Swappable range extender for electric vehicles

Abstract

A swappable range extender includes an electric power source and a sealed body. The power source is configured to be coupled to a power train of a vehicle. The sealed body contains the power source. The sealed body includes a main body, a lid, and a screw. The lid is configured to cover the main body. The screw is configured to seal the lid to the main body. The screw has a unique profile that is designed according to a unique barcode.

Description

SWAPPABLE RANGE EXTENDER FOR ELECTRIC VEHICLESTECHNICAL FIELD

[0001] The present disclosure generally relates to electric vehicles, and particularly, to range extenders and swappable batteries for electric vehicles.BACKGROUND ART

[0002] Among main challenges of electric vehicles are long charging time, relatively high weight of electric vehicle batteries, and supplying enough lithium to achieve zero carbon emission. Swappable batteries may overcome long charging times, but the need for special places for battery replacement - due to high weight of electric vehicle batteries - may limit their applications to specific vehicles, such as motorcycles. Some manufacturers have utilized Hydrogen as a fuel to achieve zero carbon transportation, and to replace heavier electric vehicle batteries. However, Hydrogen usage may be limited to Hydrogen vehicles. Moreover, Hydrogen may only be supplied at Hydrogen stations. Swappable Hydrogen containers, developed by some manufacturers, may obviate the need for Hydrogen stations; however, safety issues are still an obstacle in replacing Hydrogen containers.

[0003] There is, therefore, a need for a portable power source that may provide enough power for an electric vehicle to travel a distance that may be long enough to reach a power station, and may be replaced with a charged power source to avoid long charging times. There is also a need for a swappable device that may use Hydrogen as energy source in ordinary electric vehicles.SUMMARY OF THE DISCLOSURE

[0004] This summary is intended to provide an overview of the subject matter of this patent, and is not intended to identify essential elements or key elements of the subject matter, nor is it intended to be used to determine the scope of the claimed implementations. The proper scope of this patent may be ascertained from the claims set forth below in view of the detailed description below and the drawings.

[0005] In one general aspect, the present disclosure describes an exemplary swappable range extender. An exemplary swappable range extender may include an electric power source and a sealed body. An exemplary electric power source may be configured to be coupled to a powertrain of a vehicle. An exemplary sealed body may contain the electric power source. In an exemplary embodiment, the sealed body may include a main body, a lid, and one or more screws. An exemplary lid may be configured to cover the main body. An exemplary one or more screws may be configured to seal the lid to the main body. In an exemplary embodiment, the one or more screws may have a unique profile that may be designed according to a unique barcode. An exemplary sealed body may include a plurality of slits on one or more sides of the sealed body. In an exemplary embodiment, the plurality of slits may be configured to let air into the sealed body.

[0006] In an exemplary embodiment, the electric power source may include a battery. An exemplary battery may be fixedly attached to the sealed body. In an exemplary embodiment, the electric power source may include a fuel cell and a Hydrogen storage. An exemplary Hydrogen storage may be coupled to the fuel cell. In an exemplary embodiment, the electric power source may include one of an internal combustion engine or a free-piston engine and a fuel storage. An exemplary fuel storage may be coupled to one of the internal combustion engine or the free free-piston engine.

[0007] In an exemplary embodiment, the swappable range extender may be configured to be placed on a stand in a compartment that may be built inside a trunk of the vehicle. An exemplary stand may be configured to couple the electric power source to the power train.

[0008] An exemplary swappable range extender may further include a cable that may be configured to couple the electric power source to a charging inlet of the vehicle by being connected between the electric power source and the charging inlet. An exemplary cable may be fixedly connected to the charging inlet. An exemplary cable may be fixedly attached to a body of the vehicle. An exemplary range extender may further include a protective layer that may be wrapped around the cable.

[0009] In an exemplary embodiment, the swappable range extender may further include a connector. An exemplary connector may be connected to the charging inlet and may be configured to couple the charging inlet to an outlet of an electric vehicle charger.

[0010] In an exemplary embodiment, the swappable range extender may further include one or more stands that may be attached to a bottom surface of the sealed body and may be configured to fixedly attach the range extender to a roof of the vehicle. In an exemplary embodiment, the sealed body may have an aerodynamic shape. An exemplary sealed body mayinclude a plurality of holes on one or more sides of the sealed body. In an exemplary embodiment, the plurality of holes may be configured to let air into the sealed body.

[0011] Other exemplary systems, methods, features and advantages of the implementations will be, or will become, apparent to one of ordinary skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description and this summary, be within the scope of the implementations, and be protected by the claims herein.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.

[0013] FIG. 1 shows a schematic of a first implementation of a swappable range extender, consistent with one or more exemplary embodiments of the present disclosure.

[0014] FIG. 2A shows a schematic of a first implementation of an electric power source, consistent with one or more exemplary embodiments of the present disclosure.

[0015] FIG. 2B shows a schematic of a second implementation of an electric power source, consistent with one or more exemplary embodiments of the present disclosure.

[0016] FIG. 3A shows a schematic of compartments built inside a trunk of a vehicle, consistent with one or more exemplary embodiments of the present disclosure.

[0017] FIG. 3B shows a schematic of a swappable range extender placed in a compartment built inside a trunk of a vehicle, consistent with one or more exemplary embodiments of the present disclosure.

[0018] FIG. 3C shows a schematic of different range extenders utilized in different electric vehicles, consistent with one or more exemplary embodiments of the present disclosure.

[0019] FIG. 3D shows a schematic of electric connection of a range extender to a power train of an electric vehicle via a stand, consistent with one or more exemplary embodiments of the present disclosure.

[0020] FIG. 4 shows a schematic of a second implementation of a swappable range extender, consistent with one or more exemplary embodiments of the present disclosure.

[0021] FIG. 5A shows a schematic of a magnified view of a charging inlet of an electric vehicle, depicting a substitute charging inlet and a cable connecting an electric power sourceto a charging inlet of the electric vehicle, consistent with one or more exemplary embodiments of the present disclosure.

[0022] FIG. 5B shows a schematic of electric connection of a range extender to a power train of an electric vehicle via a cable through a charging inlet, consistent with one or more exemplary embodiments of the present disclosure.

[0023] FIG. 6 shows a schematic of a swappable range extender placed on a roof of a vehicle, consistent with one or more exemplary embodiments of the present disclosure.DESCRIPTION OF EMBODIMENTS

[0024] In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and / or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

[0025] The following detailed description is presented to enable a person skilled in the art to make and use the methods and devices disclosed in exemplary embodiments of the present disclosure. For purposes of explanation, specific nomenclature is set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosed exemplary embodiments. Descriptions of specific exemplary embodiments are provided only as representative examples. Various modifications to the exemplary implementations will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other implementations and applications without departing from the scope of the present disclosure. The present disclosure is not intended to be limited to the implementations shown, but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

[0026] Herein is disclosed an exemplary swappable range extender for electric vehicles. In an exemplary embodiment, a “range extender” may refer to a device that may provide enough power to a vehicle so that the vehicle may travel a distance that may be long enough to reach a power station when a main power source of the vehicle is discharged. An exemplary swappable range extender may house different types of power sources, such as fuel cells (equipped with Hydrogen tanks), internal combustion engines or free-piston engines (equipped withcompressed natural gas tanks), and electric vehicle batteries. An exemplary swappable range extender may be sealed with special screws so that ordinary users may not have access to internal parts of the rage extender so that it may only be charged or replaced by authorized manufacturers or their representatives, thereby maintaining the safety of the device. An exemplary swappable range extender may be light enough to be placed inside a trunk or on a roof of an exemplary electric vehicle and it may be easily coupled to or detached from the exemplary electric vehicle. Therefore, an exemplary swappable range extender may be easily replaced by a charged range extender when it is discharged. As a result, long charging times of electric vehicles in power stations may be avoided by swapping a discharged range extender with a charged one. In an exemplary embodiment, the swappable range extender may be designed and fabricated to have a same size, shape, and connections as conventional swappable batteries to be used instead of conventional swappable batteries.

[0027] FIG. 1 shows a schematic of a first implementation of a swappable range extender, consistent with one or more exemplary embodiments of the present disclosure. An exemplary swappable range extender 100 may include an electric power source 102 and a sealed body 104. In an exemplary embodiment, electric power source 102 may be configured to be coupled to a power train of a vehicle. In an exemplary embodiment, sealed body 104 may contain electric power source 102.

[0028] In an exemplary embodiment, sealed body 104 may include a main body 106, a lid 108, and one or more screws 110. In an exemplary embodiment, lid 108 may be configured to cover main body 106. In an exemplary embodiment, one or more screws 110 may be configured to seal lid 108 to main body 106. In an exemplary embodiment, one or more screws 110 may have a unique profile that may be designed according to a unique barcode 112 of swappable range extender 100, preventing from unauthorized access to electric power source 102. As a result, in an exemplary embodiment, ordinary users may not have access to the inside of range extender 100 and therefore, range extender 100 may only be charged or repaired by manufacturers or authorized representatives who may have corresponding codes and screwdrivers for opening one or more screws 110.

[0029] In an exemplary embodiment, sealed body 104 may include a plurality of slits 114 on one or more sides of sealed body 104. In an exemplary embodiment, plurality of slits 114 may be configured to let air into sealed body 104. As a result, in an exemplary embodiment, aircirculation may prevent range extender 100 from becoming excessively hot, thereby keeping it at a normal working condition.

[0030] FIG. 2A shows a schematic of a first implementation of an electric power source, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 1 and 2A, an exemplary electric power source 200 may be a first implementation of electric power source 102. In an exemplary embodiment, electric power source 200 may include a battery 202. In an exemplary embodiment, battery 202 may be fixedly attached to sealed body via a fixation interface 204.

[0031] FIG. 2B shows a schematic of a second implementation of an electric power source, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 1 and 2B, an exemplary electric power source 206 may be a second implementation of electric power source 102. In an exemplary embodiment, electric power source 206 may include a fuel cell 208 and at least one Hydrogen storage 210. In an exemplary embodiment, Hydrogen storage 210 may include compressed or liquid Hydrogen. In an exemplary embodiment, Hydrogen storage 210 may be coupled to fuel cell 208.

[0032] FIG. 2C shows a schematic of a third implementation of an electric power source, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 1 and 2C, an exemplary electric power source 212 may be a third implementation of electric power source 102. In an exemplary embodiment, electric power source 212 may include an engine 214 and a compressed fuel storage 216. In an exemplary embodiment, engine 214 may be an internal combustion engine or a free-piston engine. In an exemplary embodiment, fuel storage 216 may be a Hydrogen storage or an appropriate Hydrocarbon tank (such as a compressed natural gas (CNG) tank or a gasoline tank). In an exemplary embodiment, fuel storage 216 may be coupled to engine 214.

[0033] FIG. 3A shows a schematic of compartments built inside a trunk of a vehicle, consistent with one or more exemplary embodiments of the present disclosure. FIG. 3B shows a schematic of a swappable range extender placed in a compartment built inside a trunk of a vehicle, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 1, 3A, and 3B, exemplary swappable range extenders 300A and 300B may be implementations of swappable range extender 100. In an exemplary embodiment, swappable range extenders 300A and 300B may be configured to be placed on respective stands in compartments 302A and 302B that may be built inside a trunk 304 of a vehicle 306. Anexemplary stand may be configured to couple electric power source 102 to the power train. For example, range extender 300A may fit into compartment 302A to connect electric power source 102 to the electric vehicle power train via a connector fitted on a bottom of compartment 302A.

[0034] FIG. 3C shows a schematic of different range extenders utilized in different electric vehicles, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, swappable range extender 100 may be designed or fabricated in a wide range of power and energy sizes for various electrical vehicles, including motorcycles, passenger cars, buses, and trucks, and may be used to supply electricity for off-grid applications or to enhance resiliency of consumers and power grid in emergencies. For example, a swappable range extender 307 (similar to swappable range extender 100) may be utilized in a motorcycle 308, and swappable range extenders 309 and 310 (each similar to swappable range extender 100) may be utilized in a truck 311.

[0035] FIG. 3D shows a schematic of electric connection of a range extender to a power train of an electric vehicle via a stand, consistent with one or more exemplary embodiments of the present disclosure. An exemplary range extender 312 (that may be similar to any of range extenders 300A or 300B) may be electrically connected to a stand 313 that may transfer power generated by range extender 312 to a busbar 314 via a DC / DC converter 315. In an exemplary embodiment, busbar 314 may be connected to a power train 316 of an electric vehicle so that electric power that is generated by an electric power source (similar to electric power source 102 of FIG. 1) inside range extender 312 may be transferred to power train 316.

[0036] FIG. 4 shows a schematic of a second implementation of a swappable range extender, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 1 and 4, an exemplary swappable range extender 400 may be similar to swappable range extender 100 and may include similar elements. In an exemplary embodiment, swappable range extender 400 may include an electric power source 402 (similar to electric power source 102) and a sealed body 404 (similar to sealed body 104). In an exemplary embodiment, sealed body 404 may contain electric power source 402. In an exemplary embodiment, electric power source 402 may be configured to be coupled to a power train of a vehicle. In an exemplary embodiment, sealed body 404 may include a main body 406 (similar to main body 106), a lid 408 (similar to lid 108), and one or more screws 410 (similar to screw 110). In an exemplary embodiment, lid 408 may be configured to cover main body 406. In an exemplary embodiment, one or more screws 410 may be configured to seal lid 408 to main body 406. In an exemplaryembodiment, one or more screws 410 may have a unique profile that may be designed according to a unique barcode similar to barcode 112. As a result, in an exemplary embodiment, ordinary users may not have access to the inside of range extender 400 and therefore, range extender 400 may only be charged or repaired by manufacturers or authorized representatives who may have associated codes and corresponding screwdrivers for opening one or more screws 410

[0037] FIG. 5A shows a schematic of a magnified view of a charging inlet of an electric vehicle, depicting a substitute charging inlet and a cable connecting an electric power source to a charging inlet of the electric vehicle, consistent with one or more exemplary embodiments of the present disclosure. Referring to FIGs. 4 and 5A, in an exemplary embodiment, electric power source 402 may be configured to be coupled to a charging inlet 502 of a vehicle 504. In an exemplary embodiment, range extender 400 may further include a cable 412 that may be configured to couple electric power source 402 to charging inlet 502 by being connected between electric power source 402 and charging inlet 502. An exemplary charging inlet end of cable 412 may be configured to simultaneously function as an outlet for connection to charging inlet 502 and as an inlet for connection of a charger outlet of an exemplary charger. In an exemplary embodiment, cable 412 may be fixedly connected to charging inlet 502. In an exemplary embodiment, charging inlet 502 may be configured to couple cable 412 to the power train. In an exemplary embodiment, range extender 400 may further include a protective layer 414 that may be wrapped around cable 412.

[0038] FIG. 5B shows a schematic of electric connection of a range extender to a power train of an electric vehicle via a cable through a charging inlet, consistent with one or more exemplary embodiments of the present disclosure. An exemplary range extender 506 (that may be similar to range extender 400) may be electrically connected to a cable 508 (similar to cable 412) that may electrically couple range extender 506 to a charging inlet 510 (similar to charging inlet 502). In an exemplary embodiment, charging inlet 510 may be configured to electrically couple cable 508 to a busbar 512 via a DC / DC converter 514. In an exemplary embodiment, busbar 512 may be connected to a power train 516 of an electric vehicle so that electric power that is generated by an electric power source (similar to electric power source 102 of FIG. 1) inside range extender 506 may be transferred to power train 516.

[0039] FIG. 6 shows a schematic of a swappable range extender placed on a roof of a vehicle, consistent with one or more exemplary embodiments of the present disclosure. Referring toFIGs. 5 and 6, an exemplary vehicle 600 may be similar to vehicle 504. In an exemplary embodiment, cable 412 may be fixedly attached to a body 602 of vehicle 600.

[0040] Referring to FIGs. 2B and 6, in an exemplary embodiment, swappable range extender 400 may include an electric power source similar to electric power source 206 with a fuel cell similar to fuel cell 208 and four Hydrogen tanks similar to Hydrogen tank 210 with a capacity of about 35 liters of Hydrogen. In an exemplary embodiment, such configuration may lead to a weight less than about 80 kg (which is significantly lighter than conventional batteries) and may extend a range of vehicle 600 more than about 200 km.

[0041] Referring to FIGs. 2C and 6, in an exemplary embodiment, swappable range extender 400 may include an electric power source similar to electric power source 212 with an engine similar to engine 214 and a CNG tank similar to CNG tank 216. In an exemplary embodiment, such configuration may lead to a weight less than about 66 kg (which is significantly lighter than conventional batteries) and may extend a range of vehicle 600 more than about 100 km.

[0042] Referring to FIGs. 4, 5A, and 6, in an exemplary embodiment, swappable range extender 404 may further include a two-sided connector 416. In an exemplary embodiment, connector 416 may be connected to charging inlet 502 and may be configured to couple charging inlet 502 to an outlet of an electric vehicle charger, with no need to disconnect cable 412 from charging inlet 502.

[0043] In an exemplary embodiment, sealed body 404 may have an aerodynamic shape to improve fuel efficiency and reduce wind noise. In an exemplary embodiment, sealed body 404 may include a plurality of holes 604 on one or more sides of sealed body 404. In an exemplary embodiment, plurality of holes 604 may be configured to let air into sealed body 404. As a result, in an exemplary embodiment, air circulation may prevent range extender 400 from becoming excessively hot, thereby keeping it at a normal working condition.

[0044] In an exemplary embodiment, swappable range extender 400 may further include one or more stands 606. In an exemplary embodiment, stands 606 may be attached to a bottom surface of sealed body 404 and may be configured to fixedly attach range extender 400 to a roof 608 of vehicle 600.

[0045] While the foregoing has described what are considered to be the best mode and / or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been describedherein. It is intended by the following claims to claim any and all applications, modifications, and variations that fall within the true scope of the present teachings.

[0046] Unless otherwise stated, all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. They are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain.

[0047] The scope of protection is limited solely by the claims that now follow. That scope is intended and should be interpreted to be as broad as is consistent with the ordinary meaning of the language that is used in the claims when interpreted in light of this specification and the prosecution history that follows and to encompass all structural and functional equivalents.

[0048] Except as stated immediately above, nothing that has been stated or illustrated is intended or should be interpreted to cause a dedication of any component, step, feature, object, benefit, advantage, or equivalent to the public, regardless of whether it is or is not recited in the claims.

[0049] It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

[0050] The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various implementations. This is for purposes of streamlining the disclosure, and is not to be interpretedas reflecting an intention that the claimed implementations require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed implementation. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.

[0051] While various implementations have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more implementations and implementations are possible that are within the scope of the implementations. Although many possible combinations of features are shown in the accompanying figures and discussed in this detailed description, many other combinations of the disclosed features are possible. Any feature of any implementation may be used in combination with or substituted for any other feature or element in any other implementation unless specifically restricted. Therefore, it will be understood that any of the features shown and / or discussed in the present disclosure may be implemented together in any suitable combination. Accordingly, the implementations are not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.

Claims

What is claimed is:

1. A swappable range extender, comprising: an electric power source configured to be coupled to a power train of a vehicle; and a sealed body containing the electric power source.

2. The swappable range extender of claim 1, wherein the electric power source comprises a battery fixedly attached to the sealed body.

3. The swappable range extender of claim 1, wherein the electric power source comprises: a fuel cell; and a Hydrogen storage coupled to the fuel cell.

4. The swappable range extender of claim 1, wherein the electric power source comprises: one of an internal combustion engine or a free-piston engine; and a fuel storage coupled to the one of the internal combustion engine or the free free-piston engine.

5. The swappable range extender of claim 1, wherein the sealed body comprises: a main body; a lid configured to cover the main body; and one or more screws configured to seal the lid to the main body, the one or more screws comprising a unique profile designed according to a unique barcode.

6. The swappable range extender of claim 1, wherein the sealed body comprises a plurality of slits on one or more sides of the sealed body, the plurality of slits configured to let air into the sealed body.

7. The swappable range extender of claim 6, wherein the swappable range extender is configured to be placed on a stand in a compartment built inside a trunk of the vehicle, the stand configured to couple the electric power source to the power train.

8. The swappable range extender of claim 1, further comprising a cable configured to couple the electric power source to a charging inlet of the vehicle by being connected between the electric power source and the charging inlet, the charging inlet configured to couple the cable to the power train.

9. The swappable range extender of claim 8, further comprising a protective layer wrapped around the cable.

10. The swappable range extender of claim 8, wherein the cable is fixedly attached to a body of the vehicle.

11. The swappable range extender of claim 10, wherein the cable is fixedly connected to the charging inlet.

12. The swappable range extender of claim 11, further comprising a connector connected to the charging inlet and configured to couple the charging inlet to an outlet of an electric vehicle charger.

13. The swappable range extender of claim 8, wherein the sealed body comprises an aerodynamic shape.

14. The swappable range extender of claim 13, further comprising one or more stands attached to a bottom surface of the sealed body and configured to fixedly attach the range extender to a roof of the vehicle.

15. The swappable range extender of claim 14, wherein the sealed body comprises a plurality of holes on one or more sides of the sealed body, the plurality of holes configured to let air into the sealed body.

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