GB2516120A

GB2516120A - Methods and systems for delivering electric energy

Info

Publication number: GB2516120A
Application number: GB1316294.6A
Authority: GB
Inventors: Bert Holtappels; Juha Tuomola; Timo Rissanen
Original assignee: Tanktwo Oy
Current assignee: Tanktwo Oy
Priority date: 2013-09-13
Filing date: 2013-09-13
Publication date: 2015-01-14
Anticipated expiration: 2033-09-13
Also published as: GB2516120B; GB201316294D0

Abstract

A dispenser 140 for dispensing charged battery units into a tank of an electrically powered apparatus, preferably a vehicle 125, comprises a dispensing container for accommodating a plurality of charged battery units, and a conduit 147 having a first end coupled to the dispensing container and a second end adapted to be coupled to a tank to be filled. The dispenser further comprises a dispensing mechanism 143 for selectively dispensing battery units to the tank through said conduit, the dispensing mechanism comprising a metering unit for monitoring and controlling the number and or state of battery units dispensed. Preferably, the dispenser 140 can be used to retrieve used battery units from the apparatus 125 via the conduit 147, with the dispensing mechanism 143 including means 145 to direct the used battery units to the top of the dispensing container via a conduit 149 or to a separate charging chamber. The same conduit 147 can then be used to replace the used battery units with fully charged battery units from the dispensing container. The used battery units may be charged within the dispensing container or in a separate charging chamber. The battery units have electrical contact pads on their outer surface and are dynamically programmable to enable an optimal electrical energy path through adjacent battery units. This arrangement not only enables electric energy to be supplied to a load (e.g. the vehicle), but can also be used to charge the battery units.

Description

Methods and Systems for Delivering Electric Energy

Field of the Invention

The invention relates to methods and systems for delivering electric energy. In particular, though not necessarily, the invention relates to apparatus and methods of replenishing energy capacity of electric devices. The invention can be used, for example, in the field of automotives.

Background of the Invention

Electric Vehicles (EV5) are growing in popularity for reasons such as a different driving experience, higher performance, better reliability and lower maintenance, lower operational cost, and the potential to decrease the environmental impact of transportation. Electricity is used exclusively to propel the vehicle, or can be used to assist other methods such as internal combustion engines (ICEs).

The main types of the EVs are battery electric vehicles (BEV), plug-in hybrid electric vehicles (FHEV) and hybrid electric vehicles (F-IEV). EVs use an electric motor for propulsion. Electric energy is stored in batteries using, e.g. lithium-ion technology or any other form of battery chemistry. Other forms of energy storage are applicable too, such as supercapacitors or fuel cells.

The HEV and the PHEV combine a conventional combustion engine with an electric drive system.

HEVs use typically regenerative breaking to charge the batteries. FHEV contains rechargeable batteries that can be fully charged by connecting a plug to an external electric power source. BEVs are all electric vehicles without an internal combustion engine. The BEV and the PHEV also allows a user to choose alternative energy for charging the batteries by choosing external power source which is using for example a solar or wind power to produce electricity.

A common problem with current PHEVs and BEVs using rechargeable batteries is the charging time. In a typical case charging requires hours and there are also a lot of city center apartments without any plug-in capabilities for vehicles. There are also fast charging stations but also at these charging times are much longer compared with cars using combustion engines which can be quickly "charged" in fuel stations. Fast charging also means that batteries tend to wear out faster.

Also energy density is not so high which means bigger and heavier batteries. Power losses are also higher with fast charging. Also charging an 80 kWh battery in for example 30 minutes sets such high power requirements that it is not possible typically at a residential home.

Another problem is that fast charging sets extra requirements for an electric infrastructure which is already stretched to the limit in many countries. In many industrialized nations, spare capacity in the order of magnitude of 50% or more, is periodically available and predictable. However, these are also times of lowest human and economic activity, which would be when fast charging is of no use. Although a typical user would charge at home during night time, a user could still prefer sourcing his energy from a commercial station which might offer lower prices than available to residential users. Other options include positive discrimination of renewable energies. For these cases current charging times are not what users are expecting.

There are several different proposals for changing the batteries for BEVs to overcome the problems described above. Typically, rechargeable cells are grouped as modules and each module consists of a plurality of cells. These modules are monitored and controlled as one entity. If needed, a module can be changed in service station to another module containing charged cells to supply quickly energy for BEV. One issue is that the available size for the battery varies a lot of depending on the use case and it might not be rectangular; one module doesn't fit well to all the use cases. It is possible to have modules with different size and form depending on the use case, meaning service stations should have stock of different modules also which do not make sense financially.

Examples of modular energy storage systems of the kind described above are disclosed in US 7948207 and US 2012/094162. There are also many multicell battery designs available having the possibility to connect on and off individual cells of the battery. Examples of this kind of designs are disclosed in CN 202535104, CN 102832646, US 8330420 and US 7075194.

There are also several proposals as to how to monitor individual cells and how to use the characteristics of individual cells to configure a system dynamically. For example US 2010/0261043 proposes a system for dynamically reconfigurable battery framework for a large-scale battery system. This solves a problem how individual cells can be monitored and controlled but this system does not fit if the requirement is to replace hundreds of the depleted cells quickly in service station to supply electric energy for BEVs since the cells are located in certain way in a battery pack. Other control, failure-detection, reconfiguration, bypass and lifecycle management systems for batteries are disclosed for example in US 2005/242776, US 2006/192529, EP 2582009 and US 8084994. These systems suffer at least partly from the same disadvantages.

Thus, there is a need for improved solutions for quickly supplying electric energy to electric vehicles and other power-intensive battery-operated devices.

Summary of the Invention

It is an aim of the invention to provide a novel electric energy dispenser for quickly replenishing the energy capacity of a battery-operated device. One aim is to allow for quicker energy replenishment of electric vehicles compared with known charging methods.

A specific aim is to provide a method of replenishing the energy reserve of an electric apparatus, such as the motive energy reserve of an EV.

An aim is also to provide a technical solution for operators of service stations, which can be visited with an electric vehicle to quickly gain more energy. An important aspect of the invention is that the S cost of the servicing equipment is significantly lower and less complex than certain competing solutions, such as battery swapping robots.

According to a first aspect of the invention there is provided a dispenser for dispensing charged battery units into a tank of an electrically powered apparatus. The dispenser comprises a dispensing container for accommodating a plurality of charged battery units, and a conduit having a first end coupled to the dispensing container and a second end adapted to be coupled to a tank to be filled. The dispenser further comprises a dispensing mechanism for selectively dispensing battery units to the tank through said conduit, the dispensing mechanism comprising a metering unit for monitoring and controlling the number and or state of battery units dispensed.

According to a second aspect of the invention there is provided a method of storing electric energy and comprising loading a plurality of battery units into a container of a charging system such that electrical contact pads of adjacent battery units are or have a high probability of being in contact and the orientation and location of individual battery units within the tank is unknown a priori, identifying one or more optimal electrical energy charging paths through the loaded battery units via contacting electrical contact pads, and programming the battery units to cause positive and negative battery unit charging terminals to be coupled to appropriate battery unit contact pads, thereby establishing said optimal energy charging path(s). Power is then supplied via the established energy supply path(s) to charge the battery units.

According to a third aspect of the invention there is provided a method of providing electric energy to an electric vehicle, the vehicle comprising a tank for storing a plurality of battery units, the method comprising locating the vehicle in close proximity to a battery unit dispenser, coupling the tank to the dispenser via one or more battery unit transfer conduits, and extracting depleted battery units from the tank via the or at least one conduit. The method further comprises dispensing charged battery units into the tank via the or at least one conduit, and performing metering of the extracted and dispensed battery units for the purpose of financial charging.

The proposal is based on the idea of providing a battery unit dispenser capable of accommodating and manipulating a plurality of individual battery units. The units are accommodated in a container of the dispenser reserved for that purpose in essentially random, i.e. arbitrary, order and orientation. When needed, they are transferred from the container to an electric device by taking them from the container and conveying to the electric device using suitable dispensing means.

Typically, the dispensing means comprises a mechanical unit adapted to take a desired amount of the battery units from the container either one by one or as a set and a movable channel for guiding the battery units to a desired target. In addition, there is an electrical control unit controlling the mechanical dispensing means.

S The service station comprises a dispenser and a parking zone within reach of the dispensing means. A vehicle can therefore be parked by the dispenser and new batteries provided into its battery pack, herein called an "electric tank". The service station may also comprise means for removing used battery units from the vehicle before providing the new ones.

The method may comprise removing some or all used battery units from an electric apparatus and replacing them with other ones having larger energy content in order to replenish the energy reserve of the apparatus. Typically these battery units have been used in another apparatus before, but have been removed and recharged at the service station. The apparatus may be an electric vehicle.

The battery units to be dispensed comprise a rechargeable energy reservoir and a plurality of contact areas on surface thereof for the energy to and out of the energy reservoir. The number of contact areas is preferably at least three and the battery units comprise means for configuring connections between terminals of the energy reservoir and the contact areas such that energy can be drawn to and from the energy reservoir through at least one route.

The proposal provides significant advantages. First, it allows for electric energy to be dispensed to vehicles and other electric apparatuses in unit form, or "liquified" form, i.e. in a similar way as conventional liquid-form fuels. A single battery unit can logically be seen as a unit of power, resembling a certain volume of gasoline or any other combustible or consumable form of energy.

Transfer of energy from a vendor or retailer is therefore accomplished by physically transferring a certain number of charged battery units from retailer storage to a vehicle's tank. Users may choose to purchase only a limited amount of energy from a retailer at a certain point in time, in order to limit the out-of-pocket expense for a particular transaction. The presently described battery unit, container and dispenser technologies make this possible. An important argument for operators of vehicle infrastructure such as service stations and users alike, is the familiarity with the user scenario and therefore a lower uptake threshold, but also to avoid unnecessarily disrupting existing auxiliary businesses built around retail of automotive fuels.

As an example, assume that a fully charged tank holds about 100 units of energy. If this tank has been depleted of 90% of this energy, the 10 remaining units of energy are typically distributed over all the battery units in the tank. Removing 50 % of the battery units will mean that about 5 units worth of energy remain in the tank, but 50% of the physical space has been freed up. If the units which will be placed in to the tank are of equal capacity and are fully charged, the tank now holds units of energy. Since the removed battery units held still 5 units of energy, only 45 new units of energy will need to be paid for.

The present concept allows the cost of the battery units themselves could be taken into account also. For this purpose, the battery units may be designed to uniquely identify themselves and/or store and report relevant information. For example, wear, quality, age, capacity, brand, cycle of use amongst any other parameter affect to the depreciation and residual value of the battery units and it can be accurately calculated each time its owner/operator changes. Usage data and other information can be tracked and managed throughout the useful life of battery units. A battery unit can remain under ownership of a larger entity and its use is paid for by the ultimate user on a range, time or cycle basis. Alternatively, the battery unit can be sold to the said user, who incurs the upfront cost.

The proposal can also have a significant impact on the electricity generation and distribution industries. In a scenario where BEVs have become a significant part of the vehicle fleet. There, the proposed method can significantly contribute to maximization of the installed generation and transmission capacity, by charging the battery units when demand is low. Due to the significant economic damage caused, utilities try to avoid brownouts or other disruptions, and have a strong incentive to shift the load to periods when there is excess generation and distribution capacity.

There are programmable systems available, which charge batteries when the price of electricity is lower, typically when demand is low. These same systems can be used in service stations to charge the battery units described in this document. This could have a big economical effect for stabilizing the electrical grid. These programmable systems can also take into account when noncontinuous and unpredictable forms of, typically renewable, energy are being generated. As a practical example, when wind energy or solar power is available, battery units are charged, but when solar output suddenly drops due to a rapidly appearing cloud cover, battery units can be instructed to hold off on charging for a while, if there would be a scarcity of backup power from the continuous grid. Another example is when sudden wholesale electricity price fluctuations make charging batteries economically undesirable.

Embodiments of this approach are so versatile that not only the "service station" paradigm is fulfilled, but also completely new use cases of acquiring and transferring energy become possible.

Examples include: residential installations comprising a container with charging capability filled with battery units, charged with excess electricity produced by solar panels when no one is at home; railway stations fitted with a container filled with battery units, and charged by recovering energy from decelerating trains; containers fitted at sites where renewable energy is plentiful, but intermittent, and grid connectivity is not financially viable; to name a few.

According to one embodiment there is provided a dispenser comprising a dispenser container for accommodating a plurality of battery units in essentially random order and orientation such that the battery units are in touch with each other. The dispenser further comprises dispensing means for transferring a portion of the battery units out of the container in essentially random order, preferably from the bottom of the container, and a dispenser control unit for controlling dispensing of battery units through said dispensing means.

According to one embodiment, the dispenser container has an inner shape of a silo, i.e., a tapering lower portion, whereby the battery units are conveyed to the dispensing means at least partly by means of gravity from the bottom of the silo.

According to one embodiment, the dispenser container can be loaded, i.e., provided with new battery units from a level higher than the battery unit output level.

According to one embodiment, the dispensing means comprise a movable channel having a first end connected to the dispensing container and a second end connectable to another battery unit container in the vicinity of the dispenser. According to a further embodiment, the channel comprises a hose or the like flexible pipe. The second end of the channel may be provided with a gun", such as conventional fuel hose, functionally connected to the dispenser control unit, in order to allow for the user of the dispenser to control the dispensing process. By this embodiment, the refueling" process can be made to resemble as much as possible the conventional internal combustion engine powered vehicle liquid refueling process.

According to one embodiment, the dispenser comprises means for transferring the battery units through the channel or hose by means of pneumatic conveying to the desired target. Pneumatic conveying is one of the most widely used methods to transfer bulk material from one container to other, Pneumatic conveying system can be either pressure conveying or vacuum conveying.

Pressure conveying is preferred for dispensing battery units, because dispenser needs only one channel to deliver both gas and battery units to desired target. If vacuum conveying is used, two channel dispenser is needed: One channel is used to transfer the battery units to target and the second channel creates the vacuum in the target. According to one embodiment the conveying gas supply that is needed to provide the necessary energy to convey the gas is compressor, fan, blower, or vacuum pump.

The dispenser control unit can be programmable to dispense for example a predefined number of battery units or a predefined amount of electric energy stored in the battery units.

According to one embodiment, the dispenser comprises necessary means for the dispenser control unit to communicate individually with each of the battery units dispensed so as to retrieve information on the state of the battery unit or other information stored in the battery units. The information may comprise for example identification code, charge level, charge cycle and/or voltage level of the battery unit. Thus, the system can keep track on the properties of the dispensed units and for example for quality control purposes or for estimating the value of vehicle battery change -According to one embodiment, the dispenser container is capable of charging the battery units in the container. For this purpose, there are a plurality of contact surfaces on the inner surface of the container for making electrical contact with at least part of the battery units in the container. The dispenser additionally comprises power supply means for feeding charging power through the contact surfaces to the energy reservoir of the battery units.

For charging randomly packed containers, there is typically also a management unit capable of programming the battery units such that suitable power delivery paths, i.e. so-called electric energy paths or strings, are formed in the container. The paths are used to conduct the charging current from one unit to another such that a plurality of units are charged simultaneously. In more detail, according to one embodiment, the charging means comprise means for receiving from the battery units information on their contacting state with respect to other battery units, means for determining one or more electric energy paths through the battery units from one contact surface of the container to another contact surface of the container based on the contacting state information received, means for transmitting programming signals to the battery units for programming the battery units to form said electric energy paths, and means for delivering electric power through said one or more electric energy paths so as to charge at least part of the battery units part of the electric energy paths and means for sending and receiving signals e.g. the state of charge, temperature, or any other information to or from the battery unit.

According to a further embodiment, the charging means comprise a control unit adapted to communicate with the battery units for discovering the presence of battery units and contact of the battery units with other battery units and contact surfaces of the container, to define said electric energy path(s) using a routing algorithm, and to communicate with the battery units for changing their configuration to correspond with said electric energy path(s).

According to one embodiment, the charging functionality is provided, instead or in addition to the dispenser container, in another container connected to the dispenser container. The battery units charged in this separate container can be conducted to the dispenser container for further delivery to mobile devices.

According to one embodiment, the dispenser comprises intake means for transferring battery units from a container external to the dispenser, to the dispenser container or another container functionally connected to the dispenser container. The intake means can utilize at least partly the same channel for transferring of battery units as the dispensing means or there may be provided different battery unit transfer channels for the intake means and dispensing means. According to one embodiment transferring the battery units from the external container to the dispenser container or another functionally connected container is done by means of pneumatic conveying.

Pneumatic conveying system can be either pressure conveying or vacuum conveying. Vacuum conveying is preferred for transferring battery units to dispenser, because dispenser needs only one channel to deliver both gas and battery units to the dispenser container or another functionally connected container. If pressure conveying is used, two channel dispenser is needed: One channel is used to transfer the battery units to target and the second channel creates pressure in the external container.

In a typical embodiment, the dispenser container is large enough to hold at least 1000, in particular at least 10000 battery units, whose largest dimension may be e.g. 1 -10 cm. The battery units may have any shape desired. Special benefits are gained by using spherical or in particular ellipsoidal shapes.

According to another aspect, there is provided an apparatus for installation and use at typical automotive service stations, for providing motive energy for vehicles comprising a tank capable of accommodating and utilizing battery units of the described kind, the station comprising an electric energy dispenser as described above and a vehicle parking zone within reach of the dispensing means of the electric energy dispenser for allowing dispensing of battery units to a battery unit container of an electric vehicle at the parking zone.

According to one embodiment, there is provided a point of sale system functionally connected to the electric energy dispenser for allowing a vehicle owner to buy motive energy in the form of battery units dispensed by the electric energy dispenser.

The service station is preferably equipped also with means for transferring used battery units from the electric vehicle to a charging container located at the service station. As discussed above, the charging container may be the same as the dispenser container or a separate container feeding the dispenser container. This allows for quick replenishment of the energy reserve of the vehicle.

Indeed, there is proposed a method of replenishing electric energy reserve of an electric apparatus, which may be a vehicle or any other battery-operated apparatus utilizing a power source comprising a plurality of co-operating battery units. The battery units are preferably accommodated in an electric tank of the apparatus in essentially random order and orientation. The method comprises first removing at least portion of said battery units from the electric tank, and then dispensing a plurality of new battery units to the electric tank in essentially random order from a battery dispenser container, the new battery units having a total energy content which is larger than the total energy content of the removed battery units. In some scenarios, existing battery units may be replaced by "upgraded" battery units having improved characteristics. These may be charged or uncharged when dispensed into the tank.

The dispensing of new battery units is preferably carried out using a dispenser of the kind described above. The method may comprise receiving a dispensing order at the dispenser control unit, the order originating for example manually from the user or automatically from the tank or dispenser electronics. Then, the dispensing means are controlled using the dispenser control unit so as to transfer a portion of the battery units from the dispenser container to the electric tank.

The method preferably comprises determining the total energy content of both the removed battery units and the dispensed battery units. The effective amount of energy transferred from the dispenser to the tank, i.e. energy balance, equals to the difference of the energy contents. The balance may be calculated to a point of sale system for making transactions at least partly dependent on the balance. For example, an account of a vehicle driver can be debited based on the amount of energy sold.

Like in the dispenser container, the battery units in the tank are preferably randomly packed. This makes the dispensing process easy as intelligence or special equipment is not required for positioning the battery units, which can therefore be taken from the container and spouted to the tank using relatively simple mechanics. Indeed, by avoiding this requirement, re-fueling infrastructure costs are dramatically reduced, as compared, e.g. with the costs required to implement battery replacement robots, and hence there is an increased likelihood of the required infrastructure being rolled-out.

Brief Description of the Drawings

Fig. 1A shows in a schematic view an overall illustration of a system comprising components of the proposal.

Fig. lB illustrates in a block diagram a battery unit according to one embodiment.

Figs. 2A -2D show schematic presentation of a battery unit in a general level and in three exemplary configurations.

Figs. 2E and 2F illustrate an ellipsoidal battery unit according to one embodiment in a three-dimensional perspective view and in top view, respectively.

Figs. 2G and 2H illustrate an ellipsoidal battery unit according to another embodiment in a three-dimensional perspective view and in top view, respectively.

Figs. 21 and 2J illustrate contact area patterns further an ellipsoidal battery units according to alternative embodiments.

Fig. 3 illustrates an exploded view of a housing of a battery unit according to one embodiment.

Fig. 4 shows in a schematic perspective view a contact surface configuration of an electric lank according to one embodiment.

Figs. 5A and SB illustrate a block diagram of a non-randomly packed electric tank in a two-dimensional cross-sectional view.

Figs. 6A -6D represent randomly packed electric tanks in two-dimensional cross-sectional views to illustrate battery unit discovery process.

Fig. 7 illustrates an exemplary circuit of the battery unit as block diagram.

Figs. 8-10 show block diagrams of an electric tank according to embodiments.

Figs. 1 1A and 11 B contain flow charts illustrating operation of the electric tank according to embodiments.

Fig. 12 illustrates schematically a dispenser for dispensing battery units.

Fig. 13 illustrates schematically an alternative dispenser in which separate dispensing and charging containers are provided.

Fig. 14 illustrates schematically a system for dispensing/extracting battery units to and from an electric vehicle using a shared conduit.

Fig. 15 illustrates schematically a system for dispensing/extracting battery units to and from an electric vehicle which allows selection of battery units being dispensed/extracted.

Fig. 16 is a flow diagram illustrating a method of recharging a battery unit tank with battery units.

Fig. 17 illustrates schematically a battery unit silo and a separator for separating battery units according to battery type or "tier".

Figs. 18 and 19 illustrates schematically a battery unit fill configuration prior to and after recharging.

Fig. 20 illustrates schematically a battery unit fill configuration after recharging according to an alternative recharging model.

Detailed Description of Embodiments

The following definitions may be helpful in understanding the description which follows: "Battery unit" is an electric device comprising an electric energy reservoir and means for delivering electric energy out of the electric energy reservoir to the outside of the battery unit.

Housing" of a battery unit is a shell enclosing and/or providing a mounting point for other components of the battery unit. Typically the housing defines the general outer shape of the battery unit. The housing may be a separate physical part but may be at least partly be formed of other components of the battery unit.

"(Electric) energy reservoir" means any entity capable of storing electric energy and transferring electric power through its terminals.

Contact area" or "electric contact pad" of a battery unit means a conductive zone accessible from the outside of the battery unit for making a galvanic contact with the battery unit. In particular, a contact area is contactable by a contact area of another similar battery unit when the battery units are placed next to each other.

Configuration" of a battery unit means primarily the combination of connections between a plurality of contact areas of a battery unit and terminals of the energy reservoir of the battery unit. To give some examples, if the terminals of the energy reservoir are denoted with N and P, in the case of a battery unit with three contact areas A, B and C connections A-N/B-P, A-N/C-P, A-P/B-N and A-P/C-N form different combinations of connections, i.e., different configurations. In the case of embodiments with an additional capability to disconnect contact areas, connect contact areas to internal ground of the battery unit, and/or to interconnect contact areas, also variations in these (dis)connections form different combinations of connections, i.e., different configurations. For example, in the case of a battery unit with five contact areas A, B, C, D and E connections A-N/B-P/C-D, A-N/B-P/C-E, A-P/C-N/B-D, etc form different combinations of connections.

"Bypass connection" means an electric connection between at least two contact areas of a battery unit without involving the energy reservoir, i.e. simply a low resistance path between the contact areas.

"Connecting means" of a battery unit refer to necessary means for changing and maintaining the configuration of a battery unit. The connecting means being "programmable" means that it can be given instructions internally or externally of the battery unit to change the configuration. The connecting means being able to selectively connect the terminals of the energy reservoir to the contact areas in different combinations means that the configuration to be connected can be selected from a set of plurality of potential configurations.

"State" of a battery unit means the current configuration of a battery unit, and may also include one or more other parameters such as the voltage of the energy reservoir, current through the battery unit, energy level of the energy reservoir, temperature, condition of the energy reservoir, etc. (Electric energy) tank" is a structure (container of any sort) capable of accommodating a plurality of battery units and means for transferring energy from the battery units to the outside of the tank (power delivery mode) and/or from the outside of the tank to the battery units inside the tank (charging mode). There are two main types of tanks, depending on their intended use: power delivery tanks and charging tanks, but a single tank can involve both these functions, like a tank of an EV typically would do for allowing direct charging. The tank may include also a control unit for programming the battery units, but the control unit needs not be an integral part thereof, but a partly or entirely separate unit connectable with the tank. In a broad sense, "tank" refers to a tank system comprising also the control unit as a functional part. The term "battery pack" may also be used to describe a power delivery tank filled with battery units.

"Contact surface" or tank contact pad of a tank is a conductive zone accessible from the direction of the battery units accommodated in the tank for making a galvanic contact between contact areas of a battery unit and the zone in order to transfer electricity through the zone.

"Fill ratio" means the ratio of volume taken by the battery units in a tank to free space in a tank, when the tank has been filled up with battery units. Since the fill ratio depends in practice on the volume and shape of the tank (in particular with small tank sizes), references to fill ratio herein assume a theoretical tank with unlimited total volume in each direction filled with an unlimited number of battery units, unless otherwise mentioned. The terms "packing" and "packing density" are also used to describe filling and fill ratio of a tank, respectively.

"Random fill ratio" is a fill ratio achieved by providing a number of battery units in random order under prevailing physical conditions (e.g. gravity) to a tank, i.e., without using intelligence to position each unit. Such random packing may occur for example by means of pouring or spouting the battery units to the tank and potentially by additionally shaking or otherwise agitating the tank and/or battery units to increase the fill ratio. In real life, the tank walls and borders may, depending on the shape of the walls and the shape of the battery unit, slightly guide the nearest battery units into a non-random order and orientation. Herein the term "random packing" covers also essentially (nearly) random packing, i.e., any border effect caused by tank walls limiting true randomness is not taken into account.

"Programming" of battery units (or a tank) means changing the configuration of battery units inside a tank. In the case of a randonily filled tank, programming is typically preceded by a discovery and routing process to find out available connections and potential energy paths inside the tank.

"Control unit" of a tank means necessary communication and computing means for communicating with battery units inside a tank and for programming the battery units.

"Discovery" of battery units means a process where a tank determines which battery units are present in a tank and how they are connected with each other and the contact surfaces of the tank through their contact areas.

"(Electric) energy path" means a potential power delivery path inside a tank between its contact surfaces through contact surfaces and/or energy reservoirs of one or more battery units. When the battery units are suitably configured, electrical power can be delivered along this path, either from the battery units to a load outside the tank (power delivery mode) or from an external energy source to the battery units (charging mode). There may be one or more simultaneous electric energy paths in a tank. In a typical case, there are at least two, e.g., 2 -50, energy reservoirs of different battery units arranged in series in this path. There may be energy reservoirs arranged also in parallel in each path. The energy paths are herein also called "strings".

"Routing" means a process where one or more electric energy paths are determined to be able to program the battery units accordingly. In a routing process, it is decided for example how the terminals of the electric energy reservoirs shall be internally connected to the contact areas of the battery units and whether optional bypass connections are needed so that electric energy reservoirs are connected in series to form one or more strings. Routing can be done in various ways based on the information obtained by the discovery process using a suitable routing algorithm. For example the discovery process described in this document gives already route information, which could be used for forming the strings.

"Monitoring" means a process where information is collected on the state of battery units by an external electronic device, such as a tank control unit.

"Container" as herein used means a structure having a space capable of accommodating a plurality of individual battery units. Typically, the space is open, i.e., allows for the battery units to randomly self-order themselves within its boundaries. The size of the container may vary a lot depending on the type and intended use of the container (e.g. an electric tank, a dispenser container or a storage container). Sizes of typical electric tanks vary from fractions of litres to hundreds of litres, whereas dispenser containers for EV use may have a size of e.g. 0.1 -10 m3 and storage containers e.g. 5 -1000 m3. "Silo" is a container having at least partly downwards narrowing shape. A silo may include internal structures such as spiral or helical blades, corkscrew channels, paddles, or any other structure to prevent the weight of a very large volume of battery units apply potentially destructive force on the battery units at the bottom part of the silo.

Charging container" is a container equipped with means for charging the battery units while being accommodated in the container.

The term "essentially random order and orientation" of battery units accommodated in a container means that the battery units are in the container in purposely non-ordered way under prevailing physical conditions (e.g. gravity), i.e., no human or artificial intelligence has been used to position each unit within the container. The container also does not include any guides, which would strictly define the position and orientation of each unit put to the container. In real life, the container walls may, depending on the shape of the walls and the shape of the battery unit, slightly guide the nearest battery units into non-random order and orientations. The container may be subdivided to assist in this guiding process. The word "essentially" means that such border effects are not taken into account. In particular, there may be a small zone of very low randomness near the output of a container (e.g. a taper of a silo-type container) due to the border effect. A shorter expression used for the randomly ordered and oriented battery units is "randomly packed", which covers also essentially (nearly) random packing, i.e., any border effect caused by tank walls limiting true randomness is not taken into account. Random packing may occur for example by means of pouring or spouting the battery units to the container and potentially by additionally shaking or otherwise agitating the container and/or battery units to increase the fill ratio.

The term "essentially random order" of battery units during dispensing means the battery units are taken from the randomly packed container in an order in which they appear to the dispensing means. An analogy of an essentially randomly packed container with essentially randomly ordered dispensing is an hourglass in which grains of sand are first in a silo in random order and orientation under gravity and then go through the waist of the hourglass in the order they appear to the waist because of gravity.

System overview As introduced above, what is proposed here is a novel utilization scheme for portable energy sources, such as secondary batteries, by providing battery units (BUs) capable of forming larger battery packs with the aid of an electric tank also described herein.

Fig. 1A illustrates an electrical device 10, such as an electric vehicle (EV), comprising an electric tank 12. The tank 12 is connected to an electric load 15, such as an electric motor. The tank 12 is filled with battery units 14 providing power to output of the electric tank 12 and further the electric load 15. The system may also comprise an external battery unit container 16 having transfer means 18 for receiving battery units 14 from the tank 12 and/or transferring them back to the tank 12. Either the tank 12, the external container 16 or both of them may have the capability to charge battery units 15 using electricity from a power network or from other sources such as regenerative braking, solar panels, fuel cells, flywheels or even a hydrocarbon-fueled generator.

As will be described later in more detail, the battery units 14 are equipped with an energy reservoir and contact areas for conducting electrical power out from the electrical reservoir and for recharging the electrical reservoir. In addition, there are connecting means, including a switching logic circuit, for making the desired connections between the energy reservoir and the contact areas. The connection means is programmable to change the configuration upon varying needs and circumstances, most importantly the desired output voltage and power requirements of the load 15 and condition, physical positioning and contacting of the battery unit 14 among and with other similar battery units 14. In particular, the contact areas can be configured freely to act as positive or negative contacts. The configuration of the contacts can preferably be done automatically and dynamically by the switching logic circuit, preferably with the aid of programming signals received by the battery unit from the tank system. Thus, to facilitate the programming, there may be built-in communication capability in the battery units 14. Communication includes receiving programming instructions from outside the battery unit 14 and may include also transmitting information on the state of the battery unit 14 to an external programming or monitoring unit of the tank system or to other battery units.

According to one embodiment, battery units 14 have a smooth self-contained outer shape, that allows them to be transferred from one container (e.g. electric tank 12) to another (e.g. external charging container 16, or vice versa) by non-intelligent, cost-effective methods, such as pumping or pouring.

Freedom of movement of randomly packed battery units 14 is limited by their shape and friction and optionally additionally by immobilization means, such as means for applying physical pressure to the battery units 14 in the tank 12.

When in use, the battery units are contained in the electric tank 12. The tank 12 comprises a physical container with a cavity capable of accommodating a plurality of battery units 14 in one, two or most preferably three-dimensional configuration. In a typical embodiment, the tank 12 is capable of accommodating at least 10, preferably at least 50 battery units 14. There is no upper limit for the battery units, but in typical embodiments the number of units per one tank is less than 10000, usually less than 5000.

To be able to power the load 15, besides accommodating the battery units 14, the tank 12 comprises electrical contact surfaces on inner surface thereof in order to be able to make electrical contact with two or more battery units 14 and to conduct the electric power from the battery units 14 outside the tank 12. The contact surfaces may be arranged on one or more walls of the tank 12, for example on two opposite inner walls of the tank 12.

According to an embodiment, where the battery units 14 are of externally programmable type, the tank 12 also comprises programming means, most notably a control unit including a computing unit and communication unit, for communicating with the battery units 14. Communicating includes at least controlling, i.e., delivering programming signals to the battery units 14 in order to change their configuration. Communicating may also include monitoring, i.e., receiving information from the battery units 14 for example for gaining data on the relative position and contacts of each battery unit 14 among other battery units. The computing unit is capable of making necessary programming for the battery units 14 to be delivered to the battery units through the communication unit.

It should be noted that the programming means does not need to know the physical position of each battery unit 14 in the tank 12 or most of those. The programming means need to have only a knowledge to form at least one electrical path so that the tank 12 can deliver electricity.

The present system may comprise also one or more charging stations comprising means for replacing used battery units of a device brought to the charging station with charged battery units from another container. The container may for example be a charging silo, comprising means for charging a plurality of battery units and means for providing a desired amount of charged battery units from the silo to the electric tank of the device. The battery units may be randomly packed in the charging silo like on the tank of the device.

Exemplary structures and functional parts of the battery unit and tank system and methods of programming the battery unit are described in more detail below. Unless specifically mentioned or there are obvious technical reasons to the contrary, the embodiments described above and also hereinafter can be freely combined to form a variety of different kinds of operative baftery units.

Battery unit Overview and functions (battery unit) Basic and additional functionalities of the battery unit are described below. Exemplary electronics for implementing these functionalities are described in more detail in a separate subsection below.

Fig. lB illustrates a block diagram of main components of a battery unit 150. There is an energy reservoir 162 whose terminals are connected to switching circuitry 156 further connected to contact areas 152A-D. The switching circuitry 156 together with a microcontroller 160 functionally connected thereto form the switching logic.

Fig. 2A shows in a more illustrative view an exemplary battery unit 200. Inside the unit there is an energy reservoir 222 connected to switching logic 220. The switching logic 220 is connected to contact areas 202a, 202b, 202c and 202d, the number of which is this example is four. The switching logic makes it possible for any of the contact areas to be connected either to the positive (+) or negative (-) terminal of the energy reservoir.

Figs. 2B-2D illustrate exemplary configurations of the battery unit. Fig. 2B shows a configuration where all contact terminals 202a, 202b, 202c, 202d are connected in star configuration to a common star point 205 through resistors 204a, 204b, 204c, 204d, respectively by the switching logic. The resistors 204a, 204b, 204c, 204d have preferably equal resistances. The common star point represents internal (floating) ground of the battery unit. This embodiment is beneficial in the routing and discovery processes, as explained later in more detail.

Fig. 20 shows a configuration where two contact areas 202a, 202d are connected to a positive and negative terminal of an energy reservoir 222 and two remaining contact areas 202b, 202c are in star configuration connected to a common start point 205 through resistors 204b, 204c.

Additionally, the switching logic may allow any two or more contact areas 202a, 202b, 202c, 202d to be connected together to short circuit those (bypass connection). Fig. 2D represents a configuration where two contact areas 202a, 202d are short circuited by a bypass connection 206ad and two remaining contact areas 202b, 202c are in star configuration connected to a common start point 205 through resistors 204b, 204c. Equally well the remaining two contact areas 204b, 204c could be connected to the terminals of the energy reservoir, or to form a second bypass connection.

The above examples show only a small portion of all available configurations. The switching logic 220 is preferably capable of making any of the described connections for any of the contact areas 202a, 202b, 202c, 202d. In this way, the polarity or state of each contact area 202a, 202b, 202c, 202d can be freely controlled with the switching logic 220 to match various situations and needs.

According to one embodiment, the switching logic is additionally capable of entirely disconnecting one or more of the contact areas from other contact areas, the common start point and the terminals of the energy reservoir.

A key feature of the battery unit is its ability to cooperate with other battery units so as to form a larger power source. For this purpose, the positive and negative poles of the energy reservoir can be connected to any of the contact areas of the battery unit. This enables that the battery units, even if randomly packed inside a tank, can be connected in series and/or in parallel, forming strings of many units. It is irrelevant which battery unit touches which other unit, because the strings are defined by dynamic programming once the relative positioning of the battery units has been determined.

According to one embodiment, the battery unit includes also one or more bypassing connection options. In a bypass connection, current can flow through the battery unit through a low resistance path from one contact area to another without connecting the energy reservoir inside the battery unit to this low resistance path. This option allows the battery unit for example to be used for helping the completion of strings that would otherwise not be possible due to the probabilistic nature of random placement or orientation.

According to one embodiment, the battery unit can be configured to simultaneously deliver energy through two or more contact areas and to be in bypass mode between two or more other contact areas or to disconnect or ground one or more contact areas. Any combination of these functions can be possible, if the switching circuit is designed to allow this.

The above mentioned connection, bypass, disconnect and/or connecting to virtual star point configurations for each contact area are set and updated by suitable connecting means typically built inside the housing of the battery unit. The connecting means may comprise a microcontroller and a switching circuit functionally connected to the microcontroller. These two together form the switching logic.

The switching logic is preferably configured so that it is not possible to contact both terminals of the energy reservoir to the same contact area to avoid undesirable paths or connections. In addition or alternatively, this precautionary function may be implemented in the tank control unit level.

According to one embodiment, the battery unit can monitor environmental and/or electrical characteristics of the unit. These characteristics may include one or more of the following: charge and discharge current, energy reservoir voltage, temperature, state of charge. There are suitable measurement and monitoring circuits for this purpose. There may also be necessary means for changing the configuration of the battery unit based on the monitoring. For example, if the battery unit notices that the discharge current, temperature, or other parameter is outside a desirable range for the chosen pattern, then it can temporarily disconnect the energy reservoir, decrease current draw, or alter behavior otherwise.

According to one embodiment, the battery unit includes a unique identifier coded therein on the hardware or software level. The unique identifier can be used when communicating with an external central control unit. That is, a battery unit can transmit its unique identifier to the external control unit when announcing its presence in the tank or delivering monitoring information. On the other hand, the control unit may include the identifier in its programming commands such that the battery units are able to distinguish between commands intended for the particular battery unit and commands intended for other battery units.

It is also a basic functionality of the exemplary battery unit that it may communicate with other battery units and/or a central control unit of an electric tank and/or host apparatus of the unit, such as an electric vehicle. For this purpose, the battery unit comprises an internal communication unit adapted to operate using a predefined communication protocol either through the contact areas or wirelessly. The communication unit is functionally connected with the switching logic and optional monitoring circuit. Communication is necessary for being able to define and form the energy paths that allow electric current to be drawn from the tank.

The battery unit may additionally, or in order to assist in carrying out the abovementioned functions, comprise power supply circuitry, charging circuitry, flash, EEFROM, RAM, over-current protection circuitry and clock oscillators, which are also described in more detail later.

Energy reservoir (battery unit) The energy reservoir may comprise an electrochemical cell of any rechargeable type. Alternatively, the energy reservoir may comprise a high-energy capacitor. A further alternative is a hydrogen fuel cell. One specific example is a lithium-ion cell (nominal voltage of 3.7 V).

The energy reservoir may comprise a plurality of cells or capacitors connected in series and/or in parallel.

The capacity of the energy reservoir may be in the order of magnitude from millianipere hours or even less, all the way to dozens of ampere-hours or even larger. The capacity may be e.g. 1 uWh - 1 kWh, such as I mWh -100 Wh, in particular I -100 Wh.

The energy reservoir typically takes a major portion, for example at least 75 %, in particular at least % of the total internal volume of the housing of the battery unit, to obtain high energy density. A smaller volume is needed for the switching logic with communication electronics.

Contact areas (battery unit) The battery unit comprises a plurality of contact areas or "electric contact pads" on outer surface of its housing. In a preferred embodiment, the housing determines the general shape of the battery unit and contact areas are arranged as coatings or films on the housing material. Wiring from the contact areas to the switching logic inside the housing must be arranged through the housing.

However, the contact areas themselves can also extend in full or partly through the housing material. The contact areas are preferably metallic.

The main purpose of the contact areas in the battery unit is to be able to charge and discharge the battery unit while being randomly packed in a container. Two contact areas would be enough if the exact position and orientation of the battery unit could be controlled, like a standard battery attached in a battery holder. In case of randomly or near randomly packed battery units, more connections areas are typically needed to minimize the number of the battery units in the container which cannot be used for supplying power (i.e., battery units whose energy reservoirs cannot be taken as part of any string).

According to one embodiment, the number of contact areas is between 4 and 20, in particular between 6 and 14. This range is estimated to be optimal for at least ellipsoidal battery units but is workable also for other shapes. The exact optimal number of contact areas depends on at least the following: shape of the battery unit, cost and size of electronics, routing process, number of bypasses available in the battery unit, needed creepage and clearance distances, materials used, required physical and environmental protection, chemical and/or corrosion resistance (e.g. when using liquid cooling), thermal conductivity requirements, assembly process, projected lifetime, available technology, serviceability, reliability, cost and budget constraints.

Figs. 2E and 2F illustrate an ellipsoidal battery unit 240 with eight contact areas (four symmetrically on each half-ellipsoid). Four contact areas 242a-242d are visible in the figures. The contact areas 242a-d are separated by gaps 244, which are herein provided with a ridge of insulating material, preferably the housing material. The half-ellipsoids have been fastened together from attaching points 248 on each end of the half-ellipsoids. The contact areas are connected to internal parts of the housing using conductive vias 249.

A via is an electrical connection between two electrically conductive layers through insulating material. Typically a via is a small opening that is made conductive by electroplating or by inserting a rivet. Vias are typically used in printed circuit boards and integrated circuits. Several injection molded plastic materials can be also plated with conductive metal layer. Plating process can be electroplating or electroless plating. This makes it possible to utilize vias also in plastic part, where both sides of the plastic part are plated and electrical connection between the plated sides is required.

Figs. 2G and 2H show another ellipsoidal battery unit 260 with six contact areas (four areas symmetrically on a circumference of the ellipsoid and two symmetrically on each end). Five contact areas 262a-e are shown. The contact areas 262a-e are separated by gaps 264 herein shown as grooves. An attaching point 268 is also shown.

There are also various other fully operative contact area configurations available. Figs. 21 and 2J further illustrate some examples of the almost endless possibilities of contact area positioning. In these embodiments, there are 10 -20 oval-shaped contact areas arranged on different sides of the battery units such that a considerable space remains around the areas. With these configurations too, the possibility of contact area to contact area connection has high probability in random packing. At the same time, the possibility that two different units make a contact with a single contact area is smaller than in embodiments of Figs. 20 and 2H, for example. The conductive via 269 is used to connect the contact areas to internal parts.

The contact areas can be applied on a surface of the housing with as suitable method, which are known per Se. Examples include film or sheet application methods (by e.g. using adhesive, stamping, heat and/or pressure) and direct coating methods. The film or sheet or the coating substance is preferably a metal, such as copper, gold, silver, aluminum, or a metal alloy or metal composite. The film or sheet may be pre-formed to match the shape of the outer surface of the housing or formed during the application process.

Fig. 3 illustrates one possible realization of the housing mechanics and internal structure of the housing for a battery unit 280 having a contact area configuration according to Figs. 2E and 2F.

The housing is formed by two preferably identical hollow half-ellipsoid portions 281A, 281B which are attachable together using screws, glue, ultrasonic welding, potting, moulding or any other suitable attaching means. Attaching can take advantage of attaching zones 288A, 2888 designed to the portions 281A, 2818, respectively.

The contact areas are connected to internal parts of the housing using conductive vias 285A, 285B.

The vias 285A, 285B may simultaneously act as anchor points for internal members of the battery units, most importantly the energy reservoir and/or a circuit board for its configuration electronics.

In this case, the vias 285A, 285B contain apertures through which screws or like fixing members can be assembled. There may be a conductive plating on the inner surface of the apertures or the fixing members may be conductive to form a robust connection between the contact areas and the electronics. In one embodiment, there are snap-on connectors on the inner surface of the housing.

Electrical contacts between the battery units are important for their co-operation. Using hard gold plating on all the electrical contact areas provides a small and stable contact resistance already with small normal force. To give some rough informal and non-limiting values, electrical contact, between gold plated contacts having only 0.4 N normal force, results about 20 mOhm contact resistance. Even smaller normal forces like 0.1 -0.2 N are usable. Hard gold is also good in corrosive environments. Wear properties of hard gold are good, giving about 1000 insertion cycles to failure with 1 pm coating thickness. Wear properties can be often drastically improved by usage of lubrication. Another potential coating material is palladium-nickel combined with flashed hard gold surface. For high-volume versions where cost constraints dominate, more cost effective materials, plating and methods are workable, possibly with some trade-offs in performance.

The necessary normal force can be achieved by means of gravity only, using additional pressure subjected to the battery units in the tank or a combination of these. Additional pressure applied also helps to immobilize the battery units in the tank. Pressure can be applied using one or more springs, elastic members, movable members or gas-inflatable members inside the tank or assembled on or as a wall thereof Size and shape (battery unit) The size of the battery units depends on their intended use. The optimal size of the battery units depends on several parameters. If the battery units are to be transferred via a hose or other conduit (to fill or empty a tank), the maximum size is limited by the maximum practical diameter of the hose or conduit. For EVs, as a rough assumption, a battery unit that can be pumped through 5 cm diameter hose could be still practically used. The minimum reasonable size of the battery unit is limited by components, like control electronics, which cost and size remains about constant independent of the battery unit size if the number of the contact areas is the same. When the battery unit size gets smaller, cost per capacity increases and capacity per volume decreases.

The shape of the battery unit can in principle be almost anything. For an optimized design however, several parameters should be considered. Most importantly, the shape has a big impact to capacity per volume. The container could be filled with the battery units by pumping or pouring. As a result, the battery units are mostly randomly packed in the container. Every geometrical shape has its own typical fill ratio range. Fill ratio is a parameter used to characterize the maximum volume fraction of the objects obtained when they are packed.

According to one embodiment, the battery unit has a smooth shape, i.e. a shape without sharp corners or edges. According to a specific further embodiment, the shape is free from flat surfaces.

Such shapes are typically entirely convex, like an ellipsoid or sphere.

According to one preferred embodiment, the battery unit has an ellipsoidal shape. This allows for high random fill ratio and stable positioning of individual battery units in a container. One of the densest known random fill ratios, with a number of about 0.74, is a particular type of ellipsoid, with semi-axes of 1.25:1:0.8. For this ellipsoid, random fill ratio is also very close to the densest known possible fill ratio, making it a good candidate for battery unit shape. At the same time, the fill ratio is low enough to allow the use of a gas or liquid between the battery units for cooling the container and the battery units. The term "ellipsoid" herein means a true ellipsoid, i.e., at least one of its semi-axes has a different length than the two others.

According to one embodiment, the battery unit has spherical shape. For a sphere, the fill ratio is in the range from 0.56 to 0.64. Typically a fill ratio of 0.56 can be achieved when the spheres are poured to a container. A fill ratio of 0.64 is achievable after extensive agitation, like by shaking the container. On the other hand, if spheres are manually placed to the densest possible packing, 0.74 fill ratio is achieved. The large difference between the densest possible packing and typical random packing means that although being possible, the spherical shape is not the best for the battery unit, because random packing leaves lot of potentially "loose" battery units, which are not stationary during the operation in the container. Additional and unique drawback of spheres is that the shape does not lock to any of its rotational freedoms. It is therefore preferred to use a shape having always at least one rotational freedom restricted or entirely locked when randomly ordered in a large container.

Surface finish and surface friction rates of the battery units also affect the fill ratio to some degree.

Smoother surface and less friction generally result in better fill ratios. Also, the shape and the size of the container compared to the size and the orientation of the battery units affects the fill ratio.

The closer the battery units are to the typically flat walls of the container, the less likely they are to be randomly oriented because of the effect of the wall. Consequently, in larger containers, more battery units are fully randomly oriented, resulting typically better fill ratios.

Another important parameter is the energy reservoir fill ratio inside the battery unit. Shapes like cylinder and rectangular box would be ideal shapes as far as this parameter is concerned, because these are typical existing shapes of electrochemical battery cells. For general ellipsoid, good energy carrier fill ratio can be achieved by using the so called jelly roll" cell design for lithium batteries, allowing efficient use of space available for the cell in the battery unit. Jelly roll design is known per se and presently used for rechargeable batteries. In the design, an insulating sheet is laid down, then a thin layer of an anode material is laid down, a separator layer is applied, and a cathode material is layered on top. Then those are rolled up for example into form of cylinder. By using other forms than rectangular for the layers, it is possible to have different forms for the cell.

A further important shape-related parameter is the average number of contacts between the battery units in random order. More mechanical contacts between the battery units mean more potential working electrical contacts between the battery units, which allow more possibilities to form the strings. Also, more mechanical contacts between the battery units will help keeping the battery units stationary during the operation. According to a preferred embodiment, the shape of the battery unit is chosen to provide at least 5, preferably at least 9 contacts in average with other battery unit in random order. For example randomly packed spheres have around 6 contacts, while the preferred ellipsoid (1.25: 1:0.8) is found to have even 11 contacts on average.

Still another important shape determined parameter is the curvature. On high curvature areas it is beneficial to have small electrical contact shapes or avoid them completely to minimize the number of the battery units, which form a connection with the same electrical contact area.

A relevant shape determined parameter is also the maximum outer dimension of shape per volume of shape. Big values lead to small sized battery units increasing the system cost and decreasing the system capacity per volume. As far as only this parameter is concerned, sphere is the most optimal shape. The preferred ellipsoid form is also relatively good.

Finally, an important shape determined parameter is also the deviation in cross sectional area in different orientations: less deviation means more even speed and less probability for clogging while pumped through a hose or conduit. A sphere, which has zero deviation, would be an optimal shape for pumping, but ellipsoids can also be well pumped. Shapes that would stack to each other should be avoided in pumping applications. Sharp corners in shapes should also be avoided because of excessive wear and problems while pumping.

Electronics (battery unit) The battery unit includes, preferably within the housing, necessary electronic components and connections for controlling the connection configuration of its contact areas, for discharging and charging the energy reservoir, and optionally for monitoring the state of the battery unit and for communicating with an external control unit monitoring and connection programming information.

Most importantly, the electronics includes necessary switching logic defining contact areas are connected to the terminals of energy reservoir and optionally which contact areas are functioning as bypass routes.

According to one embodiment, the battery unit includes a microprocessor, such as a microcontroller, a clock oscillator, memory, communication circuitry, monitoring circuitry, power supply circuitry, switching circuitry. In addition, depending on its functionalities it may include one or more of the following: charging circuitry, over-current protection circuitry, and circuits for bypass buses. The memory may include flash, EEPROM and/or RAM.

The internal functions and communication functions of the battery unit are preferably powered by the energy reservoir. However, there may also be provided a separate power source, such as a coin battery or the like small power source, for providing the necessary electricity for these functions. The separate source may also be arranged to be used only if the main energy reservoir of the battery unit is completely depleted.

To avoid unwanted paths and connections, over-currents and the like problems during random filling of a container, the terminals of the energy reservoir are preferably disconnected from the contact areas. Only once the filling has been completed, a battery unit connects the terminals of the energy reservoir based on viable routes towards the load, established by communicating with peer battery units, a centralized control unit, or both.

Transmission part of the communication circuitry is used for sending messages out from the battery unit, to other battery units or to the central management unit. Receiving part of the communication circuitry is used for reception of messages.

Monitoring circuitry preferably measures the voltage, current and temperature of the energy reservoir, current and temperature. In addition, it may measure the voltage of each contact area referenced to a virtual ground point of the battery unit. These voltages correlate directly to the current floating through the contact areas of the battery unit. The monitoring circuitry may also track battery health, number of cycles, and how it behaves against an expected wear curve for the particular energy reservoir in question. Internal memory of the battery unit can be used for storing temporary or permanent monitoring data.

The communication circuitry is typically used for sending and receiving messages to and from an external central control unit of a tank. This is typically achieved through conductive contact surfaces on the inside wall of the tank and contact areas of the battery units, but also other methods such as light pulses in the infrared or visible spectrum, or radio frequency induced, or wireless communication are possible.

Individual battery units may in a specific configuration thereof have their contact areas connected to each other through resistors in a star pattern, which can be taken advantage of if a galvanic communication method is used. To facilitate pass through of data, if a large number of the battery units are present in a container, most of the battery contact areas are connected to other contact areas through relatively high impedance resistors forming a resistor network. When one battery unit applies a voltage on one or more of its contact areas, while grounding one or all of the remaining contact areas to its internal ground, it will induce a current through some or many of the other battery units and the resistors connected to the contact surface on the inside of the tank. This induced current can likely be measured by some or all of the other battery units, and by the control unit. By using modulation techniques, such as on-off keying, or any other, data can be transmitted and received by other battery units and the control unit.

In order to maximize the probability that the induced currents for communication are large enough, to be measured with a sufficiently large signal to noise ratio, an elevated voltage level could be desirable. Battery units and the external control unit may generate a higher voltage using a power supply that can be switched off during periods when no communication is needed.

Most to all of the above functions can be implemented into an application specific integrated circuit, or ASIC, yielding the lowest possible component cost in volume, in addition to being footprint optimal. The semiconductor technology chosen depends on the required performance in certain areas: power consumption, switching losses, any needed RF circuitry, analog performance, amongst others.

Electronics example (battery unit) Next, a specific non-limiting example of battery unit electronics is described to illustrate how the invention can be carried out in practice.

Fig. 7 shows a block diagram of the battery unit which contains 4 contact areas 701.The battery unit is managed by a CPU 721, such as a microcontroller. Clock oscillator(s) (not shown) are connected to the CPU and are used for timekeeping. There may for example be two clock oscillators: a higher frequency crystal for high speed operations and timing, and a lower frequency crystal for timekeeping in low power sleep mode. Each contact area 701 is connected separately via connection bus 731 to the other units described below.

The battery unit has an optional bypass mode, in which any contact can be connected to any other contact and pass signals and power. CPU controls the bypass connectors 705. It is possible to conned any contact to bypass bus 723 by switching connectors 705 on/off. The battery unit can include also include more than one bypass bus, buses are independent from each other. The bypass switches can utilize MOSFET technology, for example.

Data is received by the battery unit through the measurement and data receiver unit 717. The measurement and data receiver unit 717 includes a comparator per each contact. The comparator receives on one terminal a reference threshold voltage, which is produced by the CPU. On the other terminal is a (divided) contact voltage. In low noise environments, the threshold can be set very low and the battery unit can receive very small signals. In a high interference environment, the threshold can be set as high as needed. Noise immunity improves, but at the cost of sensitivity.

The output 723 from the comparators is fed into the CPU and decoded as needed.

The measurement and data receiver unit 717 can include also, e.g. a temperature coefficient resistor or any other type of temperature sensor to enable to measure the temperature of the battery unit. The unit includes also the energy reservoir current measurement circuit, which optionally amplifies the voltage drop over the shunt resistor 725, which is then sampled by the measurement and data receiver unit 717. The unit also measures various voltages and tracks the energy reservoir state of charge.

Each contact 701 can be connected via a resistor 719 to the virtual ground point 711 ("star point") of the battery unit. This allows for a star network inside the battery units through which all the battery units can communicate. Unless circuitry is employed that allows disconnection of the resistors, some power is dissipated under certain conditions. Such conditions could be when the energy reservoir is connected to certain contact areas, and when the battery unit transmits data.

The power levels, however, are negligible if such resistor values are chosen suitably. The voltages measured over the resistors 719 are a function of the current flowing through the contact, and this information is used for routing and other purposes. The voltages are measured by the measurement and data receiver unit 717.

In order to transmit data from the battery unit, an uplink voltage is fed into the most appropriate contact area 701 from the CPU via lines 729. Optionally data can be transmitted using several contact areas 701. The resistors 715 limit the current. The data format and coding can be one of many, e.g. standard serial data, PWM or PPM methods. Typically, many or all other contact areas could be connected to the virtual ground point 711 of the battery unit using switches 707 and benefit the signal strength on the receiver side.

The negative terminal of the energy reservoir 713 is connected to one of the contact areas via shunt resistor 725. The CPU controls the switches 707 to determine to which contact area negative terminal is connected. The positive terminal of the energy reservoir 713 can be connected to a one of the contact areas by switching on/off switches 709.

The battery unit can include several power supplies (not shown) e.g. for providing reference supply, standard low dropout regulator and boost supply which can be used to fully activate MOSFETS and to provide a higher voltage to enable stronger transmit signals.

It should be noted that the above example is intended to illustrate the principles of implementation of a battery unit and there are various other ways of implementing the functions of the battery units.

In practice, most or all of the components and wrings discussed may be integrated into a single custom chip, allowing considerable reduction in cost and size compared with separate components.

The battery unit may rest for a certain time period in each cycle, meaning that it does not deliver power or communicate during that period. When the tank is filled with the battery units, the control unit starts the synchronization process. The control unit sends first wake-up signal to the battery units so that the battery units are prepared for the communication. After that the control unit sends synchronization signals: based on the synchronization signals battery units can synchronize the internal clock. This enables that, e.g. all the battery units in certain string delivers power at the same time, e.g. 90% of time and rest of the time 10% is reserved for the communication.

Synchronization process can be repeated periodically during the operation. According to one embodiment, the battery unit is capable of being driven into several separate power states, e.g. a low power consumption state (resting state) and high power consumption state There could be several power states (sleeping states) between these two states which are used during normal operation to minimize the power consumption, e.g. there is no need to power everything on in CPU when there is no communication between the control unit and the battery unit. In high power consumption state the battery unit delivers power to outside of the battery unit. In the sleeping state(s), the battery unit is capable of communicating, and changing its configuration. In the resting state, the internal functions of the unit are at minimum, the battery unit still being capable of waking up upon receipt of a wake-up signal typically through the contact areas. The battery unit goes to the resting state to prevent damaging the energy reservoir, e.g. if the cell voltage is low which is monitored periodically.

Environmental aspects (battety unit) The present battery units can be designed from the onset with minimal environmental impact in mind; maximum recyclability is a primary objective. Raw materials, such as housing plastics, lithium battery cells, silicon, metal wiring, etc. can be chosen to allow for as close as possible to 100% of recycling. Additionally, the recycling methods chosen allow for low-maintenance and low-threshold recycling methods, such as shredding. Material separation, recovery, and re-use or recycling can reach very high levels and be performed using simple methods, after which practically all material can be used for the production of new battery units or other products. Also, because for each battery unit, its history, ownership, usage pattern etc. could be uniquely identified throughout its lifecycle, only battery units at the actual end of their economic lifespan are recycled. Additionally, if battery units were not to be recycled and to end up in a landfill or elsewhere in the environment, they are almost completely non-toxic and of no impact to living organisms.

The energy reservoir in the battery unit can be replaceable and the identification and/or history data of the battery unit at least partly rewritable or erasable such that the same housing and electronics can be used again with a fresh energy reservoir once the previous one has degraded too much.

The contact areas may also be re-plated if worn.

Other aspects (battery unit) Battery units providing a random fill ratio of less than 100 %, in particular less than 80 %, can be cooled, if needed, by allowing air or other gas to flow between the units. Thus, a certain amount of cooling for components dissipating power or that are otherwise temperature sensitive can easily be provided. The battery unit can be used in an environment optimized for certain requirements, whereby controlled circulation of air, or any other gas or coolant, between the units can be employed.

The battery units herein described withstand typical working environments, including physical stresses induced by filling and emptying the battery unit container, or by mobile use of the device it powers. Typical environmental stresses include static and dynamic stresses, vibration, shocks, wear, temperature cycling, humidity, dust and corrosion.

Electric tank The electric tank herein described enables the formation of one battery from plurality of the battery units which could be randomly packed inside the tank in common space where there are no exact position or compartments for battery units. The space may have a regular form, such as rectangular form, but may as well be non-rectangular or irregularly shaped.

The tank can be emptied partly or fully and re-filled quickly with partly or fully charged battery units from another container using cost-effective methods. Thus, a user can "refuel" a BEV in about the same time as cars using a combustion engine and filling resembles the familiar process of filling up vehicle with motor fuel. The tank can be also charged by plugging in the vehicle, without removing the battery units.

The tank described herein can be used as a source of power for EVs. It can be used in a FHEV or BEV. In an EV, the tank can hold hundreds, thousands or even tens of thousands of units simultaneously, but it is equally suitable for small electric devices using only a few battery units, such as power tools. Indeed, in addition to EVs, the invention has also many other potential applications, where rapid and easy replacement of electrical energy or electrical energy storage units is desirable -typically cases where devices are predominantly mobile and using a power cord is inconvenient or impossible.

The tank described herein is not limited to use as an energy source for a load, such as in the case of EVs, but can be used as a recharging tank too. Such recharging tanks can be used, e.g. at service stations for storing and recharging used battery units emptied from EVs tanks. A tank can also have both functionalities, i.e. electric supply and recharging functionalities, like tanks of EVs preferably do.

Overview (tank) The operation and configuration possibilities of an exemplary tank are illustrated below by means

of an example.

First, Fig. 4 shows a schematic tank 400 with a container 406 (front, back and top walls not shown).

The container has two opposite walls serving as contact plates 401, 402 for battery units (not shown) placed inside the container 406. Each contact plate 401, 402 comprises a plurality of contact surfaces 411, 412 (in this case sixteen) capable of individually contacting contact areas of battery units. In general, the number of contact surfaces in a plate may be, any number, but tanks of larger capacity will typically have more contacts. The contact surfaces 411, 412 need not necessarily be arranged into two groups as herein shown but this arrangement is advantageous because separate switching logic units can be provided for each plate, as will be described later in more detail. On the other hand, there may be more than two plates (and switching logic units). The number of plates can be 1 -8, preferably 2 -4. Placement of the plates on opposite walls of the container is also not necessary. However, the illustrated placement symmetrically on opposite walls of the container ensures equal average contact forces between the battery units and the plates 401, 402. Plates do not necessarily need to be rectangular or flat surfaces, but can be shaped in any form if tanks are of a particular non-uniform shape.

The sizes, forms and placements of the contact surfaces are designed such that the probability that the contact areas of battery units randomly filled to the tank make electrical contacts with the contact surfaces is high. Of course, this depends on the design of battery units too. It may for example be desirable that at least 10 % of the battery units that come into physical contact with tank walls are also in electrical contact with a contact surface, or that 50 % of battery units that come into physical contact with the contact plates make an electrical contact with a contact surface of that plate.

Fig. 5A illustrates in a two-dimensional schematic view an electric tank comprising several battery units of kind described above. The tank provides electricity out from outlets 512 (+) and (-). There are 13 battery units A, B, C M inside a battery unit cavity 518 of the tank. Although herein illustrated in well-ordered configuration for simplicity, the battery units are in practice typically randomly or essentially randomly packed inside the tank. Each battery unit has contact areas a, b, c and d (in clockwise order starting from top left in Fig. 5A). The tank has two sets of contact surfaces 504A-F, 505A-F. Contact surfaces 505A-F are connected to tank switching logic 508 and contact surfaces 504A-F to tank switching logic 506. The tank switching logics 508 and 506 are connected to main switching logic 510. The switching logics 506, 508 and/or 510 can send commands to battery units to modify the polarity of the contact areas a, b, cord or to disconnect or short circuit those in arbitrary manner, as described above in connection with the battery units.

To be able to program the battery units, the control unit of the tank needs to discover which battery units are present in the tank and how they are connected with other battery units and the contact surfaces of the tank. In a simplified exemplary process, the discovery can start by configuring all contact surfaces to have resistivity R between them. Then a current I would be fed from one, e.g. the leftmost contact surface 505A of contact surface set 505A-F to contact surfaces 504A-F. Thus, contact surface d of battery unit K is in contact with the contact surface 505A. Based on ohms law the current in battery unit K between contact areas band d would be largest of all possible contact pairs in the system. Then using a communication protocol, the control unit can request current information from each of the battery units A -M. The battery unit/certain contact area of the unit with largest current and with certain direction of the current (as same current if going through band d) would be determined to be in contact with contact surface 505A: the same procedure can be used to determine which battery unit/contact area is connected to contact surface 505B by feeding the current I from contact surface 505B to contact surfaces 504A-F. By connecting contact area d to contact area b of the battery unit K and by feeding current I from contact 505A to contact surfaces 504A-F the biggest current is flowing via contact area d of the battery unit I, and this information can be used to determine which battery unitlcontact area is connected to the contact KJb etc.... until the relative location of each battery unit would be found, though it is not needed to know all the locations for forming strings.

The battery units can, after discovery, be connected in various different ways to correspond with different needs, e.g. depending upon what is the preferred output voltage or output power. In an example, each battery unit of Fig. 5A has an energy reservoir having the voltage of X volts. One way to form the string is that energy reservoirs are configured so that positive terminals are connected to contact area b for the battery units K, F and A; positive terminals are connected to contact area a for the battery units I and D; negative terminals are connected to contact area c for the battery units K,F and A; negative terminals are connected to contact area d for the battery units I and D. This way battery units K, I, F, D and A form one string between contact surfaces 505B and 504B with five energy reservoirs connected in series. Output voltage of the string would be 5X volts. This string is shown as a dashed curve in Fig. SB.

Another string could be formed, e.g. using battery units L, J, G, E, B between contact surfaces 505D and 504D, output voltage of the string would be also 5*X volts. This string is shown as a dash-dot curve in Fig. 5B. Strings could be combined in power combiner to form one output. There is, however, no need that the output voltages of the strings are the same to enable to combine those.

Some of the contact areas of the battery units A-M or contact surfaces 504A-F, 505A-F of the tank can be also in bypass mode in the string if, e.g. energy reservoir is faulty, not all available power is needed, or a long string is to be formed. For example, a longer string can be formed, e.g. by connecting the battery units K, I, G, D and B in series between contact surfaces 505A and 5040, the battery units C, E, H, J and M can be connected in series between contact surfaces 504F and 505E. By further connecting contact surface 5040 to contact surface 504F, a string including ten battery units between contact surfaces 505A and 505F can be formed. This string is shown as a solid curve (alternative to other curves) in Fig SB.

Another exemplary long string between contact surfaces 504A and 505F, employing bypassing in some of the battery units, is shown as dotted curve in Fig. 5B (again alternative to other curves shown). When the curve goes through a battery unit for the first time its energy reservoir is connected in series and when it goes through the same battery units for the next time, the respective contact surfaces are short circuited with each other to achieve a bypass connection.

Thus, a continuous energy path is formed.

To be able to individually program each battery unit in a desired way, each unit preferably has unique identifier, as explained above.

Next, preferred properties and operation principles of the tank are described in more detail.

Physical aspects and filling (tank) The tank comprises a container defining a cavity for containing a plurality of battery units. The size and form of the container can vary broadly. The wall material of the container may be uniform or meshed, as long as the battery units cannot easily escape the container and the wall is sufficient to support the contact surfaces.

Typically, the container comprises an opening, preferably a closable opening, through which the battery units can be inserted to and removed from the container for filling and emptying the tank.

There may also be separate openings for filling and emptying. For example, there may be a removal opening in the bottom of the container and insertion opening on top of the container.

Filling and emptying the tank can be done using various methods, such as gravity, over-or under pressure or gas stream. According to one embodiment, an air pump is used to create an overpressure or partial vacuum capable of moving battery units to or from the tank. In particular, quick emptying of the tank can be done by a partial vacuum which sucks used battery units from the tank away to another container, such as a recharging silo. Emptying purely or partly by gravity is possible too, if there is an opening at the bottom of the tank. Quick refilling can be done for example using a pressure or gas flow transfer along a hose or by pouring the battery units from an opening on the tank. Change of the battery units can be done manually also.

The tank need not be filled completely, provided that at least some of its contact surfaces still come into contact with at least some battery units. There may also be a minimum power requirement.

Thus, in practice there is a predefined minimum number of battery units required. The minimum can be for example 10 -90 %, typically 20-50 % of the maximum number of battery units. Thus, the size of the battery pack can be adjusted and optimized for various needs. For example in the case of EVs, a user can fill the tank fully only when there would be need for maximum driving range. On the other hand, if a typical daily driving range is only tens of kilometers, the user does not need the maximum number of the battery units. This makes the EV lighter and more efficient.

Certain provisions may be necessary to restrict physical movement of the battery units in the tank.

One possibility to achieve this is to fill the empty space of the tank with empty battery units that do not include the power source but might still have full, partial or no intelligence built in.

The filling and emptying system of the tank can be designed to be either open or closed, i.e. allowing gases to enter and exit the battery unit cavity or making it gas-tight, if not hermetically sealable. An open system is simpler than a closed system, but as a drawback, in open system the battery units are exposed to ambient air and possible contaminations. It is preferred that the tank provides environmental protection for the battery units at least against dust, water and other contaminants. It can additionally be designed to be air-tight at least during operation.

For practical reasons, the emptying and/or filling process should be a quick operation, resulting that battery units are moving at relatively high speeds. For this reason, the filling and emptying system should be designed to avoid excessive collisions between the battery units and the tank. When filled, a tank must be able to pack the battery units tightly, generating enough normal force for the most of the connections between the battery units and between the battery units and the tank. This enables to have stable and low resistance electrical contacts. The tank maintains at least most of these normal forces, keeping the battery units stationary within typical working conditions that can include several environmental stresses like thermal cycling, dynamic and static loads, vibration and shocks.

Thus, non-complex shapes such as cylinders, cuboids, spheres, semi-spheres, cones or combinations thereof are preferred shapes of the cavity.

The tank preferably provides good enough cooling to dissipate the heat generated by battery units and electrical contacts between the battery units and the tank. For example for several battery cell chemistries, the preferable operating temperature range can be quite narrow, like -20°C to +50°C for typical lithium-ion cells.

Battery unit cooling in the tank can be implemented in several different ways. The maximum random fill ratio of the battery units in a tank is typically around 70%. This means that there is always about 30% void in a tank that can be used to circulate cooling fluid, typically air or cooling liquid. Cooling area per battery capacity is inversely proportional to battery unit size. Because the optimal battery unit size is relatively small, excellent cooling area to battery capacity ratios can be achieved. To avoid tank contamination, internal fluid circulation and heat removal from heat transfer fluid via some type of heat exchanger is preferred. Fluid circulation can be improved by using a pump, fan or blower, depending on the fluid type and construction used. The cooling arrangement is preferably entirely passive, utilizing passive heat transfer through tank walls and gas convection within the tank.

According to one embodiment, there are provided active means, such as a fan, for circulating of flowing gas within the tank and/or in and out of the tank to provide more efficient cooling.

According to one embodiment, there are provided active means for circulating a cooling fluid, such as liquid, in a closed fluid circulation system to provide more efficient cooling.

The fill ratio of the tank can be improved if the tank is agitated after filling. The improvement in fill ratio this way can be several percentages, depending at least on type of the agitation applied, shape of the battery unit and friction of the shell of the battery unit. Also after the agitation there are less loose battery units in the tank that could move during the operation which could cause that some connections between the battery units break which might have effect to the programmed energy paths and there would be a need for rerouting. Agitation can be achieved many ways, for example by vibrating the tank or some parts of it. Another possibility is to use an air pump for agitation by changing the flow direction rapidly several times.

According to one embodiment, the tank comprises integral means for agitating the battery unit container.

According to one embodiment, the tank is capable of providing and maintaining a static overpressure (in relation to the pressure caused by pure gravity) between the battery units. Using such means, after filling and potential agitation and before operation, an additional static pressure can be applied to the tank to increase normal forces between the contact areas of the battery units and between the contact areas of battery units and contact surfaces of the tank. In addition, if the static pressure is large compared with the forces of gravity, the normal forces will be more uniform between different contacts. Applied pressure also improves the ability of the system to withstand vibration and shocks during the operation.

According to one embodiment, the tank comprises one or more mechanical springs capable of causing the static pressure. According to another embodiment, the tank comprises an elastic member, which can be pressed against the battery units after filling. According to a further embodiment, the tank comprises a gas-inflatable member, which can be pressurized with gas after filling the container in order to cause the static pressure.

According to one embodiment, the battery unit container itself is designed to be at least partly elastic or flexible, thus allowing slight "overfilling" of the tank (in relation to its resting volume).

Resulting deformation and elastic forces will cause the static pressure between the battery units and tank walls. Elastic design also makes easier applying and maintaining of static pressure easier by external means.

System elements and electronics (tank) On the inner wall of the container, there are a plurality, i.e. at least two, contact surfaces that are positioned such that at least some of them necessarily come into contact with the battery units. The contact surfaces are used to deliver power form the battery units to an external load, or to the battery units for recharging their energy reservoirs. The total number of contact surfaces is typically at least 4, in particular at least 8, and typically at least 16. The number may be e.g. 16-128. The theoretical maximum number of individual parallel strings, i.e., electrical energy paths through the tank is half of the number of contact surfaces, since the strings typically start from one contact surface and end to another contact surface. The contact surfaces may be divided into two or more groups partly controlled by separate switching logic units.

The contact surfaces are preferably configurable such that each contact surface may be in a disconnected (high-impedance) state or defined as a positive or negative terminal. Optionally, the contact surfaces may be grounded and/or provided with a predefined voltage. There is provided a corresponding switching circuitry, so-called switching matrix, connected to the contact surfaces and connected or connectable to a control unit, also called a tank management unit. The control unit is typically also capable of transmitting programming signals to the battery units through the contact surfaces.

According to one embodiment it is also possible to connect a contact surface to another contact surface using the switching circuitry for forming a low-resistance connection between the contact surfaces. By this arrangement it is possible to have a string which starts for example from one contact surface and after a number of battery units reaches a second contact surface which is internally connected to third contact surface from where the string continues again via battery units until it reaches a fourth contact surface. Thus, the strings need not end once meeting a contact surface but may continue through another contact surface.

According to a preferred embodiment, the contact surfaces are separated into two or more arrays comprising a plurality of contact surfaces each. For example, each array may comprise at least two, preferably at least four individual contact surfaces. The arrays may be placed on different inner walls of the battery unit container. In a typical case the contact surface arrays are placed on opposite sides of the tank, as shown in Fig. 4. Here each contact array includes 16 contact surfaces.

According to one embodiment, the tank comprises a control unit herein called a tank management unit (TMU) and at least two switching matrixes (SMXs) functionally connected to the TMU and to groups of contact surfaces of the tank. In a preferred embodiment, there are also at least two power buses for delivering energy to or from the SMXS and a power combiner for combining the power delivered by the power buses. In addition, there may be user interface means for allowing a user to control the TMU and/or for visualizing the operation and/or charge level of the tank. The tank can also include an extra energy reservoir to supply energy for some time if the supply of power is temporarily interrupted.

The TMU monitors and controls the battery units, the strings, the SMXs and the power buses. The SMXs are used for connecting the strings to the power buses and a communication between the TMU and the battery units happen via the SMX.

The power buses are used to connect several strings to external positive and negative electrical connections.

Fig. 8 illustrates one potential SMX architecture. The contact surfaces 810, power buses 830 and a ground bus 835 are connected in a matrix where each contact surface 810 can be connected to any of the power buses 830 or the ground using connecting elements 870. The matrix is controlled by a switch matrix controller 840, which may be a separate unit or the main control unit of the tank.

In addition, there is a power combiner block 820 and current and/or voltage measurement components 880 connected to each power bus 830 and contact surface 810. The measurements are controlled by a measurement and communication unit 850. The measurement information can be delivered to the switch matrix controller 840. Unified voltage is provided at output 860.

The switch matrix controller 840 preferably comprises switching circuitry, a CPU, transmission circuitry, receiving circuitry, monitoring circuitry, and the described interfaces towards the power buses, the contact surfaces and the TMU. In addition to connecting the contact surfaces to a power bus or ground, the SMX can preferably set the contact surfaces to a high impedance state or connect them to a certain voltage.

Fig. 9 illustrates the system in more general level. The contact surfaces are denoted with reference numeral 815 and are connected to the switching matrix 875. It can be seen that the power buses from the switching matrix 875 are connected to a power combiner 825. The power combiner 825 is needed to combines the supply from several power buses into a single tank output terminal pair for a load, such as a BEV. The power combiner 825 is preferably capable of combining strings with different voltage levels to a single tank output terminal pair. There may also be several power combiners if several tank outputs, e.g. with different output voltages, are needed. The TMU, which typically provides most computational power for the tank system, is denoted 845 in Fig. 9.

The TMU contains necessary software means for performing the required business logic operations such as running routing algorithms and potential safety checks, system metrics, etc. There are also software means for translating the computational results of the business logic operations into messages and vice versa according to a messaging protocol used. These messages contain instructions for other parts of the system such as the SMX or the battery units.

There is also a hardware interface providing a link between the software means of the TMU and the other parts of the system. This layer controls the hardware of the tank.

According to one embodiment, the transmitting circuitry of the SMX enables the communication between the TMU and the battery units. The SMX forwards messages meant for the battery units coming from the TMU to the battery units. The messages can be sent via a certain contact surface or it can be broadcasted over several contact surfaces at the same time. The TMU decides on the contact surfaces used for the communication.

According to one embodiment, the receiving circuitry receives messages coming from the battery units and the SMX forwards those messages to the TMU. The messages can be received using several contact surfaces at the same time or using one specific contact surface again decided by the TMU.

According to one embodiment, the monitoring part of the SMX enables measuring the current and the voltage of the power buses, measuring the current and voltage of the contact surfaces. Also monitoring of the temperature of the SMX is possible.

Finally, Fig. 10 shows a continuity enabler arrangement according to a preferred embodiment of the tank. There are two tank segments A and B, each like illustrated in Fig. 8, with separate switching matrixes 975A, 975B and power combiners 925A, 925B, typically connected to different battery unit strings. The segments are connected to tank segmentation logic 985 between the segments and the load. The purpose of the tank segmentation logic is to ensure that while one segment of the tank is communicating, re-routing or otherwise unavailable for power delivery, another segment can take over the power delivery function without interrupting power delivery to load. There may be also an additional buffer energy reservoir connected to the tank segmentation logic for ensuring power delivery during short periods of unavailability of the segments, for example if all battery units are engaged in a communication or synchronization sequence.

Overall operation process (tank) Fig. hA illustrates an example of a tank operation process from a start 1101, where the tank is filled with battery units but not yet delivering power, to maintenance of the tank in a power delivery state 1115. First, the TMU starts the discovery process 1103 Fig.11B, and discussed below more detail, to find available strings in the tank. TMU stores the information received from the battery units. The discovery process as pictured in Fig. 11B describes how a string can be identified and constructed. In case there are several contact surfaces available, the same process can be repeated several times with different contact surface pairs if several strings are formed. The discovery process collects or constructs information on how the route can be establish between two contact surfaces. Based on this information, the calculate route process 1105 determines how the terminals of the energy reservoirs are connected to the contact areas of the battery units so that those are connected in series.

In step 1107, the TMU communicates to the battery units which contact area terminals of the energy reservoirs are to be connected. The battery units store this information. Before connecting the terminals, the established strings are verified in step 1109. Exemplified verification can be done by connecting contact areas determined in the previous step in bypass mode. Then current is fed from the different contact surfaces. By measuring if the current is within certain range, the TMU can determine that there is route available between two contact surfaces. The battery units monitor also the currents during the operation and if it exceeds the threshold terminals are disconnected from the contact areas.

After verification step 1109 the TMU commands the battery unit to connect terminals of the energy reservoirs to the contact areas 1111. Once this has been done, the power buses and power combiner(s) can be powered up in step 1113 to provide an output voltage from the tank to a load.

The TMU commands in this step to which power bus certain contact surfaces is connected and it measures the power bus voltages which should correspond to earlier calculated values. Calculated voltages can be computed within certain limits of precision, as TMU knows which battery units are part of a particular string, and the battery units report the voltage of the energy reservoir during the discovery process. The system in operation is maintained in a maintenance loop in step 1115, where the power buses and strings are repeatedly monitored in order to be able to react to essential changes in the tank.

Discovety and routing (tank) After the tank is filled with battery units and a communication link established with the battery units, the tank starts a process to find out what kind of connections there are available between the battery units and between the tank and the battery units. This process is called the discovery process.

According to one embodiment, in addition to finding the available connections, the discovery process includes collecting other information stored in or measurable from the battery units. This information can be e.g. voltages of the energy reservoirs, charge levels of the energy reservoirs, the temperature of battery units and the number of charging cycles. The information collected is stored in the control unit.

It should be noted that there is no need to have all the contact information available for all the battery units in a tank to operate. It is sufficient that one string can be established to allow the tank to deliver power. Few long strings with higher output voltages enable in principle smaller power losses, compared to many shorter strings with a lower output voltage. The disadvantage of long strings and the high voltages associated with it, are higher voltage tolerance levels required for the parts. It increases the possibility that the voltage difference between two neighboring battery units goes over the used semiconductors specified breakdown voltage. Many shorter strings require more power buses and thus more components needed in the switching circuitry and the power combiner to manage all the strings.

With reference to Figs. 6A -6D, according to one embodiment, discovery is carried out when the battery units form a resistor network. The contact areas of each single battery unit are arranged in a virtual star configuration. In a star configuration, illustrated in more detail earlier with reference to Fig. 2B, one terminal of a resistor is connected to each contact area of the battery unit and the other terminal of the resistor is connected to common star point of the battery unit (Figs. 6A-6D do not show individual resistors inside the battery units but a general switching logic between the contact areas). This means that their contact areas are connected to each other such that each battery unit has a known internal resistance between each pair of its contact areas. Some of the contact areas of the battery units in the network are in contact with contact surfaces 604a-d, 605a-d of the tank, some in contact with contact surfaces of other battery units and some remain unconnected.

With additional reference to Fig. 11B, the discovery starts by connecting a predefined voltage to a first contact surface (051 in Fig. I1B), connecting a second contact surface (052 in Fig. 1IB) to the ground, and setting other contact surfaces into a high impedance state. Then, by measuring the current which is flowing via the first contact surface, the tank can determine if there a string available between these two contact surfaces because the battery units form a big resistor network.

If there is no current flowing, the TMU connects a voltage to another contact surface or another contact surface to ground and repeats the current measurement and conclusion on string availability. For example in Fig. 6A there are strings available between contact surfaces 605b1604a, 605b1604c and 604a1604c. If the control unit does not get expected answer from any of the battery units in some phase of the process it can use other contact areas of the current battery unit for finding a string or the control can start the new process by connecting a voltage to another contact surface or another contact surface to ground (not shown in the figure). Figs. 6B-6D illustrate a more complex situation. Fig. 6B shows an exemplary battery unit network with all available current paths between contact surfaces 605c and 604c drawn (assuming also that the network continues to left and right). Figs. 60 and 6D illustrate a situation where some strings have been visually eliminated to illustrate the following procedure.

To gain more exact information on the strings, the TMU commands that each battery unit measures the current flowing through all of its contact areas. The TMU can also command that a battery unit will answer only if the measurement result is within certain range. For example, the TMU can set the range so that it corresponds to current flowing through a specific contact surface (say, contact surface 605c in Figs 6B-6D). This is done to minimize the messages sent between the battery units and the TMU.

According to one embodiment, each battery unit has a unique identification number which the battery unit reports when answering to the TMU. Based on the measurement results, the TMU can decide which contact area of the certain battery unit is connected to a specific contact surface of the contact plate. This can be deduced because the current flowing via each resistor in the network is the same as current flowing through the contact surface corresponding to that resistor. The current is also the largest through the contact areas which are in touch with contact surfaces of the tank. In a typical case each battery unit has several connections, and the current is divided between multiple resistors connected to contact areas to several paths over the resistor network.

The nominal value of the current flowing through the resistor connected to contact surface which is connected to the ground is the same as flowing through resistor connected to the voltage, because all the divided current flows are combined to one current flowing to the ground. Based on this, the TMU can deduce which contact area of a certain battery unit is connected to the contact surface connected to ground and therefore to unambiguously find the end points of the string.

The discovery process continues by disconnecting the other contact areas except two for the two battery units A in contact with contact surfaces 605c discovered in the previous step (see Figs. 6C).

The shortest route between these contact areas can be found out by using the contact areas via which the largest current flows. The largest current route is known based on reported current measurements for each contact areas which battery units report to the TMU. After disconnecting the other contact areas for battery unit A, the TMU asks the current measurement report from the battery unit A to find out what is the current flowing through it. Then the TMU commands that each battery unit measures the current flowing through all of its contact areas and the battery unit will answer only if the measurement corresponds to the current flowing via battery A. Based on this information, the TMU can deduce which contact area of a certain battery unit is connected to the contact surface of the battery unit A. In such case, when a connection is not found: the TMU can use another contact area to try to identify a string. Such measurement can be repeated for all contact areas of the battery unit A to find out all the available connections. This is not necessary for determining the strings but might be useful for optimizing the strings in some applications.

The whole string is determined by repeating the steps described above until the whole string is known, e.g the next step starts by disconnecting the other contact areas except two for the battery unit C (see Fig. 6D). The TMU stores the information about the possible connections and what was the route used for each battery unit. For longer strings it is possible to use bypassing for the already known route so that the measured current is bigger. This means that the battery units along the known route are programmed to bypass mode between the contact areas on the route, whereby their star resistors do not dissipate power and increase the current flowing through the route which increases the probability for successful detection of the signal.

After the first string has been determined, the same process is repeated for other potential contact surface pairs of the tank, i.e. a known discovery voltage is connected between some other contact surface pair and all other contact surfaces are set to a high impedance state.

The TMU knows which battery units are already in use in another string and, according to one embodiment, it takes this into account when forming the new strings to save time and energy. The battery units already determined to be used in a previously constructed string, are programmed to disconnect contact areas needed for those strings, so that when connecting the discovery voltage and ground to some other contact surfaces, it is immediately known by measuring the current if a string can be formed between these two contact surfaces.

According to one embodiment, the process described above is repeated until there are several strings available. The process can be done from several contact surfaces at the same time to minimize the time needed for the discovery, at least for a large tank.

It should be noted that the described discovery process is exemplary only and can be implemented in many other ways utilizing current flow measurements in the resistor network, or in some completely different way.

Based on the discovery process, the control unit of the tank decides on the tank configuration, i.e., how many parallel strings there are, how many energy reservoirs are included in each string, which contact surfaces of the tank are used as string end points and how the strings are formed, i.e. how each individual battery unit is to be configured. This process is called the routing process.

Based on routing, the tank control unit finally configures the tank, i.e., communicates to individual battery units how the positive and negative terminals of their energy reservoirs are connected to the contact areas of the battery units so that the energy reservoirs of different units are connected in series, and potential bypass connections as well, to form the strings.

Bypassing may enable better usage of the battery units, for example when there is a battery unit whose charge level is too low to be used for delivering power. By bypassing, it can still assist in establishing a string. Bypassing also enables that the battery unit delivering power can be used for another string in bypass mode, using other free contact areas, which are not used for connecting the energy reservoir. Thus, a single battery unit may simultaneously deliver power and bypass current through different pairs of contact areas. Bypassing can be also used for decreasing the temperature of the battery unit if it is over a predefined threshold value by connecting the battery unit to bypass mode for some time or using some duty cycle for power delivery.

The TMU preferably communicates the routing information to the battery units via the SMXs. The TMU also ensures that each battery unit acknowledges that it has received the appropriate connection commands and, if needed, the TMU can re-transmit the information. Each battery unit preferably stores its own configuration information in its own local memory.

The lank may also provide an interface to connect an external user interface for monitoring the charge level of the tank or each battery unit separately or in a statistical presentation. In a similar way, the tank can provide also other detailed information of the characteristics of the battery units and the strings.

Verification and safety (tank) According to one embodiment, before the power is connected from or to a tank, each string is verified. In the verification process, it is for example checked that there are no direct connections to other strings, which might cause short circuits. The string voltage is also verified. The voltage should correspond to a calculated voltage based on the discovery/routing information and reported energy reservoir voltages from the battery units. The battery units namely report their energy reservoir voltages during the discovery/routing processes and this information is stored to the TMU.

Before connecting energy reservoirs to the contact areas, the strings are also internally verified to be logically correct and free of short circuits. This is done for example by connecting the route for each string in the bypass mode and connecting a voltage between the ends of the string. The following step is measuring the current flowing through the string, and with a comparative algorithm, it can be determined with a high degree of confidence that the strings were formed correctly.

The TMU configures the SMXs to define which string is connected to which power bus, i.e., which contact area of the contact plate needs to be connected to which power bus and which contact area is connected to ground. After the strings are connected to the power buses, the TMU requests power bus reports from the SMXs. The SMXs report the measured voltages and the TMU compares those to a corresponding calculated value.

After string verification completes, the TMU configures all battery units in order to route the internal energy reservoirs to the appropriate contact areas according to the verified strings. Accordingly the power combining is enabled only after verifying corresponding strings whose powers are to be combined.

The tank may include also other important safety functions to prevent over-charging, over-discharging and the shorting of terminals.

Monitoring and maintenance (tank) According to one embodiment, the tank is provided with means for periodically monitoring electrical characteristics of the strings and the battery units during operation of the tank. Should the monitoring require active participation of the battery units, the battery units are correspondingly provided with means for reporting to the tank using suitable communication means. The electrical characteristics may include charge and discharge current, temperature, number of cycles and voltage or charge level of energy reservoirs. If needed, i.e., if predefined threshold values or threshold criteria for the monitored values or values derived from them are exceeded, the tank can reconfigure the strings based on the monitoring information. For example if a battery unit is depleted during operation, the system can take that into account. Reconfiguration may be preceded by a rediscovery or rerouting process. Reconfiguration may take place during normal operation of the tank.

One potential reason for reorganization is that the charge level of certain battery unit goes beyond a predetermined state of charge window. A typical decision would be that such unit can at least temporarily no longer be used for delivering power.

Another examples where reorganization is needed is when the TMU notices that the current of a string is not in line with algorithmic predictions. This could happen if a connection between some battery units have been disconnected during operation and the string is not supplying any power.

In such cases, rerouting is done in the TMU and it uses available contact information. If some contacts have been disconnected, then the discovery can be done again during the operation.

Power combining (tank) As briefly explained above, according to one embodiment, the tank includes a power combiner, which combines the strings with different number of the battery units and with different string voltage levels together. The output of the power combiner comprises at least one negative and one positive terminal, for supplying energy from the tank to a load to be possible.

The output voltage of the strings varies since the state of charge, health, age, capacity, battery chemistry, internal resistance, thermal constraints, maximum allowed power dissipation numbers (among many other parameters) of the battery units vary. As a result, the total string output voltage varies.

Before combining the strings from several parallel strings, output voltage of at least one string needs to be adapted to allow load sharing. For supplying a load, a bus voltage within relatively narrow margins is usually required. A switched mode power supply (SMPS) is used to convert the variable string voltage to the needed bus voltage, of which the exact value depends on the use case.

Different voltage converter circuit topologies can be used for SMPS like buck, boost and buck-boost. The chosen converter topology is driven by the use case. Sharing of loads can be done with various methods, e.g. the system can vary the output voltage of each string through one SMPS per string until the desired current draw level on all paths is obtained.

Charging system (tank) According to one embodiment, the tank provides a charging system which can be used for the charging battery units from plug in without removing the battery units from the tank. The tank preferably provides necessary means to provide a needed power for charging one or several strings at the same time, and for monitoring the battery units during the charging to maximize the useful life of the battery units. The tank may also comprise means for adjusting the charging voltage during charging to maximize the life of the battery units.

The tank may include an AC/DC converter to convert typical AC mains voltage to the needed DC voltage to supply the battery units. The tank connects the needed power for the strings via the contact surfaces of the tank. For charging, the tank can use information for the existing strings or it can form the new strings. The tank monitors the charge level and temperature of the battery units to stop the charging when needed. If some battery unit reaches the full charge level it can be bypassed and the charging of the rest of the battery units connected in series can still continue. On the other hand, if the temperature of some unit goes over a predefined threshold limit, it can be bypassed for some time and then continue charging.

Finally, the tank or any other part of the system may provide an interface to charging infrastructure, such as defined by the SAE J1772 or lEG 62196 standards; in addition to an interface to on-vehicle local area networks, typically based on the CAN or LIN standards.

Dispenser apparatus and method Figure 12 illustrates the main components of the present dispenser apparatus. This forms a part of the recharging architecture that might be implement, for example, at a roadside service station.

The dispenser comprises a dispenser container 101 having an inner cavity for storing a plurality of battery units 110. Connected to the container, there is a dispensing channel, in this case a dispensing hose 107. Between the dispensing hose 107 and the container 101, there is an output unit 103 capable of allowing the battery units 110 to enter the dispensing hose when desired. There is also a dispensing control unit 105 functionally connected to the output unit 103 for operating the output unit and controlling the dispensing process.

According to one embodiment, the dispenser container 101 has the form of a silo, i.e., inner walls at least partly narrowing downwards so as to guide the battery units towards the output of the container with the aid of gravity. The container may, however, have another shape in particular if there are provided active battery unit transporting means guiding the battery units to the output.

Such active means may comprise e.g. a screw conveyor, belt conveyor or pneumatic conveying system.

The output unit 103 may comprise active means for transporting the battery units through the dispensing hose 107. One example of such active means is a gas flow generator, preferably an air flow generator. The gas flow can be guided to the dispensing hose 107 and when battery units are fed to the air flow, they are guided through the hose 107 and out of the hose exit to a desired target, such as an electric tank of an EV. Another example is a flexible screw conveyor arranged inside the hose 107.

The output unit 103 could include a separate output, e.g. diverter, for removing faulty units from the system, e.g ones which silo is not able to charge The output unit 103 and the dispenser control unit co-operate to allow only a desired amount of battery units 110 to exit the dispenser. The amount can be predefined (by for example the number of battery units or the total energy content of the battery units) or there may be one or more additional sensors assisting the determination of the number (e.g. tank filling sensor comparable to sensors in conventional liquid fuel pumps).

The dispenser container 101 may comprise means for charging the battery units while being in the container 101. Thus, the dispenser container 101 may serve as an electric tank with a capability to feed current to the battery units. The electric tank technology and practical implementations thereof are discussed later in this document.

Figure 13 illustrates an embodiment where the dispenser 100 according to Figure 12 is connected to a larger storage container 121 by a battery unit loading channel 117. The dispenser container of the dispenser 100 serves as a buffer container, which can be loaded with battery units from the storage container 121 when needed. The storage container may act as an electric tank with a battery unit charging capability. A benefit of this embodiment is that the retention time of the battery units in the system can be increased so that energy can be procured during periods of low demand, and/or slow-charging algorithms can be employed that maximize the useful life of a battery unit. If the dispenser container is small, the turnover rate of battery unit therein may be short, as well as the charging time available. Rather than identifying and removing faulty units when delivering units from the dispenser 100, these may be removed when transferring units from the container 121 to the dispenser 100.

In one embodiment, a single storage container is arranged to feed many dispenser units. For example a service station may include a large storage container and several "electric energy pumps" obtaining their battery units from the storage container. A benefit of this embodiment is that the charging function can be realized in one container only instead of many, whereby costs can be reduced.

In one embodiment, a plurality of dispensing means are connected to a single dispenser container to obtain a multi-output dispenser. In this case too, the charging function can be realized in that single dispenser.

Naturally, all combinations of the above embodiments are possible, allowing for any number and cascade of storage container(s), dispensing container(s) and dispensing means to be used.

Figure 14 illustrates a service station with a battery unit dispenser 130 and a parking zone 120 within the reach of the dispensing channel 137 of the dispenser 130. Thus, a vehicle 125 parked at the parking zone 120 can be provided with battery units from the dispenser 130. The vehicle preferably comprises a battery unit input to which the output end of the dispensing channel 137 is designed to engage for safe conveying of battery units between the tank (not shown) of the vehicle and the dispenser 130. The arrangement is analogous to conventional service stations with parking zones by fuel pumps having pump guns" designed to fit into a fuel tank input channel of a fuel-driven vehicle.

Figure 15 shows an embodiment comprising a dispenser 140 capable of both outputting and inputting battery units to and from a vehicle 125 or any other target. The dispenser 140 comprises a combined output and input unit 143 connected to a dispensing channel 147. There are means in the combined output and input unit 143 for selecting the direction of battery unit transport.

The channel 147 serves to both intake battery units from the vehicle 125, whereby the combined output and input unit 143 guides the battery units to a loading channel 149 conveying the battery units to the dispenser container (or any other container of the system, like the storage/charging container shown in Figure 14) and to feed battery units to the vehicle 125, whereby the combined output and input unit acts as described with reference to Figures 12 to 14. Input to the dispenser container preferably occurs from above in order to avoid the need to move units already present in the container.

In another embodiment, the dispenser comprises an intake channel separate from the dispenser channel for conveying battery units out of the vehicle to a container.

In a still further embodiment, there is provided a separate intake apparatus for conveying battery units out of the vehicle. The dispenser and the intake apparatus may, however, be connected to one or more common containers, which can be used for charging the used battery units taken from a vehicle before dispensing to another vehicle.

The electric tanks of vehicles may be designed in various ways to allow for battery unit changes.

There can be a single tank input/output opening or there can be separate tank input and output openings, for example at the top and bottom of the tank, respectively.

According to one embodiment, the dispensing container and/or one or more of the other battery S unit containers of the system, as discussed above, comprise means for charging the battery units contained in the container. For this purpose, the container comprises contact surfaces and control electronics, which may be similar to those of an electric tank described elsewhere in this document, for forming electric energy paths, i.e. strings, inside the container. Thus, the charging container can use the same principles as a tank acting as an energy source for forming the strings, but the direction of energy transfer is the opposite. Additionally, there are means for feeding charging current to the battery units through the contact surfaces along the electric energy paths. The tank technology, in particular string forming by so-called discovery and routing processes, is described above.

When the container has been provided with battery units, the container forms the strings. After the strings are formed, the container provides the required, typically DC, voltage to the strings for charging. The DC voltage could be obtained from, for example, a residential or commercial power utility network, using an AC/DC converter. The container preferably monitors charging level of the battery units and temperatures to. The container may also control the charging cycle, speed and methodology in order to maximize battery unit useful life, or to implement requirements as set forward by a business model.

The dispenser can use any available energy source for charging the battery units, like solar or wind power. The power may be locally produced or transferred through a power grid. The dispenser can be located for example at a public service station meant for public use, in an access controlled corporate fleet environment, or in a residential setting by an individual end user.

According to one example, the dispenser is located at a home of a user whereby during a working day one set of battery units is charged using for example solar power, grid power or any other available energy source. When the user arrives at home with a vehicle powered by a battery unit tank, he can instantly replace a used set of battery units with the newly charged battery units located in the dispenser.

Figure 16 illustrates as a flow chart the presents a method according to one embodiment. The method comprises first positioning an electric tank to be replenished within reach of a dispenser (step 190). A battery unit removal channel (which may be entirely different from a dispensing channel or at least partly the same) is connected to an output of a tank (step 191). The removal channel is used to remove at least a portion of the battery units from the tank to a collecting container, possibly directly to a charging container (which may again be the same or different than the dispensing container) (step 192). As an optional step (step 193), the total energy remaining in the removed battery units is determined by measuring or requesting the battery units to report their charge level, for example. Next, a battery unit dispensing channel, if different from the removal channel, is connected to an input of the tank (which may be the same a output) (step 194). The dispenser is used to dispense a desired amount of charged battery units to the tank (step 195). The tank then performs necessary functions (discovery, routing etc) to take the newly dispensed battery units into use. As an optional step taking place before or during dispensing, the dispenser, on the other hand, has determined the charge levels of the dispensed battery units and calculates their sum (step 196). As a further optional step, necessary transactions are made with the client receiving the new battery units or his/her bank, to receive a financial compensation corresponding to the energy balance of the removed and dispensed battery units.

When the battery units are physically transferred between users and retailers, for example from the vehicle tank to a container of a retailer and vice versa, settling and clearing of energy levels and depreciation of the battery which affect to value of the battery units can be done by a secure transaction mechanism, utilizing a unique identifier and optionally other battery unit -related data stored in each battery unit. This system allows for a combination of a large number of the battery units from various manufacturers, by using a number of identifiers that define many parameters, such as manufacturer, origin, version, owner, owner history, technology, battery technology and chemistry, upgradability, serviceability, wear characteristics, battery capacity, battery degradation as a function of load level, thermal constraints, G-forces, number and nature of charge and discharge cycles, duty cycle distribution, load distribution, rejuvenation algorithms, remote shutdown options for privately owned or overdue accounts, crash or accident history. Some or all these parameters can be used when counting a value for the battery unit.

During the normal lifecycle of any battery, capacity decreases. Typically, when no longer 70% or more of the original design capacity can be supplied to the load, the battery is considered obsolete and either put to other use or recycled.

Fast Charging, as often suggested for electrical loads such as electrical cars, has typically a very significant impact on the economic life of a battery, and is therefore economically unfeasible in almost all scenarios.

The approach presented here allows removal of the battery units from the load device, and recharging in optimal conditions and with limited time pressure, which extends, rather than shortens, predicted service life: More importantly, because the performance of each individual cell is known and managed, this approach allows segregation into categories. Performance can be segregated along lines of capacity, peak current, cell voltage, temperature rise, and many other parameters. This could in practice be implemented by allowing a consumer with less stringent performance requirements or tighter budget controls, to opt for batteries that have had a longer or more intense history of use.

Figure 17 illustrates schematically how battery units may be segregated and delivered according to battery unit class.

Additionally, rather than declaring an entire "battery pack" obsolete, performance of a tank with a certain performance specification and certain wear level can be partially or totally restored by removing weaker units and replacing them with new ones. Figures 18 and 19 illustrate before and after scenarios, where a number of degraded Tier 3 (low grade) battery units have been replaced with new Tier 1 (high grade) battery units. These new battery units, in combination with the remaining degraded Tier 2 (intermediate grade) battery units, bring the tank capacity back up to the design capacity (e.g. 2OKWh).Since the performance of the new units can meet or exceed the specification of the original units, the total capacity of the tank can in principle be higher than the capacity of the tank when it was first taken into use. This is illustrated in Figure 20.

Also, when more advanced battery technology becomes available or becomes more cost viable, performance of an entire tank might gradually or instantaneously be increased. Older and newer battery technologies can be made to work together without conflict using the methods described in this innovation.

Claims

Claims 1. A dispenser for dispensing charged battery units into a tank of an electrically powered apparatus and comprising: a dispensing container for accommodating a plurality of charged battery units; a conduit having a first end coupled to the dispensing container and a second end adapted to be coupled to a tank to be filled; and a dispensing mechanism for selectively dispensing battery units to the tank through said conduit, the dispensing mechanism comprising a metering unit for monitoring and controlling the number and or state of battery units dispensed.
2. The dispenser according to claim 1, wherein said dispensing container comprises a silo and said conduit is coupled to the bottom of the silo, whereby the battery units are conveyed through the conduit means at least partly by means of gravity.
3. The dispenser according to claim 1 or 2, wherein said conduit comprises a flexible hose.
4. The dispenser according to any of the preceding claims, wherein said dispensing mechanism is arranged to transfer battery units through said conduit by means of pneumatic conveying.
5. The dispenser according to any of the preceding claims, wherein said metering unit is configured to dispense a known number of battery units into the tank and or a known amount of stored electric energy.
6. The dispenser according to any of the preceding claims, wherein said dispensing mechanism comprises means for communicating individually with each battery unit dispensed so as to retrieve information on the state of the battery unit or information stored in the battery units, such as one or more of the following: identification code, charge level, charge cycle, voltage level of the battery unit.
7. The dispenser according to any of the preceding claims and comprising a battery unit recharging system.
8. The dispenser according to claim 7, wherein said charging system is integrated into said dispensing container and comprises a plurality of electric contact pads for making electrical contact with said battery units.
9. The dispenser according to claim 7 and comprising a charging container separate from said dispensing container, wherein said charging system is integrated into said charging container and comprises a plurality of electric contact pads for making electrical contact with said battery units, the dispenser further comprising a transfer mechanism for transferring charged batteries from the charging container to the dispensing container.
10. The dispenser according to claim 8 or 9, wherein said charging system is configured to send programming signals and deliver charging power to battery units via said electric contact pads and, optionally, to receive information from the battery units.
11. The dispenser according to any of the preceding claims and comprising an extraction mechanism for extracting battery units from a tank.
12. The dispenser according to claim 11, wherein said extraction mechanism utilizes at least part of said conduit.
13. The dispenser of claim 11 01 12, wherein said metering unit is configured to detect and record unique identities of extracted battery units.
14. The dispenser of any one of the preceding claims, wherein said metering unit is configured to detect and record unique identities of dispensed battery units.
15. The dispenser according to any of the preceding claims, said dispensing container being configured to contain at least 1000 battery units, and preferably at least 10000.
16. The dispenser according to any of the preceding claims, and comprising a point-of-sale system coupled to said metering system to control the metering system and or reconcile financial charging information in accordance with dispensed battery units.
17. A method of storing electric energy and comprising: loading a plurality of battery units into a container of a charging system such that electrical contact pads of adjacent battery units are or have a high probability of being in contact and the orientation and location of individual battery units within the tank is unknown a priori; identifying one or more optimal electrical energy charging paths through the loaded battery units via contacting electrical contact pads; programming the battery units to cause positive and negative battery unit charging terminals to be coupled to appropriate battery unit contact pads, thereby establishing said optimal energy charging path(s); and supplying power via the established energy supply path(s) to charge the battery units.
18. A method according to claim 17 and comprising repeating said steps of identifying and programming at intervals in order to maintain optimal system performance.
19. A method according to claim 17 or 18, wherein said the or each optimal electrical energy supply path may be a path which branches at intermediate battery units within the tank.
20. A method according to any of claims 17 to 19, wherein said step of identifying comprises identifying two or more optimal electrical energy charging paths, and said step of supplying power via the established energy supply path to charge the battery units comprises coupling the charging paths in parallel.
21. A method according to any of claims 17 to 20, wherein the loaded battery units form a self-organising network such that said steps of identifying and programming are carried out using an exchange of information between battery units.
22. A method according to any of claims 17 to 20, wherein said steps of identifying and programming are performed by a central controller external to the battery units.
23. A method according to claim 22 and comprising transmitting state information from the battery units to the central controller, the state information including, for a given battery unit, details of the connectivity of the battery unit with neighbouring battery units.
24. A method according to any of claims 17 to 23, wherein said step of supplying power via the established energy supply path(s) to charge the battery units comprises supplying power via two or more electric contact pads provided on an inner surface of the tank and which are in contact with ends of the established energy charging path(s).
25. A method according to any of claims 17 to 24, wherein said step of identifying comprises identifying optimal electrical energy charging paths that are in contact with said two or more electric contact pads, these contact pads being a subset of a larger plurality of contact pads.
26. A method of providing electric energy to an electric vehicle, the vehicle comprising a tank for storing a plurality of battery units, the method comprising: locating the vehicle in close proximity to a battery unit dispenser; coupling the tank to the dispenser via one or more battery unit transfer conduits; extracting depleted battery units from the tank via the or at least one conduit; dispensing charged battery units into the tank via the or at least one conduit; and performing metering of the extracted and dispensed battery units for the purpose of financial charging.
27. A method according to claim 26, comprising carrying out the method at a roadside service station.
28. A method according to claim 26 0127 and comprising delivering the extracted battery units to a charging system, and subsequently recharging the depleted battery units.
29. A method according to any of claims 26 to 28, wherein the extraction and dispensing of battery units is controlled by a vehicle user so that, in conjunction with said step of metering, a user defined amount of available electric energy is added to the tank.
30. A method according to any one of claims, wherein said step of dispensing comprises selecting a battery unit type from a plurality of available battery unit types, and dispensing the selected battery unit type.Amendments to the Claims have been filed as folIows: Claims 1. A dispenser for dispensing charged battery units into a tank of an electrically powered apparatus and comprising: a dispensing container for accommodating a plurality of charged battery units; a conduit having a first end coupled to the dispensing container and a second end adapted to be coupled to a tank to be filled; and a dispensing mechanism for selectively dispensing battery units to the tank through said conduit in essentially random order and orientation, the dispensing mechanism comprising means for communicating individually with each battery unit dispensed to retrieve an identification code of the battery unit, and a metering unit for monitoring and controlling the number and or state of battery units dispensed, said metering unit being configured to store the identification codes of the battery units dispensed.2. The dispenser according to claim 1, wherein said dispensing container comprises a silo and said conduit is coupled to the bottom of the silo, wherein the conduit is configured such that battery units are conveyed through the conduit at least partly by gravity.3. The dispenser according to claim 1 or 2, wherein said conduit comprises a flexible hose.4. The dispenser according to any of the preceding claims, wherein said dispensing mechanism is arranged to transfer battery units through said conduit by means of pneumatic conveying.5. The dispenser according to any of the preceding claims, wherein said metering unit is configured to dispense a known number of battery units into the tank and or a known amount of stored electric energy.6. The dispenser according to any of the preceding claims, wherein said means for communicating is additionally configured to retrieve information on the state of the battery unit or information stored in the battery units, such as one or more of the following: charge level, charge cycle, voltage level of the battery unit.7. The dispenser according to any of the preceding claims and comprising a battery unit recharging system.8. The dispenser according to claim 7, wherein said recharging system is integrated into said dispensing container and comprises a plurality of electric contact pads for making electrical contact with said battery units.9. The dispenser according to claim 7 and comprising a recharging container separate from said dispensing container, wherein said charging system is integrated into said charging container and comprises a plurality of electric contact pads for making electrical contact with said battery units, the dispenser further comprising a transfer mechanism for transferring charged batteries from the charging container to the dispensing container.10. The dispenser according to claim 8 or 9, wherein said recharging system is configured to send programming signals and deliver charging power to battery units via said electric contact pads.11. The dispenser according to any of the preceding claims and comprising an extraction mechanism for extracting battery units from a tank.12. The dispenser according to claim 11, wherein said extraction mechanism utilizes at least part of said conduit.13. The dispenser of claim 11 or 12, wherein said metering unit is configured to detect and record unique identities of extracted battery units.14. The dispenser according to any of the preceding claims, said dispensing container being configured to contain at least 1000 battery units.15. The dispenser according to any of the preceding claims, and comprising a point-of-sale system coupled to said metering system to control the metering system and or reconcile financial charging information in accordance with dispensed battery units.16. A method of providing electric energy to an electric vehicle, the vehicle comprising a tank for storing a plurality of battery units, the method comprising: locating the vehicle in close proximity to a battery unit dispenser; coupling the tank to the dispenser via one or more battery unit transfer conduits; extracting depleted battery units from the tank via the or at least one conduit; dispensing charged battery units into the tank via the or at least one conduit in essentially random order and orientation; and communicating individually with each battery unit dispensed to retrieve an identification code of the battery unit; performing metering of the extracted and dispensed battery units for the purpose of financial charging, said metering comprising storing the identification codes of the battery units dispensed.17. A method according to claim 16, comprising carrying out the method at a roadside service station.18. A method according to claim 16 or 17 and comprising delivering the extracted battery units to a charging system, and subsequently recharging the depleted battery units.19. A method according to any of claims 16 to 18, wherein the extraction and dispensing of battery units is controlled by a vehicle user so that, in conjunction with said step of metering, a user defined amount of available electric energy is added to the tank.20. A method according to any one of claims 16 to 19, wherein said step of dispensing comprises selecting a battery unit type from a plurality of available battery unit types, and dispensing the selected battery unit type.