BACKGROUND

[0001] This invention relates generally to an energy storage system and, more specifically, to a rack structure for housing batteries.

[0002] The worldwide demand for electrical energy has been increasing year by year. Most of the electrical energy demand is met by energy produced from conventional energy sources such as coal and gas. However, in recent years, with the rising global climate change issues, there has been a push for electricity generation by renewable energy resources such as solar power and wind power.

[0003] Wind turbine generators are regarded as environmentally friendly and relatively inexpensive alternative sources of energy that utilize wind energy to produce electrical power. Further, solar power generation uses photovoltaic (PV) modules to generate electricity from sunlight. Since the intensity of wind and sunlight is not constant, the power output of wind turbines and PV modules fluctuates throughout the day. Unfortunately, the demand for electricity does not vary in accordance with solar and wind variations.

[0004] An energy storage system may help to address the issue of variability of solar and wind power. Essentially, the variable power from solar and wind power plants can be stored in the energy storage system which can then be used at a later time or at a remote location. Energy storage systems may also be charged from a power network and could be used to address the frequency variations, harmonic suppression, voltage support and power quality in the power network.

[0005] A typical energy storage system for applications such as those described above may include a considerable number of batteries that need to be housed in proximity to each other. It may also be necessary to provide a cooling mechanism to control the temperature of the batteries. The present inventor has recognized opportunities for increasing the efficiency of structures provided to house batteries in energy storage systems

BRIEF DESCRIPTION

[0006] In some embodiments, a battery support structure includes at least one column of battery receptacles. Each of the receptacles is for housing a respective battery. Each receptacle is defined at its rear by a back wall. Each receptacle is defined at its left side by a left side wall. Each receptacle is defined at its right side by a right side wall. The left side wall is joined to the back wall. The right side wall is joined to the back wall. Each receptacle is open at a front of the receptacle..

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] These and other features and aspects of embodiments of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0008] FIG. 1 is an isometric view, taken from above and to the side, of a partially assembled energy storage system according to an embodiment of the invention;

[0009] FIG. 1 A is an isometric view showing only battery support components of the energy storage system of FIG. 1.

[0010] FIG. 2 is another isometric view of the energy storage system of FIG. 1, also taken from above and to the side, but at a different angle from FIG. 1 ;

[0011] FIG. 3 is still another isometric view of the energy storage system of FIGS. 1 and 2, taken from below and to the side; and [0012] FIG. 4 is an isometric view, partially broken away, showing details of an upper corner of the energy storage system as viewed in FIG. 3.

[0013] FIG. 5 is an isometric view of an alternative embodiment of a central longitudinal component of the battery support components shown in FIG. 1 A.

[0014] FIG. 6 is a front elevation view of one of the studs included in the central longitudinal component of FIG. 5.

[0015] FIG. 7 is a front elevation view of an X-shaped stability element from among a number of such elements which form the stud of FIG. 6.

[0016] FIG. 8 is a partial isometric view of the energy storage system showing X-shaped stability elements in conjunction with one of two arrays of battery receptacles.

[0017] FIGS. 9-12 show alternative cross-sectional configurations of a spine component of the energy storage system.

DETAILED DESCRIPTION

[0018] When introducing elements of various embodiments of the present invention, the articles“a,”“an,”“the,” and“said” are intended to mean that there are one or more of the elements. The terms“comprising,”“including,” and“having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

[0019] FIGS. 1-4 show an energy storage system 100 according to aspects of the present disclosure. Referring initially to FIG. 1, the energy storage system 100 is seen to include a battery support structure 102. The battery support structure 102 includes a vertically and longitudinally extending spine component 104 (visible in FIGS. 1-3). Battery receptacles 106 are arrayed on both right and left sides of the spine component 104 and are part of the battery support structure 102. [0020] In the particular embodiment illustrated in the drawings, the battery receptacles are arrayed in 10 vertical columns 108 on each of the left and right sides of the spine component (to simplify the drawing, not all of the 20 columns of receptacles 106 are labeled with reference numerals, just as not all of the receptacles are individually labeled with reference numerals). Also in this particular embodiment, each of the columns 108 is made up of a stack of 17 receptacles 106. Either or both of the number of columns and the number of receptacles per column may be varied from one embodiment to another. For example, in some embodiments, the receptacles may be arrayed only on one side of the spine component and/or the number of columns on one side of the spine component may be five or more or less, and the number of receptacles per column may be five or more or less. Not all columns need have the same number of receptacles, although in the embodiment shown, all 20 columns do have the same number (17 receptacles, as noted above).

[0021] A portion of the structure that defines the side walls of the receptacles include left side receptacle side walls 110 (best seen in FIG. 1) and right side receptacle side walls 112 (best seen in FIG. 3), which side walls 110 and 112 are part of the battery support structure 102. (In a note on terminology for the previous sentence, the“side” referred to as“left side” or“right side” refers to a side of the spine component 104; the“side” referred to in“receptacle side wall” refers to a side of the receptacles 106 partially defined by the receptacle side walls 110, 112.) Not all the receptacle side walls are labeled with reference numerals.

[0022] The left side receptacle side walls 110 are each joined perpendicularly to the spine component 104 and extend outwardly in a leftward direction from the spine component 104, and serve to define right and left sides of the battery receptacles 106 arrayed on the left side of the battery support structure 102. The right side receptacle side walls 112 are each joined perpendicularly to the spine component 104 and extend outwardly in a rightward direction from the spine component 104, with the right side receptacle side walls 112 extending outwardly from the spine component 104 in a direction that is opposite to the direction in which the left side receptacle side walls extend from the spine component 104. The right side receptacle side walls 112 serve to define right and left sides of the battery receptacles 106 arrayed on the right side of the battery support structure 102. In the particular embodiment shown, each left side receptacle side wall 110 is co-planar with a corresponding one of the right side receptacle side walls 112, though this need not be the case in other embodiments. It will be noted that the left side receptacle side walls 110 and the right side receptacle side walls 112 are vertically oriented.

[0023] When installed in an operational condition, the energy storage system 100 may include batteries installed in some or all of the receptacles (in this example embodiment, for instance, that could amount to 340 batteries in the 340 receptacles defined by the battery support structure 102). For clarity in making the battery support structure visible in the drawings, only a few batteries 120 are shown installed in a few of the receptacles at the tops of the columns 108 of receptacles 106. Two of the installed batteries 120 are most readily seen in FIG. 4. Not all of the batteries shown in the drawings are labeled with reference numerals. The batteries may be of any type currently or hereafter in use in energy storage applications such as those described herein.

[0024] As seen particularly in FIG. 4, each receptacle 106 is open in a direction facing away from the spine component 104; i.e., each receptacle 106 is open at its front. A respective side of the spine component 104 serves as the back wall 122 (FIG. 3) of the receptacles on that side of the spine component 104. (Not all of the receptacle back walls are labeled with reference numerals— it will be recognized that in this example embodiment there are 340 receptacle back walls, of which many are not visible in the drawings.)

[0025] Each receptacle 106 is defined at its left side by a left side wall 123 (being a portion of one of the side walls 110 or 112, as the case may be). Each receptacle is defined at its right side by a right side wall 124 (being a portion of one of the side walls 110 or 112, as the case may be). From the previous description of the side walls 110 and 112, it will be recognized that the left and right side walls 123, 124 of the receptacles are joined to the back wall 122 of the receptacle.

[0026] The bottom side of most or all receptacles is defined by shelf members 130 (left side— see FIG. 4) and 132 (right side— see FIG. 3). The left side shelf member 130 extends from the left side wall 123 toward the right side wall 124. The right side shelf member 132 extends from the right side wall 124 toward the left side wall 123. According to one manner of constructing the shelf members (and as shown in the example embodiment of FIGS. 1-4), the shelf members are formed by cutting out a portion of the respective side wall and bending the cut-out portion so as to be perpendicular to the side wall. This approach may be economical in terms of use of materials and steps required to assemble the battery support structure 102. In other embodiments, other manners of providing the shelf members and/or defining the bottom side of the receptacles may be employed.

[0027] The spine component 104 and the side walls 110, 112 (and hence the back and side walls of the receptacles 106) may be formed of metal or other suitable material.

[0028] The spine component 104 may have one or more voids and/or conduits to allow passage therethrough of a liquid or gas coolant, such as air, to aid in temperature control for the batteries housed in the battery support structure 102. Accordingly, the spine component may be configured to aid in the dual functions of mechanical support and temperature control for the batteries.

[0029] The energy storage system may also include housings 140, 142 positioned at a front end of the spine component. Although not visible in the drawing, components of the energy storage system such as positive temperature control equipment, battery management systems, and the like may be housed in the housings 140, 142. [0030] The mechanical and structural arrangements as exhibited in the example embodiment of FIGS. 1-4 may be conducive to convenient and economical construction of energy storage systems and battery support structures therefor.

[0031] According to one manner of assembling the energy storage system 100, the battery support structure may first be assembled by, e.g., welding the spine component 104 to the left and right end walls of the arrays of receptacle side walls. The remaining receptacle side walls may then be stacked in starting on one side of the spine component 104, then moving to stack the receptacle side walls on the other side of the spine component 104. Then the batteries 120 may be filled in the receptacles 106 formed by stacking in the receptacle side walls.

[0032] FIG. 5 is an isometric view of an alternative embodiment of a central longitudinal component 204 of the battery support components shown in FIG. 1A, and particularly of the spine component 104. The central longitudinal component 204 may alternatively be referred to as a“stud wall”, and is formed from studs 206 positioned along a length axis of the spine component 104 (not shown in FIG. 5 apart from the stud wall 204.

[0033] FIG. 6 is a front elevation view of a typical one of the studs 206 included in the stud wall 204 shown in FIG. 5. As seen best from FIG. 6, each stud 206 is formed from a stacked configuration of X-shaped stability elements 208. FIG. 7 is a front elevation view of a typical one of the X-shaped stability elements 208, shown in a bracing position between members 210 that form back walls of the battery receptacles 106 (FIG. 1A, not shown in FIG. 7). FIG. 8 is a partial isometric view of the energy storage system showing X-shaped stability elements 208 in conjunction with one of two arrays of battery receptacles.

[0034] The stability elements 208 may be constructed so as to provide sufficient shear stiffness to mechanically couple the left and right side battery racks (i.e., the racks on either side of the spine component 104). The stability elements 208 may have sufficient material strength to resist shear load experienced in the battery support structure 102. The X-shaped configuration of the stability elements 208 may supply sufficient geometric buckling strength to resist the shear load experienced in the battery support structure 102. The stability elements 208 may serve to resist shear load that may be caused during transportation of the system/ structure during a drop event, or by a seismic event with a horizontal component to the resulting motion. Moreover, the cross- sectional space left open in the stud wall 204 by the stability elements 208 may be advantageous in allowing enhanced freedom for cooling air to pass through the spine component 104. As much as 95% of the cross-sectional space of the spine component 104 may be left open with use of the X-shaped stability elements 208.

[0035] As possible alternatives to the X-shaped members illustrated especially in FIG. 6, there may be alternative cross-sectional configurations of the spine component, such configurations being conducive to air-flow along the spine component. FIGS. 9-12 each show a respective alternative cross-sectional configuration, as provided in other embodiments.

[0036] In conceptual terms, the entire energy storage system may be thought of as being a battery, with battery modules each housed in the individual receptacles formed by the support structure.

[0037] A technical effect of the invention is to improve manufacturability of energy storage systems.

[0038] This written description uses examples to explain the disclosure, including the best mode, and also to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.