System for the Electrical Power Supply of a Vehicle

This invention relates to a system for supplying electric power to a vehicle having batteries such as, for example, a battery operated vehicle or the like.

Electrically propelled vehicles generally make use of a self-sufficient power supply which is comprised of a plurality of batteries. However, in time, these batteries are progressively discharged as the vehicle is operated. Eventually, this requires the batteries of the vehicle to be recharged. This recharging takes a relatively long period of time, which varies according to the kind and type of batteries which are used. For this reason, common practice is to recharge the batteries overnight.

As a result, battery operated vehicles are generally limited to special-service vehicles, and have not found wide application to general-service vehicles (e.g., transportation or commercial vehicles) primarily due to the limitations of battery recharging.

It is, therefore, the object of the present invention to overcome these difficulties by effectively removing the need for extended battery recharging periods in order to reduce the amount of time that the battery operated vehicle is out of service, thereby minimizing limitations to the use of such vehicles by passengers.

This and other objects are achieved in accordance with the present invention by providing a system for supplying electric power to a battery operated vehicle which employs a support plate which can receive a plurality of batteries, and which includes complimentary means for mechanically and electrically connecting the support plate and the batteries which it receives. The support plate permits a series electrical connection, or a shunt connection of batteries by including conducting parts for interconnecting the batteries with each other, and with cables for providing electric power to the point of utilization associated with the battery operated vehicle.

Such structure allows batteries to be appropriately placed onto the support plates, which then operate to support the weight of the batteries and to provide for their electrical connection with one another, and with the associated vehicle. The batteries can be retained to the support plates either resulting from their own weight, by various mechanical fasteners, or by electromagnetic action. Preferably, the support plates for receiving the batteries are manufactured as unitary elements which are molded with the necessary conducting parts for facilitating use of the support plates to receive the batteries and to interface (mechanically and electrically) with the battery operated vehicle which is to receive them.

In use, manufacture of the support plates in a manner which facilitates their incorporation into a battery operated vehicle also facilitates later disassociation of the batteries from the vehicle. To facilitate such handling, the batteries are preferably provided with articulated handles which are retractable into channels formed in the batteries.

In addition to facilitating servicing and replacement of the batteries, the system of the present invention also affords a convenient means for allowing discharged batteries to be replaced with recharged batteries. This allows the batteries to be handled as reconditioned spare units for replacement purposes (similar to replaceable gas cylinders). As a result, fresh (recharged) batteries can be distributed through road side stations to allow the operator of a battery operated vehicle to change batteries without requiring tools or special handling. Consequently, by exchanging discharged batteries for recharged batteries, the operator is permitted to continue use of the battery operated vehicle, much the same as present service stations provide for the refueling of gasoline-powered vehicles. Use of the system of the present invention is even sufficiently simple to allow for a self-service function, if desired. To assist the operator in reaching the nearest service station, a reserve battery is provided which can be accessed by an operator controlled switch.

For a further understanding of the present invention, reference is made to the following detailed description of the system of the present invention and its method of use, which are given as non-limiting examples with further reference to the accompanying drawings.

FIG. 1 is an isometric view of a battery received on a support plate in accordance with the present invention.

FIG. 2 is a bottom plan view of the battery.

FIG. 3 is an exploded, isometric view showing an interconnection of plural support plates.

FIG. 4 is a longitudinal cross-sectional view of one of the support plates shown in FIG. 3, taken along the line 4--4.

FIG. 5 is an isometric view of an alternative embodiment support plate for achieving an electrical connection similar to that of FIG. 3, and an alternative embodiment battery (in partial section) for mating with such a support plate.

FIG. 6 is an isometric view of an alternative embodiment support plate similar to that of FIG. 5, for receiving a series of nine batteries.

FIGS. 7a and 7b are isometric views showing positive and negative terminal plates for use with the alternative embodiment batteries of FIGS. 5 and 6.

FIG. 1 illustrates a battery 1 having a container which is essentially equivalent to a conventional battery case. As will be discussed more fully below, this container is able to receive operative battery components (e.g., plate groups, electrolyte, etc.) which are per se known. Upper portions of the container are provided with handles 2 which are receivable within channels 3 having openings 4 for facilitating access to the handles 2 when in their retracted position (within the channels 3).

The battery 1 is received upon a support plate 5, which will be discussed more fully below. To ensure correct positioning of the battery 1 relative to the support plate 5 (i.e., correct polarity), markings are preferably provided for visual verification by the user of the system. For example, an escutcheon 6 is advantageously provided on the battery 1 to show the terminal of negative polarity, for alignment with an escutcheon 8 which indicates the negative polarity terminal of the support plate 5. An escutcheon 9 is provided on the battery 1 to show the terminal of positive polarity, for alignment with an escutcheon 7 which indicates the terminal of positive polarity of the support plate 5.

Referring again to FIG. 1, the support plate 5 includes a series of electrical connectors. For the negative terminal, both a negative longitudinal connector 10 and a negative lateral connector 11 are provided. Similar connectors are provided for the positive terminal including a positive longitudinal connector (not visible) and a positive lateral connector 12. These connectors are formed as bores for receiving copper connecting cables (either longitudinally or laterally), such as the negative connection cable 13 and the positive connection cable 14 which are shown for purposes of illustration. As is conventional, each of the connection cables 13, 14 is formed as a copper cable surrounded by an insulating sheath 19.

Referring now to FIG. 2, the bottom of the battery 1 includes a pedestal 15 which is formed of an electrically insulating material, and a plurality of electrically conducting terminals 17. The terminals 17 are socket-shaped and are advantageously formed of lead or of another appropriate conducting material. The terminals 17 pass through protective areas 16 formed in the insulating material, to provide access to the terminals for connection purposes. The pedestal 15 can also include a metallic plate 18, if desired, for magnetic connection with the support plate 5. As illustrated in FIG. 4, the support plate 5 can be provided with an electromagnetic 32 for operatively engaging the metallic plate 18, to magnetically (or electromagnetically) retain the battery 1 in position on the support plate 5, as desired.

Referring now to FIGS. 3 and 4, each of the support plates 5 includes a sheathing 30 formed of an insulating material, and a series of three male terminals (preferably formed of brass) which correspond to the (socket) terminals 17 of the battery 1 (see FIG. 2). To automatically ensure correct positioning of the battery 1 upon the support plate 5 (in addition to the visual markings previously discussed), and in order to prevent mistaken placements with reverse polarity, a single terminal 20 is provided on one side of the support plate 5 (in this case the negative terminal) while two terminals 20 are provided on the other side of the support plate 5 (in this case the positive terminal). This creates an asymmetrical configuration which will allow the battery 1 to be seated upon the support plate 5 in only one possible position.

To improve their mechanical and electrical connection, the terminals 17, 20 preferably include cooperating series of longitudinal grooves 21. The terminals 20 also preferably include a series of threads 23, so that the terminals 20 can be screwed into corresponding bores 25 formed in the conducting parts 26, 29 which are received within each support plate 5 as shown. An access area 24 extends through the sheathing 30 of the support plate 5 (which surrounds the conducting parts 26, 29), for accessing the bores 25 of the conducting parts 26, 29 and for protecting the terminals 20. The terminals 20 include a flange 22 which limits threading of the terminals 20 into the bores 25 which are to receive them.

FIG. 1 shows how a single support plate 5 can be used to detachably receive a single battery 1. In this configuration, the connection cables 13, 14 are used to electrically connect the support plate 5 with the battery operated vehicle it is to service. FIG. 4 shows how a series of support plates 5 can be used to detachably receive a series connection of batteries 1. In this configuration, a series of connectors 34 are used to link terminals (the conducting parts 26, 29) of the support plates 5 with one another. The connectors 34 are received within a series of bores 27 which are formed in the conducting parts 26, 29. Longitudinal electrical connections are preferably made between bores 27 which are centrally located along the lateral edges of the support plates 5. Consequently, a direct electrical connection is made with singular, centrally located terminals 20 (i.e., a negative terminal), while connections with the dual, spaced terminals 20 (i.e., a positive terminal) are made with the internal conductor which extends between the spaced pair of terminals 20. The connectors 34 can also be used to make lateral connections between the bores 27 of adjacent conducting parts 26, 29, as desired. The bores 27 also receive the connection cables 13, 14 at appropriate end points of the series electrical connection which is established, for electrical connection with the battery operated vehicle which is to be serviced.

Each of the connectors 34 (and the connection cables 13, 14) are preferably retained in position by screws 33 which extend through bores 31 formed in the conducting parts 26, 29. An access 28 extends through the protective sheathing 30 of the support plate 5 to permit the screws 33 to be loosened and tightened as needed.

FIG. 5 shows an alternative embodiment support plate 48 for receiving a plurality of batteries to develop a series electrical connection similar to that shown in FIG. 3. FIG. 6 illustrates a similarly configured support plate 47 for receiving a series of nine batteries (with polarity and position markings for convenience of use). In both cases, the support plates 47, 48 are adapted to receive a series of correspondingly configured batteries 49, which differ somewhat from the batteries 1 used in conjunction with the support plates 5 illustrated in FIGS. 1 to 4.

The support plate 48 (as well as the support plate 47) includes a series of U-shaped pedestals 46 for receiving complimentary (U-shaped) recessed portions 45 of the batteries 49, and a series of cavities 36 for receiving the stands 15 of the batteries 49 which project from opposite sides of the recessed portions 45. This provides a secure and stable connection between the batteries 49 and the support plate 48 which is to receive them, while also providing a protective area for the stands 15. The pedestals 46 of the support plate 48 are provided with a series of grooves 35 which allow for cooling of the batteries while in operation. The cavities 36 are provided with positive and negative terminals 20 (which are appropriately electrically interconnected within the support plate 48) for electrical connection with the several batteries 49 which are to be received.

Internally (as shown in FIG. 5), the batteries 49 are assembled between internal walls 38 and within spaces 39 (i.e., cell compartments) for receiving the conventional elements (not shown for ease of illustration) of a storage battery (i.e., plate groups and electrolyte). A pair of plates 37, 41 are then used to electrically connect terminal posts (not shown for ease of illustration) of the plate groups received within the spaces 39 with the terminals 17 which are provided in the stands 15 of the battery 49. FIG. 7a shows a plate 37 which is used for electrically connecting the negative terminal of the battery 49 with the terminals 17, while FIG. 7b shows a plate 41 for electrically connecting the positive terminal of the battery 49 with the terminals 17.

In each case, the plate 37, 41 is provided with lugs at opposing ends which are used for purposes of interconnection. The negative plate 37 of FIG. 7a includes a lug 43 having an aperture 44 for receiving the corresponding terminal post of the battery, and an opposing lug having a single terminal 17 (similar to the single terminal 17 of FIG. 2) for engaging the terminals 20 of the cavity 36 of the support plate 48. The positive plate 41 of FIG. 7b also includes a lug 43 having an aperture 44 for receiving the corresponding terminal post of the battery, and an opposing lug having a pair of terminals 17 (similar to the paired terminals 17 of FIG. 2) for engaging the terminals 20 of the cavity 36 of the support plate 48. It should be noted that the lug 43 shown in FIG. 7a is on an opposite side of the plate as is the lug 43 shown in FIG. 7b. This is done to accommodate traditional placement of the terminal posts of conventional storage batteries. It should also be noted that the plate 37 of FIG. 7a has a single terminal 17, while the plate 41 of FIG. 7b has two such terminals 17. This is done to accommodate the polarity-defining location of the terminals 20 associated with the cavity 36 of the support plate 48, as previously described in connection with the alternative embodiments of FIGS. 1 to 4.

Externally, the batteries 49 include a surrounding container having characteristics similar to the container of the battery 1 shown in FIG. 1. The container includes a cover 42 having fill holes 44 for receiving electrolyte in conventional fashion, retractable handles 2 and corresponding recesses 3 for receiving them.(as previously described in connection with the battery 1 shown in FIG. 1), and a voltage controller 40 for purposes of regulating the system's output characteristics.