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The power coupler in a Southern California Edison / DEMI Zinc-Air powered Chrysler research minivan is detailed including circuit theory, performance and road testing experience. A coupler is defined here to mean an electrical device which connects two different power sources together such that each source can individually contribute its optimal power characteristics. The power coupler connects long operating range Zinc-Air batteries with peak power (acceleration) NiCd batteries in a battery-battery hybrid configuration. This circuit could also be used in a motor generator -battery hybrid, and with various battery types. The power coupler uses a single 18 kHz IGBT (Insulated Gate Bipolar Transistor) switching circuit to provide main vehicle cruise power to 12 kW from the Zinc-Air battery at 95% conversion efficiency. When power demand exceeds 12 kW the difference is made up by the NiCd pack.

Two second-generation Zinc-Air powered minivans are in development for Southern California Edison by Dreisbach ElectroMotive, Inc. (DEMI). These vehicles utilize two 52.2-kW-peak (70-hp-peak) drive motors in parallel, driving a conventional 3-speed Torqueflite™ transmission and the Chrysler minivan's conventional power steering and air conditioning. The vehicles are equipped with electric heat and electric / vacuum power brakes. A 60-kWh Zinc-Air battery in conjunction with a 10-kWh NiCd load-leveling battery provides a peak power of 104.4-kW (140-hp, 120-kW electrical peak) and over 322 km (200 miles) range at 64 km/h (40 mph) while maintaining a 454 kg (1000 lb) payload capability. The vehicles are equipped with on-board high-medium-low rate chargers which can accommodate a range of available recharge power feeds.

Dreisbach ElectroMotive, Inc. (DEMI) is developing a maintenance-free rechargeable Zinc-Air Battery that operates at room temperature. This new battery has an energy density of 200 Wh/kg or about eight times conventional Nickel-Cadmium or Lead-Acid technology now used in electric vehicle applications. This paper will cover the performance characteristics of DEMI's Zinc-Air Batteries to date and the results of a 48-cell test in a Chrysler minivan* which was converted to electric drive under the sponsorship of Southern California Edison. In addition, work in progress on a 168 cell long range vehicle configuration will be presented.