WO2024059679A1

WO2024059679A1 - Portable power device for an electrical vehicle

Info

Publication number: WO2024059679A1
Application number: PCT/US2023/074138
Authority: WO
Inventors: James Richard STANFIELD; Bruce Moore
Original assignee: The Noco Company
Priority date: 2022-09-15
Filing date: 2023-09-14
Publication date: 2024-03-21

Abstract

A portable power device for an electric vehicle (EV) is described herein. The portable power device may comprise a portable battery, an electronic energy module and an output port. The portable battery may be configured to store a predetermined amount of charge. The electronic energy module may be coupled to the portable battery and configured to provide an output voltage and an output current based on the predetermined amount of charge stored in the portable battery. The output port may be coupled to the electronic energy module and configured to receive the output voltage and the output current and provide the output voltage and output current via a charging cable to an output connector. The output connector may be configured to couple to a charge port of the EV and charge the EV based on the output voltage and the output current.

Description

PORTABLE POWER DEVICE FOR AN ELECTRICAL VEHICLE CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application 63/375,775, filed September 15, 2022, which is incorporated herein by reference in its entirety. TECHNICAL FIELD [0002] The present disclosure relates to charging devices and systems for charging an electrical vehicle (EV). BACKGROUND [0003] A traction battery is a rechargeable battery used to power electric motors such as those in an EV. EV batteries differ from starting, lighting, and ignition (SLI) batteries as these batteries are designed to give power over sustained periods and are deep-cycle batteries. Batteries for EVs are characterized by their relatively high power- to-weight ratio, specific energy, and energy density; smaller, lighter batteries are desirable because such batteries reduce a weight of an EV and therefore improve vehicle performance, such as extending a vehicle’s range. SUMMARY [0004] Various details of the present disclosure are hereinafter summarized to provide a basic understanding. This summary is not an extensive overview of the disclosure and is neither intended to identify certain elements of the disclosure nor to delineate the scope thereof. Rather, the primary purpose of this summary is to present some concepts of the disclosure in a simplified form prior to the more detailed description that is presented hereinafter. [0005] In an example, a portable power device for an EV can include a portable battery configured to store a predetermined amount of charge. The portable power device can further include an electronic energy module coupled to the portable battery and an output port coupled to the electronic energy module. The electronic energy module may be configured to provide an output voltage and an output current based on the predetermined amount of charge stored in the portable battery. The output port may be configured to receive the output voltage and the output current and provide the output voltage and the output current via a charging cable to an output connector. The output connector may be configured to couple to a charge port of the EV and charge the EV based on the output voltage and the output current. [0006] In another example, a method of charging an electric vehicle can include charging a portable battery of a portable power device. The method may further include storing the portable power device in an electric vehicle. The method can further include determining that an electric vehicle battery within the electric vehicle is below a predetermined charge level. The method can further include charging the electric vehicle battery with the portable power device based on the determination that the battery of the electric vehicle is below the predetermined charge level. [0007] Any combinations of the various embodiments and implementations disclosed herein can be used in a further embodiment, consistent with the disclosure. These and other aspects and features can be appreciated from the following description of certain embodiments presented herein in accordance with the disclosure and the accompanying drawings and claims. BRIEF DESCRIPTION OF THE DRAWINGS [0008] FIG.1 depicts an electric vehicle having a portable power device, in accordance with some embodiments. [0009] FIG.2 depicts a portable power device, in accordance with some embodiments. [0010] FIG.3 depicts a method of charging an electric vehicle, in accordance with some embodiments. DESCRIPTION [0011] Embodiments of the present disclosure will now be described in detail with reference to the accompanying Figures. Like elements in the various figures may be denoted by like reference numerals for consistency. Further, in the following detailed description of embodiments of the present disclosure, numerous specific details are set forth in order to provide a more thorough understanding of the claimed subject matter. However, it will be apparent to one of ordinary skill in the art that the embodiments disclosed herein may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the description. Additionally, it will be apparent to one of ordinary skill in the art that the scale of the elements presented in the accompanying figures may vary without departing from the scope of the present disclosure. [0012] EVs are range-limited based on a capacity of a battery system. An operating range of an EV is dependent on numerous environmental variables (e.g., weather, temperature, traffic, etc.) and vehicle variables (e.g., use of air conditioning, heating, lights, etc.), such that an actual range of the EV between points, for example, on different days varies. Because an EV operating range depends on environment and vehicle variables, in some instances there may be insufficient range to reach an intended destination as it is unknown beforehand whether the EV has a sufficient stored charge to reach the intended destination. Variability in EV operating range can give rise to what is known as “range anxiety” to a driver and/or occupant(s) of the EV. Range anxiety is a driver's fear that a vehicle has insufficient energy storage to cover a road distance needed to reach the intended destination, and would thus strand the driver mid-way. If the EV is not in range of a charging station or source at a location (e.g., a work parking lot, a parking structure, residence, etc.) for replenishing the battery system or driving the EV to a charging station is undesirable (e.g., due to heavy traffic), the EV may run out of charge, and leave the driver stranded in a midst of a trip. [0013] Examples are described herein addressing problems associated with range anxiety and depletion of EV batteries in a midst of a trip. Examples are presented herein wherein an EV is provided with a partial charge so that the EV can reach a location and in some instances a more favorable location (e.g., location A for charging the EV may be a more preferred location over location B for charging the EV). In other examples, the partial charge can be used to allow the EV to be moved around a shop, a garage, a driveway, and/or the like. [0014] According to the examples herein, EVs can include one or more sources of stored energy that can be designed to provide electrical energy to the EV, wherein the electrical energy is used at least in part for propelling the EV. The term “electrical vehicle” as used herein may include vehicles designed for carrying passengers, to transporting goods, or providing specialty work capabilities. For example, EVs include passenger automobiles, trucks, and recreational water crafts such as boats. In some examples, EVs include specialty vehicles, such as fork trucks used to lift and move cargo, vehicles that incorporate conveyor belts to move objects, such as mobile conveyor belt vehicles used to load and unload cargo such as luggage from airplanes, and specialty equipment used in areas where exhaust fumes from typical gasoline, diesel, or propane powered equipment may present hazards to personnel, such as in underground mining operations. In various examples, EVs are designed and intended to be operated on public roadways (e.g., highways, streets, etc.), including both cars and trucks. [0015] FIG.1 depicts an electric vehicle having a portable power device, in accordance with some embodiments. The portable power device 102 can be configured to provide a charge to a battery 104 of the EV 100. In some examples, the battery 104 may be referred to as a traction battery. For example, if the EV 100 has a dead battery, and is stranded on a side of a road or in a parking lot, a driver can remove the portable power device 102 from a storage compartment in the EV 100 and position the portable power device 102 relative to a charge port 106 to deliver charge to the battery 104 of the EV 100. In other examples, the driver can remove and use the portable power device 102 to provide charge to the battery 104 in response to a battery level of the battery 104 being below a predetermined or desired battery level. [0016] In some examples, the portable power device 102 is connected to the charge port 106 even when the battery 104 is charged above the predetermined or desired battery level. For example, the portable power device 102 may be stored in a truck bed and the driver can attach the portable power device 102 to the charge port 106 via a charging cable from the truck bed to the charge port 106. Alternatively, the portable power device 102 may be connected to the charge port 106 from an inside of the EV 100 via an internal access point of the charge port 106 when the battery 104 is charged above the predetermined or desired battery level. However, the portable power device 102 may begin providing charge to the charge port 106 to charge the battery 104 after a determination that the battery level of the battery 104 is below the predetermined battery level. For example, the energy converter 108 may be configured to generate a battery level signal indicating the battery level of the battery 104. The battery level signal can be received by the portable power device 102 through the charge port 106, and the portable power device 102 can determine the battery level of the battery 104 based on the battery level signal. [0017] In the example of FIG.1, the EV 100 includes the battery 104 and at least one motor 110 for converting battery energy into mechanical motion, such as rotary motion. In some examples, the battery 104 is part of an energy storage system (ESS). The ESS can include various components for transmitting energy to and from the battery 104, such as safety components, cooling components, heating components, rectifiers, etc. Examples herein should not be construed and/or limited to the configurations disclosed herein, as other configurations of the ESS are possible. The battery 104 can include a lithium-ion battery. In some examples, the battery 104 includes a plurality of lithium-ion batteries coupled in parallel and/or series. In some instances, the battery 104 includes cylindrical lithium-ion batteries, or different shaped and/or sized lithium-ion batteries. [0018] The EV 100 further can include an energy converter 108. The energy converter 108 can be configured to convert energy from the battery 104 into energy useable by a motor 110 of the EV 100. In some instances, the energy flow is from the motor 110 to the battery 104. For example, the EV 100 may use regenerative braking, and kinetic energy from the EV 100 may be transferred through the motor 110 and the energy converter 108 and stored in the battery 104. Furthermore, in some examples, the battery 104 provides energy to the energy converter 108, which converts the energy into energy usable by the motor 110 to propel the EV 100. In further examples, the motor 110 can be configured to provide energy that can be transmitted to the energy converter 108. In these examples, the energy converter 108 converts the energy into energy that can be stored in the battery 104. [0019] By way of example, the energy converter 108 can include transistors. Some examples include one or more field effect transistors. Some examples include metal oxide semiconductor field effect transistors. Some examples include boost, buck or flyback converter circuits. In some examples, the energy converter 108 can include a switch bank that can be configured to receive direct current (DC) power from the battery 104 and output alternating current (AC) power to drive the motor 110. In some examples, the energy converter 108 can be configured to convert a three phase output from the motor 110 to DC power to be stored in the battery 104. The motor 110 can be a three phase AC motor, in some instances. [0020] In some examples, the EV 100 can further include transmission 112. The transmission 112 can be a 1-speed transmission, and in some instances a 2-speed transmission, or a different transmission type. Rotary motion is transmitted from the transmission 112 to wheels 114 via one or more axles 116. For clarity and brevity, additional wheels of the EV 100 have been omitted from the example of FIG.1. [0021] FIG.2 depicts a portable power device, in accordance with some embodiments. The portable power device 200 depicted in FIG.2 may be substantially similar to the portable power device 102 depicted in FIG.1. Accordingly, FIG.2 may be best understood when described in conjunction with FIG.1. The portable power device 200 can be used for charging the EV 100, for example, when a power source or power station is not available, or the battery 104 does not have sufficient stored charge that would permit the EV 100 to reach the power station. The portable power device 200 can be coupled to the charge port 106 to provide electrical energy to the battery 104 of the EV 100. [0022] The portable power device 200 includes a housing 202, a portable battery 204, an electronic energy module 206, an output port 208, and an input port 210. The portable battery 204 stores the electrical charge that can be used for charging the battery 104. The portable battery 204 can be implemented as a removable battery pack or a removable power pack, and in some instances, include one or more battery packs for extending an amount of charge that can be stored at the portable power device 200. In some examples, the portable battery 204 can be a high voltage portable battery. [0023] To store or provide charge to the battery 104, the portable power device 200 can be coupled to a power source, such as a power grid. The portable power device 200 can include an input cable 212 that can be coupled to the input port 210 and can have an input connector 214. For example, the input connector 214 can be a movable connector, such as a plug that can mate with a corresponding socket to receive an input current (identified as “I_C” in the example of FIG.2) for storing the charge at the battery 104. The corresponding socket can be used to provide a given amount of AC power, for example, 120 VAC. The portable power device 200 may include an indicator (e.g., one or more LEDs) on its exterior to indicate a level of charge stored in the portable battery 204. When the level of charge stored at the portable battery 204 is low, the input connector 214 can be mated with the corresponding plug and the input current can flow from the grid through the input cable 212 to the electronic energy module 206. The electronic energy module 206 can convert the input current and provide converted input current to the portable battery 204 to store charge therein. [0024] The electronic energy module 206 can include, for example, semiconductor switches (e.g. IGBT, MOSFET), electronic boards (gate drives), sensors (e.g., voltage, temperature, current sensors), mechanical interconnections (e.g., Copper or Aluminum bus bars), and/or inputs/outputs for electrical connections with the portable battery 204 and the output and input ports 208 and 210. In some examples, the electronic energy module 206 can be cooled with air or liquid coolant. For example, the portable power device 200 may include one or more coolant hoses near the electronic energy module 206. The portable power device 200 may further include a coolant pump to pump coolant (e.g., water) through the coolant hoses to cool the electronic energy module 206. In addition or alternatively, the portable power device 200 may include a cooling fan to dissipate heat generated by the electronic energy module 206. [0025] For example, the electronic energy module 206 can include a power conversion circuit for converting AC input current to direct current (DC) current, which is referred to as an AC-to-DC circuit 216 in the example of FIG.2. For example, if the input current is an AC input current, the AC-to-DC circuit 216 can convert the AC input current into the DC input current for charging the portable battery 204. In some instances, the AC-to-DC circuit 216 is a 12V AC-to-DC converter that can provide a high output current for rapid charging of the portable battery 204. [0026] In some examples, the electronic energy module 206 can include a controller (e.g., a micro-controller unit) with memory that can store machine-readable instructions for controlling an amount of electrical energy that flows to and from the portable battery 204. For example, the electronic energy module 206 can be configured to adjust parameters of the electrical energy flowing from the portable battery 204 prior to being provided to the output port 208. The adjusted parameters can include a current, a voltage, or both. For example, if the battery 104 can be charged via a DC fast charge procedure, the electronic energy module 206 can be configured to adjust a voltage of the electrical energy from the portable battery 204 (e.g., to 220V). The electrical energy adjusted by the electronic energy module 206 can then be provided to the output port 208 as adjusted electrical energy. The electrical energy adjusted by the electronic energy module 206 then flows through a charging cable 218 to the charge port 106 of the EV 100. The portable power device 200 may also be used to charge electronic devices other than the battery 104 of the EV 100. In some examples, the electronic energy module 206 can be configured to negotiate voltage and current levels required when sending or receiving power. When sending power to an electronic device, the electronic device receiving the power can send one or more signals to the electronic energy module 206 indicating a voltage and current level and respective limits needed to charge the electronic device DC-DC, for example. Furthermore, the charging cable 218 may include an electrical component (e.g., a resistor) indicating appropriate charging parameters to be employed by the electronic energy module 206. Accordingly, charging cables other than the charging cable 218 depicted in FIG.2 may be used with the portable power device 200 based on differing charging parameters necessary to charge different electronic devices. [0027] As shown in the example of FIG.2, the charging cable 218 can be coupled at one end to the output port 208 and can have at another end an output connector 220. In some examples, the output connector 220 can be implemented as a Type 1 or a Type 2 connector. In examples wherein the output connector 220 is implemented as a Type 2 connector, the charging cable 218 can be a Type 2 cable. By way of further example, if the output connector 220 is implemented as a Type 1 connector (e.g., as an SAE J1772 connector), the charging cable 218 can be a Type 1 connector. The output connector 220 can be a connector type that allows the portable power device 200 to be coupled to the charge port 106 of the EV 100 so that stored charge at the portable battery 204 can be delivered to the EV 100. [0028] In some examples, the electronic energy module 206 includes a DC-to-AC circuit 222. While the example of FIG.2 illustrates AC-to-DC and vice-versa power conversion circuits, in other examples, a single bidirectional power conversion circuit can be used. The DC-to-AC circuit 222 can be used to provide an output current (e.g., a charge current) (identified as “I_O” in the example of FIG.2) based on an amount of charge stored at the portable battery 204. For example, the DC-to-AC circuit 222 can be configured to provide the charge current at a level (e.g., at a Level 2 charge) based on the charge stored at the portable battery 204, enabling the portable power device 200 to operate as a Level 2 charger. Thus, in some examples, the portable power device 200 can be referred to as a portable class 2 power charger or module. [0029] As described herein, the portable power device 200 can be stored (e.g., located) in a storage compartment of the EV 100. In some examples, the EV 100 is an EV truck, and in these examples, the portable power device 200 can be located in a truck bed, or toolbox in the truck bed. In examples wherein the portable power device 200 is located such that sufficient sunlight can be received, the portable power device 200 can include one or more solar cells 224. The one or more solar cells 224 can be configured to convert solar energy to electricity (e.g., DC electricity), which can be provided to the electronic energy module 206 for storing the charge at the portable battery 204. In some examples, the solar cells 224 may be external from the portable power device 200, and the portable power device 200 may be configured to receive electricity from the solar cells 224 (e.g., through a cable) while being in a place that receives little or no sunlight. For example, the portable power device 200 may be located under a cover of a truck bed and receive power generated by solar cells 224 located on a cover of the truck bed through a cable. [0030] Accordingly, because the portable power device 200 is on-board the EV 100, it may alleviate range anxiety and/or enable a driver to move the EV 100 around a repair shop or a garage, for example, when no Level 2 or DC charging station is available for more efficient or rapid charging. Furthermore, the ability to charge the portable power device 200 by conventional methods (e.g., through input port 210) may alleviate range anxiety even when the portable battery 204 is depleted or discharged. For example, such conventional methods may be more readily accessible than an EV charging station, rendering it easier to charge the portable power device 200 and subsequently charge the EV 100 with the portable power device 200 than to reach the EV charging station. [0031] While examples are described herein wherein the portable power device 200 is on-board the EV 100, in other examples, the portable power device 200 can be located at a consumer location, for example, residence. In such an example, the portable power device 200 can be positioned at the residence, such as at a garage at a preferred location therein so that a user (e.g., the driver) can get a short, quick charge at home, if needed. [0032] FIG.3 depicts a method of charging an electric vehicle, in accordance with some embodiments. In the example shown in FIG.3, the method 300 includes a first step 301 of charging a portable battery of a portable power device. The method 300 may further include a second step 302 of storing the portable power device in an electric vehicle. The method 300 may further include a third step 303 of determining that an electric vehicle battery within the electric vehicle is below a predetermined charge level. The method 300 may further include a fourth step 304 of charging the electric vehicle battery with the portable power device. [0033] What have been described above are examples. It is, of course, not possible to describe every conceivable combination of components or methods, but one of ordinary skill in the art will recognize that many further combinations and permutations are possible. Accordingly, the invention is intended to embrace all such alterations, modifications, and variations that fall within the scope of this application, including the appended claims. Where the disclosure or claims recite “a,” “an,” “a first,” or “another” element, or the equivalent thereof, it should be interpreted to include one or more than one such element, neither requiring nor excluding two or more such elements. As used herein, the term “includes” means includes but not limited to, the term “including” means including but not limited to. The term “based on” means based at least in part on.”

Claims

CLAIMS What is claimed is: 1. A portable power device for an electrical vehicle (EV), the portable power device comprising: a portable battery configured to store a predetermined amount of charge; an electronic energy module coupled to the portable battery, the electronic energy module configured to provide an output voltage and an output current based on the predetermined amount of charge stored in the portable battery; and an output port coupled to the electronic energy module, the output port configured to receive the output voltage and the output current and provide the output voltage and the output current via a charging cable to an output connector, wherein the output connector is configured to couple to a charge port of the EV and charge the EV based on the output voltage and the output current.

2. The portable power device of claim 1, wherein the electronic energy module is further configured to provide an input voltage and an input current to the portable battery, the input voltage and the input current configured to charge the portable battery.

3. The portable power device of claim 2, wherein the electronic energy module includes a controller having a memory, the memory including machine-readable instructions for controlling the output voltage and the output current.

4. The portable power device of claim 3, wherein the machine-readable instructions are further configured to control the input voltage and the input current.

5. The portable power device of claim 1, further comprising a solar cell coupled to the electronic energy module, the solar cell configured to receive sunlight and to generate electrical power based on the sunlight, the electronic energy module configured to receive the electrical power and to charge the portable battery based on the electrical power.

6. The portable power device of claim 5, further comprising a housing, the electronic energy module and the portable battery located inside the housing.

7. The portable power device of claim 6, wherein the solar cell is located on a surface of the housing.

8. The portable power device of claim 6, wherein the solar cell is located externally from the housing.

9. The portable power device of claim 1, further comprising a cooling path configured to cool the electronic energy module with air or liquid coolant.

10. The portable power device of claim 1, wherein the portable battery includes a lithium-ion battery.

11. The portable power device of claim 1, wherein the output connector is a Type 1 connector.

12. The portable power device of claim 1, wherein the output connector is a Type 2 connector.

13. A method of charging an electric vehicle comprising: charging a portable battery of a portable power device; storing the portable power device in an electric vehicle; determining that an electric vehicle battery within the electric vehicle is below a predetermined charge level; based on the determination that the electric vehicle battery is below the predetermined charge level, charging the electric vehicle battery with the portable power device.

14. The method of claim 13, wherein the portable power device comprises an electronic charging module coupled to the portable battery, the electronic charging module configured to receive an input current from an external power source and to charge the portable battery with the input current.

15. The method of claim 14, wherein the electronic charging module is further configured to generate an output voltage and an output current based on electric power from the portable battery, the output voltage and the output current used to charge the electric vehicle battery.

16. The method of claim 15, further comprising adjusting the output voltage and the output current based on one or more characteristics of the electric vehicle battery.

17. The method of claim 16, wherein the one or more characteristics of the electric vehicle battery include whether the electric vehicle battery can be charged via a DC fast charge procedure.

18. The method of claim 14, wherein the portable power device further comprises a solar cell coupled to the electronic energy module, the solar cell configured to receive sunlight and to generate electrical power based on the sunlight, the electronic energy module configured to receive the electrical power.

19. The method of claim 18, wherein the portable power device further includes a housing surrounding the electronic energy module and the portable battery, the solar cell located on a surface of the housing.

20. The method of claim 14, further comprising cooling the electronic energy module with air or a liquid coolant.