from electrical and thermal damage, and for safety against electrical shock and arc flash to protect the public against risks related to misusage of the battery.

[0029] - In another aspect of the invention, the proposed battery is provided with at least one DC-DC power converter unit; the power converter has an input fed from the main electrical conductors or bus bars and an output that is electrically connected to one head of the battery; The power converter play a double role of a booster or a buck converter allowing the battery to deliver power for use and to receive power in order to be recharged.

[0030] - In another aspect of the invention, each one of the battery modules is provided with at least one (+) connector allowing electrical contact between each one of the cells and at least one bus bar, and one main (-) connector allowing electrical contact between the cells and one of the bus bars.

[0031] - In another aspect of the invention, the battery management system combined with the power converter implement smart capabilities in reducing the heat generated by the cells and protecting the cells and improving their lifespan during discharging and recharging processes of the battery. This is achieved by managing, in real time, the optimum amounts of current injected into or withdrawn from each cell group; (outer) high heat reaction cells and (inner) low heat reaction cells, without compromising the needed output power from the battery at that time.

[0032] -In another aspect of the invention, the battery management system BMS of the battery is provided with a mean of wireless communication to receive and transmit data between the battery and a vehicle control system or any system where the battery is used.

[0033] Therefore, this will make the proposed battery a robust, light weight, very convenient, reliable, safe to use, and multi-purpose battery that will resist eventual mechanical shocks, stresses and vibrations and will contain any internal fire caused by temperature runaways of the cells or any discharge of the cells.

[0034] And depending on the chemistry of the cells, the battery will get rid of its excess heat simply through its heat sink envelope, passively or with the help of a circulating air.

[0035] Furthermore, the battery simple design will result in the streamline of its manufacturing process, lowering its manufacturing cost and making its operation unlikely to have technical issues resulting in lowering the service costs associated with its use as well. Thus, this will a potential for this battery to be standardised and widely used resulting in its mass production and further lowering its cost.

[0036] - In another aspect of the invention, a battery compartment housing located on an electrical vehicle (preferably underside) or on any other moving or stationary application, and that could be loaded with one battery or several batteries. This battery compartment housing with its simplest design, comprising a battery jamming mechanism, a spring repulsion mechanism, and a container. For a battery to be loaded into the battery compartment housing, it will be pushed in by an external mechanism typically located in a swapping station. The battery will then be jammed in the housing by the jamming mechanism and hold in place by the help of spring repulsion mechanism, if there is more than one battery to be loaded, the next battery will be loaded the same way and then it will push the first battery further inside, and with the two mentioned mechanisms, both batteries will be jammed and hold in place inside the housing. And so on if there are other batteries to be loaded into the battery compartment housing.

[0037] The unloading of each battery starts with the jamming mechanism being disengaged first via a servomotor, then the spring repulsion mechanism will push out the battery from the battery compartment housing in order for the battery to be disposed off typically at the swapping station, one battery will be pushed from the battery compartment housing each time and disposed off, and the remaining batteries will be hold in place by the jamming mechanism. And so on for the next battery to be unloaded until all the batteries are unloaded from the housing.

[0038] As mentioned above, this battery compartment housing is simple in design, and it will have a direct effect on the cost of producing battery driven vehicles and in the adoption of battery swapping technology.

[0039] - Another aspect of the invention is the battery compartment housing mentioned above that has a self loading / unloading capability with a loading / unloading mechanism that is an integral part of it. In order for a battery to be loaded into the housing, it is put on at least one lifter before the control system of the electrical vehicle detect its presence and then the lifter driven by a servomotor will lift it and push it inside the housing. The battery will then be jammed in the housing by the jamming mechanism and hold in place by the spring repulsion mechanism. The next battery will be loaded the same way and then it will push the first battery further inside. And with the two mentioned mechanism, both batteries will be jammed and hold in place inside the housing. And so on for the remaining batteries to be loaded. Unloading of each battery starts with the jamming mechanism being disengaged first via another servomotor, then the spring repulsion mechanism will push out the batteries and with the intervention of the lifters, one battery will be pulled from the housing each time and disposed off the EV, and the remaining batteries will be hold in place by the jamming mechanism. And so on for the next battery to be unloaded from the housing until all the batteries are unloaded.

[0040] Even with adding the loading / unloading mechanism as an integral part of the battery compartment housing, it is still relatively simple in design compared to other battery swapping solutions. And especially, this design is very useful such that only a simple mechanism is needed at the swapping station for loading the batteries into the battery compartment housing of a vehicle. Also, the loading / unloading mechanism could also be optionally used for loading batteries without any external mechanisms at the swapping stations with the batteries being fed manually to the vehicle by an operator with added safety protocol.

[0041] - Another aspect of the invention is that each battery in the battery compartment housing is hold in its position by a retaining plug member or 2 retaining plug members preferably driven by linear actuators, and every retaining plug member penetrates one battery head via its passageway at its center to hold it in place. At the same time, at least one of the plug members play the role as an electrical contactor delivering power via two battery terminals, the positive (+) and the negative (-). Each electrical contact point for every battery is connected to a common electrical bus bars via 2 spring shaped flexible wires to allow for the linear movement of the retaining / contact plug member. The fact that all the batteries are independently connected in parallel with their respective contactors to common electrical bus bars will make the battery system very reliable in the case of failure of one battery or one contactor in the battery compartment housing.

[0042] - Another aspect of the invention is the cooling of the batteries through their heat sink envelopes using air that circulate through the battery compartment housing by entering via an inlet and exiting from an outlet.

[0043] - Another aspect of the invention consists of the location of battery compartment housing at the bottom of the EV in a way that integrate the vehicle frame in a convenable way. The battery housing will be embedded to the EV from the bottom during manufacturing process of the vehicle in a way that is like embedding a stationary battery pack. To protect the batteries from the elements, the battery compartment housing is equipped with a sealed lid that swing downward when open.

[0044] - Another aspect of the invention is the swapping station, where discharged batteries are disposed off and charged batteries are loaded into the EV The disposal of the discharged batteries is done through an opening at the flour of the station. The loading of the charged batteries could be done automatically or manually.

[0045] The procedure is as follow:

[0046] - the driver will bring the vehicle at the exact location by some guiding techniques.

[0047] - then the driver will initiate the unloading process by electrically disengaging the batteries from the battery compartment housing.

[0048] - then the batteries will be unloaded one by one, with the station controller counting the number of batteries being unloaded. - then a corresponding number of charged batteries will be released for delivery from a battery reservoir, and whether loaded automatically by using a mechanism that pushes the batteries inside the battery compartment housing of the EV, or by using a mechanism that delivers the batteries one by one to the battery compartment housing that has its self loading capabilities, or loaded manually by an operator that has to pick the batteries and delivers them to the battery compartment housing that has self loading capabilities.

[0049] - Another aspect of the invention is the introduction of the serial engaging battery swapping system with the use of 2 battery reservoirs. One reservoir where several charged batteries are stored and only a given number of charged batteries is taken from that reservoir to be engaged electrically at one time. Another reservoir is where the discharged batteries are disposed off. This system is suitable for application with high energy demand like heavy machinery where several batteries are used, but only the minimum needed battery to produce the desired power are engaged electrically at the same time.

[0050] NOTE: While this invention is susceptible of embodiments in many different forms, this specification and accompanying drawings disclose only some specific forms as examples of the invention. The invention is not intended to be limited to the embodiments so described; however, the scope of the invention is pointed out in the appended claims. Brief Description of the Drawings:

[0051] - Fig 1 is showing the overall view of the UNiBat battery preferred embodiment, that is made of two heads and a body with a slotted heat sink envelope and showing a detailed view of one head.

[0052] - Fig 2 is showing the UNiBat battery without the heat sink envelope where are shown the stacked battery modules and the BMS / Power converter

[0053] - Fig 3 is showing the UNiBat battery with some modules that are removed and the main electrical bus bars of the battery that connect all the modules to the BMS / Power converter.

[0054] - Fig 4 is showing the top of one isolated module with outer and inner positive connectors that connect respectively the high heat reaction Li-ion cells (at the periphery) and the low heat reaction cells (at the middle) to the main bus bars of the battery (not shown). The high heat reaction cells are wrapped in a heat dissipater plate (made of highly heat transfer material) that covers the module body as well and is in direct contact with the heat sink envelope of the battery body to insure proper heat exchange.

[0055] - Fig 5 is the bottom of one isolated module showing the negative connector that connects all the negative poles of the cells to the negative main bus bar of the battery (not shown).

[0056] - Fig 6 is showing an exploded view of the module, including the module holding body, the module heat dissipator plate, the Li-ion cells, the connectors, and the separation layer. - Fig 7 showing the energised head of the battery and its cross-section view, where are shown the electrical terminals, the electrical connections with the BMS / Power converter and the aeration openings of the head.

[0057] - Fig 8 showing the second non-energised head of the battery and its cross section, where are shown the aeration openings of the head.

[0058] - Fig 9 is the overall view of the battery compartment housing showing the container of the batteries with its opening for battery loading / unloading, and the cooling air inlet and outlet.

[0059] - Fig 9-a is an isolated view of the container of the batteries with a detailed view showing the openings for air flow at each side of the container.

[0060] - Fig 10 is showing a UNiBat battery on the lifting mechanism in the process of loading or unloading.

[0061] - Fig 11 is the fully loaded battery compartment housing with 10 batteries (with the container not shown for clarity). Showing the lifting mechanism, the jamming mechanism, and the spring repulsion mechanism (with the spring fully compressed).

[0062] - Fig 12 is a simplified representation of the battery compartment housing with one loaded battery in it and showing only the loading / unloading mechanism, the jamming mechanism, and the spring repulsion mechanism (with expanded spring).

[0063] - Fig 13 is a view of detailed representations of the loading / unloading mechanism showing the lifting arms (with their respective servomotors), the lifting bar and its servomotor as well the jamming mechanism with the jams, the jamming bar, and its servomotor. - Fig 14 is a view of the battery compartment housing without the container and the side covers and a detailed view showing the retaining / contactor plug members with their corresponding linear actuators and their flexible wires that are connected to the main electrical bus bar, and the bracket as well that is holding them.

[0064] - Fig 15 is showing the DC output power terminals and the control / communication ports on the back side of the battery compartment housing.

[0065] - Fig 16 is a view of the battery compartment housing (without the container and the side covers) and a detailed view of the retaining plug members and the retaining / contactor plug members that are disengaged with the batteries.

[0066] - Fig 17 is a top view of Fig 16.

[0067] - Fig 18 is the same as Fig 16 but with the retaining / contactor plug members that are engaged with the batteries.

[0068] - Fig 19 is showing a sectional view of one battery with a retaining plug member and a retaining / contactor plug member that are disengaged and their respective linear actuators. Also showing the electrical terminals (contact points) of the energised battery head, the BMS / Power Converter, and the battery modules.

[0069] - Fig 20 is showing a typical emplacement of the system on an electrical vehicle.

[0070] - Fig 21 is showing the emplacement of an EV at the swapping station.

[0071] - Fig 22 is a view of a swapping station and a detailed view showing the opening for a disposal of discharged batteries and a release mechanism for charged batteries.

[0072] - Fig 23 is an EV at the swapping station in the process of loading a charged battery. - Fig 24 is an illustration of an example of the serial engaging technique, with contactor engagement mechanism, charged batteries reservoir and discharged batteries reservoir.

[0073] Detailed Description of the Preferred Embodiments:

[0074] Detailed descriptions of the preferred embodiments are provided herein. It is to be understood however, that the present invention may be embodied in various forms.

[0075] - The UNiBat Battery:

[0076] In some embodiments, the UNiBat battery as shown in Fig 1 is cylindrical in shape, has a body (3) and two heads (1) (2) that are attached to the ends of the body. In some embodiments, the battery has one energised head (1) with a positive and a negative terminal and both heads (1) (2) are used for immobilising the battery. The heads (1) and (2) shown in figures (7) and (8) are made with high resistant and electrically insulating material preferably coated with a layer of rubber material to withstand impacts during loading and unloading processes of the battery.

[0077] In some embodiments, the body is provided with a heat sink envelope made with a high heat transfer and rigid material preferably aluminum alloy and is slotted along its length to increase its heat transfer capability.

[0078] In some embodiments, the heat sink envelope is reinforced with steel rods that are going along its length and fitted around it to enhance its strength, the steel rods extremities are preferably threaded and used to fasten the heads (1) (2) to the envelope by using appropriate hardware.

[0079] In some embodiments, to allow for air flow to circulate along the heat sink envelope and cool down the battery, the heads (1), (2) are equipped with openings (14) along each head periphery, as Fig 7 and Fig 8 show.

[0080] As fig2 and Fig 3 show, Inside the body, many individual modules (4) are stacked and connected electrically via 3 bus bars (6) to a power converter / BMS module (5) that is connected electrically to the energised head (1).

[0081] In some embodiments, for making electrical contact with the rest of the battery system, the passageway of the head (1) has a pin shaped positive terminal (15) and a cylindrical shaped negative terminal (16), and both terminals are made with a conductive material preferably copper. On the inner side of the head (1), there is 2 bolted electrical connections (17) for making contact between the wires from the Power converter / BMS (5) and the head (1) (shown as well in Fig 19).

[0082] In some embodiments, the battery module shown in Fig 4, 5 and 6 contains 19 Li- ion cells (7), 12 outer cells with high heat reaction as NMC cells (Nickel Manganese Cobalt Oxide) or NCA cells (Nickel Cobalt Aluminum oxide) and 7 inner cells with low heat reaction as Lithium Iron Phosphate cells.

[0083] The outer cells are all connected to one of the bus bars (6) (shown in Fig 3) via a ring-shaped outer (positive) connector (9) and every cell is electrically protected with a fuse (9-a). The same for the inner cells, they are all connected to one of the bus bars (6) (shown in Fig 3) via a ring shaped inner (positive) connector (10) and every cell is electrically protected with a fuse (9-a). And to prevent the inner connector (10) to make an electrical contact with the outer connector (9), a ringshaped sheet (13) made of an adequate electrically insulating material is put between the two connectors (shown in Fig 6 only for clarity). To prevent the outer connector (9) and the inner connector (10) from making electrical contact with the bodies of the cells (that have a negative polarity), a disk-shaped sheet (not shown for clarity of the drawings) made of an adequate electrically insulating material should be put between the top of the cells and the connectors. At the bottom side of the module as shown in Fig 5, all the 19 cells are connected to the third bus bar via the main (negative) connector (11).

[0084] The outer cells are wrapped in a heat exchanging plate (8) (made of high heat transfer material) and are engulfed in the module holding body (4-a). The heat exchanging plate (8) will transfer the excess heat from the outer cells to the heat sink envelope of the battery body (3).

[0085] The module holding body (4-a) is made preferably of cork, given the many thermal and mechanical proprieties of this material. In fact, cork is a fire-resistant, fire- retardant material and has high heat storage capacity that will contain any localised fire in the case of a cell temperature run away and will contain any cell gas / liquid discharge given its gas / liquid proofing. Also, given that cork has a good shock and vibration absorption and impact resistance properties, this will make the UNiBat robust enough to withstand all mechanical stresses that it will be subject to when in moving vehicles and during loading and unloading processes.

[0086] The use of cork as the principal material for holding the cells in the battery modules and between the modules (as discussed below) along the use of aluminum allow as the material for the heat sink envelope will make the UNiBat battery a very light weighted compared to its volume, making it an easy-to-handle battery.

[0087] In order to isolate the stacked modules one from each other electrically and for thermal, chemical and mechanical protection of the modules, an inter-module separation (12) is inserted between the modules and is made preferably of cork, given its proprieties discussed above.

[0088] In some embodiments, the Power Converter / BMS (05) has three principal roles: boosting the DC voltage of the cells to an adequate level (preferably hundreds of volts) when the battery is delivering power, lowering the DC voltage to the cell charging voltage level when the battery is recharging, and as a battery management system, protecting the battery from overheat, electrical and chemical damages. The Power Converter / BMS (05) input is fed directly from the 3 bus bars (6) (as shown in Fig3); one main negative bar (-) and two positive bars (+). Each positive bar is connected to one of the two groups of cells of each module (inner cells and outer cells) and are managed separately by the BMS during power delivery and recharging of the battery (given that each cell group has its own electrical and thermal characteristics).

[0089] It is worth noting that the fact all the cells are connected in parallel configuration offers an advantage over combined serial / parallel configuration in a way that the battery operation and performance will not be affected in the case of any blown cell fuses or cell failure.

[0090] The power converter (5) must combine these two low voltage inputs and convert them to one higher voltage at its output. The output has two wires (+) (-) that go from the power converter to the energised head and connect with it using a wire connection (17) preferably with lugs and bolts as shown in Fig 7.

[0091] In some embodiments, the BMS have some safety features to protect the public from electric shock and arc flash hazards. These safety feature comprises cutting off the power output of the battery in a faulty condition or to prevent electric shock and arc flash hazards. As well, enabling / disabling the power output of the battery as needed, by wireless or direct control.

[0092] In some embodiments, in order for the BMS to receive and send data with the vehicle central computer directly or indirectly, a wireless communication module (as Bluetooth) is installed on the battery energised head and connected with the BMS (not shown in the drawings for simplicity).

[0093] In some embodiments, the battery has 2 Power Converter / BMS units coupled with two energised heads if more power is needed to be delivered by the battery or the battery need to be recharged faster.

[0094] In some embodiments, the BMS implements smart capabilities in further reducing the heat generated by the cells and further protecting the cells and enhancing their lifespan during the use and recharging processes of the battery. This is achieved by the BMS when managing in real time, the optimum amounts of current withdrawn from each different cell group (inner cells and outer cells) at a given time without compromising the needed total output power from the battery at that time.

[0095] - The Battery Compartment Housing:

[0096] In some embodiments, the battery compartment housing is as shown in Fig 9 with its cooling air inlet (19) and outlet (20) and its container (18).

[0097] In some embodiments, the container (18) as shown in Fig 9-a where the batteries are stacked and has several openings (19-a) on its sides, allowing cooling air to circulate through to cool down the batteries.

[0098] In some embodiments, the battery compartment housing is comprising: the container (18), the loading / unloading mechanism (21), the battery Jamming mechanism (22), the Spring repulsion mechanism (32) and the battery retaining and electrical contact mechanism (34).

[0099] In these embodiments, the Loading / Unloading Mechanism (21) as shown in Fig 10, load and unload the batteries one by one into and from the container (18). The battery jamming mechanism (22) as shown in Fig 11, helps in the process of loading / unloading a battery by holding the other batteries from coming out of the container. The spring repulsion mechanism (32) allows for the ejection of the batteries one by one from the container in the unloading process as well regulating the loading process and correctly positioning the batteries in the container (18) especially in the case it is not fully loaded. The Battery Retaining and Electrical Contact Mechanism (34) has the role of engaging electrical contact with the batteries as well retaining the batteries firmly in place.

[0100] Explanation of the loading process of the batteries into the battery compartment housing:

[0101] By Referring to Fig 10,11,12 and 13, the process begins by depositing one battery on the 4 lifters (24) of the loading / unloading mechanism (21). The two lifters on the sides are equipped with proximity detectors (27) to indicate the presence of the battery to the vehicle control system. The control system will then rotate the lifter bar (25) via a servomotor (23) to bring the battery by the lifters inside the container via its opening. During this process at some point, the controller will engage the lifter arms (35) (of the four lifters) to extend using the lifter servomotor (26) to push the battery further inside the container until it will reach and push down (release) the three jams (29) of jamming mechanism (22). While the battery is pushed in by the lifters (24) and de-engaging (releasing) the jams (29), it will also push back the spring pulling plate (31) of the spring repulsion mechanism (32). And with the help of the jam retention spring (36) the jams (29) will be engaged again once the battery has passed through them and jam the loaded battery in place. The spring repulsion mechanism (32) with its pulling plate (31) along the engaged jams (29) will then hold the battery in place, the lifters (24) then, return to their initial position and be ready to load the next battery.

[0102] When all the batteries are loaded as shown in Fig 16 (without the container), the battery electrical contact / retaining mechanism (34) is then ready to be engaged with the batteries.

[0103] Explanation of the battery retaining and electrical contact procedure:

[0104] As shown in Fig 19, the Contactor / Retainer plug members (37) and Retainer plug members (43) driven by the linear actuators (41) and (44) are pushed inside each battery head passageway to make the electrical contact and to retain the batteries solidly in place (as shown in Fig 18).

[0105] The electrical continuity is then obtained between the battery terminals (15) (16) and the electrical buses of the housing (38) via flexible wires (40) that allow for linear movement of the Contactor / Retainer plug members.

[0106] Each side of the Battery Retaining and Electrical Contact Mechanism (34) has a holding bracket (39) as shown in Fig 14, that is fixed to the container and has the linear actuators that are bolted to it. Explanation of the unloading (ejection) process of the batteries from the battery compartment housing:

[0107] The unloading of the batteries starts by disengaging the Retaining and Electrical Contact Mechanism from the batteries, where all the Contactor / Retainer plug members (37) and Retainer plug members (43) driven by their corresponding linear actuators (41) and (44) are pushed out from the battery head passageways, resulting of the batteries being isolated electrically from the electrical buses (38) as shown in Fig 14. Then the batteries will be ejected one by one from the container in three steps. The first step is releasing the jams (29) via the jam release bar (30) and the jam release servomotor (28) as shown in Fig 12. The second step is driving out the battery by the spring repulsion mechanism (32) and the loading / ej ection mechanism (21) where the battery is pushed by the spring puling plate (31) against the four lifters (24).

[0108] The four lifters(24) driven by the servomotor (23) and the driving bar (25) with the help of their respective lifter arms (35) and their respective lifter servomotors (26) (Fig 13) will catch the battery, and guide it while pushed out by the spring repulsion mechanism (32) until dropping it completely from the housing (disposed of), or alternatively, bring the battery to a position (initial position) where it can be picked up from the lifters (24) as shown for example in Fig 10.

[0109] At some point during this second step, the jams (29) will be engaged again by driving counter wise the jam release bar (30) via the jam release servomotor (28) and with the help of the jam retention spring (36) as shown in Fig 12, 13 to hold the remaining batteries in place and prevent them from being pushed out by the spring repulsion mechanism (32). The third step is when the vehicle controller detect that the battery is disposed off or taken from the lifters via the two sensors (27), the 4 lifters (24) then will be brought to the position where they will be ready to unload the next battery, as shown in Fig 11. And so on for the next battery to be unloaded until all the batteries are unloaded from the housing.

[0110] In some embodiments, the battery compartment housing is comprising: the container (18), the battery Jamming mechanism (22), the Spring repulsion mechanism (32) and the battery retaining and electrical contact mechanism (34).

[0111] In this case, an external loading / unloading mechanism typically located a swapping station is needed to load and unload the batteries to and from the battery compartment housing.

[0112] In some embodiments, as shown in Fig- 15, for the battery compartment housing to be connected to the rest of the vehicle in term of electrical power and data transmission, it is provided with 2 DC power terminals (45), 2 actuator control ports (46) and a data communication port (47).

[0113] In some embodiments, in order for the battery compartment housing to exchange data with each battery in it, it is provided with a wireless communication mean preferably Bluetooth technology allowing such communication. The battery compartment housing exchanges the data with the vehicle control system via the data communication port (47).

[0114] In some embodiments, the batteries inside the battery compartment housing could be configured in a way such that the power is withdrawn from the batteries in a sequential way (battery by battery) rather then in parallel way (all the batteries). The sequential way works such that one or more batteries are used at the same time depending on the needed power until they are discharged, and one or more batteries are in standby mode to be used next when needed. Some advantages of this are that there is no need to wait for all the batteries to be discharged to go to the swapping station and replace them, and the possibility of having one or more spare charged batteries to use latter when in need.

[0115] -The Swapping Station:

[0116] In some embodiments, as shown in Fig 20, the battery compartment housing is located underside of an electrical vehicle and has a swinging lid (49) allowing for the loading / unloading of the batteries which is done typically at a swapping station.

[0117] In some embodiments, the swapping station comprise two reservoirs one for discharged batteries and another one for the charged batteries, the discharged batteries are recharged locally or withdrawn from the first reservoir and transported to another location by special trucks to be recharged.

[0118] The recharged batteries are brought the same way to the station to be put in the second reservoir and ready to be used.

[0119] In some embodiments, as shown in Fig21,22 and 23, the swapping operation works as follow:

[0120] The vehicle is brought to the right position by the driver with some guiding technics, the driver then interacts with the swapping station via its control panel (51) and start the swapping process of the batteries by a mean of a wireless communication from inside the vehicle, or as an option, by using the control panel interface (51).

[0121] Depending on the configuration of the system that the user wants as explained above, the disposed discharged batteries at the station could be the total batteries that are in the battery compartment housing or just some of them (as in the case of the gas tank that is totally empty or partially full of gas).

[0122] If the green light is given by the control panel (51) of the station, the process then begins.

[0123] The battery disposal gate (52) opens to allow for the dropping of the discharged batteries from the vehicle. Then the same number of the charged batteries (54) will be dispensed and loaded one by one via the battery release mechanism (53).

[0124] This begins with the retractable train (61) coming out of the battery dispensing machine (50), then the charged batteries are pulled one by one from the second reservoir and put one by one onto the battery dispensing pans (58). The pans(58) are driven by a servomotor (59) via a bar (60) to swing downward in order to deposit the charged battery in the battery system of the vehicle and swing back upward to be ready to receive the next battery, until all the batteries are loaded into the battery compartment housing of the vehicle.

[0125] -The Serial Electrically Engaging Battery Swapping System:

[0126] In some embodiments, as shown in Fig24, the serial electrical engaging system works such that the batteries go through an appropriate mechanism (57) to be engaged to make an electrical contact in a serial method. Wherein depending on the amount of power needed for the usage, only a given number of batteries are electrically engaged at the same time by that system.

[0127] Once the engaged batteries are used and drained from their stored energy, they will be disengaged by the system and recovered in a reservoir (55) made for this purpose. Then, the same number of charged batteries is pulled from another reservoir (56) that is made for storing the charged batteries. The new batteries in their turn, will be electrically engaged with the battery system, and so on.

[0128] It is however worth noting that a device for storing and releasing the energy needed during the transitional step is necessary, preferably super capacitors given their high-power output, so there will be no power shortage from the battery system during that transitional step.

[0129] Typically, this system, given the high number of batteries involved, is suitable for applications that uses a lot of energy in relatively a short period of time like heavy machinery, trains, ships, or trucks for example.

[0130] Note:

[0131] Although the invention has been described in connection with a preferred embodiment, it should be understood that various modifications, additions and alterations may be made to the invention by one skilled in the art without departing from the spirit and scope of the invention as defined in the appended claims.

Claims

AMENDED CLAIMS received by the International Bureau on 30 June 2025 (30.06.2025)

1. A swappable batery, comprising:- one or more stacked batery modules, each of said one or more stacked battery module comprises: a holding body defines a conduit; one or more electrical energy storage cells that are engulfed in said holding body made of a material that is heat insulating, heat resistant, flame retardant, shock / vibration absorbent and / or liquid / gasproof; and one or more connectors for electrically connecting terminals of said one or more electrical energy storage cells;- one or more electrical conductors disposed in said conduit of said holding body, wherein said one or more electrical conductors are connected electrically to said one or more connectors of said one or more stacked battery modules, whereby said one or more stacked batery modules are electrically connected in parallel to each other through said one or more electrical conductors;- a mechanically resistant elongated tubular body member having two ends, said elongated tubular body member is mechanically resistant to lateral compressive force and houses said one or more stacked battery modules inside said elongated tubular body member; and- two heads, each of said two heads is attached to a corresponding one of said two ends of said elongated tubular body member, and said each of said two heads is made of a material comprising an electrically insulating material and is mechanically resistant to lateral compressive force; wherein said each of said two heads defines a passageway for receiving a plug member to hold said swappable battery in a position; and at least one said passageway is provided with an electrical contact point for electrically connecting with said plug member, and said one or more electrical conductors are in communication with said electrical contact point directly or via a power converter.

2. The swappable battery as recited in claim 1, wherein said elongated tubular body member is made of aluminum alloy or any high heat transfer index material; such that said elongated tubular body member works as a heat sink.

3. The swappable battery as recited in claim 1 or 2, wherein said each of said two heads receives said plug member in a water-tight manner.

4. The swappable battery as recited in claim 2, wherein said elongated tubular body member is reinforced with steel rods going along its length to enhance its strength said steel rods extremities are threaded and used to fasten said heads to said envelope by using a hardware.

5. The swappable battery as recited in claim 1, 2, 3 or 4, wherein each one of said battery modules is provided with a heat dissipater plate that is wrapped around part or all said cells and around said holding body to allow for heat transfer from said cell.

6. The swappable battery as recited in claim 2 or 4, wherein said heads are provided with aeration openings to let cooling air circulate along said elongated tubular body member.

7. The swappable battery as recited in claim 1, 2, 3 or 4 further comprising a battery management system.

8. The swappable battery as recited in claim 7, wherein said battery management system is provided with a mean of wireless communication to receive and transmit data between said swappable battery and a control system of a vehicle or of any other application.

9. The swappable battery as recited in claim 8, wherein said battery management system is provided with a mean of safety features against electrical shock and arc flash to protect the public against risks related to misuse of the swappable battery.

10. The swappable battery as recited in claim 9, wherein each one of said battery modules, comprising:- one outer group of said cells that have a high heat reaction and wrapped in said heat dissipater plate;- an inner group of said cells that have low heat reaction without being wrapped in said heat dissipater plate; and wherein the two groups of said cells have two separate (+) connectors with each (+) connector allowing electrical contact between one group of said cells and one of said one or more electrical conductors; and the two groups of said cells have one main (-) connector allowing electrical contact between said cells and one of said one or more electrical conductors.

11. The swappable battery as recited in claim 10, wherein said heads are provided with aeration openings to let cooling air circulate along said elongated tubular body member.

12. The swappable battery as recited in claim 10 or 11, wherein said battery management system combined with said power converter implement smart capabilities in reducing the heat generated by said cells and protecting said cells and improving their lifespan during discharging and recharging processes; this is done by managing in a given time the optimum amounts of current withdrawn from each said cells group; without compromising the needed power output from said swappable battery at that particular time.

13. A magazine battery compartment housing for one or more batteries that defines an opening, said magazine battery compartment housing comprising:- a jamming mechanism disposed at said opening of said magazine battery compartment housing, wherein, during a loading process of said one or more batteries through said opening, said jamming mechanism allow said one or more batteries to be loaded inside said magazine battery compartment housing while said jamming mechanism releasably holds said one or more batteries from coming out of said magazine battery compartment housing; wherein said jamming mechanism comprises a release system to cause said jamming mechanism to release said one or more batteries through said opening of said magazine battery compartment housing;- at least one holding member that holds said one or more batteries releasably in place within said magazine battery compartment housing; wherein said at least one holding member maintains electrical contact between said one or more batteries and said magazine battery compartment housing; and- a repulsion mechanism, wherein said release system allows said repulsion mechanism to push said one or more batteries inside said magazine battery compartment housing toward said opening during an unloading process of said one or more batteries; wherein, during said loading process of said one or more batteries through said opening, said repulsion mechanism works with said jamming mechanism to cause said one or more batteries to be positioned correspondingly to said at least one holding member.

14. The magazine battery compartment housing as recited in claim 13, wherein said jamming mechanism comprising; at least one jam; and at least one jam release servomotor that drives said jam directly or via a driving bar.

15. The magazine battery compartment housing as recited in claim 14, wherein during said loading process of said one or more batteries, each one of them pushes and releases said jam by direct pressure on it and allowing said one or more batteries to be loaded inside said magazine battery compartment housing; wherein said jam is provided with a jam retention spring which shifts and keeps said jam in an engaged jamming position after each one of said one or more batteries are loaded into said magazine battery compartment housing.

16. The magazine battery compartment housing as recited in claim 13, 14 or 15, wherein said repulsion mechanism, comprising:- a pulling plate that pushes said one or more batteries out of said magazine battery compartment housing; and- at least one spring attached to one side of said pulling plate and on the other side attached to the back of said magazine battery compartment housing;- wherein said spring is compressed toward the back of said magazine battery compartment housing when said one or more batteries are loaded and said spring is elongated along said magazine battery compartment housing toward its opening when said one or more batteries are unloaded.

17. The magazine battery compartment housing as recited in claim 13, wherein said at least one holding member is driven by at least one linear actuator into said at least one or more batteries passageway; and wherein one or more of said at least one holding member that shall make electrical contact is connected electrically with at least one bus bar within said magazine battery compartment housing via at least one flexible electrical conductor in order to be driven freely in and out of said one or more batteries passageway.

18. The magazine battery compartment housing as recited in claim 13 further comprising a battery loading and unloading mechanism for loading and unloading of said one or more batteries in and from said magazine battery compartment housing.

19. The magazine battery compartment housing as recited in claim 18, wherein said loading and unloading mechanism comprising of: at least one lifter; and at least one first servomotor that drives said lifter directly or via a driving bar.

20. The magazine battery compartment housing as recited in claim 19, wherein said at least one lifter is provided with an arm to which a second servomotor is attached; said second servomotor will rotate said at least one lifter relative to said arm allowing said at least one lifter to expand or retract during said loading and unloading processes of said one or more batteries; the movements of both said first servomotor and said second servomotor are being harmonised in the processes of loading / unloading of said one or more batteries into / from said magazine battery compartment housing.

21. The magazine battery compartment housing as recited in claim 13 further comprising a cooling air inlet; a cooling air outlet and aeration openings to let air flow to cool down the interior of said magazine battery compartment housing and said one or more batteries within.

22. The magazine battery compartment housing as recited in claim 13 further comprising a mean of wireless data communication between each of s loaded said one or more batteries and said magazine battery compartment housing.

23. The magazine battery compartment housing as recited in claim 16, wherein said at least one holding member is driven by at least one linear actuator into said at least one or more batteries passageway; and wherein one or more of said at least one holding member that shall make electrical contact is connected electrically with at least one bus bar within said magazine battery compartment housing via at least one flexible electrical conductor in order to be driven freely in and out of said one or more batteries passageway.

24. The magazine battery compartment housing as recited in claim 23 further comprising a loading and unloading mechanism for loading and unloading of said one or more batteries in and from said magazine battery compartment housing.

25. The magazine battery compartment housing as recited in claim 24, wherein said loading and unloading mechanism comprising of: at least one lifter; and at least one first servomotor that drives said lifter directly or via a driving bar.

26. The magazine battery compartment housing as recited in claim 24, wherein said at least one lifter is provided with an arm to which a second servomotor is attached; said second servomotor will rotate said at least one lifter relative to said arm allowing said at least one lifter to expand or retract during the loading and unloading processes of said one or more batteries; the movements of both said first servomotor and said second servomotor are harmonised in the process of loading / unloading of said one or more batteries into / from said magazine battery compartment housing.

27. The magazine battery compartment housing as recited in claim 26 further comprising a cooling air inlet; a cooling air outlet and aeration openings to let air flow to cool down the interior of said magazine battery compartment housing and said one or more batteries within.

28. The magazine battery compartment housing as recited in claim 27 further comprising a mean of wireless data communication between each of the loaded said one or more batteries and said magazine battery compartment housing.

29. A battery swapping station compatible for use with an electrically powered vehicle equipped with said magazine battery compartment housing according to any one of claims 18, 19, 20, 24, 25, 26, 27, and 28 comprising:- a first reservoir to receive and store discharged batteries disposed from said battery compartment housing of said electrically powered vehicle;- a second reservoir that stores charged batteries; and- a battery dispenser comprising: a battery release mechanism that receives the charged batteries from the second reservoir and delivers the charged batteries to said magazine battery compartment housing of the electrically powered vehicle; wherein said battery release mechanism comprises:- at least one pan that carries the charged battery coming out of said battery dispensing machine and deposit the charged battery into said magazine battery compartment housing of said electrically powered vehicle by said pan swinging downward;- a servomotor that drives said pan by swinging upward and downward directly or by a driving bar; and- a retractable train that is carrying said pan and said servomotor; wherein said retractable train is coming out of said battery dispensing machine only when a vehicle is at the swapping station and ready for swapping the battery.

30. A magazine battery compartment housing for one or more swappable batteries as recited in any one of claims 1 to 12, wherein said magazine battery compartment housing defines an opening, said magazine battery compartment housing comprising:- a jamming mechanism disposed at said opening of said magazine battery compartment housing, wherein, during a loading process of said one or more batteries through said opening, said jamming mechanism allow said one or more batteries to be loaded inside said magazine battery compartment housing while said jamming mechanism releasably holds said one or more batteries inside said magazine battery compartment housing;- a holding member that holds said one or more batteries releasably in place within said magazine battery compartment housing and maintains electrical contact between said one or more batteries and said magazine battery compartment housing; and- a repulsion mechanism biases said one or more batteries toward said opening, allowing said jamming mechanism to release said one or more batteries from said magazine battery compartment housing through said opening during an unloading process of said one or more batteries; wherein, during said loading process of said one or more batteries through said opening, said repulsion mechanism works with said jamming mechanism to cause said one or more batteries to be positioned correspondingly to said holding member.

31. A battery swapping system, comprising:- a first reservoir that stores one or more charged batteries;- a second reservoir that stores one or more discharged batteries; and- a mechanism for carrying out a swapping process repeatedly by pulling one or more charged batteries from said first reservoir; and electrically engaging said one or more charged batteries to be in communication with said battery swapping system to deliver power; after stored energy in said one or more charged batteries is drained, transferring the discharged batteries to said second reservoir; and initiating said swapping process.

32. The magazine battery compartment housing as recited in any one of claims 13 to 28 and claim 30 further comprising a reservoir that store said one or more batteries after being used and unloaded from said magazine compartment housing; wherein said one or more batteries inside said magazine battery compartment housing are held and electrically connected by said holding member in a serial manner; and wherein only one or some of the said one or more batteries that were previously loaded inside said magazine battery compartment housing are held and electrically connected by said holding member in any given time.

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