USOO7455134B2
`
`(12) United States Patent
`US 7,455,134 B2
`(10) Patent N0.:
`
`(45) Date of Patent: Nov. 25, 2008
`Severinsky et al.
`
`(54)
`
`(75)
`
`HYBRID VEHICLES
`
`Inventors: Alex J. Severinsky, Washington, DC
`(US); Theodore Louckes, Holly, MI
`(US)
`
`(73)
`
`Assignee: Paice LLC, Bonita Springs, FL (US)
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 384 days.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`913,846 A
`
`3/ 1 909 Pieper
`
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`DE
`
`2517110
`
`10/1975
`
`(Continued)
`OTHER PUBLICATIONS
`
`(21)
`
`Appl. N0.: 11/429,457
`
`(22)
`
`Filed:
`
`May 8, 2006
`
`Trial and deposition transcripts of witnesses relied upon to assert
`invalidity of parent patents in Civil Docket No. 2:04-VC-211-DF (E.
`D. Texas).
`
`(65)
`
`(60)
`
`(60)
`
`(51)
`
`(52)
`
`(58)
`
`Prior Publication Data
`
`(Continued)
`
`US 2006/0231305 A1
`
`Oct. 19, 2006
`
`Related US. Application Data
`
`Division of application No. 10/382,577, filed on Mar.
`7, 2003, now Pat. No. 7,104,347, which is a division of
`application No. 09/822,866, filed onApr. 2, 2001, now
`Pat. No. 6,554,088, and a continuation-in-part ofappli-
`cation No. 09/392,743, filed on Sep. 9, 1999, now Pat.
`No. 6,338,391, which is a continuation-in—part of
`application No. 09/264,817, filed on Mar. 9, 1999, now
`Pat. No. 6,209,672.
`
`Provisional application No. 60/122,296, filed on Mar.
`1, 1999, provisional application No. 60/ 100,095, filed
`on Sep. 14, 1998.
`
`Int. Cl.
`
`(2007.10)
`B60K 6/00
`US. Cl.
`..................... 180/652; 180/65.4; 180/205;
`180/65.1;180/65.8; 180/65.7; 180/701; 701/54
`Field of Classification Search ................ 180/65.2,
`180/654, 205, 65.1, 65.8, 65.7, 701; 701/54
`See application file for complete search history.
`
`Primary ExamineriChristopher Ellis
`Assistant Examiner%ynthia F. Collado
`(74) Attorney, Agent, or FirmiMichael de Angeli
`
`(57)
`
`ABSTRACT
`
`A hybrid vehicle comprises an internal combustion engine, a
`traction motor, a starter motor, and a battery bank, all con-
`trolled by a microprocessor in accordance with the vehicle’s
`instantaneous torque demands so that the engine is run only
`under conditions of high efiiciency, typically only when the
`load is at least equal to 30% of the engine’s maximum torque
`output. In some embodiments, a turbocharger may be pro-
`vided, activated only when the load exceeds the engine’s
`maximum torque output for an extended period; a two-speed
`transmission may further be provided, to further broaden the
`vehicle’s load range. A hybrid brake system provides regen-
`erative braking, with mechanical braking available in the
`event the battery bank is fully charged, in emergencies, or at
`rest; a control mechanism is provided to control the brake
`system to provide linear brake feel under varying circum-
`stances.
`
`62 Claims, 17 Drawing Sheets
`
`(J'I0
`
`
`
`
`MAXIMUM ERGANE
`
`8
`ne‘z,
`/
`POWER
`/. r152,
`/
`
`ENGNE
`/
`3Q OPERATING
`
`2,000
`3,000
`enema spec—.0, (RPM)
`
`
`4.000
`
`Page 1 of 55
`Page 1 of 55
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`FORD 1201
`FORD 1201
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`POWER0NweenemaEMMY,(HP)
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`10
`
`Keumvsa FUEL/
`CONSUMPTION,
`/ GAL/HP-HR/
`
`
`
`

`

`US 7,455,134 B2
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`Page 2
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`US. PATENT DOCUMENTS
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`1,824,014
`2,666,492
`3,211,249
`3,454,122
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`3,623,568
`3,650,345
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`
`>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
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`7/1969
`3/1970
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`3/1971
`11/1971
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`7/1976
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`11/1978
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`3/1984
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`9/1984
`1/1985
`4/1985
`8/1985
`1/1986
`4/1986
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`5/1986
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`6/1986
`6/1986
`7/1986
`9/1986
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`5,558,173
`
`>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
`
`10/1988
`3/1989
`8/1989
`5/1990
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`
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`Kawamura
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`Severinsky ................. 180/65 .2
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`
`Page 2 of 55
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`US 7,455,134 B2
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`Page 3
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`5,558,175 A
`5,558,588 A
`5,558,595 A
`5,562,565 A
`5,562,566 A
`5,565,711 A
`5,566,774 A
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`5,570,615 A
`5,586,613 A
`5,588,498 A
`5,589,743 A
`5,608,308 A
`5,614,809 A
`5,621,304 A
`5,623,194 A
`5,632,352 A
`5,635,805 A
`5,637,977 A
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`5,643,119 A
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`5,650,713 A
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`5,653,302 A
`5,656,921 A
`5,660,077 A
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`5,667,029 A
`5,669,842 A
`5,672,920 A
`5,675,203 A
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`5,678,646 A
`5,679,087 A
`5,680,050 A
`5,685,798 A
`5,691,588 A
`5,697,466 A
`5,698,905 A
`5,698,955 A
`5,704,440 A
`5,705,859 A
`5,713,425 A
`5,713,426 A
`5,713,427 A
`5,713,814 A
`5,714,851 A
`5,722,502 A
`5,722,911 A
`5,725,064 A
`5,755,302 A
`5,755,303 A
`5,757,151 A
`5,767,637 A
`5,771,478 A
`5,773,904 A
`5,775,449 A
`5,778,326 A
`5,778,997 A
`5,785,136 A
`5,785,137 A
`5,785,138 A
`5,786,640 A
`5,788,003 A
`5,788,004 A
`5,788,006 A
`5,788,597 A
`5,789,823 A
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`
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`8/1998 Bollet a1.
`8/1998 Sherman
`8/1998 Yamada et a1.
`8/1998 Egamiet a1.
`8/1998 Ibarakiet a1.
`
`............. 180/65.2
`
`5,789,935 A
`5,791,426 A
`5,791,427 A
`5,799,744 A
`5,801,497 A
`5,804,947 A
`5,806,617 A
`5,816,358 A
`5,818,116 A
`5,820,172 A
`5,823,280 A
`5,823,281 A
`5,826,671 A
`5,831,341 A
`5,833,022 A
`5,833,570 A
`5,839,530 A
`5,839,533 A
`5,841,201 A
`5,842,534 A
`5,844,342 A
`5,845,731 A
`5,846,155 A
`5,847,469 A
`5,851,698 A
`5,856,047 A
`5,856,709 A
`5,862,497 A
`5,865,263 A
`5,873,426 A
`5,875,691 A
`5,883,484 A
`5,883,496 A
`5,887,670 A
`5,887,674 A
`5,890,470 A
`5,890,555 A
`5,893,895 A
`5,895,100 A
`5,895,333 A
`5,898,282 A
`5,899,286 A
`5,904,631 A
`5,905,360 A
`5,907,191 A
`5,908,077 A
`5,909,720 A
`5,914,575 A
`5,915,488 A
`5,915,489 A
`5,923,093 A
`5,924,395 A
`5,927,415 A
`5,927,417 A
`5,928,301 A
`5,929,594 A
`5,931,271 A
`5,934,395 A
`5,935,040 A
`5,943,918 A
`5,944,630 A
`5,947,855 A
`5,951,115 A
`5,951,118 A
`5,951,614 A
`5,964,309 A
`5,967,940 A
`5,969,624 A
`5,971,088 A
`5,971,092 A
`5,973,460 A
`5,973,463 A
`5,979,158 A
`
`........... 180/65.2
`
`8/1998 Suga et a1.
`8/1998 Yamada
`8/1998 Yamaguchiet a1.
`9/1998 Yamaguchiet a1.
`9/1998 Shamoto et a1.
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`9/1998 Yamaguchiet a1.
`10/1998 Adler et a1.
`10/1998 Nakae
`10/1998 Brigham et a1.
`10/1998 Lateur ....................... 180/65.2
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`10/1998 Nakae et a1.
`11/1998 Selfors et a1.
`11/1998 Welke
`11/1998 Tabata
`11/1998 Dietzel
`11/1998 Mikamiet a1.
`11/1998 Tabata et a1.
`12/1998 Frank ........................ 180/65.2
`12/1998 Miyataniet a1.
`12/1998 Buglione et a1.
`12/1998 Taniguchiet a1.
`12/1998 Tabata
`12/1998 Reichmann et a1.
`1/1999 Venkatesan et a1.
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`1/1999 Yano et a1.
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`4/1999 Woon
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`5/1999 Yamaguchiet a1.
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`5/1999 Ukita
`5/1999 Sasakiet a1.
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`6/1999 Sasaki
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`7/1999 Tabata
`7/1999 Moriya et a1.
`7/1999 Ibarakiet a1.
`7/1999 Brunner et a1.
`7/1999 Sogaet a1.
`7/1999 Nonobe et a1.
`8/1999 Haka
`8/1999 Koide et a1. ................ 180/65.2
`8/1999 Tabata et a1.
`8/1999 Reed, Jr. et a1.
`8/1999 Omote
`9/1999 Weiss
`9/1999 Sakai etal.
`9/1999 Soejima
`9/1999 Tabata
`10/1999 Kimura et a1.
`10/1999 Yamaguchiet a1.
`10/1999 Sakai et a1.
`................. 340/636
`10/1999 Smith
`10/1999 Walker
`10/1999 Taga et a1.
`10/1999 Okuda et a1.
`11/1999 Kaiser
`
`............ 180/65.6
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`5,979,257 A
`5,982,045 A
`5,983,740 A
`5,984,034 A
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`5,988,307 A
`5,991,683 A
`5,993,169 A
`5,993,350 A
`5,993,351 A
`5,996,347 A
`6,003,626 A
`6,005,297 A
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`6,006,620 A
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`6,009,365 A
`6,018,198 A
`6,018,694 A
`6,019,183 A
`6,019,698 A
`6,020,697 A
`6,026,921 A
`6,032,753 A
`6,041,877 A
`6,044,922 A
`6,048,289 A
`6,053,841 A
`6,053,842 A
`6,054,844 A
`RE36,678 E
`6,059,059 A
`6,059,064 A
`6,064,161 A
`6,067,801 A
`6,070,680 A
`6,074,321 A
`6,077,186 A
`6,081,042 A
`6,087,734 A
`6,090,007 A
`6,098,733 A
`6,109,025 A
`6,110,066 A
`6,116,363 A
`6,119,799 A
`6,123,163 A
`6,123,642 A
`6,131,538 A
`6,131,680 A
`6,135,914 A
`6,142,907 A
`6,146,302 A
`6,155,364 A
`6,155,365 A
`6,158,541 A
`6,161,384 A
`6,166,499 A
`6,170,587 131
`6,176,807 Bl
`6,183,389 131
`6,190,282 131
`6,203,468 131
`6,204,636 131
`6,205,379 B1
`6,209,672 B1
`6,225,784 B1
`6,231,135 Bl
`6,232,733 B1
`6,232,748 B1
`6,247,437 B1
`Page 4 of 55
`Page 4 of 55
`
`
`
`................ 477/5
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`................ 701/102
`
`............ 180/65.2
`
`................. 477/15
`
`11/1999 Lawrie
`11/1999 Tabataetal.
`11/1999 Saleckeretal.
`11/1999 Morisawa
`11/1999 Otomo etal.
`11/1999 Werson
`11/1999 Yamadaetal.
`11/1999 Takaokaetal.
`11/1999 Adachietal.
`11/1999 Lawrie et al.
`11/1999 Deguchietal.
`12/1999 Nagae etal.
`12/1999 Ibarakietal.
`12/1999 Sasakietal.
`12/1999 Saleckeretal.
`12/1999 Lawrie etal.
`12/1999 Onimaiu
`12/1999 Matsuietal.
`12/1999 Takaharaetal.
`1/2000 Tsuzukietal.
`1/2000 Egamietal.
`2/2000 Shimaseki
`2/2000 Lawrie etal.
`2/2000 Shimaseki
`2/2000 Aoyamaetal.
`3/2000 Yamazaki etal.
`3/2000 Yamadaetal.
`4/2000 Field
`4/2000 Hattorietal.
`4/2000 Koide etal.
`................... 477/5
`4/2000 Kitadaetal.
`4/2000 Frank .......................... 322/16
`5/2000 VIoroto etal.
`5/2000 Schmidt-Brucken
`5/2000 \Jagano etal.
`5/2000 Takahara
`5/2000 Haradaetal.
`6/2000 oyama
`6/2000 VIaeda etal.
`6/2000 Kojima etal.
`6/2000 Tabata etal.
`7/2000 VIaeda etal.
`7/2000 \Iakajima
`8/2000 Ibarakietal.
`8/2000 VIurata etal.
`8/2000 \Iedungadietal.
`9/2000 Frank
`9/2000 VIorisawa
`9/2000 Otsu etal.
`9/2000 Sajto
`10/2000 Kauai
`10/2000 \Iiietal.
`10/2000 Yamaguchietal.
`11/2000 VIinowa
`11/2000 Kashiwase
`12/2000 \Jagano etal.
`12/2000 Boberg
`12/2000 Tabataetal.
`12/2000 Reinboldetal.
`12/2000 Kanamorietal.
`1/2001 Bullock
`1/2001 Obaetal.
`2/2001 Tabataetal.
`2/2001 Deguchietal.
`3/2001 Nitta
`3/2001 Kinoshita etal.
`3/2001 Morisawaetal.
`4/2001 Severinsky
`5/2001 Kinoshitaetal.
`5/2001 Boweretal.
`5/2001 Obayashietal.
`5/2001 Kinoshita etal.
`6/2001 Yamaguchietal.
`
`.............. 475/5
`
`............ 180/65.2
`
`................ 477/5
`
`............ 701/22
`
`7/2001 Suzuki
`6,253,865 B1
`7/2001 Wakutaetal.
`6,258,001 B1
`7/2001 Otsu
`6,260,644 B1
`7/2001 Umebayahiet al.
`6,265,692 B1
`8/2001 Yamaguchietal.
`6,278,195 B1
`8/2001 Deguchietal.
`6,278,915 B1
`8/2001 Abe
`6,281,660 B1
`9/2001 Lovatt etal.
`6,291,953 B1
`10/2001 Stemler
`6,300,735 B1
`6,306,057 B1* 10/2001 Morisawa et al.
`6,307,276 B1
`10/2001 Bader
`6,315,068 B1* 11/2001 Hoshiyaetal.
`6,317,665 B1
`11/2001 Tabataetal.
`6,318,487 B2
`11/2001 Yanaseetal.
`6,321,150 B1
`11/2001 Nitta
`6,328,122 B1
`12/2001 Yamada
`6,328,670 B1* 12/2001 Minowaetal.
`6,328,671 B1
`12/2001 Nakajima
`6,330,498 B2* 12/2001 Tamagawa etal.
`6,332,257 131
`12/2001 Reed, Ji. etal.
`6,334,498 131
`1/2002 Morisawa
`6,338,391 131
`1/2002 Severinskyetal.
`6,340,339 131
`1/2002 Tabata
`6,344,008 131*
`2/2002 Nagano etal.
`6,357,541 131
`3/2002 Matsudaetal.
`6,359,404 131*
`3/2002 Sugiyamaetal.
`6,383,114 131
`5/2002 Hoshiyaetal.
`6,387,007 131
`5/2002 Fini
`6,394,209 131
`5/2002 Goehring etal.
`6,435,296 131
`8/2002 Arai
`6,470,983 131* 10/2002 Amano etal.
`.............. 180/65.2
`6,481,516 131* 11/2002 Field etal.
`.. 180/65.2
`
`.. 290/40C
`5/2003 Nada .....
`6,563,230 132*
`
`7/2003 Tsaietal.
`...................... 475/5
`6,592,484 131*
`11/2001 Nogietal.
`2001/0037905 A1
`2003/0085577 A1
`5/2003 Takaokaetal.
`
`................. 475/1
`
`........... 318/432
`
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`DE
`DE
`BE
`3
`EP
`EP
`EP
`11:31:
`JP
`JP
`JP
`g
`g
`JP
`JP
`JP
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`JP
`JP
`JP
`JP
`JP
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`JP
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`JP
`JP
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`
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`19814402
`1951232:
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`0510582
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`35332::
`54849115
`55030223
`4864626
`{£32333
`5&2?ng
`55069724
`55110328
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`gifg‘ggé
`6382283
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`FORD 1201
`FORD 1201
`
`

`

`US 7,455,134 B2
`
`Page 6
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`Page 6 of 55
`
`FORD 1201
`FORD 1201
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`

`

`US. Patent
`
`Nov. 25, 2008
`
`Sheet 1 of 17
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`US 7,455,134 B2
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`US. Patent
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`Nov. 25, 2008
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`US 7,455,134 B2
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`US. Patent
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`Nov. 25, 2008
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`Sheet 5 of 17
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`US 7,455,134 B2
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`US. Patent
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`Nov. 25, 2008
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`Sheet 8 of 17
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`US 7,455,134 B2
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`US. Patent
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`Nov. 25, 2008
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`Sheet 9 of 17
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`FORD 1201
`FORD 1201
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`

`

`US. Patent
`
`Nov. 25, 2008
`
`Sheet 10 of 17
`
`US 7,455,134 B2
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`US 7,455,134 B2
`
`2
`
`1
`HYBRID VEHICLES
`
`CROSS-REFERENCE TO RELATED
`APPLICATIONS
`
`This is a divisional application of application Ser. No.
`10/382,577 filed Mar. 7, 2003, now US. Pat. No. 7,104,347,
`which was a divisional application of Ser. No. 09/822,866
`filed Apr. 2, 2001, now US. Pat. No. 6,554,088, which was a
`continuation-in-part of Ser. No. 09/264,817 filed Mar. 9,
`1999, now US. Pat. No. 6,209,672, issued Apr. 3, 2001,
`which in turn claimed priority from provisional application
`Ser. No. 60/100,095, filed Sep. 14, 1998, and was also a
`continuation-in-part of Ser. No. 09/392,743, filed Sep. 9,
`1999, now US. Pat. No. 6,338,391 issued Jan. 15, 2002, in
`turn claiming priority from provisional application Ser. No.
`60/122,296, filed Mar. 1, 1999.
`
`FIELD OF THE INVENTION
`
`in hybrid
`to improvements
`This application relates
`vehicles, that is, vehicles in which both an internal combus-
`tion engine and one or more electric motors are provided to
`supply torque to the driving wheels of the vehicle. More
`particularly, this invention relates to a hybrid electric vehicle
`that is fully competitive with presently conventional vehicles
`as regards performance, operating convenience, and cost,
`while achieving substantially improved fuel economy and
`reduced pollutant emissions.
`
`DISCUSSION OF THE PRIOR ART
`
`For many years great attention has been given to the prob-
`lem of reduction of fuel consumption of automobiles and
`other highway vehicles. Concomitantly very substantial
`attention has been paid to reduction of pollutants emitted by
`automobiles and other vehicles. To a degree, efforts to solve
`these problems conflict with one another. For example,
`increased thermodynamic efficiency and thus reduced fuel
`consumption can be realized if an engine is operated at higher
`temperatures. Thus there has been substantial
`interest in
`engines built of ceramic materials withstanding higher com-
`bustion temperatures than those now in use. However, higher
`combustion temperatures in gasoline-fueled engines lead to
`increase in certain undesirable pollutants, typically NOX.
`Another possibility for reducing emissions is to burn mix-
`tures of gasoline and ethanol (“gasohol”), or straight ethanol.
`However, to date ethanol has not become economically com-
`petitive with gasoline, and consumers have not accepted etha-
`nol to any great degree. Moreover, to make an alternate fuel
`such as ethanol available to the extent necessary to achieve
`appreciable improvements in nationwide air quality and fuel
`conservation would require immense costs for infrastructure
`improvements; not only the entire nation’s motor fuel pro-
`duction and delivery system, but also the vehicle manufac-
`ture, distribution, and repair system, would have to be exten-
`sively revised or substantially duplicated.
`One proposal for reducing pollution in cities is to limit the
`use of vehicles powered by internal combustion engines and
`instead employ electric vehicles powered by rechargeable
`batteries. To date, all such “straight electric” cars have had
`very limited range, typically no more than 150 miles, have
`insufficient power for acceleration and hill climbing except
`when the batteries are substantially fully charged, and require
`substantial time for battery recharging. Thus, while there are
`many circumstances in which the limited range and extended
`recharging time of the batteries would not be an inconve-
`Page 24 of 55
`Page 24 of 55
`
`nience, such cars are not suitable for all the travel require-
`ments ofmost individuals. Accordingly, an electric car would
`have to be an additional vehicle for most users, posing a
`substantial economic deterrent. Moreover, it will be appreci-
`ated that in the United States most electricity is generated in
`coal-fired power plants, so that using electric vehicles merely
`moves the source of the pollution, but does not eliminate it.
`Furthermore, comparing the respective net costs per mile of
`driving, electric vehicles are not competitive with ethanol-
`fueled vehicles, much less with conventional gasoline-fueled
`vehicles. See, generally, Simanaitis, “Electric Vehicles”,
`Road & Track, May 1992, pp. 126-136; Reynolds, “AC Pro-
`pulsion CRX”, Road & Track, October 1992, pp. 126-129.
`Brooks et al US. Pat. No. 5,492,192 shows such an electric
`vehicle; the invention appears to be directed to incorporation
`of antilock braking and traction control technologies into an
`otherwise conventional electric vehicle.
`
`Much attention has also been paid over the years to devel-
`opment of electric vehicles including internal combustion
`engines powering generators, thus eliminating the defect of
`limited range exhibited by simple electric vehicles. The sim-
`plest such vehicles operate on the same general principle as
`diesel-electric locomotives used by most railroads. In such
`systems, an internal combustion engine drives a generator
`providing electric power to traction motors connected
`directly to the wheels of the vehicle. This system has the
`advantage that no variable gear ratio transmission is required
`between the engine and/the wheels of the vehicle.
`More particularly, an internal combustion engine produces
`zero torque at zero engine speed (RPM) and reaches its torque
`peak somewhere in the middle of its operating range. Accord-
`ingly, all vehicles driven directly by an internal combustion
`engine (other than certain single-speed vehicles using friction
`or centrifugal clutches, and not useful for normal driving)
`require a variable-ratio transmission between