Modular thermal storage cell with internal vasculature and pneumatic management for high-flux thermal transfer

Abstract

A modular thermal storage cell comprises an outer housing 100 containing a phase change material (PCM) 400. A central telescopic spine 200 supports a network of S-shaped arteries 300 that extend to th

Description

The present invention relates to a modular thermal energy storage cell configured for high-flux thermal transfer. Specifically, it relates to a cell featuring a telescopic mechanical spine, a multi-scale internal vasculature for rapid heat exchange, and an integrated pneumatic system designed to promote volumetric solidification and high-velocity thermal cycling suitable for grid-balancing and automotive battery cooling applications. Background As the global energy landscape shifts toward renewable sources and electrified transportation, there is a critical need for thermal storage alternatives that can balance grid power and protect Electric Vehicle (EV) battery systems. In EV applications, precise temperature management is the primary determinant of battery degradation rates and ultra-fast charging capability. To be viable, thermal storage cells must achieve significantly reduced charge / recharge cycle times and maintain strict thermal stability. Conventional PCM cells fail this requirement due to "circumferential freezing," where an insulating layer of solid material forms at the outer walls, trapping a liquid core and slowing heat transfer. Furthermore, standard cells lack the mechanical resilience to handle the rapid thermal cycling required for high-output EV cooling or grid balancing, and provide no mechanism to verify a "solid core" state. There is a need for a protected, breathable, and serviceable modular assembly that can match the rigorous demands of modern green energy and automotive ecosystems. The Mechanical Skeleton and Vasculature As illustrated in FIG. 2A, the device comprises a Telescopic Central Spine (200) including a Female Telescopic Sleeve (210), allowingthe spine to adjust its longitudinal length during thermal expansion. The spine supports a plurality of S-Curved Arteries (300). This vasculature drives a cooling front directly into the heart of the Phase Change Material (PCM) (400). The S-curve geometry allows the vasculature to flex during rapid thermal cycling, protecting the Mushroom Contact Welds (105) from fatigue. To bridge gaps between arteries, the PCM (400) is infused with a Graphene Particulate Suspension (405) (FIG. 4A). The Internal Probes (800) are secured via a Probe Support (815), ensuring sensors remain correctly positioned relative to the spine and the Main Housing Cylinder (100). Volumetric Solidification and Multi-Scale Thermal Transfer As illustrated in FIG. 2A and 2B, the device utilizes a multi-scale thermal architecture to achieve volumetric freezing. • Macro-Scale Transfer: A Telescopic Central Spine (200) supports a plurality of S-Curved Arteries (300) that act as main arteries for heat transfer. This vasculature drives a "cooling front" directly into the heart of the Phase Change Material (PCM) (400). The S-curve geometry allows the vasculature to flex "spring-like" during rapid thermal cycling, protecting the Mushroom Contact Welds (105) from fatigue. • Micro-Scale Transfer: To bridge the gaps between the arteries, the PCM (400) is infused with a Graphene Particulate Suspension (405) (FIG. 4A). This combination ensures that heat is extracted from the entire volume of the cell simultaneously, ratherthan relying on slow conduction through the material's bulk External Airflow Modulation and Heat Bridge The cell is designed to act as a direct thermal bridge to the atmosphere. As shown in FIG. 4B, the primary contributors to enhanced convective heat exchange are the Leading Induction Shoulder (985) and the Inductive Flutes (980). This geometry is configured to intercept Planar Airflow (1000), disrupting laminar flow and converting it into high-velocity Turbulent Impingement (1010). To further optimize this exchange, the exterior surface features Turbulators / Nodules (420) (FIG. 4A), which provide secondary disruption of the boundary layer. This ensures the entire external "skin" of the Main Housing Cylinder (100) operates as a high-flux convective interface. Pneumatic Management and Serviceability The internal pressure and volumetric shifts during rapid cycling are managed by the Bellows Module (600). Referring to FIGS. 3A, 3B, and 3C, the module facilitates the "breathing" of the cell. In FIG. 3B, volumetric expansion of the hot PCM drives the Piston Actuator (215) against the Elastic Diaphragm (615). In FIG. 3C, as the core solidifies and contracts, the diaphragm responds to the pressure drop. This ensures a constant external footprint. Serviceability is maintained via the Rigid Retaining Rim (617) and Peripheral Injection Port (620), allowing for the maintenance of the Communication Module (810) and Internal Probes (800). Core-State Sensing To confirm the cell is ready for a new cycle, the Internal Probes (800) detect the differential temperature between the core and the housing surface. Supported by Internal Strain Relief (802), these sensors provide the real-time data necessary to mathematically confirm a "solid core," ensuring the cell is fully charged forgrid-balancing or EV thermal management duties.

Claims

1. A modular thermal storage cell comprising an outer housing (100) and a phase change material (PCM) (400), characterized in that a central telescopic spine (200) supports a multi-scale internal vasculature comprising a macro-scale network of S-curved arteries (300) extending to the housing and a micro-scale graphene particulate suspension (405) within the PCM, wherein the vasculature is configured to promote volumetric solidification of the PCM.

2. Athermal storage cell according to claim 1, wherein the S-curved arteries (300) are configured to elastically deform in response to volumetric shifts in the PCM to prevent mechanical fatigue at the housing interface.

3. Athermal storage cell according to claim 1 or 2, wherein the internal vasculature is secured to the housing via mushroom contact welds (105) positioned within induction flutes (980).

4. Athermal storage cell according to any preceding claim, wherein the outer housing (100) is configured as a high-flux convective heat exchanger comprising a leading induction shoulder (985) and a plurality of induction flutes (980) configured to convert planar airflow (1000) into turbulent impingement (1010).

5. Athermal storage cell according to claim 4, further comprising a plurality of external surface turbulators or nodules (420) configured to disrupt the atmospheric boundary layer across the housing surface.

6. Athermal storage cell according to any preceding claim, further comprising an integrated pneumatic bellows module (600) comprising an elastic diaphragm (615) and a piston actuator (215), configured to manage internal pressure and volume changes while maintaining a constant external device footprint.

7. Athermal storage cell according to claim 6, wherein the bellows module (600) is housed within a dry-zone cavity defined by a conical aero-fairing (652) and a terminal end cap (650).

8. Athermal storage cell according to any preceding claim, further comprising a sensing array of internal thermal probes (800) positioned to detect a differential temperature between the spine (200) and the housing (100).

9. Athermal storage cell according to claim 8, wherein the internal thermal probes (800) comprise integrated strain relief loops (802) to accommodate mechanical displacement of the internal vasculature.

10. Athermal storage cell according to claim 8 or 9, wherein the sensing array is configured to mathematically verify a solid-state core through the monitoring of the thermal gradient during phase transition.11 .Athermal storage cell according to any preceding claim, wherein the device is serviceable via a rigid retaining rim (617) providing access to the bellows and sensors, and a peripheral injection port (620) for the PCM medium.

12. A method of manufacturing a thermal storage cell according to any preceding claim, comprising the steps of simultaneously die-stamping induction flutes (980) into a housing sheet (1200) and pulse-welding internal arteries (300) to the interior of said flutes.A

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