Powered Electric Vehicle

TECHN ICAL FIELD

The present invention relates generally to energy replenishment in fuel cells. Especially, the invention relates to a handle for fil ling liquid fuel into a fuel-cell powered electric vehicle, a fuel- filler compartment for receiving liquid fuel into a fuel-cell powe- red electric vehicle, and a method of filling liquid fuel from a fuel pump station into a fuel cell powered electric vehicle.

BACKGROUND

Electric vehicles are becoming increasingly popular, for example due to the stricter requirements on reduced carbon dioxide emissions. One problem with today’s electric vehicles is that the charging stations are fairly few and distant from one another. The drivers are therefore often concerned with the risk of run- ning out of battery power. To tackle this problem, in turn, the ve- hicle can be equipped with a so-called range extender. The ran- ge extender is an auxiliary power unit that drives an electric generator, which charges the electric vehicle’s battery. This ar- rangement is known as a series hybrid drivetrain. The most commonly used range extenders are based on internal combus- tion engine technology. Of course, from a carbon-dioxide emis- sion perspective, this is a less attractive option. Therefore, a fuel-cell based power source is preferable, i.e. where electricity is produced based on hydrogen. Nevertheless, the production and distribution of hydrogen is associated with other problems. For instance, pollutants may be released at the production sites, where hydrogen is typically derived from reformed natural gas. Transporting and storing hydrogen may also create pollutants. SUMMARY

The object of the present invention is therefore to offer a solu- tion for the above-referenced problems, thus providing an envi- ronmental-friendly and convenient way of fueling up a fuel cell based energy source in an electric vehicle.

According to one aspect of the invention , the object is achieved by a handle for filling liquid fuel into a fuel-cell powered electric vehicle. The handle has a nozzle piece configured to feed at least one fuel component into the vehicle. Specifically, the nozz- le piece contains a set of output conduit openings each of which is configured feed a particular one of at least two fuel compo- nents into the vehicle. For example, as will be elaborated upon below, a first output conduit opening may deliver a suspension containing aluminum particles, a second delivers water while a third delivers a sodium hydroxide solution. The conduit openings in the set of output conduit openings are arranged in a first pat- tern relative to one another. The first pattern is adapted to match a second pattern of receiver conduit openings in a fuel-filler compartment of the vehicle in a key-lock manner. This handle is advantageous because it significantly reduces the risk that the fuel components are fed into the wrong container in the electric vehicle. Thus, the safety is improved for both the personnel and the equipment.

According to one embodiment of this aspect of the invention , the nozzle piece contains a sealing sleeve that encircles the set of output conduit openings. The sealing sleeve is configured to be fitted with a mating member that encircles the set of input con- duit openings in a manner analogous to that of the sealing slee- ve so as to prevent leakage of the at least one fuel component from the nozzle piece when nozzle piece is fitted to the fuel-filler compartment.

According to another embodiment of this aspect of the invention, the nozzle piece also contains an input conduit opening con- figured to receive at least one waste component from the ve- hicle. Preferably, the input conduit opening is arranged relative to the first pattern so as to match a dispatch opening in the fuel- filler compartment when the first pattern matches the second pattern in said key-lock manner. Thereby, for example sludge produced when generating electricity can be removed from the vehicle in a highly convenient manner

According to still another embodiment of this aspect of the in vention, the handle has a user-operable activation member, e.g. a trigger or a button, configured to cause commands for initiating and aborting the feeding of the at least one fuel component into the vehicle. Thus, it is straightforward for an operator may start and stop the fuel filling.

According to yet another embodiment of this aspect of the in- vention, the nozzle piece includes a first short-range wireless transceiver configured to exchange data with a second short- range wireless transceiver in the fuel-filler compartment in con- junction with filling liquid fuel into the vehicle.

Preferably, the first short-range wireless transceiver is configu- red to receive fill-level data indicating a filling status of the at least two fuel components and/or cell-health data reflecting a fuel-cell status. It is further advantageous if the first short-range wireless transceiver is configured to transmit service data ref lecting a maintenance status of the vehicle and/or authorization data specifying a permit status of a user of the vehicle. As a re- sult, specific fuel-cell related information as well as general ve- hicle information can be exchanged with the fuel station, and an backbone network connected thereto.

According to another embodiment of this aspect of the invention, the handle has at least one visual indicator e.g. a display and/or a LED, configured to show at least one aspect of the data being exchanged between the first and second wireless transceivers. Consequently, the fuel-filling progress can be illustrated along with various other parameters relating to the vehicle and/or the fuel cells.

According to a further embodiment of this aspect of the inven- tion, the user-operable activation member may cause the feeding of the at least one fuel component into the vehicle to be initiated if only if the authorization data specify that the user of the vehic- le is permitted fuel acquirer. Typically, here, adequate payment capacity is one prerequisite for authorization.

According to another embodiment of this aspect of the invention, the nozzle piece contains at least one locking cavity, which is configured to engage with at least one locking member in the fuel-filler compartment so as to fixate the nozzle piece in the fuel-filler compartment when the nozzle piece is positioned such that the first pattern matches the second pattern in said key-lock manner. Thereby, when nozzle piece is correctly fitted to the ve hicle, and for example, the user is found authorized, the handle can be secured in a leakage-safe manner before the fuel transfer is initiated.

According to another aspect of the invention, the object is achie- ved by a fuel-filler compartment for receiving liquid fuel into a fuel-cell powered electric vehicle via a nozzle piece. The fuel- filler compartment contains a second set of input conduit ope- nings each of which is configured receive a particular one of at least two fuel components into the vehicle. The conduit openings in the second set of input conduit openings are arranged in a second pattern relative to one another. The second pattern is adapted to match a first pattern of output conduit openings in the nozzle piece in a key-lock manner. The advantages of this fuel- filler compartment, as well as the preferred embodiments there- of, are apparent from the discussion above with reference to the handle.

According to a further aspect of the invention , the object is ac- hieved by a method of filling liquid fuel from a fuel pump station into a fuel-cell powered electric vehicle, where the fuel pump station is connected to a handle containing a nozzle piece for feeding at least one fuel component into the vehicle. The vehic- le, in turn, is equipped with a fuel-filler compartment for recei- ving the at least one fuel component. The nozzle piece contains a set of output conduit openings each of which is configured feed a particular one of at least two fuel components into the vehicle. The fuel-filler compartment contains a set of input conduit ope- nings each of which is configured receive a respective one the of at least two fuel components into the vehicle. The method invol- ves positioning the nozzle piece in front of the fuel-filler compart- ment, such that a first pattern of the conduit openings in the set of output conduit openings matches a second pattern of receiver conduit openings in the fuel-filler compartment in a key-lock manner. The advantages of this method, as well as the preferred embodiments thereof, are apparent from the discussion above with reference to the handle.

Further advantages, beneficial features and applications of the present invention will be apparent from the following description and the dependent claims.

BRI EF DESCRIPTION OF THE DRAWINGS

The invention is now to be explained more closely by means of preferred embodiments, which are disclosed as examples, and with reference to the attached drawings.

Figure 1 shows a handle with a nozzle piece according to one embodiment of the invention ;

Figure 2 shows a vehicle-mounted fuel-filler compartment according to one embodiment of the invention ; Figure 3 shows a display and indicator arrangement of the handle according to one embodiment of the in- vention ;

Figure 4 shows a cross section side view of the nozzle piece and the fuel-filler compartment according to one embodiment of the invention ;

Figure 5 illustrates, by means of a flow diagram, the gene- ral method according to the invention ; and

Figure 6 represents a flow diagram of the method according to one embodiment of the invention.

DETAILED DESCRIPTION

Hydrogen is a key constituent when producing electric power in a fuel cell. However, extracting, transporting , handling and filling hydrogen is problematic for numerous reasons. Therefore, it is desirable if hydrogen itself is produced from other fuel compo- nents at the beginning of the energy-producing process; and then, electricity is generated based on this hydrogen.

It has been found that hydrogen can be produced safely and ef- ficiently in a reaction between aluminum and water in the pre- sence of sodium hydroxide, NaOH, or potassium hydroxide, KOH, which behave as catalysts. NaOH typically promotes a faster reaction and higher real yields than KOH . The main ad- vantages of using aluminum for indirect energy storage are: re- cyclability, non-toxicity and easiness to shape.

In Figure 1 , we see a handle 1 00 with a nozzle piece 1 10 accor- ding to one embodiment of the invention . The handle 100 is ad- apted for filling liquid fuel into a fuel-cell powered electric vehicle 460, the body of which is schematically illustrated in Figure 4. Referring to the above, the nozzle piece 1 10 is preferably con- figured to feed at least two fuel components into the vehicle 460; and further preferably, at least two fuel components, namely a suspension containing aluminum particles, water and a sodium hydroxide solution. To this aim, the nozzle piece 1 10 contains a set of output con- duit openings 1 1 1 , 1 12 and 1 13 respectively. Each of these ope- nings 1 1 1 , 1 12 and 1 13 is configured feed a particular one of the fuel components into the vehicle 460. For example, a first con- duit opening 1 1 1 may provide a suspension containing aluminum particles; a second conduit opening 1 12 may provide water and a third conduit opening 1 13 may provide a sodium hydroxide so- lution.

In any case, the conduit openings in the set of output conduit openings 1 1 1 , 1 12 and 1 13 are arranged in a first pattern rela- tive to one another. Referring now to Figure 2 showing a vehicle- mounted fuel-filler compartment 200 according to one embodi- ment of the invention, we see that the first pattern is adapted to match a second pattern of receiver conduit openings 21 1 , 212 and 213 in the fuel-filler compartment 200 in a key-lock manner. This means that there is one and only one way to fit the nozzle piece 1 10 into the fuel-filler compartment 200, namely such that the first output conduit opening 1 1 1 meets a first receiver con- duit opening 21 1 , the second output conduit opening 1 1 1 meets a second receiver conduit opening 212 and the third output con- duit opening 1 13 meets a third receiver conduit opening 213 res- pectively. It is further advantageous if the nozzle piece 1 10 contains a sea- ling sleeve 1 16 that encircles the set of output conduit openings 1 1 1 , 1 12 and 1 13. The sealing sleeve 1 16 is configured to be fitted with a mating member 216 of the fuel-filler compartment 200, which mating member 216 encircles the set of input conduit openings 21 1 , 212 and 213 in a manner analogous to the sealing sleeve 1 16. Thereby, when the nozzle piece 1 10 is fitted into the fuel-filler compartment 200, leakage of the fuel components from the nozzle piece 1 10 is prevented.

For efficiency, it is preferable if the nozzle piece 1 10 further con- tains an input conduit opening 1 14 configured to receive at least one waste component from the vehicle 460. Thereby, sludge re- sulting from the hydrogen production can be extracted from the vehicle 460. Naturally, for compatibility, the input conduit ope- ning 1 14 should be arranged relative to the first pattern so as to match a dispatch opening 214 in the fuel-filler compartment 200 when the first pattern matches the second pattern in the key-lock manner. Consequently, when the nozzle piece 100 is positioned so that the conduit patterns 1 1 1 , 1 12, 1 13 and 21 1 , 212, 213 matches one another, the input conduit opening 1 14 meets the dispatch opening 214.

If one of the fuel components is more aggressive than the other, for example the liquid fuel component containing aluminum, it is advantageous if the conduit opening 21 1 in the set of input con- duit openings 21 1 , 212 and 213 of the fuel-filler compartment 200 that is configured for receiving this fuel component is encirc- led by a dedicated sealing member 21 1 s being configured to pre- vent leakage of that liquid fuel component when passing through the nozzle piece 1 10. For practical reasons, the handle 100 preferably contains a user- operable activation member 145, for example in the form of a trigger, a button or a knob, which is configured generate com- mands arranged to control initiation and abortion respectively of the feeding of the at least one fuel component into the vehicle 460. As a result, an operator may indicate that he/she wishes to start refueling by triggering the activation member 145, and indi- cate that he/she wishes to stop the process by releasing the ac- tivation member 145.

To further enhance the safety, the user interaction and/or provi- de convenient authorization, the interface between the nozzle- piece and the fuel-filler compartment may be associated with a pair of wireless transceivers. Specifically, the nozzle piece 1 10 contains a first short-range wireless transceiver 1 15, the fuel- filler compartment 200 contains a second short-range wireless transceiver 215, and the first and second short-range wireless transceivers 1 15 and 215 are configured to exchange data with one another.

For example, the first short-range wireless transceiver 1 15 is preferably configured to receive at least one of fill-level data indicating a filling status of the at least two fuel components and/or cell-health data reflecting a fuel-cell status. The first short-range wireless transceiver 1 15 is further preferably confi- gured to transmit service data reflecting a maintenance status of the vehicle 460 and/or authorization data specifying a permit sta tus of a user of the vehicle 460.

Analogously, the second short-range wireless transceiver 215 is preferably configured to transmit fill-level data indicating a filling status of the at least two fuel components and/or cell-health data reflecting a fuel-cell status. Further preferably, the second short- range wireless transceiver 215 is configured to receive service data reflecting a maintenance status of the vehicle 460 and/or authorization data specifying a permit status of a user of the vehicle 460.

To assist the user interaction, it is beneficial if the handle 100 contains one or more visual indicators. Figure 3 shows a display 31 0 and an indicator arrangement of a first, a second and a third LED, 31 1 , 312 and 31 3 respectively. The first LED may show a red light before the operator has proven to be authorized, for example while a payment procedure is being completed, and a green light in response to successful authorization. The second LED may show a red light before the fuel-filling process has started, and a green light when it is in progress, and the third LED may flash during a subsequent cleaning procedure for the interface between the nozzle-piece and the fuel-filler compart- ment. The display preferably reflects further aspects of the data being exchanged between the first and second wireless trans- ceivers 1 15 and 215, for instance relating to the fill-level of the fuel cells and/or their health statuses.

Due to authorization requirements, such as payment, it may not be sufficient that the user-operable activation member 145 is triggered to cause feeding of the at least one fuel component into the vehicle 460. Therefore, according to one embodiment of the invention, the user-operable activation member 145 may cause the feeding of the at least one fuel component into the vehicle 460 to be initiated if only if the authorization data specify that the user of the vehicle 460 is permitted fuel acquirer. The authorization data, in turn, may be based on a combination of in- formation sent over the first and second wireless transceivers 1 15 and 215 and information received in the fuel station, via a backbone network.

For improved safety, and to obstruct manipulation, the nozzle piece 1 10 preferably contains at least one locking cavity 1 17 configured to engage with at least one locking member in the fuel-filler compartment 200. Figure 4 shows a cross section side view of the nozzle piece 1 10 when fitted to the fuel-filler com- partment, however before the locking members 431 and 432 en- gages with the matching locking cavities in the nozzle piece 1 10. The at least one locking cavity 1 17 and the at least one locking member 431 and 432 renders it possible to fixate the nozzle pie ce 1 10 in the fuel-filler compartment 200 when the nozzle piece 1 10 is positioned such that the first pattern matches the second pattern in said key-lock manner. Consequently, it becomes very difficult to manipulate the interface between the nozzle piece 1 10 and the fuel-filling compartment 200.

Returning now to Figure 2 showing the vehicle-mounted fuel- filler compartment 200 according to one embodiment of the in- vention, we see that the fuel-filler compartment 200 contains the second set of input conduit openings 21 1 , 212 and 213 respec- tively each of which is configured receive a particular one of the at least two fuel components into the vehicle 460. As mentioned above, the conduit openings in the second set of input conduit openings 21 1 , 212 and 213 are arranged in a second pattern re- lative to one another. The second pattern is adapted to match a first pattern of output conduit openings 1 1 1 , 1 12 and1 13 in the nozzle piece 1 10 in the key-lock manner.

Preferably, the fuel-filler compartment 200 also contains the dis- patch opening 21 4 configured to discharge waste components, such as sludge, out from the vehicle 460. As mentioned earlier, the dispatch opening 214 is preferably arranged relative to the second pattern so as to match an input conduit opening 1 14 in the nozzle piece 1 10 when the first pattern matches the second pattern in the key-lock manner. Thereby, the risk of leaking, or unintentional mixing of the fuel components is rendered very low.

Referring now again to Figure 4 showing the cross section side view of the nozzle piece 1 10 and the fuel-filler compartment 200, we see one embodiment of the invention where fuel-filler compartment 200 contains a heating member 450 configured to warm up the nozzle piece 1 10 in conjunction with filling liquid fuel into the vehicle 460. Preferably, the heating member 450 encircles the mating member 216, so that all the openings 21 1 , 212, 213, 214 and the nozzle piece 1 10 can be warmed up jointly. Further preferably, the heating member 450 is activated after transferring data between the first and second wireless interfaces 1 15 and 215 respectively, which data represents a successful authorization of the vehicle operator. As mentioned earlier, the fuel-filler compartment 200 preferably contains at least one locking member, here represented by 431 and 432, configured to engage with at least one locking cavity in the nozzle piece 1 10. Thereby, the nozzle piece 1 10 can be fixa- ted in the fuel-filler compartment 200 when the nozzle piece 1 10 is positioned such that the first pattern matches the second pat- tern in said key-lock manner. It is advantageous if the heating member 450 is activated first after that the nozzle piece 1 10 has be fixated in the fuel-filler compartment 200 because this redu- ces the risk of heat-related damages to personnel and equip- ment.

To further reduce the impairment risk and avoid manipulation of the openings 21 1 , 212 and 213, and preferably 214, the fuel-filler compartment 200 may contain a selectably removable protective member 440, e.g. implemented as a rotatable disc with ope- nings, which in a first rotation position leaves a free passage to the openings 21 1 , 212 and 213, and preferably 214; and in a second rotation position covers these openings. The protective member 440 is configured to cover said openings when no nozz- le piece 1 10 is fixated in the fuel-filler compartment 200, and ex- clusively allow the openings to be uncovered when the nozzle piece 1 10 is fixated in the fuel-filler compartment 200.

In order to sum up, and with reference to the flow diagram in Fi- gure 5, we will now describe the general method according to the invention of filling liquid fuel from a fuel pump station into a fuel-cell powered electric vehicle. Here, it is presumed that the fuel pump station is connected to the handle 100 with the nozzle piece 1 10 for feeding at least one fuel component into the vehic- le. It is further presumed that vehicle contains the above-descri- bed fuel-filler compartment 200 for receiving the at least one fuel component. Moreover, the nozzle piece 1 10 has a set of output conduit openings 1 1 1 , 1 12 and 1 13 each of which is configured feed a particular fuel component into the vehicle. Analogously, the fuel-filler compartment 200 contains a set of input conduit openings 21 1 , 212 and 213 each of which is configured receive a respective one of the fuel components into the vehicle.

In a first step 510, it is checked whether or not the nozzle piece 1 10 has been positioned in front of the fuel-filler compartment 200, such that a first pattern of the conduit openings in the set of output conduit openings 1 1 1 , 1 12 and 1 13 matches a second pattern of receiver conduit openings 21 1 , 212 and 213 in the fuel-filler compartment 200 in a key-lock manner. If the matching criterion is fulfilled, a step 520 follows which enables the fuel- filling procedure; and otherwise the procedure loops back and stays in step 510.

Figure 6 represents a flow diagram of the method according to one embodiment of the invention, which assumes that the above- described steps 510 and 520 have been completed. In a step 610, the nozzle piece 1 1 0 is fixated in the fuel-filler compartment 200 via the arrangement with locking member(s) of the fuel-filler compartment 200 engaging with the locking cavit/y/ ies of the nozzle piece 1 10. Thereafter, in a step 620, it is checked if an initiation command has been received, for instance from a user-operable activation member. If the initiation command has been received, the pro- cedure continues to a step 630, and otherwise it loops back and stays in step 620. As mentioned above, due to authorization re- quirements, such as payment, it may not be sufficient that the user-operable activation member 145 is triggered to cause feeding of the at least one fuel component into the vehicle 460. Therefore, before proceeding to step 630, it may be necessary to ascertain that the user of the vehicle 460 is permitted fuel ac- quirer.

In step 630, fuel components are fed into the vehicle via the nozzle piece 1 10 and the fuel-filler compartment 200. Preferably, in parallel with this, at least one visual indicator 310, 31 1 , 312 and/or 313 shows one or more aspects data being exchanged between the pump station and the vehicle, such as data repre- senting the fuel-filling progress. Said data are preferably ex- changed via the first and second wireless transceivers 1 15 and 215 respectively.

In a subsequent step 640, it is checked if a user-generated abort command has been received, or if the fuel tanks are full. If so, a step 650 follows, or possibly a step 660. Otherwise the procedu- re loops back to step 630 for continued filling.

In step 660, the nozzle piece 1 10 is released from the fixating in the fuel-filler compartment 200. Thereafter, the procedure ends. Preferably, between steps 640 and 660, i.e. after completing the feeding of the at least one fuel component into the vehicle and before releasing the nozzle piece 1 10 from the fixating in the fuel-filler compartment 200, there is a step 650. In this step, the fuel-filler compartment 200 is rinsed with a cleaning fluid, such as water from the output conduit 1 12 in the nozzle piece 1 10.

The term“comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components. However, the term does not preclude the presence or addition of one or more additional features, inte gers, steps or components or groups thereof.

The invention is not restricted to the described embodiments in the figures, but may be varied freely within the scope of the claims.