Energy storage system

Abstract

An energy storage system (10) comprising a base frame (12), an upper frame (14) and a plurality of tubular members (16) each receiving a first column (13) of cells (11) and a second column of cells (15) parallel to the first column (13) of cells (11). A battery management system provided to inject charge into or extract charge from each of the cells individually and a plurality of connection boards (56) are located between the first and second columns (13, 15) of cells (11). Each of the connection boards (56) is oriented parallel to a longitudinal axis of the tubular member (16) and includes first and second tabs (64, 65) extending outwardly to connect to electrical contacts on an adjacent pair of cells (11) from the first and second column (13, 15).

Description

“ENERGY STORAGE SYSTEM”Field of the Invention

[0001] The present invention relates to system for storage of energy within batteries.Background to the Invention

[0002] With increasing use of renewal energy power sources such as solar and wind, the ability to store this generated energy for use as required is becoming increasingly important. Energy storage devices comprising batteries contained within a suitable housing can certainly be used for this purpose but present a variety of problems, such as high cost, lifespan limitations and safety and maintenance issues.

[0003] The present invention comprises an energy storage system provided to store energy within batteries contained within the system. The energy storage system is aimed at being cost effective, long lasting, easy to service and useful in a variety of applications and environments.Summary of the Invention

[0004] According to one aspect of the present invention there is provided an energy storage system comprising: a base frame; an upper frame; a plurality of tubular members extending between the base frame and the upper frame, each of the tubular members provided to receive a first column of cells and a second column of cells parallel to the first column of cells;a battery management system provided to inject charge into or extract charge from the cells; and a plurality of connection boards in communication with the battery management system, the connection boards each being located between the first and second columns of cells of each tubular member; wherein each of the connection boards is oriented parallel to a longitudinal axis of the tubular member and includes first tabs extending outwardly from a first side to connect to electrical contacts on an adjacent pair of cells from the first column and second tabs extending outwardly from a second side of each of the connection boards to connect to electrical contacts on an adjacent pair of cells from the second column.

[0005] Preferably the first and second electrical contacts connect to each adjacent pair of cells to allow charge to be extracted or injected into each cell.

[0006] Preferably each of the tubular members includes first and second side walls being parallel and first and second end walls connecting the first and second side walls.

[0007] Preferably the tubular members are obround in transverse cross-section such that the first column of cells is received adjacent the first end wall and the second column of cells is received adjacent the second end wall.

[0008] Preferably the tubular members are provided in a generally rectangular array.

[0009] Preferably the tubular members are arranged in the array into rows, where each tubular member within the row has the second side wall thereof located parallel and adjacent to the first side wall of an adjacent tubular member and columns, where each tubular member within the column has the second end wall thereof located adjacent the first end wall of an adjacent tubular member.

[0010] In a preferred embodiment, each of the tubular members includes first and second guide rails extending longitudinally down inner surfaces of the first and second side walls, each of the first and second guide rails including a channel to receive an edge of the connection boards.

[0011] Preferably each of the guide rails includes a longitudinal groove which receives in use a corresponding rib extending along an inner surface of the first and second side walls of the tubular member.

[0012] Preferably the base frame generally a planar member having a plurality of openings corresponding in shape to the cross-sectional shape of the tubular members such that lower ends of the tubular member engage around the periphery of the openings.

[0013] Preferably protrusions are provided on an upper surface of the base frame located between each set of four adjacent openings to assist with locating the lower ends of the tubular members.

[0014] Preferably the protrusions include tapered distal ends.

[0015] Preferably the protrusions include apertures passing centrally through from distal ends thereof to a lower side of the base frame to allow air to flow downwardly through tubular spaces between the tubular members and outwardly through the protrusions.

[0016] Preferably the base frame is pivotally mounted to a base plate, the base plate being securable to the ground.

[0017] Preferably the base frame is connected to the base plate to be selectively pivotable about more than one axis.

[0018] Preferably the base plate comprises a planar base wall having an edge wall extending upwardly from around the periphery thereof, the edge walls including a plurality of slots each provided for receiving a corresponding hinge member extending outwardly from around the periphery of the base frame suchthat a hinge pin may be inserted through aligned holes in the hinge members to allow pivotal movement of the base frame relative to the base plate.

[0019] Preferably the base frame is provided with hinge members on three sides thereof to be received in corresponding slots on three sides of the edge wall of the base plate.

[0020] Preferably the upper frame includes a fan provided to direct air flow downwardly through the tubular spaces between the tubular members.

[0021] In one embodiment, the base plate comprises a planar base wall having an edge wall extending upwardly from around the periphery thereof, the edge walls including a plurality of slots each provided for receiving a corresponding hinge member extending outwardly from around the periphery of the base frame such that the hinge members are rotatable within the slots to allow pivotal movement of the base frame relative to the base plate.

[0022] Preferably the hinge members include rounded lower ends and the slots each include a concave base wall corresponding to the curvature of the lower ends of the hinge members.

[0023] Preferably the base frame is provided with a plurality of first and second wall portions extending between an adjacent pairs of the hinge members and the base plate is provided with first and second upright walls extending between pairs of the slots such that the first wall portions can engage with the first upright walls to restrict the hinge members from moving out from the slots in a first direction and second wall portions can engage with the second upright walls to restrict the hinge members from moving out from the slots in a second opposite direction.

[0024] In one embodiment, the first and second ends of the tubular members are arcuate such that the tubular members are obround in transverse cross section.

[0025] In a further embodiment, the tubular members include third and fourth columns of cells such that the tubular members are generally square in transverse cross section.Brief Description of the Drawings

[0026] The invention will now be described, by way of example, with reference to the following drawings, in which:

[0027] Figure 1a is an upper perspective view of an energy storage system in accordance with the present invention;

[0028] Figure 1 b is a front view of the energy storage system of Figure 1 a;

[0029] Figure 2 is a perspective view of the lower end of the energy storage system of Figure 1 ;

[0030] Figure 3 is a perspective view of the lower end of the energy storage system of Figure 1 with the base plate removed;

[0031] Figure 4 is a perspective view of a row of the tubular members of the energy storage system of Figure 1 ;

[0032] Figure 5 is a perspective view of an end of the tubular members of Figure 4;

[0033] Figure 6a is an upper perspective view of the tubular members of Figure 4 engaged with the base frame of the energy storage system;

[0034] Figure 6b is a close-up view of the lower ends of the tubular members of Figure 6a;

[0035] Figure 7 is a bottom view of the base frame of the energy storage system;

[0036] Figure 8 is a lower perspective view of the base frame of the energy storage system;

[0037] Figure 9 is a lower perspective view of lower ends of the tubular members of Figure 5;

[0038] Figure 10 is a perspective view of the energy storage system in a tilted position;

[0039] Figure 11 a is a perspective view of the upper frame of the energy storage system;

[0040] Figure 11 b is a lower perspective view of the upper frame; and

[0041] Figure 12 is a perspective view of upper ends of the first and second columns of cells to be received in the tubular members of the energy storage system;

[0042] Figure 13 is a perspective view of the lower end of a second embodiment of an energy storage system of the present invention;

[0043] Figure 14 is a view of the base frame of the energy storage system of Figure 13;

[0044] Figure 15 is a view of the base plate of the energy storage system of Figure 13; and

[0045] Figure 16 is a cross sectional view of the base plate of Figure 15.Detailed Description of Preferred Embodiments

[0046] Referring to the Figures, there is shown an energy storage system 10 comprising generally a base frame 12, an upper frame 14 and a plurality of tubular members 16. The base frame 12 is to be mounted adjacent the ground in use such that the tubular members 16 extend upwardly from the base frame12 and the upper frame 14 engages with upper ends of the tubular members 16. Each of the tubular members 16 is provided for receiving a plurality of cells 11 . The cells 11 may comprise cylindrical batteries of a standard construction for receiving and storing energy and delivering electrical energy as required.

[0047] Each of the tubular members 16 is provided for receiving a first column13 of cells 11 adjacent a first end thereof and a second column 15 of cells 11 adjacent a second end. The first and second columns 13 and 15 of cells 11 are parallel in use and extend throughout the length of the tubular member 16. Each of the tubular members 16 includes a first side wall 22, a second side wall 23, a first end wall 24 and a second end wall 25. The first and second side walls 22 and 23 are parallel and planar and each of the first and second end walls 24 and 25 are arcuate in transverse cross section. The tubular members 16 in theembodiment shown are therefore generally obround in transverse cross-section to receive the first and second columns 13 and 15 of cylindrical cells 11 .

[0048] The tubular members 16 are provided in a generally rectangular array and lower ends thereof engage with the base frame 12 which is rectangular in shape. The tubular members 16 are arranged in the array into rows, where each tubular member 16 within the row has the second side wall 23 thereof located parallel and adjacent to the first side wall 22 of an adjacent tubular member 16, and columns, where each tubular member 16 within the column has the second end wall 25 thereof located adjacent the first end wall 24 of an adjacent tubular member 16.

[0049] The base frame 12 comprises generally a planar member having a plurality of openings 26. The openings 26 corresponds in shape to the cross- sectional shape of the tubular member 16 and are dimensioned such that lower ends of the tubular member 16 engage around the periphery of the openings 26. Protrusions 28 are provided on an upper surface of the base frame 12 located between each set of four adjacent openings 26 to assist with locating the lower ends of the tubular members 16. The protrusions 28 include tapered distal ends and include apertures 30 passing centrally through the protrusions 28 from the distal ends thereof to a lower side of the base frame 12 to allow air to flow downwardly through the space between the tubular members 16 and outwardly through the protrusions 28.

[0050] The base frame 12 is mounted to a base plate 20. The base plate 20 is to be secured to the ground in use by suitable means, such as by threaded fasteners passing into the ground. The base plate 20 comprises a planar base wall 32 having an edge wall 34 extending upwardly from around the periphery thereof. The edge walls 34 include a plurality of slots 36 each provided for receiving a corresponding hinge member 38 extending outwardly from around the periphery of the base frame 12. Each of the hinge members 38 includes a hole such that a hinge pin 40 may be passed through a side of the edge wall 34 to pass through the aligned holes in the hinge members 38.

[0051] In the embodiment shown, the base frame 12 is provided with hinge members 38 on three sides thereof to be received in corresponding slots 36 on three sides of the edge wall 34 of the base plate 20. The hinge pins 40 are provided on each of the corresponding three sides of the base plate 20. By removing the hinge pins 40 from two of the three sides of the edge wall 34, the base frame 12 and therefore the tubular members 16 may be tilted between a vertical position (as shown in Figure 1 ) to a tilted position (as shown in Figure 10) by pivoting about the remaining hinge pin 40. The tubular members 16 may therefore be tilted about whichever hinge pin 40 is most suitable given the mounting position of the energy storage system 10 and access is then provided to the lower side of the base frame 12 such that cells 11 may be slid outwardly from the tubular members 16 for maintenance and / or replacement.

[0052] Inner sides of each of the first and second side walls 22 and 23 of the tubular members 16 are provided with corresponding first and second ribs 42 and 43 extending along the length of the tubular member 16. Each of the first and second ribs 42 and 43 are located centrally on the first and second side walls 22 and 23 such that the ribs 42 and 43 are located generally between the first and second columns 13 and 15 of the cells 11. Each of the openings 26 also includes first and second rib portions 52 and 53 having positions corresponding to the first and second ribs 42 and 43. Each of the ribs 42 and 43 and rib portions 52 and 53 includes a central bore 44 such that the bores 44 in the first and second ribs 42 and 43 align with the bores 44 in the first and second rib portions 52 and 53. Fasteners 46 (as can be seen in Figure 9) may be passed through the rib portions 52 and 53 into the corresponding ribs 42 and 43 from below the base frame 12.

[0053] Each of the tubular members 16 is provided with a cap 48 securable across the lower end of the tubular member 16 in order to retain the cells 11 within the tubular member 16. As can be seen in Figure 9, the caps 48 correspond in shape to the cross-sectional shape of the tubular members 16 and are therefore obround in shape. The caps 48 are held in place by securing members 50. Each of the securing members 50 includes a pair of holes for receiving a pair of the fasteners 46. The fasteners 46 passed through each oneof the securing members 50 are received into the second rib 43 of the tubular member 16 and the first rib 42 of an adjacent tubular member 16 such that the securing members 50 are located adjacent a lower side of the base frame 12. Each of the securing members 50 thereby secures a pair of adjacent caps 48 and engages also with the base frame 12. Tightening of the fasteners 46 pulls the cells 11 towards each other within the tubular member 16 and retains the cells 11 in electrical contact.

[0054] The upper frame 14 is provided to engage with upper ends of the tubular members 16 and to engage upper ends of the columns of 13 and 15 of cells 11 . The upper frame 14 includes circuitry provided to electrically connect to each column 13 and 15 of cells 11 such that the voltages produced by the columns 13 and 15 of cells 11 may be switched in and out of series connections to provide a stepwise approximation of an AC signal. The stepwise approximation of an AC signal formed may be smoothed by suitable means to generate an output AC signal.

[0055] The upper frame 14 includes a fan 54 provided to direct air flow downwardly between the tubular spaces defined between each adjacent set of four tubular members 16 for cooling purposes. Air passing downwardly through the tubular spaces may exit outwardly through the apertures 30 in the protrusions 28.

[0056] The energy storage system 10 includes a battery management system provided to allow balancing of the voltages of each individual cell 11 within the columns 13 and 15. Connections are therefore provided to each individual cell 11 by means of connection boards 56 provided within each of the tubular members 16. Each of the connection boards 56 provides connection to adjacent pairs of cells 11 in both the first and second columns 13 and 15.

[0057] As can be seen in Figure 5, each of the tubular members 16 includes first and second guide rails 58 and 59 extending longitudinally down inner surfaces of the first and second side walls 22 and 23. Each of the guide rails 58 and 59 includes a longitudinal groove 60 which receives in use the corresponding rib 42 or 43. Extending outwardly from adjacent the groove 60there is provided a channel 62 in each of the guide rails 58 and 59. The channels 62 are provided such that the connection boards 56 may be slid longitudinally into the tubular members 16 so that opposed edges of the connection boards 56 are received in the channels 62 and located between the adjacent columns 13 and 15 of cells 11 .

[0058] Each of the connection boards 56 includes a first tab 64 extending outwardly from first side thereof and a second tab 65 extending outwardly from a second side thereof. The first tabs 64 are provided to engage between an adjacent pair of cells 11 in the first column 13 and the second tabs 65 are provided to engage between adjacent pair of cells 11 in the second column 15. The connection boards 56 thereby provide connection to opposed ends of each individual cell 11 and the connection boards 56 are connected and controlled by the battery management system to allow energy to be extracted from or injected to each individual cell 11 to allow balancing of the cells within the columns 13 or 15. The connection boards 56 are connected together by flexible cables including wires provided to pass electrical signals to and from the connection boards 16. The flexible cables may comprise flexible ribbon cable.

[0059] It will be appreciated that while the embodiment described shows first and second columns of cells 11 in each of the tubular members 16, the tubular members 16 may also include additional columns of cells 11. In a further embodiment for example (not shown), each of the tubular members 16 may have greater width in order to accommodate third and fourth columns of cells. The tubular members 16 therefore accommodate four cells 11 at each layer with two to four of them being paralleled. Thus charge is injected or extracted from two or four paralleled cells 11 .

[0060] Figures 13 to 16 show a second embodiment of an energy storage system 10 in accordance with the present invention. The energy storage system 10 of this embodiment is similar to the previous embodiment and like reference numerals are used to denote like parts.

[0061] The hinge members 38 of the base frame 12 in the embodiment include rounded lower ends 66, as can be seen in Figure 14. The slots 36 in the baseplate 20 also each include a concave base wall 68 corresponding to the curvature of the lower ends 66 of the hinge members 38. This arrangement allows the hinge members 38 to pivot within the slots 36 without the need for a hinge pin 40.

[0062] The base frame 12 is also provided with a plurality of first and second wall portions 70 and 71 extending outwardly from edges thereof. The first wall portions 70 each extend between an adjacent pair of the hinge members 38 and the second wall portions 71 extend between alternating pairs of the hinge members 38. The base plate 20 is provided with first and second upright walls 72 and 73. The first uprights walls 72 each extend between an adjacent pair of the slots 36 and the second upright walls 73 extend between alternating pairs of the slots 36. The first upright walls 72 are adjacent an outer edge of the edge wall 34 and the second upright walls 73 are located adjacent an inner edge of the edge wall 34. When the base frame 12 pivots relative to the base plate 20, the first wall portions 70 engage with the first upright walls 72 to restrict the hinge members 36 from moving out from the slots 36 in a first direction and second wall portions 71 engage with the second upright walls 73 to restrict the hinge members 36 from moving out from the slots 36 in a second opposite direction.

[0063] It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention.

[0064] For example, where a fan is used so that airflow is directed between the tubular members 16, the shape of the base plate 20 is modified to accommodate that air flow. Also, when multiple energy storage systems 10 are arranged in a grid and mounted on a pallet for commercial storage, the pallet may have matching holes to also accommodate air flow.

Claims

Claims1 . An energy storage system comprising: a base frame; an upper frame; a plurality of tubular members extending between the base frame and the upper frame, each of the tubular members provided to receive a first column of cells and a second column of cells parallel to the first column of cells; a battery management system provided to inject charge into or extract charge from the cells; and a plurality of connection boards in communication with the battery management system, the connection boards each being located between the first and second columns of cells of each tubular member; wherein each of the connection boards is oriented parallel to a longitudinal axis of the tubular member and includes first tabs extending outwardly from a first side to connect to electrical contacts on an adjacent pair of cells from the first column and second tabs extending outwardly from a second side of each of the connection boards to connect to electrical contacts on an adjacent pair of cells from the second column.

2. An energy storage system in accordance with claim 1 , wherein the first and second electrical contacts connect to each adjacent pair of cells to allow charge to be extracted or injected into each cell.

3. An energy storage system in accordance with claim 1 or 2, wherein each of the tubular members includes first and second side walls being parallel and first and second end walls connecting the first and second side walls.

4. An energy storage system in accordance with claim 3, wherein the tubular members are obround in transverse cross-section such that the first column of cells is received adjacent the first end wall and the second column of cells is received adjacent the second end wall.

5. An energy storage system in accordance with any one of the preceding claims, wherein the tubular members are provided in a generally rectangular array.

6. An energy storage system in accordance with claim 5, wherein the tubular members are arranged in the array into rows, where each tubular member within the row has the second side wall thereof located parallel and adjacent to the first side wall of an adjacent tubular member and columns, where each tubular member within the column has the second end wall thereof located adjacent the first end wall of an adjacent tubular member.

7. An energy storage system in accordance with any one of the preceding claims, wherein each of the tubular members includes first and second guide rails extending longitudinally down inner surfaces of the first and second side walls, each of the first and second guide rails including a channel to receive an edge of the connection boards.

8. An energy storage system in accordance with claim 6, wherein each of the guide rails includes a longitudinal groove which receives in use a corresponding rib extending along an inner surface of the first and second side walls of the tubular member.

9. An energy storage system in accordance with any one of the preceding claims, wherein the base frame generally a planar member having a plurality of openings corresponding in shape to the cross-sectional shape of the tubular members such that lower ends of the tubular member engage around the periphery of the openings.

10. An energy storage system in accordance with claim 9, wherein protrusions are provided on an upper surface of the base frame located between each set of four adjacent openings to assist with locating the lower ends of the tubular members.

11. An energy storage system in accordance with claim 10, wherein the protrusions include tapered distal ends.

12. An energy storage system in accordance with claim 11 , wherein the protrusions include apertures passing centrally through from distal ends thereof to a lower side of the base frame to allow air to flow downwardly through tubular spaces between the tubular members and outwardly through the protrusions.

13. An energy storage system in accordance with any one of the preceding claims, wherein the base frame is pivotally mounted to a base plate, the base plate being securable to the ground.

14. An energy storage system in accordance with claim 13, wherein the base frame is connected to the base plate to be selectively pivotable about more than one axis.

15. An energy storage system in accordance with claim 14, wherein the base plate comprises a planar base wall having an edge wall extending upwardly from around the periphery thereof, the edge walls including a plurality of slots each provided for receiving a corresponding hinge member extending outwardly from around the periphery of the base frame such that a hinge pin may be inserted through aligned holes in the hinge members to allow pivotal movement of the base frame relative to the base plate.

16. An energy storage system in accordance with claim 15, wherein the base frame is provided with hinge members on three sides thereof to be received in corresponding slots on three sides of the edge wall of the base plate.

17. An energy storage system in accordance with any one of claims 1 to 16, wherein the upper frame includes a fan provided to direct air flow downwardly through the tubular spaces between the tubular members.

18. An energy storage system in accordance with claim 14, wherein the base plate comprises a planar base wall having an edge wall extending upwardlyfrom around the periphery thereof, the edge walls including a plurality of slots each provided for receiving a corresponding hinge member extending outwardly from around the periphery of the base frame such that the hinge members are rotatable within the slots to allow pivotal movement of the base frame relative to the base plate.

19. An energy storage system in accordance with claim 18, wherein the hinge members include rounded lower ends and the slots each include a concave base wall corresponding to the curvature of the lower ends of the hinge members.

20. An energy storage system in accordance with claim 19, wherein the base frame is provided with a plurality of first and second wall portions extending between an adjacent pairs of the hinge members and the base plate is provided with first and second upright walls extending between pairs of the slots such that the first wall portions can engage with the first upright walls to restrict the hinge members from moving out from the slots in a first direction and second wall portions can engage with the second upright walls to restrict the hinge members from moving out from the slots in a second opposite direction.21 . An energy storage system in accordance with any one of claims 3 to 20, wherein the first and second ends of the tubular members are arcuate such that the tubular members are obround in transverse cross section.

22. An energy storage system in accordance with any one of claims 3 to 20, wherein the tubular members include third and fourth columns of cells such that the tubular members are generally square in transverse cross section.

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