Auxiliary power system for a semi-truck

Abstract

An auxiliary power system for an electric semi-truck Is disclosed. The auxiliary power system Includes a power storage device mounted to a semi-trailer. One or more main batteries provide propulsion to a semi-truck and are in electrical communication with the power storage device to receive auxiliary power therefrom. The power storage device is operable to increase the range over which the semi -truck travels between recharging. 'The power storage device may be configured to either provide supplemental power to increase the power output of the semi-truck in real-time or may be configured to increase the range between recharging of the main batteries of the semi-truck.

Description

APPLICATIONFOR UNITED STATES LETTERS PATENTAUXILIARY POWER SYSTEM FOR A SEMI-TRUCKInventor:Sean ReesCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] 'fhe present application claims priority to U. S. Nonprovisional Patent Application No.19 / 078,895 filed March 13, 2025, titled “AUXILIARY POWER SYSTEM FOR A SEMI¬ TRUCK,” which is hereby incorporated by reference in its entirety.TECHNICAL FIELDSUMMARY OF THE INVENTION

[0006] This summary is provided to introduce a variety of concepts in a simplified form that is further disclosed in the detailed description of the embodiments. This summary is not intended for determining the scope of the claimed subject matter.

[0007] The embodiments provided herein relate to an auxiliary power system for an electric semi- truck. The auxiliary power system includes a power storage device mounted to a semi-trailer. One or more mam batteries provide propulsion to a semi-truck and are in electrical communication with the power storage device to receive auxiliary power therefrom. The power storage device is operable to increase the range over which the semi -truck travels between recharging. The power storage device may be configured to either provide supplemental power to increase the power output of the semi-truck in real-time or may be configured to increase the range between recharging of the main batteries of the semi-truck.

[0008] The auxiliary power system provides multiple functionalities depending on its configuration. In one configuration, the auxiliary power system may be used to significantly increase the power output capabilities of the semi-truck. This may be selectively controlled by an operator to provide an on-demand increase in power. This may be especially useful when accelerating from a stop, or when accelerating uphill. In such, the on-demand increase in power preserves the stored power within the semi-truck’s main battery or batteries, extending the range it is capable of travelling between charges. The additional power may also be useful when transporting heavy loads which require additional power to move efficiently and effectively.

[0009] Alternatively, the auxiliary power system may be used to significantly increase the range of the semi-truck while hauling the semi-trailer. This configuration allows for the semi-truck to

[0010] The system may include allow the operator to select, between various operation modes

[0012] The system features modular battery configurations, a power management system (PMS),BRIEF DESCRIPTION OF THE DRAWINGS

[0015] A complete understanding of the present embodiments and the advantages and features tnereot win be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:[00201 FIG, 5 illustrates a block diagram of the auxiliary power system infrastructure. according[0021 FIG. 6 illustrates a block diagram of the auxiliary power system power flow according to some embodiments;an auxiliary BMS, according toDETAILED DESCRIPTION

[0024] The specific details of the single embodiment or variety of embodiments described herein are set forth in this application. Any specific details of the embodiments described herein are used for demonstration purposes only, and no unnecessary limitationfs) or inference(s) are to be understood or imputed therefrom.

[0025] Before describing in detail exemplary embodiments, it is noted that the embodiments reside primarily in combinations of components related to particular devices and systems. Accordingly, the device components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

[0026] In general, the embodiments provided herein relate to an auxiliary power system which is mounted to a semi-trailer typically hauled by a semi-truck. The auxiliary power system is used to extend the range over which the truck my travel between recharging and / or to substantially increase the power output of the semi-truck. The system includes a power storage device (i.e., a battery, fuel cell, or similar power storage device known in the arts).

[0027] The system addresses fundamental limitations of electric semi-trucks by providing additional power capacity without compromising the truck's primary design or cargo capacity.

[0028] The auxiliary power system functions in various configurations, including range extension and / or performance enhancement modes. In the range extension configuration, the system significantly increases the distance an electric semi-truck can travel between charging events by supplementing the truck's main batteries with additional power stored in the auxiliarypower system. In performance enhancement configuration, the system provides on-demand power boosts during high-demand operational scenarios, such as acceleration from standstill, uphill driving, or transportation of particularly heavy loads.

[0029] In some embodiments, the auxiliary power system may be utilized to substantially increase the range between recharging of the semi-trucks main battery. In this configuration, the power storage device Is mounted to the semi-trailer. This may be useful for providing sustained auxiliary power throughout a long-distance haul, or to provide power to the semi -truck once its main battery has been depleted.

[0630] In some embodiments, the auxiliary power system may be mounted to most any component of the trailer including the exterior surfaces of the trailer, the interior surfaces of the trailer, the roof of the trailer, the front of the trailer, the underside of the trailer, etc.

[0631] In some embodiments, the auxiliary power system may be configured to be utilized as a means for delivery additional power to the main battery of the semi-truck in order to substantially increase the power output of the semi-trucks main batery. In such, the auxiliary power system may provide on-demand auxiliary power to the semi-truck. This may be especially useful when accelerating from a stop or when accelerating uphill.

[0632] While using range extension mode, the auxiliary power system 100 the system prioritizes supplementing the truck's main batteries to maximize the distance traveled between charging events. Power distribution is optimized to maintain consistent energy availability throughout the vehicle’s route, reducing the need for frequent recharging stops and improving operational efficiency.

[0033] While using power-boost mode, the system is configured to provide supplemental and on- demand power during high-demand operational scenarios, such as while accelerating, during uphill driving, or during heavy load transport.

[0034] FIG’s 1-3 illustrate the auxiliary power system 100 within a semi-trailer 101 to provide auxiliary power to a semi -truck (not shown). In the illustrated embodiments, the auxiliary power system 100 is configured to be utilized to extend the range of the semi-truck. The auxiliary power system 100 includes a power storage device 103 mounted to the interior of the semi-trailer 101.

[0035] FIG. 2 illustrates the semi-trailer 101 with an auxiliary power system 100 installed on the frame (or other structure) of the semi-trailer 101. This configuration optimizes space utilization while protecting the power storage components from external environmental factors.

[0036] In specific reference to FIG. 3, the semi-trailer.101 may include one or more solar cells 300. The solar cells 300 are in electrical communication with the power storage device 103. The solar cells 300 are positioned on the top 301 of the semi-trailer 101 to convert light from the sun into electricity which is stored by the power storage device 103. Mounting the solar cells 300 to the top 301 of the semi-trailer 101 advantageously orients the solar cells 300 to capture the most possible sunlight while driving or while parked.

[0037] In some embodiments, the solar cells 300 may be mounted to any exterior surface of the trailer including the sides, front, and rear surfaces to optimize power output of the solar ceils 300.

[0638] In some embodiments, the solar cells 300 may transmit electricity to the power storage device 103 in real-time while the vehicle is parked and / or while in motion.auxiliary power system may occur m tannem with charging the m m battery or the semi-truck or

[0042] To provide auxiliary power to the semi-truck, the truck is connected to the semi-trailer and m

[0043] switch. which allows for the automated delivery of power liom the auxiliary power system. In thisintegration system 536 includes solar panels 531, charge controllers 533, and power conversion means 535.

[0048] The auxiliary batery system 506 includes modular high-capacity battery packs 501 designed for both rapid charging and swapping, a standardized connection interface 503 that facilitates quick disconnection and reconnection, and a protective enclosure 505 designed for rapid deployment. The battery modules 501 may comprise high-capacity lithium-ion cells, solid-state batteries, or graphene-based ultracapacitors, depending on the specific implementation requirements. The swappable nature of the battery modules enables depleted units to be quickly exchanged with fully charged ones at designated swapping stations, virtually eliminating downtime associated with recharging.

[0049] The power management system (PMS) 510 functions as the central control unit managing power flow and Incorporates DC-DC converters 511 for voltage regulation, load balancing components 513, a safety monitoring system 515, and an energy transfer system 517. This subsystem is responsible for ensuring safe and efficient power distribution between the auxiliary battery system 500 and the truck’s main batteries.

[0050] The vehicle battery management system (BMS) 520 includes components for battery health monitoring 521, thermal management 523 for regulating operating temperature, and safety circuits 525. The BMS 520 continuously evaluates the charge levels, battery degradation, and overall health of both the external and onboard batery systems to ensure optimal operation and longevity.

[0051] The solar integration system 530 comprises solar panels 531 mounted on the truck roof or trailer, charge controllers 533, and power conversion means 535. This subsystem functions as an independent power source that harvests renewable energy to supply power to the 500 auxiliarybatery system, without being structurally integrated into the modular battery components themselves. The solar system reduces dependence on grid electricity, generates supplemental energy during operation, and continues to charge the auxiliary batery even when the vehicle is

[0052] The auxiliary battery is a modular energy storage solution designed to be housed within or mounted auxiliary on a semi-trailer. This system provides additional power to supplement the truck’s primary battery, thereby increasing the vehicle’s range and optimizing energy consumption.

[0053] The auxiliary battery system comprises one or more high-capacity lithium-ion battery packs. Alternative embodiments may include solid-state batteries or graphene-based ultracapacitors to enhance energy density and charge-discharge efficiency.

[0054] The auxiliary battery system is securely mounted to the trailer using reinforced brackets and shock-absorbing materials to minimize vibrations and mechanical stress. It is connected to the truck’s powertrain via a bidirectional power transfer system, which allows seamless energy exchange between the auxiliary battery and the truck’s main power source.

[0055] The auxiliary battery system is integrated with multiple safety features, including thermal monitoring sensors, overvoltage protection, short-circuit prevention circuits, and an emergency disconnection mechanism.

[0056] The system supports multiple charging methods, including direct grid charging, regenerative braking energy recovery, and solar energy harvesting through the solar integration system.

[0057] The power management system is responsible for regulating energy distribution between the truck’s main battery, the auxiliary batery system, and renewable energy inputs. This intelligent system ensures optimal power utilization while preventing batery degradation and energy losses. The power management system provides dynamic load balancing and continuously monitors power demand and dynamically allocates energy from the auxiliary batery system or solar integration system based on driving conditions, acceleration, and load requirements. Utilizing advanced microcontrollers and artificial intelligence (AI) algorithms, the PMS predicts energy requirements and optimizes power flow to maintain peak vehicle performance.

[0058] The power management system provides adaptive energy prioritization such that energy from the auxiliary battery is reserved for future use in the case wherein the vehicle batery is charged to a threshold level. If the vehicle batery drops below a threshold level, the auxiliary battery system prioritizes charging the truck’s battery to extend range. During high-load conditions, the system may temporarily redirect additional power to the truck’s propulsion system,. The system may operate using a Controller Area Network (CAN) or Modbus communication protocol, enabling real-time data exchange between the truck, the auxiliary battery system, and the vehicle's BMS.

[0059] The vehicle battery management system (BMS) oversees the truck’s main batery and auxiliary power system, ensuring safe and efficient operation. The BMS continuously evaluates the charge levels, battery degradation, and overall health of both foe truck’s main battery and the auxiliary batery system. Equipped with liquid cooling modules and thermal insulation, the BMS actively regulates temperature to prevent overheating, improving battery lifespan and efficiency.

[0060] The BMS communicates with the PMS to ensure seamless integration between the truck’s propulsion system and the auxiliary battery. It also prevents deep discharge and overcharging by adjusting charge rates dynamically.

[0061] In some embodiments, the BMS logs performance data and alerts the driver or fleet operator regarding potential battery issues. Al-driven predictive maintenance reduces downtime by forecasting potential failures before they occur.

[0062] The solar integration system provides a renewable energy source to extend the vehicle's operational range and reduce dependency on auxiliary charging infrastructure. High-efficiency solar panels are mounted on the roof of the semi-trailer to capture maximum sunlight exposure. Some embodiments may include retractable or tilting solar panels to optimize energy capture throughout the day.

[0063] A charge controller optimizes power conversion efficiency, ensuring that maximum solar energy is stored in the auxiliary battery system.

[0064] FIG. 6 and FIG. 7 illustrate block diagrams of the auxiliary power system power flow. In specific reference to FIG. 7, the system is shown including an auxiliary BMS 620 and control unit- 621. The solar panel array 600 provides power to the solar controller 601 which transmits power to the auxiliary battery 603. In either embodiment, once the auxiliary battery 603 receives power it is transmitted to the converter 511 which and switch mechanism which allows the user to select between a parallel 607 or direct switch 609. Power is then transmitted to the main (vehicle) battery 611 operated by the vehicle BMS 520.

[0065] Power from the auxiliary battery 603 is transmitted through a converter 511 and switch mechanism, which allows selection between parallel 607 or direct 609 connection modes before supplying power to the main vehicle battery 611.

[0066] FIG. 8 illustrates block diagrams of the parallel ( load sharing) and direct connection modes. In the parallel mode, both the auxiliary battery 603 and vehicle battery 611 power the vehicle and are connected to a load sharing controller 800 and receive power from the solar panels 531. The controller dynamically balances power draw from both sources based on demand and conditions. The solar panels 531 generate supplementary power that charges the auxiliary battery. This mode provides redundancy and optimal power distribution during high-demand situations. The direct connection mode creates a more straightforward power path primarily for charging and steady¬ state operation. The auxiliary battery 603 connects to the vehicle battery 611 through a DC / DC converter 511 which manages voltage matching between the batteries. This mode is more efficient for steady-state operation and charging.

[0067] In some embodiments, the parallel integration mode enables both the auxiliary batery 603 and the vehicle battery 611 to simultaneously power the vehicle through a load-sharing controller 800. This controller dynamically balances power draw between the two sources based on operational demands and conditions. The parallel integration provides increased operational redundancy ~ if one battery fails, the other still provides power - and extends battery lifespan due to reduced stress on individual units.

[0068] The direction connection mode establishes a more straightforward power path, primarily for charging and steady-state operation, wherein the auxiliary battery 603 connects to the vehicle battery 611 through a DC / DC converter 511 that manages voltage matching between the baterytheir lifespan and improving reliability. Swapping stations can be designed for scalability, with modular setups that accommodate multiple vehicles simultaneously, ensuring seamless operations even, during peak demand periods. Energy storage and grid integration can also be incorporated into the swapping stations, enabling surplus power to be stored or fed back into the grid during off-peak hours. By eliminating the primary challenge of charging delays, the rapid batery swap system makes electric freight transportation more practical, cost-effective, and viable for long-haul trucking applications.

[0072] In some embodiments, the load-sharing controller utilizes adaptive power distribution algorithms that analyze energy consumption patterns and efficiently allocate power from the auxiliary battery to supplement the vehicle’s main battery. This results in a seamless transition between energy sources without disrupting vehicle performance.

[0073] A key advantage of parallel integration is redundancy, ensuring that if one power source experiences a failure or reduced efficiency, the other can compensate, preventing operational downtime. This enhances the reliability of electric semi-trucks, especially for long-haul applications. Another major benefit is extended battery lifespan — by distributing energy demands between the auxiliary and main battery packs, stress on individual cells is reduced, leading to lower degradation rates and longer operational life for both battery systems.

[0074] In some embodiments, the direct connection operation relies on a voltage-matching and regulation system that ensures the auxiliary batery seamlessly transfers power to the truck’s main battery without overloading or damaging sensitive electrical components. The direct connection system features DC / DC converters that adjust voltage levels dynamically, preventing mismatches that could lead to inefficiencies, overheating, or power loss during energy transfer. This methodsysUvHlpatterns, and route conditions to further enhance efficiency and reliability.tvvck^s O&itcrv Svstc^w O^KAS4 usin^ H C\AJS I’HXS ot K4cyibys protocol ensuring* t'CRi- time data exchange.

[0077] A voltage matching anu synchronization process is executed to equalize the voltage levels between the auxiliary battery, truck’s battery, and renewable energy sources, preventing current

[0078] If any anomalies are detected, diagnostic alerts are generated, and the system may delay or modify energy transfer to protect the batteries from damage.

[0079] In some embodiments, the PMS continuously monitors power demand by analyzing vehicle acceleration, load weight, terrain, and battery state-of-health (SOH) in real-time. A dynamic load-balancing algorithm distributes power between the auxiliary battery, track’s onboard battery, and renewable sources (e.g., solar panels) to optimize performance and reduce strain on any single power source. 'The charging / discharging cycles for both battery systems are managed through a predictive Al-based energy management model, which ensures efficient energy use based on expected driving patterns. The PMS can adapt energy flow based on different operational states, such as prioritizing direct charging from the auxiliary battery during peak demand or engaging regenerative braking energy recovery when the truck is decelerating. A failsafe mode prevents deep discharge by restricting power draw when the auxiliary battery reaches critical levels, ensuring that the truck's primary battery remains the primary energy source in emergencies,

[0080] In some embodiments, the safety monitoring system provides continuous parameter monitoring ensures safe operation by tracking temperature, voltage, and current levels across all battery systems. Regulation mechanisms include active thermal management, such as liquid cooling or fan-assisted air cooling, to maintain optimal battery temperature during high-load conditions. The fault detection system uses real-time diagnostics to identify potential risks, including overcharging, short circuits, or excessive heat generation. Emergency disconnection features include an automated cutoff relay that isolates the auxiliary battery from the truck’s main power system in case of voltage fluctuations, extreme overheating, or internal system faults. Aredundancy safety layer ensures that if one monitoring system fails, an auxiliary safety mechanism takes over, preventing potential hazards and ensuring safe energy transfer.

[0081] Swappable auxiliary battery units can be used to integrate with the system rather than using a fixed auxiliary battery pack, modular quick-swap battery units can be implemented, allowing truck operators to replace a depleted battery with a fully charged one at designated swap stations.

[0082] Wireless charging coupling can be used including inductive or resonant wireless charging systems which allow for energy transfer between the auxiliary battery and truck without physical connectors, reducing wear and improving reliability in harsh environments.

[0083] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety to the extent allowed by applicable law and regulations. The systems and methods described herein may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and it is therefore desired that the present embodiment be considered in all respects as illustrative and not restrictive. Any headings utilized within the description are for convenience only and have no legal or limiting effect.

[0084] Many different embodiments have been disclosed herein, in connection with the above description and the drawings. It will be understood that it would be unduly repetitious and obfuscating to literally describe and illustrate every combination and subcombination of these embodiments. Accordingly, all embodiments can be combined in any way and / or combination, and the present specification, including the drawings, shall be construed to constitute a complete written description of all combinations and subcombinations of the embodiments described herein,and of the manner and process of making and using them, and shall support claims to any such combination or subcombination.

[0085] The foregoing is provided for purposes of illustrating, explaining, and describing embodiments of this disclosure. Modifications and adaptations to these embodiments will be apparent to those skilled in the art and may be made without departing from the scope or spirit of this disclosure.

[0086] As used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

[0087] It should be noted that all features, elements, components, functions, and steps described with respect to any embodiment provided herein are intended to be freely combinable and substitutable with those from any other embodiment. If a certain feature, element, component, function, or step is described with respect to only one embodiment, then it should be understood that that feature, element, component, function, or step can be used with every other embodiment described herein unless explicitly stated otherwise. This paragraph therefore serves as antecedent basis and written support for the introduction of claims, at any time, that combine features, elements, components, functions, and steps from different embodiments, or that substitute features, elements, components, functions, and steps from one embodiment with those of another, even if the description does not explicitly state, in a particular instance, that such combinations or substitutions are possible. It is explicitly acknowledged that express recitation of every possible combination and substitution is overly burdensome especially given that the permissibility of each and every such combination and substitution will be readily recognized by those of ordinary skillunless theth&t not within tli8t scene

Claims

What is claimed is:

1. An auxiliary power system for an electric semi-truck, comprising:a power storage device mounted to a semi-trailer; andone or more main batteries to provide propulsion to a semi-truck, the one or more main batteries in electrical communication with the power storage device to receive auxiliary power therefrom,wherein the power storage device is operable to increase the range over which the semi¬ truck travels between recharging.

2. The auxiliary power system of Claim 1. further comprising one or more solar cells mounted to a top of the semi-trailer, the one or more solar cells to recharge the power storage device.

3. The auxiliary power system of Claim 1, further comprising a controller to provide the on-demand modulation of the power output of the power storage device, wherein the controller is operable to increase an operational range and on-demand power output.

4. The auxiliary power system of Claim 3, further comprising a load distributor in operable communication with the controller to allow for the on-demand control of load distribution throughout the auxiliary power system.

5. The auxiliary power system of Claim 4, wherein the controller is in operable communication with a manual or an automated switch.

6. The auxiliary power system of Claim 1, wherein the power storage device is removable from the semi-trailer.

7. An auxiliary power system for an electric semi-truck, comprising:

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