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Title:
MODULAR ENERGY STORAGE SYSTEM
Document Type and Number:
WIPO Patent Application WO/2014/004739
Kind Code:
A1
Abstract:
Energy storage systems are disclosed. The energy storage system may include of a cooling system and a heating system.

Inventors:
LEDBETTER KELLY (US)
FATTIG ROBERT N (US)
HAMILTON BRUCE (US)
LAVIN MARK (US)
HOPPER KARL (US)
Application Number:
PCT/US2013/048004
Publication Date:
January 03, 2014
Filing Date:
June 26, 2013
Export Citation:
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Assignee:
ENERDEL INC (US)
International Classes:
H01M10/50; H01M50/204; H01M50/264; H01M50/296; H01M50/503; H02J15/00
Foreign References:
US20110104532A12011-05-05
US20080280192A12008-11-13
EP2210764A22010-07-28
US20100104935A12010-04-29
RU68829U12007-11-27
RU29408U12003-05-10
US20070087266A12007-04-19
Attorney, Agent or Firm:
MEYERS, William, S. (300 North Meridian StreetSuite 270, Indianapolis IN, US)
Download PDF:
Claims:
Claims:

1. A modular energy storage system, comprising:

an enclosure,

a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure;

a battery management system positioned within the enclosure and operatively coupled to the plurality of battery modules;

a battery management system support member positioned within the enclosure, the battery management system support member supporting at least one component of the battery management system; and

an air plenum positioned within the enclosure, the air plenum directs air received through at least one inlet in the enclosure along a path towards at least one outlet in the enclosure, the air being used to cool a temperature of the battery modules, wherein the battery management system support forms at least a portion of a wall of the air plenum.

2. The modular energy storage system of claim 1 , wherein the air is directed within the enclosure to contact a plurality of heat transfer members of the plurality of battery modules.

3. The modular energy storage system of claim 2, wherein the air plenum includes at least one air inlet housing positioned within the enclosure and a manifold positioned within the enclosure.

4. The modular energy storage system of claim 3, wherein the plurality of battery modules are supported by a plurality of battery module housings, each of the plurality of battery module housing and associated battery modules form a battery sub-pack, the plurality of battery sub- packs are removably coupled to the enclosure and are positioned in the enclosure, each of the plurality of battery sub-packs includes at least one air inlet which is in fluid communication with the manifold and at least one air outlet in fluid communication with the at least one outlet of the enclosure.

5. The modular energy storage system of claim 4, wherein the at least one air inlet of the sub- pack is provided in a top portion of the sub-pack.

6. The modular energy storage system of claim 4, wherein the at least one air inlet of the sub- pack is provided in a first end portion of the sub-pack and a second end of the sub-pack is open and operatively coupled to a heating apparatus, the heating apparatus contacting the plurality of heat transfer members of the battery modules of the sub-pack.

7. The modular energy storage system of claim 6, wherein the first end portion is a top portion and the second end is a bottom portion, the at least one air inlet being provided in a cover of the sub-pack.

8. The modular energy storage system of claim 4, wherein the plurality of sub packs are retained with by the air plenum.

9. The modular energy storage system of claim 4, wherein the enclosure includes a first enclosure portion and each of the battery module housings includes a first battery module housing portion which is supported by the first enclosure portion and the air plenum

cooperates with the enclosure to retain a position of the first battery module housing portion relative to the first enclosure portion, wherein the first enclosure portion includes a shelf and the first battery module housing portion is a lip extending from a base portion of the battery module housing, the lip being supported by the shelf of the enclosure and the air plenum overlaps both the shelf and the lip.

10. The modular energy storage system of any of claims 1-9, wherein each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other, each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members, the plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

11. A modular energy storage system, comprising:

an enclosure,

a plurality of battery module housings being removably coupled to the enclosure, the plurality of battery module housings being positioned within the enclosure and operative ly coupled to a high voltage connector accessible from an exterior of the enclosure;

a plurality of battery module housings positioned within the enclosure, each battery module housing having at least two battery modules positioned therein; and

an air plenum positioned within the enclosure, the air plenum directs air received through at least one inlet in the enclosure along a path towards at least one outlet in the enclosure, the air being used to cool a temperature of the battery modules, wherein the air plenum retains the plurality of battery module housings within the enclosure.

12. The modular energy storage system of claim 1 1, wherein the enclosure includes a first enclosure portion and each of the battery module housings includes a first battery module housing portion which is supported by the first enclosure portion and the air plenum

cooperates with the enclosure to retain a position of the first battery module housing portion relative to the first enclosure portion.

13. The modular energy storage system of claim 12, wherein the first enclosure portion includes a shelf and the first battery module housing portion is a lip extending from a base portion of the battery module housing, the lip being supported by the shelf of the enclosure and the air plenum overlaps both the shelf and the lip.

14. The modular energy storage system of claim 13, wherein the air plenum is coupled to the shelf.

15. The modular energy storage system of claim 14, wherein each battery module housing includes at least one battery module housing air inlet in fluid communication with the air plenum and receives air from the air plenum and at least one battery module housing air outlet to exhaust air from the battery module housing.

16. The modular energy storage system of any of claims 1 1-15, wherein each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other, each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members, the plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

17. A modular energy storage system, comprising:

an enclosure,

a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure, each battery module including a plurality of battery cells;

a cooling system positioned within the enclosure, the cooling system is configured to lower a temperature of the battery modules; and

a heating system positioned within the enclosure, the heating system is configured to raise the temperature of the battery modules, both of the heating system and the cooling system being powered by the plurality of battery modules.

18. The modular energy storage system of claim 17, wherein the heating system includes a resistive heater and the heating system is powered by a DC voltage of at least 100 volts.

19. The modular energy storage system of claim 17, wherein the heating system is independent of the cooling system.

20. The modular energy storage system of claim 17, wherein each of the plurality of battery modules includes a plurality of heat transfer members in contact with the plurality of cells, the heating system and the cooling system each interfacing with the plurality of heat transfer members.

21. The modular energy storage system of claim 20, wherein the cooling system interfaces with the plurality of heat transfer members of the respective battery module on a first side of the battery module and the heating system interfaces with the plurality of heat transfer members of the respective battery module on a second side of the battery module.

22. The modular energy storage system of claim 21, wherein the second side is opposite the first side.

23. The modular energy storage system of any of claims 17-22, wherein each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other, each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members, the plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

24. A modular energy storage system for use in a plurality of environments, comprising: an enclosure,

a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure, each battery module including a plurality of battery cells;

a temperature control system positioned within the enclosure, the temperature control system is configured to alter a temperature of the battery modules; and

a battery management system positioned within the enclosure, the battery management system including at least one contactor, wherein the enclosure includes a body portion, a lower portion removable from the body portion, and a top portion removable from the body portion, the lower portion having a first configuration to mount the enclosure to a first environment of the plurality of environments and a second configuration to mount the enclosure to a second environment of the plurality of environments.

25. A battery module for connection to an external electrical conductor, comprising:

a plurality of battery assemblies removably coupled together, each battery assembly including a plurality of battery cells and a plurality of frames to hold the plurality of battery cells; a first endplate removably coupled to the plurality of battery assemblies, the first endplate including a body and a first power bus terminal, the first power bus terminal is electrically connected to the battery cells of the battery assemblies; and

a second endplate removably coupled to the plurality of battery assemblies, the second endplate having a second power bus terminal that is electrically connected to the battery cells, wherein the plurality of battery assemblies are positioned between the first endplate and the second endplate and the first power bus terminal is supported by the first endplate, the first power bus terminal being formed from a plate having a top plate surface and a bottom plate surface, the plate being bent to provide a first connector having a first contact surface electrically coupled to the plurality of battery cells and a second connector having a second contact surface electrically coupled to the external electrical conductor, wherein the first contact surface is part of one of the top plate surface and the bottom plate surface and the second contact surface is part of one of the top plate surface and the bottom plate surface.

26. The battery module of claim 25, wherein the plate has a base and at least one layer coupled to the base, the at least one layer forming at least one of the top plate surface and the bottom plate surface

27. The battery module of claim 25, wherein the at least one layer is plated to the base.

28. The battery module of claim 25, wherein the first power bus terminal has a minimum width to thickness ratio of about 10: 1 between the first connector and the second connector.

29. The battery module of claim 25, wherein the first power bus terminal has a minimum width to thickness ratio of about 18: 1 between the first connector and the second connector.

30. The battery module of claim 25, wherein the first power bus terminal carries about 160 amperes continuous.

31. A battery module, comprising: a plurality of battery assemblies removably coupled together, each battery assembly including a plurality of battery cells and a plurality of frames to hold the plurality of battery cells;

a first endplate removably coupled to the plurality of battery assemblies, the first endplate including a body and a first power bus terminal, the first power bus terminal is electrically connected to the battery cells of the battery assemblies; and

a second endplate removably coupled to the plurality of battery assemblies, the second endplate having a second power bus terminal that is electrically connected to the battery cells, wherein the plurality of battery assemblies being positioned between the first endplate and the second endplate and the first power bus terminal is supported by the first endplate and the first power bus terminal is positioned between an internal face of the first endplate and an external face of the first endplate.

32. The battery module of claim 31 , wherein the first endplate power bus terminal includes a first connector and a second connector, each of the first connector and the second connector extend outside of the body of the first endplate.

33. The battery module of claim 32, wherein the first connector extends from a first side of the first endplate and the second connector extends from a second side of the first endplate.

34. The battery module of claim 33, wherein the first side of the first endplate is a top side of the first endplate.

35. The battery module of claim 33, wherein the second side of the first endplate is adjacent to the first side of the first endplate.

36. The battery module of claim 33, wherein the first connector extends in a first direction over towards the second endplate.

37. The battery module of claim 36, wherein the second connector extends in the first direction.

38. The battery module of claim 33, wherein the body is made of a moldable material and the first power bus terminal is overmolded by the body.

39. An endplate for a battery module having a plurality of battery cells, the endplate comprising:

a power bus terminal having a first connector and a second connector; and

a body supporting the power bus terminal, wherein the power bus terminal is positioned between an internal face of the body and an external face of the body and the first connector and the second connector extend outside of the body.

40. The endplate of claim 39, wherein the body is made of a moldable material and the power bus terminal is overmolded by the body.

41. The endplate of claim 39, wherein the first connector extends from a side of the body and is adapted to be electrically coupled to the battery cells of the battery module.

42. The battery module of claim 39, wherein the first connector extends from a first side of the first endplate and the second connector extends from a second side of the first endplate.

43. The battery module of claim 42, wherein the first side of the first endplate is a top side of the first endplate.

44. The battery module of claim 42, wherein the second side of the first endplate is adjacent to the first side of the first endplate.

45. The battery module of claim 42, wherein the first connector extends in a first direction over towards the second endplate.

46. The battery module of claim 45, wherein the second connector extends in the first direction.

47. A modular energy storage system, comprising:

an enclosure,

a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure;

a battery management system positioned within the enclosure, the battery management system including at least one contactor; and

an air plenum positioned within the enclosure, air enters at least one inlet in the enclosure, passes through the air plenum, across a plurality of heat sink fins associated with the plurality of battery modules, and exits through at least one outlet in the enclosure, wherein the at least one contactor is positioned within the enclosure to a first side of the plurality of battery modules and above the at least one inlet.

48. The modular energy storage system of claim 47, further comprising a heating system positioned within the enclosure, the heating system being spaced apart from the air plenum.

49. The modular energy storage system of claim 48, wherein the heating system is positioned within the enclosure below the plurality of battery modules.

50. The modular energy storage system of claim 49, wherein the heating system is accessible through a bottom cover of the enclosure and the at least one contactor is accessible through a top cover of the enclosure.

51. The modular energy storage system of claim 48, wherein the heating system is a resistive electric system.

Description:
MODULAR ENERGY STORAGE SYSTEM

RELATED APPLICATIONS

[0001] This application claims the benefit of US Provisional Application Serial No.

61/664,446, filed June 26, 2012, titled MODULAR ENERGY SYSTEM FOR A

TROLLEYBUS, docket ENERD-P12-003-01-US, and US Provisional Application Serial No. 61/781,507, filed March 14, 2013, titled MODULAR ENERGY SYSTEM FOR A

TROLLEYBUS, docket ENERD-P12-003-02-US-E, the disclosures of which are expressly incorporated by reference herein.

FIELD

[0002] The present invention is directed to energy storage systems and methods and more particularly to battery energy storage systems and methods.

BACKGROUND

[0003] Energy storage systems including battery storage systems are known. Further, it is known to monitor and control a temperature of a battery cell in a battery storage system.

SUMMARY

[0004] In an exemplary embodiment of the present disclosure, a battery module is provided. The battery module comprising a plurality of battery assemblies removably coupled together, each battery assembly including a plurality of battery cells and a plurality of frames to hold the plurality of battery cells; a first endplate removably coupled to the plurality of battery assemblies, the first power bus terminal is electrically connected to the battery cells of the battery assemblies; and a second endplate removably coupled to the plurality of battery assemblies. The first endplate including a body and a first power bus terminal. The second endplate having a second power bus terminal that is electrically connected to the battery cells. The plurality of battery assemblies being positioned between the first endplate and the second endplate. The first power bus terminal is supported by the first endplate. The first power bus terminal is positioned between an internal face of the first endplate and an external face of the first endplate. [0005] In one example thereof, the first endplate power bus terminal includes a first connector and a second connector, each of the first connector and the second connector extend outside of the body of the first endplate. In a variation thereof, the first connector extends from a first side of the first endplate and the second connector extends from a second side of the first endplate. In another variation thereof, the first side of the first endplate is a top side of the first endplate. In still another variation thereof, the second side of the first endplate is adjacent to the first side of the first endplate. In yet another variation thereof, the first connector extends in a first direction over towards the second endplate. In a refinement thereof, the second connector extends in the first direction. In a further variation thereof, the body is made of a moldable material and the first power bus terminal is overmolded by the body.

[0006] In another exemplary embodiment of the present disclosure, an endplate for battery module having a plurality of battery cells is provided. The endplate comprising a power bus terminal having a first connector and a second connector; and a body supporting the power bus terminal. The power bus terminal is positioned between an internal face of the body and an external face of the body and the first connector and the second connector extend outside of the body.

[0007] In an example thereof, the body is made of a moldable material and the power bus terminal is overmolded by the body.

[0008] In another example thereof, the first connector extends from a side of the body and is adapted to be electrically coupled to the battery cells of the battery module.

[0009] In still another example thereof, the first connector extends from a first side of the first endplate and the second connector extends from a second side of the first endplate. In a variation thereof, the first side of the first endplate is a top side of the first endplate. In another variation thereof, the second side of the first endplate is adjacent to the first side of the first endplate. In still another variation thereof, the first connector extends in a first direction over towards the second endplate. In a refinement thereof, the second connector extends in the first direction.

[0010] In a further exemplary embodiment of the present disclosure, a modular energy storage system is provided. The modular energy storage system comprising an enclosure, a plurality of battery modules positioned within the enclosure and operative ly connected to a high voltage connector accessible from an exterior of the enclosure; a battery management system positioned within the enclosure, the battery management system including at least one contactor; and an air plenum positioned within the enclosure. Air enters at least one inlet in the enclosure, passes through the air plenum, across a plurality of heat sink fins associated with the plurality of battery modules, and exits through at least one outlet in the enclosure. The at least one contactor is positioned within the enclosure to a first side of the plurality of battery modules and above the at least one inlet.

[0011] In an example thereof, the modular energy storage system further comprises a heating system positioned within the enclosure, the heating system being spaced apart from the air plenum. In a variation thereof, the heating system is positioned within the enclosure below the plurality of battery modules. In a refinement thereof, the heating system is accessible through a bottom cover of the enclosure and the at least one contactor is accessible through a top cover of the enclosure. In another variation thereof, the heating system is a resistive electric system.

[0012] In a further exemplary embodiment, a modular energy storage system is provided. The modular energy storage system comprising an enclosure, a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure; a battery management system positioned within the enclosure and operatively coupled to the plurality of battery modules; a battery management system support member positioned within the enclosure, the battery management system support member supporting at least one component of the battery management system; and an air plenum positioned within the enclosure. The air plenum directs air received through at least one inlet in the enclosure along a path towards at least one outlet in the enclosure. The air being used to cool a temperature of the battery modules. The battery management system support forms at least a portion of a wall of the air plenum.

[0013] In one example, the air is directed within the enclosure to contact a plurality of heat transfer members of the plurality of battery modules. In a variation thereof, the air plenum includes at least one air inlet housing positioned within the enclosure and a manifold positioned within the enclosure. In a refinement thereof, the plurality of battery modules are supported by a plurality of battery module housings, each of the plurality of battery module housing and associated battery modules form a battery sub-pack, the plurality of battery sub-packs are removably coupled to the enclosure and are positioned in the enclosure, each of the plurality of battery sub-packs includes at least one air inlet which is in fluid communication with the manifold and at least one air outlet in fluid communication with the at least one outlet of the enclosure. In another refinement thereof, the at least one air inlet of the sub-pack is provided in a top portion of the sub-pack. In still another refinement thereof, the at least one air inlet of the sub-pack is provided in a first end portion of the sub-pack and a second end of the sub-pack is open and operatively coupled to a heating apparatus, the heating apparatus contacting the plurality of heat transfer members of the battery modules of the sub-pack. In still yet another refinement, the first end portion is a top portion and the second end is a bottom portion, the at least one air inlet being provided in a cover of the sub-pack. In still a further variation, the plurality of sub packs are retained with by the air plenum. In still yet a further variation, the enclosure includes a first enclosure portion and each of the battery module housings includes a first battery module housing portion which is supported by the first enclosure portion and the air plenum cooperates with the enclosure to retain a position of the first battery module housing portion relative to the first enclosure portion, wherein the first enclosure portion includes a shelf and the first battery module housing portion is a lip extending from a base portion of the battery module housing, the lip being supported by the shelf of the enclosure and the air plenum overlaps both the shelf and the lip. In a further refinement, each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other. Each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members. The plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

[0014] In a further exemplary embodiment, a modular energy storage system is provided. The modular energy storage system comprising an enclosure, a plurality of battery module housings being removably coupled to the enclosure, the plurality of battery module housings being positioned within the enclosure and operatively coupled to a high voltage connector accessible from an exterior of the enclosure; a plurality of battery module housings positioned within the enclosure, each battery module housing having at least two battery modules positioned therein; and an air plenum positioned within the enclosure. The air plenum directs air received through at least one inlet in the enclosure along a path towards at least one outlet in the enclosure. The air being used to cool a temperature of the battery modules. The air plenum retains the plurality of battery module housings within the enclosure.

[0015] In one example, the enclosure includes a first enclosure portion and each of the battery module housings includes a first battery module housing portion which is supported by the first enclosure portion and the air plenum cooperates with the enclosure to retain a position of the first battery module housing portion relative to the first enclosure portion. In a variation thereof, the first enclosure portion includes a shelf and the first battery module housing portion is a lip extending from a base portion of the battery module housing, the lip being supported by the shelf of the enclosure and the air plenum overlaps both the shelf and the lip. In a refinement thereof, the air plenum is coupled to the shelf. In a further refinement thereof, each battery module housing includes at least one battery module housing air inlet in fluid communication with the air plenum and receives air from the air plenum and at least one battery module housing air outlet to exhaust air from the battery module housing. In a further refinement thereof, each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other. Each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members. The plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

[0016] In a further exemplary embodiment, a modular energy storage system is provided. The modular energy storage system comprising an enclosure, a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure, each battery module including a plurality of battery cells; a cooling system positioned within the enclosure, the cooling system is configured to lower a temperature of the battery modules; and a heating system positioned within the enclosure, the heating system is configured to raise the temperature of the battery modules, both of the heating system and the cooling system being powered by the plurality of battery modules. In one example, the heating system includes a resistive heater and the heating system is powered by a DC voltage of at least 100 volts. In a variation thereof, the heating system is independent of the cooling system. [0017] In another example, each of the plurality of battery modules includes a plurality of heat transfer members in contact with the plurality of cells, the heating system and the cooling system each interfacing with the plurality of heat transfer members. In a variation thereof, the cooling system interfaces with the plurality of heat transfer members of the respective battery module on a first side of the battery module and the heating system interfaces with the plurality of heat transfer members of the respective battery module on a second side of the battery module. In a refienment thereof, the second side is opposite the first side. In yet another refinement thereof, each of the plurality of battery modules includes a plurality of battery elements electrically coupled together and removably coupled to each other, each battery element includes a plurality of prismatic cells, at least one heat transfer member, and a plurality of frame members, the plurality of frame members, the plurality of cells, and the at least one heat transfer member all being removably coupled together.

[0018] In a further exemplary embodiment, a modular energy storage system for use in a plurality of environments is provided. The modular energy storage system comprising an enclosure, a plurality of battery modules positioned within the enclosure and operatively connected to a high voltage connector accessible from an exterior of the enclosure, each battery module including a plurality of battery cells; a temperature control system positioned within the enclosure, the temperature control system is configured to alter a temperature of the battery modules; and a battery management system positioned within the enclosure, the battery management system including at least one contactor, wherein the enclosure includes a body portion, a lower portion removable from the body portion, and a top portion removable from the body portion, the lower portion having a first configuration to mount the enclosure to a first environment of the plurality of environments and a second configuration to mount the enclosure to a second environment of the plurality of environments.

[0019] In a further exemplary embodiment, a modular energy storage system for connection to an external electrical conductor is provided. The modular energy storage system comprising a plurality of battery assemblies removably coupled together, each battery assembly including a plurality of battery cells and a plurality of frames to hold the plurality of battery cells; a first endplate removably coupled to the plurality of battery assemblies, the first endplate including a body and a first power bus terminal, the first power bus terminal is electrically connected to the battery cells of the battery assemblies; and a second endplate removably coupled to the plurality of battery assemblies, the second endplate having a second power bus terminal that is electrically connected to the battery cells. The plurality of battery assemblies are positioned between the first endplate and the second endplate and the first power bus terminal is supported by the first endplate. The first power bus terminal being formed from a plate having a top plate surface and a bottom plate surface. The plate being bent to provide a first connector having a first contact surface electrically coupled to the plurality of battery cells and a second connector having a second contact surface electrically coupled to the external electrical conductor. The first contact surface is part of one of the top plate surface and the bottom plate surface and the second contact surface is part of one of the top plate surface and the bottom plate surface.

[0020] In one example, the plate has a base and at least one layer coupled to the base.

The at least one layer forming at least one of the top plate surface and the bottom plate surface. In another example, the at least one layer is plated to the base. In a further example, the first power bus terminal has a minimum width to thickness ratio of about 10: 1 between the first connector and the second connector. In still a further example, the first power bus terminal has a minimum width to thickness ratio of about 18: 1 between the first connector and the second connector. In yet still a further example, the first power bus terminal carries about 160 amperes continuous.

[0021] The above and other features of the present disclosure, which alone or in any combination may comprise patentable subject matter, will become apparent from the following description and the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 illustrates a front isometric view of an exemplary modular energy storage system;

[0023] FIG. 2 illustrates a rear isometric view of the modular energy storage system of

FIG. 1;

[0024] FIG. 3 illustrates the modular energy storage system of FIG. 1 with a top cover removed; [0025] FIG. 3A illustrates a front isometric view of another exemplary modular energy storage system with a top cover removed.

[0026] FIG. 4 illustrates the modular energy storage system of FIG. 3 including electrical connections;

[0027] FIG. 5 illustrates top view of the modular energy storage system of FIG. 4;

[0028] FIG. 6 illustrates an exploded assembly view of the modular energy storage system of FIG. 1

[0029] FIG. 7 illustrates a partial view of a cooling system and a heating system of the of the modular energy storage system of FIG. 1;

[0030] FIG. 7A illustrates a partial view of a cooling system and a heating system of the of the modular energy storage system of FIG. 3 A;

[0031] FIG. 8 is partial sectional view of components of the modular energy storage system of FIG. 1;

[0032] FIG. 9 is partial sectional view of components of the modular energy storage system of FIG. 1 illustrating a fan unit disassembled from the modular energy storage system;

[0033] FIG. 10 illustrates exemplary components of a battery management system of the modular energy storage system of FIG. 1;

[0034] FIG. 11 illustrates an exploded view of the assembly of FIG. 10;

[0035] FIG. 12 illustrates the assembly of FIG. 10 coupled to a manifold of an air plenum, the lower surface of the assembly of FIG. 10 forming a portion of the air plenum;

[0036] FIG. 13 illustrates another perspective view of the assembly of FIG. 12;

[0037] FIG. 14 illustrates a sectional view of the assembly of FIG. 12;

[0038] FIG. 15 illustrates an exemplary sub-pack of the modular energy storage system of FIG. 1;

[0039] FIG. 16 illustrates an exemplary battery module of the modular energy storage system of FIG. 1;

[0040] FIG. 17 illustrates an exemplary battery element of the battery module of FIG. 16; [0041] Fig. 18 illustrates an exploded view of the battery element of FIG. 17;

[0042] FIG. 19 illustrates a partial bottom view of the sub-pack of FIG. 15;

[0043] FIG. 20 illustrates a partial top view of the sub-pack of FIG. 15 with a first module cover;

[0044] FIG. 21 illustrates a partial top view of the sub-pack of FIG. 15 with the first module over coupled thereto;

[0045] FIG. 22 illustrates a view of the sub-pack of FIG. 15 with a seal member placed on top of the first module cover;

[0046] FIGS. 23 and 24 illustrate portions of a lower cover of the enclosure of the modular energy storage system of FIG. 1;

[0047] FIG. 25 illustrates an exploded view of a heating system of the modular energy storage system of FIG. 1;

[0048] FIG. 26 illustrates a top view of the heating system of the modular energy storage system of FIG. 1;

[0049] FIG. 27 illustrates a sectional view of the heating system of the modular energy storage system of FIG. 1;

[0050] FIG. 28 illustrates a side, sectional view of the heating system of the modular energy storage system of FIG. 1 ;

[0051] FIG. 29 illustrates the sectional view of FIG. 27 with a sub-pack positioned within the enclosure;

[0052] FIG. 30 illustrates a representative view of an exemplary heating system of the modular energy storage system of FIG. 1;

[0053] FIG. 31 illustrates a representative view of an exemplary heating system and an exemplary cooling system of the modular energy storage system of FIG. 1;

[0054] FIG. 32 illustrates an endplate of the battery module of FIG. 16 illustrating an exterior view of the endplate; [0055] FIG. 33 illustrates the exemplary endplate of FIG. 32 illustrating an interior view of the endplate; and

[0056] FIG. 34 illustrates an exemplary power bus terminal; and

[0057] FIG. 35 illustrates a representative cross section of the power buss terminal of

FIG. 34.

[0058] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

[0059] The embodiments disclosed herein are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiment is chosen and described so that others skilled in the art may utilize its teachings.

[0060] The energy storage systems of the present disclosure may be used in a stationary energy storage market or a mobile energy storage market. Exemplary applications for a stationary storage market include providing power to a power grid, providing power as an uninterrupted power supply, and other loads which may utilize a stationary power source. In one embodiment, the systems and methods disclosed herein may be implemented to provide an uninterrupted power supply for computing devices and other equipment in data centers. A controller of the data center or other load may switch from a main power source to an energy storage system of the present disclosure based on one or more characteristics of the power being received from the main power source or a lack of sufficient power from the main power source. Exemplary applications for a mobile energy storage market include all electric vehicles, hybrid vehicles, refrigeration units on semi-tractor trailers, railcars, trolleybuses, and other modes of transportation.

[0061] An exemplary application for the energy storage systems described herein is a trolleybus. A trolleybus is used to transport cargo and/or people from place to place. Exemplary trolleybuses receive power from an overhead electrical caternary or other power source to power a propulsion system of the trolleybus. Exemplary propulsion systems include electric motors, internal combustion engines, and other suitable systems to propel the trolleybus. In one embodiment, a modular energy storage system for a trolleybus is provided. The modular energy storage system may provide power to the propulsion system of the trolleybus. Exemplary modular energy storage systems are disclosed herein. The exemplary modular energy storage systems may provide power to the propulsion system of the trolleybus when the trolleybus is disconnected from the overhead electrical catenary.

[0062] Referring to FIG. 1, an exemplary modular energy storage system 100 is shown.

Modular energy storage system 100 includes an enclosure 102 having a body 104, a top cover 106 removably coupled to body 104 and a bottom cover 108 removably coupled to the body 104. Enclosure 102 provides a first air inlet 109 and a second air inlet 110 through which air is received into the enclosure 102 to lower a temperature associated with a plurality of batteries positioned within enclosure 102. In the illustrated embodiment, air is pulled into enclosure 102 with a fan unit 118 (see FIG. 3). The air is exhausted from enclosure 102 through outlets 114 (see FIG. 2) provided in top cover 106 of modular energy storage system 100.

[0063] Enclosure 102 further provides a high voltage connector 120 which is accessible from an exterior of the enclosure 102. The high voltage connector 120 is operatively coupled to the plurality of batteries positioned within the enclosure. A low voltage connector 122 is also accessible from an exterior of the enclosure 102. A master controller 124 (see FIG. 3) is accessible by removing a cover 126 from enclosure 102. The master controller 124 may be accessed without having to open cover 106 and exposing the high voltage system 504 of modular energy storage system 100.

[0064] A plurality of mounting feet 130 are provided on enclosure 102. Mounting feet

130 permit the mounting of modular energy storage system 100 in various locations. For example, in the case of a trolley bus, modular energy storage system 100 may be mounted on the roof of the trolley bus or the cabin of the trolleybus. In one embodiment, bottom cover 108 provides multiple mounting locations for mounting feet 130 so that mounting feet 130 may be moved around to accommodate different mounting requirements of a given environment. In one embodiment, a plurality of bottom covers 108 are provided each with a different mounting interface for a respective environment. Thus, a first bottom cover 108 would be configured for a first mounting environment while a second bottom cover 108 is configured for a second mounting environment. As such by selecting one of bottom covers 108, modular energy storage system 100 may be tailored for a respective environment.

[0065] Referring to FIG. 3, cover 106 has been removed from body 104. As illustrated in FIG. 3, a plurality of battery sub-packs 200 is illustrated. Further, an air plenum 150 is illustrated. As explained in more detail herein, air enters through first air inlet 109 and second air inlet 110, passes through air plenum 150, passes through battery sub-packs 200 (under a cover 222 of sub-pack 200), and exits from outlets 1 14 of energy storage system 100. The air plenum 150 illustrated in FIG. 3 extends across a plurality of sub-packs 200. The air plenum 150' illustrated in FIG. 4 includes feeder plenums that correspond to respective sub-packs 200.

[0066] Referring to FIG. 5, the electrical connections between battery sub-packs 200 and battery management system 170 are illustrated. High voltage cables connect the batteries in battery sub-packs 200 to the contactors of battery management system 170 which are in turn connected to high voltage connector 120 to form a high voltage system 504. In one

embodiment, modular energy storage system 100 provides about 700 volts DC and a current of about 160 amperes. The voltage and amperage of modular energy storage system 100 may be adjusted by adjusting the connections between the batteries of battery sub-packs 200 and by increasing or decreasing the number of battery sub-packs 200.

[0067] Referring to FIG. 15, an exemplary battery sub-pack 200 is shown. Battery sub- pack 200 includes a body 230 and a cover 232. The body 230 may be a low carbon steel case for structural protection of sub-packs. The cover 232 may be an electrical insulating polymer cover for the battery modules and remote controllers 282 of the battery management system 170 may be provided under cover 232.

[0068] Cover 232 includes an opening 234 through which air enters an interior of battery sub-pack 200 and an opening 236 through which air is exhausted from the interior battery sub-pack 200. Battery sub-pack 200 includes a plurality of battery modules 300.

[0069] Cover 232 includes an outer cover 242 and an inner cover 244 (see FIG. 20)

Both outer cover 242 and inner cover 244 include the openings 234 and 236 through which air passes. Inner cover 244 is placed adjacent battery modules 300 (see FIG. 21) and cooperates with body 230 to define the air passage through sub-pack 200. A seal 246 is positioned on top of inner cover 244 to seal off openings in inner cover 244 and restrain the air flow generally from opening 234 to opening 236. The remote controllers 282 of battery modules 300 (see FIG. 15) are supported on top of seal 246 and underneath outer cover 242.

[0070] An exemplary battery module 300 is illustrated in FIG. 16. Battery module 300 includes a plurality of elements 302. Each element includes a plurality of battery cells. Each element 302 includes a plurality of frames 330 which support the cells and a heat transfer member 332 (see FIG. 7). The heat transfer member 332 includes an upper fin 334 which is exposed to the air passing through the modular energy storage system 100. In the illustrated embodiment, battery module 300 includes twelve elements 302 and each element 302 includes two battery cells.

[0071] Referring to FIGS 17 and 18, an exemplary battery element 302 of battery modules 300 is shown. In a battery module 300, a plurality of battery elements 302 are electrically coupled together and removably coupled to each other. Each battery element 302 includes a plurality of prismatic cells 304, at least one heat transfer member 332, and a plurality of frame members 310. The plurality of frame members 310, the plurality of cells 304, and the at least one heat transfer member 332 all being removably coupled together. Each of the plurality of cells includes a pair of terminals 306.

[0072] Battery module 300 further includes a first endplate 320 and a second endplate

322. The first endplate 320, the plurality of elements 302, and second endplate 322 are retained together with a plurality of tie rods 326. Exemplary battery modules 300, battery elements 302, and sub-packs 200, are disclosed in US Patent Application Serial No.

13/508,770, filed May 9, 2012, US Patent Application Serial No. 12/746,689, filed July 7, 2010, and US Patent Application Serial No. 12/741 ,510, filed August 13, 2010, the disclosures of which are expressly incorporated by reference herein.

[0073] Referring to FIGS. 32 and 33, second endplate 322 is shown. Second endplate

322 includes a body 340 and a power bus terminal 342. Power bus terminal 342 includes a first connector 344 and a second connector 346. Power bus terminal 342 is supported by body 340. Except for first connector 344 and second connector 346, power bus terminal 342 is positioned between an internal face 350 of second endplate 322 and an external face 352 of second endplate 322. In the illustrated embodiment, body 340 is made of a moldable material and power bus terminal 342 is overmolded by body 340. [0074] Each of the first connector 344 and the second connector 346 extend outside of the body 340 of the endplate 322. The first connector 344 extends from a first side 360 of second endplate 322 and the second connector 346 extends from a second side 362 of second endplate 322. In the illustrated embodiment, first side 360 of second endplate 322 is a top side of second endplate 322. In the illustrated embodiment, second side 362 is adjacent to first side 360.

[0075] Referring to FIG. 32, first connector 344 of power bus terminal 342 of second endplate 322 extends in a first direction 370 towards first endplate 320. Referring back to FIG. 32, both first connector 344 and second connector 346 of power bus terminal 342 extend in first direction 370.

[0076] Referring to FIG. 34, power bus terminal 342 is shown. Second connector 346 includes a contact surface 382 on the rear face of second connector 346 that makes electrical contact with the battery cells 304 of battery modules 300. Referring to FIG. 32, first connector 344 includes a contact surface 380 on a top surface of first connector 344. In one embodiment, power bus terminal 342 is made from a flat sheet of material. The flat sheet of material includes a base layer 384 and at least one outer layer 386 coupled thereto. The outer layer aids power bus terminal 342 in the ability to transmit electricity. In one embodiment, the base layer 384 is copper and the outer layer 386 is tin which is electroplated to the copper base layer (see FIG. 35).

[0077] To form the power bus terminal 342, the power bus terminal 342 is stamped out of the flat sheet in an unbent configuration. Both the contact surface 382 of second connector 346 and the contact surface 380 of first connector 344 are provided on either the upper surface or lower surface of the stamped unbent power bus terminal 342. Next, the second connector 346 and first connector 344 are formed by bending the unbent power bus terminal 342.

[0078] Referring to FIG. 35, a cross section of power bus terminal 342 is shown. In one embodiment, the first power bus terminal 342 has a minimum width to thickness ratio of about 10: 1 between the first connector 344 and the second connector 346. In one example, a width of power bus terminal 342 is about 30 millimeters and a thickness of power bus terminal 342 is about 3 millimeters. In one embodiment, the first power bus terminal 342 has a minimum width to thickness ratio of about 18: 1 between the first connector 344 and the second connector 346. In one example, a width of power bus terminal 342 is about 30 millimeters and a thickness of power bus terminal 342 is about 1.6 millimeters. In one embodiment, power bus terminal 342 carries about 160 amperes DC continuous.

[0079] Referring to FIG. 7A, an exemplary air flow through modular energy storage system 100' is illustrated. Air 400 enters through a front face 402 of modular energy storage system 100'. In the illustrated embodiment, air 400 is pulled by a fan unit 114 into an interior of modular energy storage system 100. The air is then communicated through an air plenum 412 into an interior of battery sub-packs 200 where the air 400 passes by upper fins 334 of heat transfer members 332 of battery modules 300.

[0080] Referring to FIG. 7, a battery management system 170 is shown. Battery management system 170 includes at least one contactor 172. In one embodiment, the battery management system 170 includes primary contactors, secondary contactors, a current sensor assembly, fuse, and master controller. As illustrated in FIG. 3, contactor 172 is positioned within the enclosure 102 to a first side of the plurality of battery modules 300 located in battery sub-packs 200 and above the at least one air inlet 108, 110. Returning to FIG. 7A, modular energy storage system 100' further includes a heating system 180. Heating system 180 is spaced apart from air plenum 412. Further, heating system 180 is positioned within the enclosure 102 below the plurality of battery modules 300. The heating system may be a resistive element heating system.

[0081] In one embodiment, battery management system 170 includes controls for pre- charge of the system, a closing sequence of the contactors, and an opening sequence of the contactors. The battery management system 170 monitors temperature, state of charge, voltage, and state of health.

[0082] Referring to FIG. 7, a cooling system 250 of modular energy storage system 100 is shown. Cooling system 250 directs a fluid through the enclosure to cool a temperature of the battery cells of battery modules 300 of battery sub-packs 200. As shown in FIG. 7, air 400 enters a air plenum 150 of enclosure 102 through an air inlet 109, 1 10 due to a fan unit 114 drawing the air into the enclosure 102. The first portion of the air plenum 150 including the fan unit 1 14 is an air inlet housing 254. An upper portion of air inlet housing 254 is formed by a support 256 of battery management system 170. From the air inlet housing 254, the air 400 travels into a manifold 260 of air plenum 150. As shown in FIGS. 13 and 14, manifold 260 includes at least one inlet 262 and a plurality of outlets 264. Each of the plurality of outlets is positioned to correspond to one of the opening 234 in battery sub-packs 200. The air 400 travels into battery sub-packs 200 through opening 234, passes through heat transfer member 334 of battery modules 300 and exits battery sub-packs 200 through opening 236. The air 400 then exits enclosure 102 through outlets 1 14 in top cover 106.

[0083] Referring to FIGS. 8 and 9, fan unit 1 14 may be removed from modular energy storage system 100 without altering the size of air inlet housing 254. With fan unit 1 14 removed, an external temperature control system may be assembled to modular energy storage system 100. An exemplary external temperature control system is an air conditioning system of a vehicle or facility.

[0084] As mentioned above, the upper portion of air inlet housing 254 is formed by a support 256 of battery management system 170. Referring to FIG. 11, support 256 supports a plurality of components of battery management system 170. An insulating liner 270 is placed between support 256 and the components of battery management system 170. Exemplary components of battery management system 170 include contactors 172, a fuse 272, and a current sensor 274. Battery management system 170 further includes a master controller 124 which is in communication with other components of battery management system 170 through a network and with remote controllers 282 located in battery sub-packs 200 through the network. An exemplary network is a CAN network. In one embodiment, master controller 124 is operatively coupled to fan unit 1 14 to control the operation of fan unit 114 and hence the operation of cooling system 250.

[0085] Referring to FIG. 14, an upstanding portion 286 of support 256 is received in a clip portion 288 of manifold 260 to couple support 256 and manifold 260 together. In addition to routing air flow through enclosure 102, air plenum 150 retains battery sub-packs 200.

Referring to FIG. 27, body 104 of enclosure 102 includes an outer set of walls 450 and an internal divider 452 which spans the length of body 104. A front side of internal divider 452 forms part of air inlet housing 254 of air plenum 150. A rear side of internal divider 452 is adjacent the battery sub-packs 200 when the sub-packs are placed in enclosure 102 (see FIG. 29). Internal divider 452 further includes an upper shelf 454. Body 104 further includes a plurality of locators 460 which hold a bottom portion of battery sub-packs 200 when battery sub-packs 200 are placed in enclosure 102. Referring to FIG. 29, a battery sub-packs 200 is shown placed within enclosure 102. A lower portion of battery sub-packs 200 is located with locators 460, a rear upper portion of battery sub-packs 200 is located with locators, and a front lip 464 of battery sub-packs 200 rests on upper shelf 454 of internal divider 452. Exemplary locators 462 include pins or screws received in openings in battery sub-packs 200.

[0086] Referring to FIG. 14, manifold 260 includes a recessed portion 470 which is sized to accommodate front lip 464 of battery sub-packs 200. As shown in FIG. 7, front lip 464 of battery sub-packs 200 rests on upper shelf 454 of internal divider 452 and manifold 260 holds battery sub-packs 200 in place. Further, manifold 260 is secured to internal divider 452 with fasteners (see Fig. 7).

[0087] Referring to FIG. 25, an exemplary heating system 500 of modular energy storage system 100 is illustrated. Heating system 500 includes a plurality of heating apparatus 502 that are supported by bottom cover 108. Referring to FIG. 30, heating apparatus 502 are powered directly from the high voltage system 504 of modular energy storage system 100. In one embodiment, modular energy storage system 100 produces about 100 volts DC continuous and the heating apparatus 502 of heating system 500 are powered by the 100 volts provided by the high voltage system. In one embodiment, modular energy storage system 100 produces about 700 volts DC continuous and the heating apparatus 502 of heating system 500 are powered by the 700 volts provided by the high voltage system. In one embodiment, modular energy storage system 100 produces in the range of about 100 volts to about 700 volts DC continuous and the heating apparatus 502 of heating system 500 are powered by the voltage provided by the high voltage system. In one embodiment, master controller 124 controls the operation of heating system 500 and disconnects heating apparatus 502 from the high voltage system 504 when heating is not needed and connects the heating apparatus 502 to the high voltage system 504 when heating is needed. An exemplary heating system is disclosed in US Provisional Application Serial No. 61/776,667, filed March 11 , 2013, titled METHOD AND APPARATUS FOR BATTERY CONTROL, docket ENERD-012-012-01-US-E, the disclosure of which is expressly incorporated by reference herein. [0088] Returning to FIG. 25, a respective heating apparatus 502 is provided for each battery sub-packs 200. The heating apparatus 502 are thermally coupled to member 332 of battery modules 300. As shown in FIG. 19, a lower end of body 230 of battery sub-packs 200 are open to expose member 332 to heating apparatus 502. Heating apparatus 502 are supported by bottom cover 108. Returning to FIG. 25, heating apparatus 502 are supported on a compressible member 520. An exemplary compressible member includes a two inch thick section of expanded polypropylene foam and a one-quarter inch thick section of silicon foam. The compressible member 520 presses heating apparatus 502 up against the heat transfer members 332 of battery sub-packs 200.

[0089] Although a single modular energy storage system 100 is shown, in one embodiment multiple modular energy storage system 100 may be electrically coupled together to form a larger modular energy storage system 100. When multiple modular energy storage system 100 are coupled together, the master controller of one of the modular energy storage system 100 becomes a master controller for the whole system.

[0090] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.