WO2005035288A2

WO2005035288A2 - Vehicle electric battery systems

Info

Publication number: WO2005035288A2
Application number: PCT/GB2004/004267
Authority: WO
Inventors: Martin Mccann
Original assignee: Martin Mccann
Priority date: 2003-10-07
Filing date: 2004-10-07
Publication date: 2005-04-21
Also published as: GB0323436D0; WO2005035288A3

Abstract

A vehicle battery interchange system comprises an interchange bay at which the vehicle may be parked and a fresh battery store (4) containing fresh batteries (8) for loading into the vehicle. A transfer loader transfers batteries (8) between the store and the vehicle. The system operates such that the transfer loader (10) is able to manipulate the batteries to adjust position in mutually perpendicular translational movement directions and also tilt, and/or rotate or yaw about an upright axis, in order to accurately address the battery chamber of the vehicle. Additionally or alternatively, the fresh battery store includes a substantially triangular battery store chamber or cage for containing substantially triangular configuration batteries and/or the vehicle includes a substantially triangular battery chamber for receiving the triangular configuration batteries.

Description

Vehicle Electric Battery Systems

The present invention relates to vehicle electric battery systems.

In the case of batteries and vehicles, exhausted or partially exhausted batteries can be exchanged for charged or partially charged ones using manual, semi-automatic or fully automatic machinery, thus providing the vehicle with a renewed on-board fuel supply more quickly than can be achieved by recharging batteries fixed within the vehicle. However, such systems have gained limited market acceptance.

Known vehicle electric battery systems are disclosed in, for example, US-A-4342533, US-A- 5711648 and US-A-5378555.

The present invention is directed to enable electric vehicles with interchangeable batteries to be technically and commercially viable in wider applications than has been achieved to date.

The salient technical features, collectively or separately, provide advantages for battery interchange techniques for several types of vehicle, including goods and passenger vehicles, cars and niche-market application vehicles. Features of the invention can be utilised in applications where goods, materials or components, which are advantageously not handled by hand, are required to be transferred between structures which are not permanently, or semipermanently aligned.

The packaging of conventional heavy-duty batteries does not lend itself to simple techniques for making electrical connection between batteries, and/or between batteries and the vehicle. The quantity of batteries required to achieve a practical range and performance for a vehicle is considerable. Several hundred kg, in the case of a family car, and in the region of a tonne or more, for a light commercial vehicle or bus. Such a volume of batteries, passing laterally across the vehicle, presents significant difficulties for the design and practicality of some vehicles if the batteries are designed to pass over, under or otherwise around the structural chassis of the vehicle

Passing conventional batteries through appropriately shaped and sized apertures within the 'envelope' of a conventional commercial vehicle chassis presents significant structural design difficulties for some vehicles which can only be addressed by adding extra strength and or rigidity to the chassis . This extra strength and or rigidity can be achieved by making the chassis larger, by adding extra structural material (typically metal) to the chassis, by designing the batteries or battery 'module' to contribute to the structure of the chassis, or by a combination of these and or other measures, each of which may be disadvantageous. It is perceived that the above issues have combined to thwart previous attempts to achieve a viable lateral battery transfer system for vehicles in wider applications.

According to a first aspect, the present invention provides a vehicle battery interchange system comprising; an interchange bay at which the vehicle may be parked; a fresh battery store containing fresh batteries for loading into the vehicle; a transfer loader arrangement for transferring batteries between the store and the vehicle; wherein: i) the transfer loader is arranged to receive batteries retrieved from the store and manipulate the batteries to adjust position in mutually perpendicular translational movement directions and also tilt, and/or rotate or yaw about an upright axis, in order to accurately address the battery chamber of the vehicle; and/or: ii) the fresh battery store includes a substantially triangular battery store chamber or cage for containing substantially triangular configuration batteries; the vehicle including a substantially triangular battery chamber for receiving the triangular configuration batteries.

The transfer loader preferably includes a support platform or surface for the batteries, the support platform or surface being reorientatable (preferably tiltable in 'roll' and 'pitch' nature and/or being rotatable about a vertical axis for 'yaw' variation).

According to a second aspect, the present invention provides a transfer loader arrangement for manipulating the positional orientation of batteries for loading to a vehicle, the transfer loader having a support platform arranged to receive batteries retrieved from a store and manipulate the batteries to adjust position in mutually perpendicular translational movement directions and also tilt and/or permit rotation about an upright axis, in order to accurately address the battery chamber of the vehicle, or the store.

According to a further aspect, the present invention provides an electrically powered vehicle including a ^"battery chamber substantially triangular in cross section, configured to receive a substantially triangular battery.

According to a further aspect, the invention proves a triangular battery having electrical terminals enabling electrical connection to like batteries arranged in-line, or other contact means.

According to a further aspect, the invention provides a substantially triangular cross-section structural member defining a battery chamber, substantially triangular in cross-section, configured to receive a substantially triangular cross-section battery.

According to a further aspect, the invention provides a vehicle electric battery arrangement comprising a bearing element arrangement provided on the exterior of the battery facilitating positioning of the battery in a receiving chamber of the vehicle.

According to a further aspect, the invention provides a vehicle electric battery arrangement comprising a battery receiving chamber on the vehicle, the chamber having opposed open ends, enabling loading of batteries via an open end and preferably battery unloading via the opposed open end; the arrangement comprising a plurality of batteries arranged in side by side relationship in the chamber and open-able closure elements at opposed ends of the chamber. Preferred features are presented in the appended claims and/or described in the detailed description of the preferred embodiments, which follow.

The invention will now be further described in specific embodiments, by way of example only and with reference to the accompanying drawings, in which:

Figure 1 A is a schematic explanatory plan view of an exemplary vehicle battery interchange system in accordance with the invention; Figure IB is a schematic explanatory plan view of an alternative exemplary vehicle battery interchange system in accordance with the invention;

Figure 1C is an end view of the system of figure IB; Figure ID is an end view of the system of figure 1A;

Figure 2 is a schematic view of an exemplary transfer loader apparatus in accordance with the invention; Figures 3A to 3D are plan views of the apparatus of figure 2 in various operational configurations;

Figure 4 is a schematic view of a vehicle battery retaining chamber according to the invention; Figure 5 is a schematic view of a battery connection system suitable for use in accordance with the invention.

Figures 6 A to 6F show various alternative configurations of vehicle battery receiving chamber profiles and battery or battery module configurations;

Figures 7 A to 7E show possible arrangements of cells combined in to generally triangular battery or battery module profiles;

Figure 8 is a schematic view of a vehicle in accordance with the invention.

Referring to the drawings and initially to figures 1 A to D, there is shown a vehicle battery interchange system 1 comprising a parking bay 2 accommodating a vehicle 3. In the embodiment shown in figure 1 A, the parking bay 2 is positioned intermediate respective store racks 4,5 and transfer loaders 6,7. The transfer loaders 6,7 operate to remove spent batteries (or battery modules) from the receiving chamber of the vehicle 3 and transfer to a suitable receiving station in the store racks 4,5. Similarly fresh charged batteries or battery modules are transferred from the store racks 4,5 and loaded into the battery receiving chamber (or chambers) of the vehicle. The operation of the system and in particular the transfer loaders 6, 7 will be described in detail. In the embodiment shown respective store racks 4,5 and transfer loaders are shown on both sides of the vehicle (figures 1 A and ID). It should however be readily appreciated that in a simpler embodiment a store and transfer loader on one side only of the vehicle need be provided (figures IB and 1C), particularly where loading and unloading of batteries/modules to and from the vehicle is accomplished via one open end only of the vehicle battery chamber. Typically the vehicle battery chamber will be a space frame structural member of the vehicle extending transversely across the width of the vehicle.

Since batteries physically transfer between store rack 4,5, transfer loader 6,7 and vehicle , the mechanical design of the store rack 4,5, loader 6,7 and vehicle, are all compatible with the mechanical design of the batteries or battery modules. However, since other design requirements of rack, loader and vehicle vary, their detailed mechanical design may vary accordingly.

Since batteries or modules electrically (and/or otherwise) connect to both store rack and vehicle, the electrical design of rack and vehicle are compatible with the electrical design of the batteries. However, since detailed electrical requirements of rack and vehicle vary, their electrical design may vary accordingly.

The battery transfer loaders 4,5 are designed to transfer batteries between vehicles and storage racks, under manual, semi-automatic or fully automatic control.

The transfer loader (for example loader 6/7) consists of a mechanical structure which inserts and extracts batteries into and out of both store rack and vehicle battery chamber and carries batteries betweenrack and vehicle. The transfer loader canbe controlled to manoeuvre, (within limits) in the axes known as; X, Y, Z, and the orientations known as Pitch, Roll and Yaw, to accurately address apertures in rack and vehicle. 'Addressing' an aperture means to align with and manoeuvre into the position required, in order to effect battery transfer.

By means of motion control components, e.g. motors, hydraulic, pneumatic or other systems, wheels, bearings, shafts, pivots, locks, chains, cables, gears, links, couplings, etc. the loader is able to 'address' each aperture (or group of apertures) in the rack, and transfer batteries between rack and loader. Similarly, the loader is able to address each aperture (or group of apertures) in the vehicle, and transfer batteries between loader and vehicle.

Similar motion control components are arranged to propel the batteries along the associated bearings, in vehicle, loader and rack, and therefore, are designed to mechanically, or otherwise, engage and disengage with the batteries or battery modules.

The accurate addressing of the vehicle is more onerous than the addressing of the battery rack since the battery rack may be a static device, whereas the vehicle is not. For example, the vehicle may not be parked in perfect alignment with the loader and, for various reasons, the vehicle apertures may not be perfectly horizontal.

In both cases (addressing loader to rack and loader to vehicle), the addressing may be achieved under manual control by a trained operator, or by an automated or semi-automated system. The accuracy of addressing may be achieved or assisted by the use of mechanical guides and / or sensors (electromagnetic, optical, acoustic, or other type) which can, by means of an operator interface, inform the operator of loader control actions (manoeuvres) required to achieve the addressing. Alternatively when connected to a control system, accurate address may be achieved by electronically or otherwise ascertaining the location and orientation of the battery apertures within the vehicle and, by means of the control system, align the loader with the apertures with the required accuracy, and manoeuvre the loader into the required position.

Exemplary transfer loaders 6 and 7 are shown in figures 1 A to ID and in more detail in figures 2 and 3. In the embodiments shown, four support columns 9 include worm gear shafts operatively connecting to respective corners of a support platform 10. Respective motors 11 are mounted to the top of each worm gear shaft to enable selective rotation of the respective shafts. The transfer loader is mounted on respective wheels 20 or castors driven by a motor 12.

The support platform 10 supports a battery cradle 13. By manoeuvring the support frame, the cradle is also manoeuvred. Mounted in the cradle 13 when selected from the store racks or vehicle battery compartment are batteries or battery modules. The arrangement enables reorientation of the batteries in cradle (on platform 10), in X, Y and

Z directions. Movement along the length of the vehicle (X direction) is accomplished by translational movement of the wheels 20 (which may be constrained to move on rails). Movement in the Z direction (vertically) is accomplished by synchronous rotation of the motors 11 to raise the platform 10 at constant attitude.

In addition the attitude or tilt of the platform and hence the supported batteries, modules or cradle can be varied by tilting the platform about plural, for example mutually perpendicular axes. This is accomplished by rotation of individual or pairs of motors 11 to raise or lower corners of the platform 10.

Movement in the Y direction (into the paper in figure 2) is accomplished by a combination of two mechanisms.

First Mechanism: The cradle can manoeuvre, within limits, independently of the support frame, by means of motors 28 and worm gears 29. Such motion is facilitated by means of bearing surfaces 14.

When the two motors (and worm gears) are driven equally, in (say) a clockwise direction, the cradle moves towards the vehicle, when driven equally in the opposite direction, the cradle moves towards the rack. These motions provide a limited amount of motion in the Y direction, sufficient to allow the cradle to address, and make contact with, the vehicle and rack.

When the two motors (and worm gears) are driven in a clockwise direction but by differing amounts, the cradle moves towards the vehicle and also rotates about an upright axis providing orientational adjustment of yaw, either positive or negative, depending on the difference in the amounts the motors have been driven. In this case the cradle both slides on, and pivots around, the pivot point 15.

When the two motors (and worm gears) are driven in the opposite direction, it is arranged that they are always driven by equal amounts, since little or no yaw adjustment is required when addressing the rack. Furthermore, the mechanical guide 16 assists in maintaining cradle yaw alignment when addressing the rack, but has no effect (is not engaged) when addressing the vehicle.

Second Mechanism:

Each battery chamber in the cradle is equipped with a motor driven, endless, toothed belt which engages with appropriate toothed features on the batteries or battery modules and thereby propels the batteries or battery modules towards, and into, the vehicle or rack, or drags batteries or battery modules out of vehicle or rack, depending on the direction the belt is driven by the motor.

Battery movement in the Y direction, into the paper in figure 2 (Y direction in figures 1 A to ID) is accomplished by a combination of the driving of the two motors 28 and worm gears 29 and the driving of the motorised, endless, toothed belts. In one embodiment as shown for example in figures 3 A to 3D the support cradle 13 may be mounted to the underlaying support platform lObymeans ofapivotmount 15. Motors 28 and worm gear arrangements 29 can be operated to rotate the cradle clockwise or counterclockwise about the pivot mount 15 (arrow F in figure 3 A) and also advance or retract the cradle (Y direction). The rotation about pivot mount 15 corresponds to yaw movement control of the arrangement. In figure for example, figure 3A shows the cradle positioned in its 'home' position. Figure 3B shows the cradle addressing the store rack side of the transfer loader. Figure 3 C shows the cradle addressing the vehicle side of the transfer loader with positive yaw. Figure 3D shows the cradle addressing the vehicle side of the transfer loader with negative yaw.

The specific embodiments described enabling positional manipulation of the batteries, modules or cradle of the transfer loader are exemplary only. It will readily be appreciated that other arrangements such as for example pneumatic, hydraulic or solenoid systems could be utilised to achieve comparable effects.

The batteries may be packaged, or re-packaged, so as to enable a simple, convenient method of electrical connection between adjacent batteries and / or between the batteries and the vehicle.

In use the batteries are positioned within receiving chambers extending across the vehicle

(having passed into the chamber from either side of the vehicle). Typically the battery receiving chamber (see item 30 in figure 4) is a structural member of the vehicle chassis extending transversely across the vehicle. By virtue of being supported on common bearings or bearing surfaces, the batteries are mechanically aligned with each other.

In one embodiment (shown in Figure 4), the electrical (and other) terminals are located on the batteries, such that the tenninals are facing towards the side of the vehicle, along or in parallel with the axis of the aperture. Adjacent batteries are electrically (and otherwise) connected to each other by virtue of the alignment of the terminals, as is commonly achieved in a torch or flash-light. Where the chosen connectors are in 'mating' pairs, the 'male' connector on each battery is aligned with the ' female' connector on the adj acent battery , and vice versa, (except, of course, in the case of the end-most batteries).

A retractable connector mechanism is incorporated into the vehicle, at one or both open ends of the chamber (at the sides of the vehicle). In the retracted position, the Retractable connector mechanism, allows the batteries to traverse, unimpeded, into and out of the aperture, and in the closed position, electrically connect to the end-most battery in the chamber (and thereby, to all connected batteries in the chamber) . Of necessity the Retractable connector mechanism will be equipped with terminal(s) which align and 'mate' with the terminal(s) on the end-most battery when in the 'closed' position and conductor(s), to facilitate the transfer of electricity across the retraction mechanism and onto the main structure of the vehicle. The Retractable connector mechanism maybe designed so as to form 'door(s)' at the end(s) of the chamber(s) and may incorporate mechanical, electrical or other components or features, described in this patent or otherwise, for example Retractable connector mechanism, door or battery locking devices may be incorporated and/or battery or terminal compression mechanisms may be incorporated. For example the end doors 31 , 32 in the embodiment of figure 4 which can pivot from the locked closed position as shown in figure 4 to an open position about pivot axes 33. Where the vehicle is equipped with multiple chambers for the accommodation of batteries, each chamber requires an Retractable connector mechanism arrangement to facilitate battery entry / exit and connection / disconnection, hi such case, the 'Retractable connector mechanisms may be mechanically or electrically connected together or in groups, and may operate in concert, in groups or independently of each other. The motion of the Retractable connector mechanisms may be achieved manually, by means of sensors and/or actuators connected to a control system, or by other method.

In an alternative embodiment shown in Figure 5, the batteries are electrically (and otherwise) connected, on an individual basis, to the vehicle by means of the positioning of the terminals on the battery and the corresponding positioning of the terminals on the vehicle. The battery terminals may be positioned anywhere on the periphery of the battery case. The position of the vehicle terminals must correspond, within acceptable tolerances, to the position of the battery terminals. The vehicle terminals mechanically approach, and mate with, the battery terminals by moving on an axis or axes (for example axis L in Figure 5) transversely to the axis of the battery receiving chamber (or vice versa, i.e. the battery terminals maybe arranged to approach the mating terminals on the vehicle).

There are a number of techniques of achieving this including, as shown in figure 5, by means of a cam-shaft 41 running across the vehicle (or battery) which rotates to various angular positions, such that the cams 40 move the terminals 42 to be shifted between the required positions (connected and disconnected). Alternatively, electro-mechanical devices such as solenoid actuators, controlled by a control system, may move the terminals to be shifted between the required positions (connected and disconnected). The rotation of the cam-shaft(s) 41 , and or the actuation of the solenoid(s), may be achieved manually, by means of device(s) connected to a control system or by other methods. Where the vehicle is equipped with multiple chambers for the accommodation of batteries, a single actuator arrangement may be arranged to operate the connection and disconnection of batteries in one or more apertures. Where multiple actuator arrangements are provided, they may be mechanically or electrically connected and may operate in concert, in groups or independently of each other.

Batteries are equipped with positive and negative terminals. Within batteries, between battery modules, between battery modules and the vehicle and between batteries in adjacent apertures in the vehicle or rack, the connections between batteries are arranged such that the cells are connected in series or in parallel, or a combination of series and parallel, as required by the system design.

The receiving chamber (or chambers) of the vehicle maybe designed to accommodate batteries extending across the full width of the vehicle or across a lesser extent. In any event, the complement of batteries within an aperture may be designed as a single module (assembly) or may be composed of a number of separate batteries or modules. Where composed of separate batteries or modules, it maybe advantageous to design the complement of batteries within an aperture to be held together in groups by means of a rigid or flexible mechanical or other coupling device thus forming a 'train' of batteries. The device maybe selected and arranged to have a manual or automatic 'quick release' function and, or to 'engage' manually or automatically.

The Retractable connector mechanism ma be arranged to be locked or secured, in the 'open' and or 'closed' positions, by means of mechanical or electro-mechanical device(s). In addition, the function of locking the Retractable connector mechanism in the 'closed' position, may also serve the function of locking or securing the batteries in position, especially important for when the vehicle is in motion.

Alternatively (or in addition to the above), the batteries may be locked or secured in position by a separate mechanical or electro-mechanical mechanism on an individual, group or collective basis. Such locking arrangements may be a necessity for the vehicle and may also be applied on the loader and rack as deemed appropriate.

The activation of the lock(s), maybe achieved manually, by means of device(s) connected to a control system or by other methods.

Bearings can be used in any position or orientation allowed within their specification to facilitate lateral battery transfer.

The passing of batteries onto and off the vehicle without undue friction or wear may be facilitated by the use of wheels, castors, bearings or other 'sliding' components (henceforth referred to as bearings). Bearings are often constructed in two parts which maybe referred to as the bearing and the bearing surface. Either of these parts can be incorporated into or added to the battery case or module while the other part can be incorporated into or added to the vehicle. It is implicit that, where the chosen bearings come in two parts, the position of the part incorporated into the vehicle is compatible with the position of the part incorporated into the battery or module. The bearing parts incorporated into the vehicle are arranged to support the weight of the batteries in the aperture, and are themselves supported by the structure of the vehicle, or may, advantageously, be an integral part of the structure of the vehicle. In the latter case, the bearing and structural member are a single or combined feature providing two functions simultaneously; bearing function and structural function. This provides benefits in terms of weight reduction and manufacturing simplicity. The bearings extend across the vehicle, the full distance that the batteries are required to travel within the aperture. The bearings provide mechanical guidance to maintain the alignment of the batteries within the aperture during the traverse, and assist in maintaining the position of the batteries when the vehicle is in motion.

The bearings can be located at any position around the periphery of the batteries (as viewed along or in parallel with the axis of the aperture), providing there is no clash with other feature(s) or component(s). They may protrude from the periphery of the battery or may be incorporated (or partially incorporated) into the body of the battery. In some cases the bearings are advantageously located at or near the corners of the battery. For example, the battery module of figure 5 includes side frame bearing runners 52 that cooperate with complementary shaped bearing rails 53 provided in the interior of the battery receiving chamber of the vehicle. (See for example the embodiment of figure 8.)

During the battery interchange process, the batteries traverse between vehicle, loader and rack.

The batteries, vehicle, loader and rack are equipped with the same or compatible bearing devices as each other, so as to facilitate the smooth motion of the batteries throughout their manoeuvres in the system. In fact, at any point in the life of the batteries, where they are mechanically handled, the bearings may be used to facilitate low friction motion.

Of necessity, when batteries traverse between vehicle, loader, rack, etc., the batteries must successfully traverse the interfaces between these devices without undue difficulty. Alignment of the bearings fitted to the vehicle and loader, and between the bearings fitted to loader and rack must, therefore, be achieved to within acceptable tolerances. Achieving and maintaining the alignment of these 'bearing joints' during battery transfer may be onerous, particularly since the vehicle may not be parked in perfect alignment with the loader and, for various reasons, the vehicle structure may not be perfectly horizontal, and because during the battery transfer, considerable mass may be shifted between vehicle and loader which may tend to move one with respect to the other.

The security of the bearing joints may be achieved using various techniques, or combinations thereof, including; (in addition to, or instead of, any electronic alignment system) arranging for the ends of the bearings which make contact in the joint to mechanically 'mate' or lock with each other, or by arranging the bearings to securely align by virtue of other devices 'mating' or 'locking' or by arranging the joint between bearings (or other devices) to be under a compressive force which holds the joint firm. Advantages of these battery connection techniques, bearing arrangements, module arrangements and locking mechanisms include:

The battery and associated terminals, conductors, bearings, alignment, locking and other components are combined and incorporated into a single item; the battery case or module and, when so designed, along with their corresponding components in the vehicle, facilitate the lateral transfer of batteries between loader and vehicle in a single motion, along a single (largely) horizontal axis.

Electrical (and other) connection and disconnection between batteries and between batteries and vehicle, is achieved rapidly.

Combining components in this way enables some multiple functions to be provided in a single assembly.

There is no requirement to provide components for the conventional connections between batteries or between batteries and vehicle (nuts, bolts, wires, etc.).

There is no requirement to provide a heavy battery support frame with associated bearings, alignment mechanisms, locks, other components and their associated weight penalty.

Maintenance can be carried out on the batteries, conveniently off the vehicle.

Batteries can be rapidly separated from the battery module for maintenance or replacement.

Batteries and modules can be rapidly separated and joined together.

The required volume of batteries, passing laterally across the vehicle, presents significant difficulties for the design and practicality of some vehicles if the batteries are designed to pass over, under or otherwise around the structural chassis of the vehicle

Passing conventional batteries through apertures within the 'envelope' of a conventional commercial vehicle chassis presents significant design difficulties for some vehicles which can only be addressed by designing the chassis to be larger, heavier, or by designing the battery 'module' to be structural, or a combination of these and or other measures.

However, several methods of fabricating structures exist, which allow the structural material or members to occupy only a small fraction of the volume or 'envelope' of the structure, such structures are commonly known as space frames. Motor-sport vehicles, where a high strength- to-weight ratio is advantageous, are commonly constructed using space frame chassis fabricated from tubular material. Other applications exist and can be conceived of, where the space frame is fabricated by cutting sheet materials with the desired profile, and then folding and joining them into the final shape required. Space frames canbe fabricated using a variety of materials and manufacturing techniques and, in principle, any of these can be used in this application.

It can be arranged that receiving chambers in a space frame traverse the entire structure such that a solid object can pass into or through the structure, unimpeded. The object passing into or through the structure can be of any shape providing it's dimensions are such that there is adequate 'clearance' between the object and the structural members of the frame. The salient features of space frames which the present invention takes advantage of are:- a) Space frames, when compared with any other structure of the same material, provide a high strength-to-weight ratio. b) The volume occupied by space frames consist largely of empty space (or air). c) The structural members of space frames can be confined to planes within the structure, leaving 'chambers' in-between the structural members which traverse the entire structure. d) The structure can be ananged to have one or more similar chambers designed to accommodate batteries, thus allowing one or more similar battery 'modules' to be loaded.

The chambers within the structure of space frames according to the invention are preferably generally regular and triangular, or largely triangular. However, chambers in space frames can be arranged to be irregular, and any shape, providing that adequate structural integrity is provided by the overall structure.

The present invention includes a system where the chassis of a vehicle (or other structure) is fabricated as a space frame and the batteries (or other items) pass into, or through, the open ends of chambers in the frame. The batteries can be of any shape but to achieve the maximum packing density (of batteries within the space frame), the batteries would, advantageously, be the same shape as the chambers in the space frame.

It is particularly beneficial in terms of the strength-to-weight ratio of space frames, that the chambers are designed to be triangular or largely triangular. In such case, it is advantageous in terms of the packing density of batteries within the space frame, that the batteries are also designed to be triangular or largely triangular in at least one profile.

Methods are proposed for the fabrication of batteries which are triangular, or largely triangular, in at least one profile. A cell can be thought of as the smallest unit of a device which stores electro-chemical energy and, when appropriately connected to an electrical circuit, provides voltage and electrical cunent as a result of the electro-chemical activity within it. Many combinations of chemicals can be constructed to form cells. Commonly, cells are constructed with an anode (+ve) and a cathode (-ve) which are accessible via terminals on the outside of the packaging and through which the electrical energy can be stored (in the case of a rechargeable cell) and withdrawn from the cell.

A battery is a set (or collection) of cells connected in series or parallel, or a combination of series and parallel. Combining cells into batteries provides flexibility of design and convenient values for the current, voltage and other parameters required.

The cells or batteries can be arranged in any position or orientation allowed within their specification. The design of the internal construction of a cell is crucial to it's performance. The present invention, however, is concerned more with the design of the outward shape (or profile) of the cell, and how the cells can be designed to be triangular or ananged to form a triangular battery or battery module.

This can be achieved in several ways. Regardless of the chemistry or construction of the cell, it can be arranged that the individual cell has a triangular profile, either through the shape of the electro-chemical body or through the packaging of the cell. A single cell of any shape can be packaged in a case which has a triangular profile. Commonly, the internal construction of the cell is a pair, or pairs, of 'plates'. The plates can be arranged to be triangular, or arranged in a triangular formation, and so packaged to form a single cell which is triangular in at least one profile. The cells can be constructed in any shape or shapes so that when arranged in an appropriate combination, form a triangular profile.

Also commonly, the internal construction of the cell is a pair or pairs of rectangular 'plates' which have been 'rolled-up' prior to packaging thereby forming a cylinder. Cylindrical cells or batteries can also be fabricated by other methods, e.g. by the assembly of disk shaped or disk-like plates. Cylindrical cells of any internal construction can be geometrically combined to form a triangular profile. The number of cylinders required follows the mathematical series:- 3, 6, 10, 15, 21, 28, etc. Where larger numbers (than 3) of cylindrical cells are arranged into a triangular profile, cells at the comers of the triangle, and in other positions, can be omitted whilst the overall profile remains largely triangular.

A single triangular cell can pass into or through a triangular chamber space frame as described. However, by combining triangular cells in an end-to-end formation, in a tessellafing formation, or in a combination of tessellations or formations, a triangular battery can be formed which again, can pass into or through a space frame as described.

Figures 6A to 6F show various battery module shapes 65 accommodated in generally triangular (or diamond) shaped space frame structural members 62. Figures 7A to 7E show various triangular profile battery modules 71 containing various shaped battery cells 75.

The essential features and components of a system facilitating lateral battery transfer have been described. The operation and overall features of the system will now be described. There are design features for battery interchange machinery and battery charging facilities described herein, which can be used advantageously in other battery interchange or similar applications. They are intended to be included, collectively and separately, in the scope of the invention.

The batteries may pass into one side of the vehicle battery chamber and out of the other side of the battery chamber, or may be both inserted and extracted from the same side. Where the batteries do not extend across the full width of the vehicle, their normal position in the vehicle will be largely central so as to achieve an acceptable weight distribution

When the batteries are extracted from the vehicle they are stored in a battery rack. As well as storage, the battery rack may provide facilities for discharging and, or, re-charging the batteries, by means of electrical terminals within the rack, connected to battery charging or other electronic equipment. Connections for purposes other than electricity transfer may be similarly provided between batteries and rack and, or, between batteries and vehicle, e.g. for data communications.

The battery rack may accommodate one or more sets of batteries (per vehicle) so as to allow the system to provide 'off vehicle' battery recharging and virtually continuous operation of vehicles (when compared with the on-board recharging of batteries fixed within vehicles).

The vehicle may be designed with one or more chambers for the accommodation of batteries which, at any time, may or may not be occupied by batteries, as is appropriate for the journey length being undertaken (similarly to the way any fuel tank can be partially filled). This is particularly advantageous for vehicles powered using batteries because batteries are generally heavy and carrying more batteries than is necessary for the journey unnecessarily increases the weight, and thereby the fuel consumption, of the vehicle. The battery interchange stations may be installed in one or more locations such that a network is created and vehicles can refuel at one or more stations.

Vehicles originally designed and built for other types of fuel and refuelling systems can be retrofitted with equipment to make them compatible with this type of system. Combined vehicle power systems including interchangeable electric batteries are also envisaged as encompassed by the scope of the present invention, for example hybrid vehicles.

As well as, or instead of, loading batteries onto a vehicle using lateral transfer, the loading of cargo onto a vehicle may be achieved in largely the same way using largely the same types of components and or principles.

The batteries or battery modules may incorporate electronic or other components for the purposes of battery management, monitoring, metering, control, electronic memory, communications and, or, other functions. Such components may advantageously communicate with the vehicle and, or, with the charging station or both.

The vehicle itself, and battery interchange station may communicate with each other, either continuously, periodically, on approach to the station, or when within it.

The battery interchange station may communicate with other battery interchange stations and, or, with remote control and monitoring points.

All such communications, between batteries, vehicles, stations and remote monitoring and control points may be simplex or duplex and may be achieved by use of any appropriate and available technology and communications protocol including electronics, infra-red, optical, dedicated or fixed telephone line, radio (including mobile phone network), internet or other means.

The communications may include monitoring and control data on, for example^ a) Battery, vehicle, route, driver, owner and fleet identification. b) System and component status, capacity, content, condition, performance, safety and, or, security. c) Vehicle mass, cargo mass, destination, range or battery requirement. d) Historical data.

There may be a requirement for the driver to provide confirmation of identity and, or, other data which would be conveniently provided in the form of magnetic media, smart card, P. IN. and, or, other automatic or manual input. Such facilities may be provided in the form of a 'Driver Interface' which would be conveniently accessible to the driver, advantageously without the need for the driver to disembark. The Driver Interface may be a fixed item in the cab of the vehicle or could be could be integral to the station and conveniently accessed by the driver, e.g. through the window of the vehicle.

The entire battery interchange station, or major components within it, e.g. the battery racks may be enclosed within walls, fitted with appropriate doors and, or, gates for authorised personnel and, or, vehicle access. Such enclosing may provide or assist with environmental (weather) protection, heat recovery, Health and Safety requirements and site security.

Both the vehicle and station may be provided with integrated safety and security features including an emergency shutdown function which may be triggered by various detected conditions including manual activation by the driver or other personnel.

There may be a requirement for an operator for security purposes and, or, to monitor the machine and system function during the battery interchange process. This may be a dedicated operator or may be the driver of the vehicle. In either case, they would be provided with an appropriate system interface providing relevant data and shutdown facilities.

The components and sub systems of the system would, where appropriate, be controlled and monitored by dedicated systems (sub-system controllers) which would, advantageously, communicate with overall control and monitoring equipment, thus forming an integrated system. Typically, the overall control and monitoring equipment would be a programmable logic controller.

Claims

Claims:

1. A vehicle battery interchange system comprising; an interchange bay at which the vehicle may be parked; a fresh battery store containing fresh batteries for loading into the vehicle; a transfer loader arrangement for transferring batteries between the store and the vehicle; wherein: i) the transfer loader is arranged to receive batteries retrieved from the store and manipulate the batteries to adjust position in mutually perpendicular translational movement directions and also tilt, and/or rotate or yaw about an upright axis, in order to accurately address the battery chamber of the vehicle; and/or: ii) the fresh battery store includes a substantially triangular battery store chamber or cage for containing substantially triangular configuration batteries; the vehicle including a substantially triangular battery chamber for receiving the triangular configuration batteries. 2. A vehicle battery interchange system according to claim 1 , wherein the transfer loader is positioned adjacent a battery chamber of the vehicle and the fresh batteries loaded via one open end of the chamber whilst spent batteries are unloaded via the opposed open end of the chamber.

3. A vehicle battery interchange system according to claim 2, wherein spent batteries exit the chamber as fresh batteries enter the chamber.

4. A vehicle battery interchange system according to any preceding claim, wherein the transfer loader is arranged to facilitate battery movement in three mutually perpendicular axes (x,y,z).

5. A vehicle battery interchange system according to any preceding claim, wherein the transfer loader facilitates positioning adjustment in tilt orientations and also enables positional yaw adjustment.

A vehicle battery interchange system according to any preceding claim, wherein the transfer loader is manually controllable to be positionally adjustable.

7. A vehicle battery interchange system according to any preceding claim, wherein the transfer loader is computer controlled to be positionally adjustable.

8. A vehicle battery interchange system according to claim 7, wherein a control system monitors the relative positions of the target vehicle battery chamber and the transfer loader and appropriately adjusts the position of the transfer loader to ensure accurate alignment for battery transfer.

9. A vehicle battery interchange system according to any preceding claim, wherein the spent batteries are received by a transfer unloader arrangement which transfers the batteries to a spent battery store.

10. A vehicle battery interchange system according to any preceding claim, wherein the system includes a battery charge system for charging batteries in the system.

11. A vehicle battery interchange system according to claim 10, wherein the battery charge system facilitates monitoring of charging of batteries.

12. A vehicle battery interchange system according to any preceding claim, wherein, in each transfer event, batteries are transferred into the vehicle as a series of end to end aligned batteries either arranged to have mate-up battery to battery connectors, or connectors connected by means of connection to the vehicle when installed in the battery chamber of the vehicle.

13. A vehicle battery interchange system according to any preceding claim, wherein the transfer loader includes a support platform upon which the batteries are supported during transfer, preferably including a support cradle within which the batteries are supported.

14. A vehicle battery interchange system according to claim 13, wherein the support platform and/or the support cradle comprises a conveyor facilitating 'roll-on' 'roll-off transfer to and from the loader.

15. A vehicle battery interchange system according to any preceding claim including data communication means for data communication between the vehicle (including vehicle systems) and the vehicle battery interchange system, and the vehicle batteries orbattery modules.

16. A vehicle battery interchange system according to claim 15, wherein data communicated relates to one or more of: on-board battery charge status; battery, vehicle, route, driver or fleet identification; system and component status, capacity, content, condition, performance; safety or security; vehicle weight, cargo weight, destination, range or battery requirement; historical data.

17. A vehicle battery interchange system according to claim 15 or claim 16, wherein data is communicated via wireless means such as radiofrequency, microwave, optical or other means. 18. An electrically powered vehicle including a battery chamber substantially triangular in cross section, configured to receive a substantially triangular battery.

19. A vehicle according to claim 18, wherein the battery chamber extends across the vehicle in a direction transverse to the direction of travel of the vehicle.

20 A vehicle or system according to any preceding claim, wherein the battery chamber comprises a structural frame member of the chassis.

21. A vehicle according to claim 20, wherein the frame member comprising the battery chamber extends across and is connected to at least two longitudinally running chassis frame members of the vehicle.

22. A vehicle according to any of claims 18 to 21, wherein the battery chamber comprises a structural frame member of the vehicle chassis passing transversely through a longitudinally running chassis frame member of the vehicle.

23. A vehicle according to any of claims 18 to 22, wherein the battery chamber has opposed ends permitting battery passage such that a battery loaded from one end may be ejected via the other end.

24. A vehicle according to any of claims 18 to 23 , wherein the battery chamber is arranged to house a plurality of triangular batteries in end to end relationship.

25. A vehicle according to any of claims 18 to 24, wherein a plurality of substantially triangular cross-section battery chambers are provided in side by side relationship. 26. A vehicle accordingto claim25, wherein the sidebyside substantially triangular cross section battery chambers are arranged in tessellated relationship.

27. A vehicle according to any of claims 18 to 26, wherein the battery chamber is in cross section a substantially equilateral triangle.

28. A triangular battery having: i) electrical terminals enabling electrical connection to like batteries arranged inline, or other contact means; and/or ii) generally circular section cells disposed internally of the generally triangular outer profile of the battery.

29. A triangular battery according to claim 28, wherein an outer substantially triangular cross-section casing houses a plurality of smaller battery cells.

30. A triangular battery according to claim 29, wherein the smaller battery cells are generally triangular in cross-section and ananged in tessellated relationship.

31. A triangular battery according to claim 29 or claim 30, wherein the outer casing has terminals for connection to like batteries arranged in-line, or other contact means.

32. A triangular battery according to any of claims 29 to 31 , wherein walled compartments are provided internally of the outer triangular casing defining a plurality of smaller triangular battery cells.

33. A substantially triangular cross-section structural member defining a battery chamber, substantially triangular in cross-section, configured to receive a substantially triangular cross-section battery.

34. A vehicle electric battery arrangement comprising a bearing element arrangement provided on the exterior of the battery facilitating positioning of the battery in a receiving chamber of the vehicle.

35. A vehicle electric battery arrangement according to claim 34, wherein the bearing arrangement comprises a slider or skid, rail or track mount for the battery arrangement.

36. A vehicle electric battery anangement according to claim 34 or 35 , wherein the bearing arrangement comprises a rotatable support member arrangement comprising one or more rotatable support members such as wheels, rollers castors or the like.

37. A vehicle electric battery arrangement according to any of claims 34 to 36, wherein the bearing element arrangement includes a bearing surface of friction reducing material or finish.

38. A vehicle electric battery arrangement according to any of claims 34 to 37, wherein the bearing elements comprise complementary engaging bearing elements provided for the battery arrangement and the battery receiving chamber of the vehicle.

39. A vehicle electric battery arrangement comprising a battery receiving chamber on the vehicle, the chamber having opposed open ends, enabling loading of batteries via an open end and battery unloading via the opposed open end; the arrangement comprising a plurality of batteries arranged in side by side relationship in the chamber and open- able closure elements at opposed ends of the chamber.

40. A vehicle electric battery arrangement according to claim 39, wherein one or both of the closure elements are provided with biassing means (such as a spring arrangement) to bias the batteries in the chamber into engagement with one another.

41. A vehicle electric battery arrangement according to claim 39 or claim 40, wherein one or both closure elements are lockable in the closed position.

42. A vehicle according to any of claims 39 to 41, wherein the batteries in the chamber have complementary contacting or mating connector elements facilitating electrical connection of the batteries, the closure elements including electrical connector means to connect to the end most batteries in the chamber.

3. A transfer loader for manipulating the positional orientation of batteries for loading to a vehicle, the transfer loader having a support platform arranged to receive batteries retrieved from a store and positionally adjustable in mutually perpendicular translational movement directions and also tilt orientation, and/or permit rotation about an upright axis in order to accurately address the vehicle or store.