Conductive brick assembly

Abstract

An assembly comprising insulating bricks, configured for use in an electrically resistive heating system or an electrically heated thermal energy storage system for heating air or gas. The insulating bricks include a non-hollow portion and a hollow internal region. There are conductive bricks configured to be disposed within the hollow internal region of the insulating bricks.

Description

Technical Field

[0002]

[0001] Cross - Reference to Related Applications This application claims the benefit of priority of and incorporates by reference in its entirety the disclosures of U.S. Provisional Application No. 63 / 516,999 and U.S. Provisional Application No. 63 / 516,997, both filed on August 1, 2023. This application incorporates by reference in its entirety each of the related provisional applications of the same owner having the titles Gas Turbine with an Electrically Heated Thermal Energy Storage System (U.S. Application No. ), Chromium Electrodes to Deliver Electric Power to Oxide Brick Circuits (U.S. Application No. ), Ceramic - Metal Composites for Use as Heating Elements for Electrified Resistance Heating and Thermal Energy Storage Systems (U.S. Application No. ), Electrically Conductive Brickwork Module for Use as a Heating and / or Thermal Storage System (U.S. Application No. ), Modulating Electrical Resistance along a Column of E - Bricks (U.S. Provisional Application No. ), and Bent Pipe - Shaped Electrically Conductive Cross Brick Design (U.S. Provisional Application No. ).

[0002] This disclosure relates to conductive and insulating brick assemblies, and more particularly, to conductive and insulating brick assemblies for use in electric direct - resistance heating and thermal - energy storage systems.

Background Art

[0003] Traditional refractory bricks are a type of brick designed to insulate against heat and withstand high temperatures, with common applications including furnace linings, kilns, and chimneys. Conductive refractory brick systems combine this traditional heat-resistant quality with conductivity to enable heating and heat storage solutions that can reach temperatures of 1000C to over 2000C and reliably maintain a cyclical temperature change within a given temperature range (e.g., ~1000C to ~1800C) daily without the need for fossil fuel combustion. In such systems, air / gas may be flowed through the refractory brick system to extract heat in a variety of applications, including use in industrial processes. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] U.S. Patent No. 11,877,376 [Patent Document 2] U.S. Patent Application No. 17 / 462,244 [Overview of the project] [Problems that the invention aims to solve]

[0005] Such a refractory brick system is described in U.S. Patent No. 11,877,376. In the refractory brick system disclosed therein, air / gas flows directly over the conductive bricks. In the case of chromium oxide bricks that may be used in this system, it is known that chromium oxide volatilizes, which impairs the electrical properties of the bricks over time and also generates toxic gases (CrO3) that must be kept below regulated levels and as low as possible. [Means for solving the problem]

[0006] According to one embodiment of the present invention, there is an assembly configured for use in an electrically resistive heating system or an electrically heated thermal energy storage system for heating air or gas. The assembly includes an insulating brick having a non-hollow portion and a hollow internal region. There is a conductive brick configured to be disposed within the hollow internal region of the insulating brick.

[0007] One or more embodiments may include the following features: A hollow internal region may be located at the center of the insulating brick. The conductive brick may include a hollow internal region. The conductive brick may have one of the following cross-sectional shapes: dogbone shape, cross shape, rectangular shape, circular shape, elliptical shape, bow tie shape, square shape, or rhombus shape. The insulating brick may have one of the following cross-sectional shapes: rectangular shape, circular shape, elliptical shape, square shape, or rhombus shape. The insulating brick may have an external surface and an internal surface defined by a hollow internal region, the cross-section of the internal surface having the same shape as the cross-section of the external surface. The insulating brick may have an external surface and an internal region, the internal surface being defined by a hollow internal region, the cross-section of the internal surface having a different shape from the cross-sectional shape of the external surface. The conductive brick may include an external surface and a hollow internal region, the internal surface being defined by a hollow internal region, and the cross-section of the internal surface having the same shape as the cross-section of the external surface. An insulating brick may have an internal wall defined by a hollow internal region, and the internal wall may include at least one projection extending from the internal wall. A conductive brick may include two or more intersecting conductive brick portions, each of which may have a rectangular cross-sectional shape. The rectangular conductive bricks may intersect to form one of the following shapes: U, N, Z, or 2. A conductive brick may include two or more intersecting conductive brick portions, each of which may have a rectangular cross-sectional shape, and the two or more intersecting conductive brick portions may fit to at least one projection extending from the internal wall of the insulating brick. The hollow internal region of the insulating brick may include a first convex portion and a second convex portion opposite the first convex portion. The hollow internal region of the insulating brick may include a first plurality of recesses and a second plurality of recesses opposite the first plurality of recesses. The hollow internal region of the insulating brick may have an internal surface defined by the hollow internal region, the internal surface may include a first semicircular portion and a second semicircular portion opposite the first semicircular portion, each of which may be configured to receive a conductive brick having a circular cross-sectional shape.The insulating brick may have an internal surface defined by a hollow internal region, and the cross-section of the internal surface may be rectangular in shape. First and second triangular projections may protrude from a first side of the internal surface, with a first convex projection between them. Third and fourth triangular projections may protrude from a second side of the internal surface opposite to the first side, with a second convex projection between them. A conductive brick having a bow tie cross-section may be disposed between the first side and the second side of the internal surface. The hollow internal region of the insulating brick may comprise a first portion having a first arched surface and a first open end opposite the first arched surface, and the second portion may comprise a second arched surface and a second open end opposite the second arched surface. Each of the first and second portions may be configured to receive different conductive bricks.

[0008] According to another embodiment of the present invention, there is an electrically resistive heating system configured to heat a material. The system includes a surface configured to receive a material and at least one brick structure comprising a plurality of electrically interconnected brick assemblies arranged in close proximity to the surface. Each brick assembly comprises insulating bricks having a non-hollow portion and a hollow internal region, and conductive bricks disposed within the hollow internal region of the insulating bricks.

[0009] One or more embodiments may include the following features: At least one brick structure may comprise a plurality of brick walls, each brick wall having a plurality of electrically interconnected brick assemblies positioned in close proximity to its surface. At least one brick structure may further comprise a brick floor, which forms a surface and includes a plurality of electrically interconnected brick assemblies. At least one brick structure may comprise a brick ceiling, which includes a plurality of electrically interconnected brick assemblies. The system may comprise a housing having an internal region for receiving at least one brick structure to form a furnace. The material may be non-hollow material.

[0010] The above-described features of the embodiment will be more easily understood by referring to the following detailed description along with the attached drawings. [Brief explanation of the drawing]

[0011] [Figure 1] This is a perspective view of an exemplary E-TESS system according to one aspect of the present disclosure. [Figure 2] Figure 1 is a cross-sectional view of an exemplary E-TESS system. [Figure 3] This is a perspective view of an exemplary conductive brick for an E-TESS system according to one aspect of the present disclosure. [Figure 4] This is a perspective view of an exemplary insulating brick for an E-TESS system according to one aspect of the present disclosure. [Figure 5] This is a cross-sectional view of an exemplary E-TESS system according to one aspect of the present disclosure, showing a circuit of conductive bricks connected to input and output electrodes. [Figure 6] This is a perspective view of an embodiment of the present disclosure that includes a double-width I-brick. [Figure 7] This is a perspective view of an embodiment of the present disclosure that includes a double-width thin I-brick. [Figure 8] This is a perspective view of an embodiment with a single-width, thin I-shaped brick. [Figure 9] This figure shows another embodiment of a thin I-brick with one or more tongues for connection. [Figure 10] This figure shows another embodiment of a double-width I-brick with one or more tongues for connecting. [Figure 11] This figure shows another embodiment of a single-length and single-width I-brick, including a tongue portion. [Figure 12] This figure shows another embodiment of the offset hollow I-brick. [Figure 13A] This is a perspective view of a partial E-TESS module according to another aspect of the present disclosure. [Figure 13B] This is a cross-sectional view of an E-TESS module used for heating a material, according to another aspect of the present disclosure. [Figure 14] A diagram showing some embodiments of cruciform (or "plus-shaped") E-bricks according to certain aspects of the present disclosure. [Figure 15] A diagram showing some embodiments of straight bar-shaped E-bricks within diamond-shaped I-bricks. [Figure 16] A diagram showing some embodiments of hollow E-bricks within I-bricks of different shapes. [Figure 17] A diagram showing an embodiment of a non-hollow cylindrical E-brick within the hollow core region of a circular I-brick. [Figure 18] A top view of two embodiments of an E-brick assembly including double-H-shaped E-bricks. [Figure 19] A top view of some additional E-brick shapes according to the present disclosure. [Figure 20] A top view of two embodiments of a possible brick stacking module structure with U-shaped E-bricks. [Figure 21] A top view of two additional embodiments of a possible brick stacking module structure with 2-shaped E-bricks. [Figure 22] A top view of an embodiment of a possible brick stacking structure for a brick stacking module having N-shaped or Z-shaped E-bricks. [Figure 23] A top view of an embodiment of a possible brick stacking structure for a brick stacking module having N-shaped or Z-shaped E-bricks. [Figure 24] A diagram showing some embodiments of butterfly tie-shaped E-bricks. [Figure 25] A diagram showing some additional embodiments of E-bricks and corresponding I-bricks according to aspects of the present disclosure. [Figure 26] A diagram showing some additional embodiments of E-bricks and corresponding I-bricks according to aspects of the present disclosure. [Figure 27] A graph of the heat storage rate of an embodiment of an E-TESS module according to certain aspects of the present disclosure. [Figure 28]"Razor blade" I is an extended bow tie within brick E is a top view of brick. [Figure 29] Figure 28 is a perspective view of an example of E-brick / I-brick. [Figure 30] This is a perspective view of an embodiment of a double cylindrical I-brick according to a certain aspect of the present invention. [Figure 31] This is a perspective view of a cylindrical E-brick according to one aspect of the present disclosure. [Figure 32] This figure shows an embodiment with two cylindrical E-brick columns. [Figure 33] This is a perspective view of a double cylindrical end connector. [Figure 34] This is a perspective view of an alternative example of a brickwork module. [Figure 35] Figure 34 is a closer side view of the brickwork module. [Modes for carrying out the invention]

[0012] The present disclosure and various features and advantageous details thereof will be more fully described with reference to non-limiting embodiments and examples described and / or shown in the accompanying drawings and detailed in the following description. Since the subject matter discussed below is not limited to any particular implementation method, various aspects of the subject matter can be implemented in any of many ways. Specific implementation and application examples are given primarily for illustrative purposes.

[0013] Unless otherwise defined, used or characterized herein, terms used herein (including technical and scientific terms) should be interpreted as having their accepted meanings in the context of the relevant art, and not as idealized or overly formal unless expressly defined herein. Terms used herein are for the purpose of describing specific embodiments and are not intended to limit exemplary embodiments. Where used herein, singular forms such as "a" and "an" should also include plural forms unless otherwise indicated by the context. In addition, the terms "includes," "including," "comprises," and "comprising" specify the presence of the element or step described, but do not exclude the presence or addition of one or more other elements or steps.

[0014] Embodiments of brickwork modules described herein may include, or utilize, conductive (and thermally conductive) bricks ("E-bricks"). When an electric current is passed through an E-brick, it generates heat via direct resistance heating (DRH). E-bricks can reach extremely high temperatures, such as 1000C or 2000C or higher, and may be capable of reliably cyclically changing their temperature within a given temperature range (e.g., ~1000C to ~1800C) daily. E-bricks may be stacked and arranged in a larger structure called a thermal energy storage system ("TESS") (also known as an electrically heated thermal energy storage system E-TESS), which may also be referred to herein as a brickwork module. Examples of E-bricks and E-TESS can be found in U.S. Patent No. 11,877,376, the entirety of which is incorporated herein by reference. Examples of brickwork modules or E-TESS may be used in various industrial and chemical processes that generate and / or consume heat, such as furnaces, kilns, smelters, and power plants, enabling these processes to significantly reduce or eliminate the burning of fossil fuels.

[0015] Figure 1 shows an exemplary embodiment of a brickwork module or E-TESS module 100, which consists mainly of a large number of conductive and thermally conductive brick assemblies 102 ("E-brick assemblies"). The E-brick assemblies 102 may include conductive bricks 300 ("E-bricks") as shown in Figure 3, housed within insulating (but thermally conductive) bricks 400 ("I-bricks") as shown in Figure 4. In some embodiments, there may be two or more E-bricks housed within an I-brick, or there may be multiple I-bricks that combine to provide insulation to one or more E-bricks. In Figures 1 and 2, only the I-bricks of the E-brick assemblies 102 are visible, as the E-bricks are housed in internal regions within the I-bricks, as shown in Figure 4 and described below. The E-bricks in each column are in physical contact with each other and are physically connected to the E-bricks in adjacent columns using interconnecting E-bricks, so that when a voltage is applied to the E-TESS module 100, they form a single continuous electrical circuit, thereby allowing current to flow through the electrical circuit formed by the E-bricks.

[0016] The E-TESS module 100 generates a large amount of thermal energy when current is passed through the continuous circuit of E-bricks. This thermal energy can be stored in the E-bricks / I-bricks for a long period of time (e.g., up to 24 hours). The thermal energy can be recovered immediately or after it has been stored by flowing a fluid, such as air or a gas such as CO2, through the E-TESS module 100. The thermal energy in the E-bricks is transferred to the I-bricks, and the flow paths or passages between the columns of the E-brick assembly 102 (shown in Figure 2) allow the fluid to flow into the E-TESS module 100. Hereafter, this application may refer to the fluid, gas, or air flowing through the flow paths or passages of the E-TESS module 100, but it should be noted that these terms may be used interchangeably herein and are intended to have the same meaning. Furthermore, any suitable fluid / gas such as air or CO2 may be used to extract heat from the E-TESS module 100. In addition, for clarity, some bricks have been omitted from the diagram in Figure 1.

[0017] Figure 2 shows a side view of one embodiment of the E-TESS module 100. The E-TESS module 100 comprises a large number of E-brick assemblies 102 arranged in a row on multiple adjacent columns, which are physically and electrically interconnected in a meandering manner to form a continuous circuit. The E-brick assemblies 102 are mostly conductive only in the vertical direction (i.e., along the length of the column) and may be electrically insulated from the outside by I-bricks in all other directions, so that when there is a potential difference between the columns, for example when powers of different phases are flowing through adjacent columns, the current flows through the meandering circuit (through the connected E-bricks) and does not arc discharge between the columns of the E-brick assemblies 102.

[0018] Between the columns are flow paths or passages 208 through which air / gas may flow (into or out of the paper) to extract or recover the thermal energy generated by the E-bricks (and transferred to the I-bricks) which will be used to heat the load. By flowing air / gas through flow paths 208, heat can be extracted from the E-TESS module 100 without the E-bricks coming into direct contact with the air. This is particularly useful because the E-bricks contain Cr2O3, and if exposed directly to flowing air, Cr2O3 is volatile, which degrades the electrical performance of the bricks over time and also produces CrO3, a toxic gas that must be kept below regulated levels and as low as possible.

[0019] Current may enter the E-TESS module 100 through a wire or cable (not shown) connected to the upper left corner (from the viewpoint of Figure 2), and exit the E-TESS 100 through a cable (not shown) connected to the upper right corner. In addition to the E-brick assembly 102, other bricks may be used in the E-TESS module 100, such as double-width bricks 202, thin bricks 204, and end-connecting bricks 206.

[0020] The double-width bricks 202 provide horizontal stability between the columns of the E-brick assembly 102 and structural integrity of the E-TESS module 100. Because the double-width bricks 202 are insulated, current can flow vertically through the columns but not across them between the columns. The double-width bricks 202 span the gaps 208 between the columns and thus partially obstruct the airflow through the gaps 208, so the double-width bricks 202 may be thinner (i.e., shorter) than the E-brick assembly 102. The double-width bricks 202 may be, for example, half the height of the E-brick assembly 102. A more detailed diagram of such a thinner double-width I-brick is shown in Figure 7.

[0021] The thin brick 204 is single-width like the E-brick assembly 102, but is thinner, i.e., shorter than the E-brick assembly 102. The thin brick 204 may be, for example, half the height of the E-brick assembly 102. The thin brick 204 may be used together with the double-width brick 202 so that the height of the stack of the double-width brick 202 and the thin brick 204 is equal to the height of the E-brick assembly 102. In situations where the double-width brick 202 is undesirable in at least one column, for example, due to its effect of obstructing airflow, but is desirable in another column of equal height, the thin brick 204 may be used instead of the double-width brick 202 to maintain the height of the brick. More detailed diagrams of two versions of the single-width thinner I-brick are shown in Figures 8 and 9.

[0022] The end connecting bricks 206 physically and electrically connect the brick columns. The end connecting bricks 206 function as end caps for the brick columns and contain interconnecting E-bricks, which may be of a different shape from those contained in the E-brick assembly 102, and physically and electrically connect E-bricks from one column of the E-brick assembly 102 to adjacent columns of the E-brick assembly 102. The current may flow, for example, downward through one brick column, make a "U-turn" through the end connecting brick 206, then flow upward through the adjacent column, and then reach the next end connecting brick 206, which makes another "U-turn," and so on. The end connecting bricks may have passages or cutouts through which air can flow. The end connecting bricks 206 may have a flat bottom (or top depending on their orientation).

[0023] Figure 3 shows a specific embodiment of the conductive brick 300 ("E-brick"). As described above, the E-bricks 300 may be configured to be stacked perpendicular to one another, which creates part of a conductive circuit through which electric current and heat can flow. The E-bricks 300 can be formed in many different shapes, including, for example, circular, rectangular, square, or cross-shaped cross-sections. Figure 3 shows an example of an E-brick in the shape of a "dogbone". The E-bricks 300 may have rounded or chamfered corners 302.

[0024] Referring also to Figure 4, the E-brick 300 is configured to fit within the insulating brick 400 ("I-brick"). The I-brick 400 may have a hollow internal region 402 in which the E-brick 300 may be housed. The E-brick assembly 102 may contain the E-brick 300 inside the I-brick 400. Depending on the design of the E-brick, the external shape of the I-brick and the shape of the hollow internal region 402 may have different shapes. Other bricks may also contain E-bricks inside the I-bricks. The cavity 402 may extend across the height of the I-brick 400, and as a result, the E-brick 300 may be electrically connected to the E-brick above and below.

[0025] Some embodiments of I-bricks may include multiple cavities, such as a double-length I-brick with two collinear cavities capable of accommodating an E-brick. The relative sizes of the E-brick 300 and I-brick 400 may be such that there is a gap of several millimeters between the outside of the E-brick and the inside of the I-brick's cavity. For example, the gap may be 1 mm, 2 mm, 5 mm, 7 mm, or 10 mm. This gap allows for thermal expansion at different rates between the E-brick 300 and I-brick 400 due to differences in material and temperature, reducing frictional damage between the E-brick 300 and I-brick 400. Rounded corners 302 also help reduce frictional forces. Other bricks may have cavities similar to the cavity 402. I-bricks may include pinholes 404 in which pins or rods may be placed to align the stack of bricks. I-bricks 400 may be made with different shapes for both their exterior and internal cavity 402. Another example of an I-brick is shown in Figure 11, which includes multiple tongues for connecting to grooves on the bottom surface of another I-brick.

[0026] Figure 5 shows a cross-sectional view of an embodiment of a conductive brickwork module 500 (or E-TESS) according to the present disclosure. In this embodiment, an electrode 502 electrically connected by an external power source (not shown) flows through an insulating cover 504 into the conductive brickwork module 500, thereby contacting a meandering circuit of E-bricks 506 (adjacent columns are physically and electrically connected by interconnecting E-bricks), which are resistively heated as current flows through them from the electrode 502. The E-bricks 506 transfer heat to heat-retaining I-bricks 508, thereby providing an efficient thermal energy storage mechanism.

[0027] Figure 6 shows another embodiment of the I-brick, a double-length I-brick 600. The double-length I-brick 600 may be the same height as the I-brick 400 but about twice as long, and may have two cavities 402, each configured to house an E-brick. Depending on the size and shape of the E-brick, the double-length I-brick 600 may have more or fewer cavities 402 than two. The cavities 402 can usually be collinear with each other. The double-length I-bricks 600 may be laid in the E-TESS, for example, in stretcher bond, to improve the structural stability of the E-TESS. In general, the bricks in the E-TESS module 100 may be laid in any way.

[0028] Figure 7 shows another embodiment of the I brick, a double-length thin brick 700. The double-length thin brick 700 is similar to the thin brick 204 but is about twice as long and may contain two cavities 402 (or more or fewer cavities) each configured to contain at least partially an E brick. The cavities 402 can usually be collinear with each other. The double-length thin brick 700 may be used with the double-width brick 202 such that the height of the stack of the double-width brick 202 and the double-length thin brick 700 is equal to the height of the E brick assembly 102. In situations where the double-width brick 202 is undesirable in at least one column, for example, due to its effect of obstructing airflow, but desirable in another column of equal height, the double-length thin brick 700 may be used instead of the double-width brick 202 to maintain the height of the brick.

[0029] Figure 8 shows an embodiment of a thin brick 204 having a flat, smooth top surface and a cavity 402. Note that the thin brick 204 is a type of I-brick.

[0030] Figure 9 shows another embodiment of a thin I-brick 204 having a cavity 402. In this embodiment, the thin brick 204 has one or more tongues 902 (which may also be studs, claws, etc.) on its top surface, configured to fit into grooves 904 (not visible from this angle) on the bottom surface of the brick, in order to fix the arrangement of stacked bricks and allow the stacked bricks to slide horizontally. This is similar to the function of LEGO blocks.

[0031] Figure 10 shows an embodiment of double-width I-bricks 202 that house two or more cavities 402. In this embodiment, the double-width bricks 202 are provided with multiple tongues 902 for connecting to grooves (not shown) at the bottom of another I-brick with which they are fitted. The double-width bricks 202 are also a type of I-brick.

[0032] Figure 11 shows another embodiment of the single-length and single-width I-brick 400. This embodiment of the I-brick 400 has a tongue portion 902.

[0033] Figure 12 shows an embodiment of the offset hollow I-brick 1200. Embodiments of the E-TESS module 100 may use the offset hollow I-brick 1200, for example, instead of or in addition to the I-brick 400. The offset hollow I-brick 1200 functions similarly to the I-brick 400, but instead of having an enclosed cavity 402, it has multiple open cavities 1202. When offset hollow I-bricks 1200 are lined up horizontally with respect to another offset hollow I-brick 1200, adjacent open cavities 1202 essentially form a closed cavity into which an E-brick can be stored. Other bricks, such as those shown and described previously, may have alternative embodiments with open cavities similar to the offset hollow I-brick 1200.

[0034] Figure 13 shows a partial view of another embodiment of the E-TESS module 1300. The E-TESS module 1300 includes E-brick columns 1302, which may consist, for example, of a single E-brick or a laminate of E-bricks 300. The E-brick columns 1302 are physically and electrically connected by interconnecting the E-bricks at the top and bottom of the columns. To electrically insulate the E-brick columns 1302, there may be offset hollow I-bricks 1200, one of which is partially drawn to show the extent of the lateral outline, and I-bricks 400, one of which is also partially drawn to show the extent of the lateral outline. Other bricks, not limited to the examples shown and described herein, may be used to complete the insulation between the E-brick circuits and the I-bricks and give structural integrity to the E-TESS module 1300.

[0035] As shown in Figure 13A, the E-TESS module 1300 includes a main internal region 1301, which may be used to heat materials (not shown) placed within it, for example, metal or other non-hollow materials placed in the center of the chamber, or they may be moved through the chamber. The E-TESS module 1300 is only partially shown, namely it may be configured with inputs and outputs, typically having walls surrounding the main internal region 1301, through which materials can be passed on a conveyor system (such as a walking beam furnace) for heating. Alternatively, it may be configured as a chamber with a door to allow materials to be fixed inside and removed after heating.

[0036] In another embodiment, there is a furnace 1350 which may include a housing 1352 made of metal or brick material having an internal region 1354 in which a non-hollow material 1356 to be heated can be placed, as shown in the cross section of Figure 13B. The non-hollow material may be placed on a surface 1358, which may be the floor of the furnace 1350. For heating, there may be an E-brick structure within the internal region of the housing 1352. The E-brick structure may include one or more walls, such as the walls 1360 and / or 1362 of the housing 1352, which are aligned with the E-brick assemblies. The walls may be aligned with the E-brick assemblies 1363 (including the E-bricks within the internal region of the I-bricks), as described above with respect to Figures 3 and 4, or below with respect to Figures 14 to 31. The E-brick structure may also include a floor 1364 and / or ceiling 1366, which may be aligned with the same or similar E-brick assemblies 1363. Each part of the E-brick structure, i.e., an E-brick in a single wall, floor, or ceiling, may be electrically interconnected and electrically connected to a power source to provide multiple separate electrical circuits through which current can flow to produce heating of the furnace 1350. Alternatively, each part of the E-brick structure (each wall, floor, and ceiling) may be electrically interconnected to form a single larger circuit through which current can flow to produce heating of the furnace 1350.

[0037] It should be noted that the furnace 1350 can be constructed in a variety of ways, including providing only a single wall structure which may or may not be included in the enclosure 1352. In other words, it may be as simple as placing a freestanding E-brick wall on the surface and placing the material to be heated near the wall. Or it may be more complex, as in the furnace 1350, which may include E-brick assemblies in each of the four interior walls, as well as in the floor and ceiling. It may even be configured with inputs and outputs through which the material can be passed over a conveyor system (such as a walking beam furnace) to be heated.

[0038] Referring back to Figure 3, the dogbone shape of the E-brick 300 in this embodiment may help reduce the risk of thermal runaway during heating cycles. As described in U.S. Patent No. 17 / 462,244 (in which the contents are incorporated), thermal runaway occurs in the chromia brick due to a circuit short-circuit fault, so the current path is preferably kept narrow and long, thus resulting in a continuous meandering circuit of the E-TESS module 100. Radiative heat conduction paths alongside conductive channels can significantly improve resilience against thermal runaway compared to heat conduction paths that are solely conductive.

[0039] Generally, a design for an E-brick that is resilient to thermal runaway maintains the radiation path regardless of how the radiation path changes within the I-brick containment structure, and minimizes the path length of non-hollow material that the heat must pass through before it "sees" the open radiation path to the cooler part of the E-brick. Note that the radiation path may include the walls of the I-brick, and radiation from the hot part of the E-brick may move to the cooler part by shallowly heating the surface of the cavity 402, in turn causing the cavity 402 to radiate heat to the cooler part of the E-brick.

[0040] The "dog bone + cavity" E-brick assembly 102 is a geometric shape that effectively resolves the problems of friction and different heating between the E-bricks and I-bricks, while simultaneously considering this radiative shape factor for effective heat conduction. Figures 14 to 23 show various embodiments of E-bricks arranged within I-bricks, each of which has a shape factor that enables effective radiative heat conduction to prevent thermal runaway in the desired operating mode. The E-brick assembly made from various embodiments of E-bricks arranged within I-bricks may be assembled into an E-TESS module equivalent to the E-TESS module 100, and it should be noted that a flow path or path like 208 in Figure 2 may be formed between adjacent columns of I-bricks.

[0041] Figure 14 shows several embodiments of cruciform (or "plus-shaped") E-bricks 1400 within a range of various shapes and sizes of I-bricks. Some of the shapes of I-bricks shown include squares 1402, rounded squares 1404, circles 1406, rhombuses 1408, elongated rhombuses 1410, rectangles 1412, and ovals with flat sides 1414. Each of the I-bricks 1402-1414 has a cavity 402 in which a cruciform E-brick 1400 is placed. The cruciform design shown here is also an alternative design that ensures the radial shape coefficient between large parts of the E-brick, regardless of how it changes within the I-brick, such as square, circular, rectangular, oval, or rhombuse.

[0042] Figure 15 shows several embodiments of linear E-bricks 1500 within rhombus-shaped I-bricks 1502. In these embodiments, the internal corners of the rhombus-shaped I-bricks 1502 maintain radial paths along the walls of the I-bricks while restricting the lateral and rotational movement of the linear E-bricks 1500. This may also have the advantage of making the E-bricks easier to manufacture.

[0043] Figure 16 shows several embodiments of hollow E-bricks 1600 within I-bricks of different shapes, including circular I-bricks 1602 and rectangular I-bricks 1604. Hollow E-bricks 1600 have the advantage of a simple internal radiation path.

[0044] Figure 17 shows an embodiment in which a non-hollow cylindrical E-brick 1700 is located within the hollow core region of a circular I-brick 1602.

[0045] Figure 18 shows several embodiments of an E-brick assembly including an E-brick 1800 with a double H shape within an I-brick 1802. In one embodiment, the I-brick 1802 has a rectangular exterior and an elliptical interior. In another embodiment, the I-brick 1802 has "teeth" 1804 protruding into the gap of the double H E-brick 1800. Other shapes of I-bricks are also possible for the double H-shaped E-brick 1800, and other shapes of E-bricks, including triple H, quadruple H, etc., will be apparent to those skilled in the art. A more general way of describing the above shapes of E-bricks is to say that they include two or more intersecting conductive brick portions, each having a rectangular cross-sectional shape.

[0046] Figure 19 shows additional embodiments of E-brick shapes, including U-shaped E-brick 1902, 2-shaped E-brick 1904, and intersecting Z-shaped E-brick 1906. The I-brick 1900 that houses these E-bricks may or may not have teeth or projections 1804.

[0047] Figure 20 shows top views of several embodiments of a brickwork module or possible brickwork module structure for E-TESS having U-shaped E-bricks 1902 with gaps formed between them, which can define a flow path for heating a flowing gas. In one embodiment, the surrounding I-bricks 1900 each have teeth 1804 in the gaps created by the "U" shape. This brickwork structure may have alternating orientations of the E-bricks 1902. Note that the relative sizes of the E-bricks 1902 and I-bricks 1900, including the gaps between them, may not be to scale. This applies to all schematic drawings in this application.

[0048] Figure 21 shows top views of several embodiments of a brickwork module or possible brickwork module structure for E-TESS having E-bricks 1904 of shape 2, including gaps formed between them, which can define a flow path for heating a flowing gas. In one embodiment, the surrounding I-bricks 1900 each have projections or teeth 1804 in the gaps created by the shape of "2". This brickwork structure may have alternating orientations of the E-bricks 1904.

[0049] Figures 22 and 23 show top views of several embodiments of a brickwork module or possible brickwork structure of E-TESS having N-shaped E-bricks 2200, which may also be E-bricks 1906 of intersecting Z shape. Gaps are formed between the brickwork structures that can define a flow path for heating a flowing gas. In one embodiment, the surrounding I-bricks 1900 have teeth 1804 in the gaps created by the "N" shape (or intersecting Z shape). The teeth 1804 may have, for example, a triangular cross-section. This brickwork structure may have alternating orientations of E-bricks 2200 (or 1906).

[0050] Figure 24 shows several embodiments of bow tie-shaped E-bricks, including a simple bow tie 2402, an extended bow tie 2404 with a flat central portion 2404a, and a curved bow tie 2406. (From this viewpoint) the bow tie E-brick widens towards the top and bottom edges, with its thickness being minimal in the center. This widening brings more heat to the hard-to-reach corners of the I-brick, while the thin central portion keeps the temperature of the core controllable. The bow tie E-bricks shown may not be to scale, and although not shown, the edges may be smoothed or chamfered.

[0051] Figure 25 shows several examples of E bricks and their corresponding I bricks. Their respective volumes and volume ratios are shown in the table below.

[0052] [Table 1]

[0053] In Figure 25, the hollow internal region of the insulating brick may include a first protrusion and a second protrusion opposite the first protrusion. The insulating brick may include a first plurality of recesses and a second plurality of recesses opposite the first plurality of recesses.

[0054] Figure 26 shows several additional examples of E bricks and corresponding I bricks. Note that for clarity, only half E brick assemblies and I brick assemblies are shown, each containing a symmetrical second half. The volumes and volume ratios are shown below in the table.

[0055] [Table 2]

[0056] Figure 27 shows a graph 2700 of the heat storage rate for one embodiment of the E-TESS module 100. Graph 2700 stores data for the maximum heat storage rate 2702 for the entire E-TESS module 100, the average heat storage rate 2704 for the E bricks, the average heat storage rate 2706 for the I bricks, and the average heat storage rate 2708 for the entire E-TESS module 100. As shown in graph 2700, the E bricks initially store heat faster than the I bricks, but their heat storage rates approach parallel over time. In addition, in this embodiment, the E-TESS module 100 reaches a target temperature of 1700°C after approximately 5 hours of charging.

[0057] Figures 28 and 29 show an embodiment of an extended bowtie E-brick 2404 within a "razor blade" I-brick 2800. The razor blade I-brick 2800 functions similarly to a double-edged razor blade (and has a slightly similar cross-section) in restricting its rotational and lateral movement. The razor blade I-brick 2800 includes projections 2802 that restrict the lateral movement of the extended bowtie E-brick 2404, as well as convex projections 2804 that restrict the rotational movement of the E-brick 2404. As seen in the perspective view shown in Figure 29, the projections 2802 may be periodically arranged through the razor blade I-brick 2800.

[0058] More generally, the E brick 2404 and I brick 2800 in Figures 28 and 29 are described as follows: The I brick 2800 may have an internal surface defined by a hollow internal region, and the cross-section of the internal surface is generally rectangular. Due to the rectangular shape, first and second triangular protrusions project from the first side of the internal surface, with a first convex portion projecting between them. From the second side facing the first surface, third and fourth triangular protrusions project, with a second convex portion projecting between them. A conductive brick having a bow tie cross-sectional shape is disposed between the first side of the internal surface and the second side of the internal surface.

[0059] Figure 30 shows an embodiment of a double cylindrical I-brick 3000, which has a cavity 402 configured to fit into two non-hollow cylindrical E-bricks 1700 (or hollow circular E-bricks 1600, or other E-bricks with a cylindrical outer shape). The double cylindrical I-brick 3000 may also have a ring projecting around the cavity 402, which may function similarly to a tongue 902.

[0060] The hollow internal region of the double-cylinder I brick has an internal surface defined by the hollow internal region, the internal surface including a first semicircular portion and a second semicircular portion opposite the first semicircular portion. Each of the first and second semicircular portions is configured to receive a conductive brick having a circular cross-sectional shape.

[0061] Figure 31 shows a perspective view of one embodiment of a non-hollow cylindrical E-brick 1700.

[0062] Figure 32 shows an embodiment of a cylindrical E-brick 1700 with two columns, which can be housed in a plurality of vertically stacked I-bricks 3000 of Figure 30. There is a double cylindrical end connector 3200, which has a flat bottom surface configured to electrically connect the two columns and stand on its own. The double cylindrical end connector 3200 is another example of the end connector 206.

[0063] Figure 33 shows an individual diagram of the double cylindrical end connector 3200.

[0064] Figure 34 shows an alternative brickwork module 3500, which may be an example of an alternative type of E-TESS module 100. The brickwork module 3500 includes a continuous meandering circuit of E-bricks 3502 separated by I-bricks 3504. Unlike the previously shown embodiment, the E-bricks 3502 are not housed within the I-bricks 3504. Gas channels are formed within the internal regions of the I-bricks 3504, through tunnels or passages, allowing air to flow through them and recover stored thermal energy. In this way, the E-bricks 3502 are not exposed to the flowing air. The gas channels may have an arched shape.

[0065] Figure 35 shows a closer side view of the shipping container brickwork module 3500.

[0066] As shown in Figures 34 and 35, the conductive bricks, which constitute the conductive brickwork module 3500, are arranged in a sequence having dimensions of a certain width and length, and the insulating barriers formed of insulating bricks 3504 are interconnected, forming a first set of barriers that extend along the length dimension of the sequence and along the width dimension, and a second set of barriers that extend along the width dimension of the sequence and along the length dimension. The barriers that extend along the width of the brickwork module intersect with the barriers that extend along the length of the brickwork module. The gas flow path can be located in one of the first set of barriers or the second set of barriers.

[0067] The sets of conductive bricks 3502 are arranged in one of several columns or rows, and each set of conductive bricks is physically and electrically connected to adjacent sets of conductive bricks by interconnecting conductive bricks.

[0068] The embodiments of the present disclosure described above are illustrative only, and numerous variations and modifications will be apparent to those skilled in the art. All such variations and modifications are within the scope of the present disclosure.

Claims

1. An assembly configured for use in an electrically resistive heating system or an electrically heated thermal energy storage system for heating air or gas, The non-hollow parts, hollow internal region and Insulating bricks, An assembly comprising a conductive brick configured to be disposed within the hollow internal region of the insulating brick.

2. The assembly according to claim 1, wherein the hollow internal region is located at the center of the insulating brick.

3. The assembly according to claim 1, wherein the conductive brick includes a hollow internal region.

4. The assembly according to claim 1, wherein the conductive brick has one of the following cross-sectional shapes: dog bone shape, cross shape, rectangular shape, circular shape, elliptical shape, bow tie shape, square shape, or rhombus shape.

5. The assembly according to claim 1, wherein the insulating brick has one of the following cross-sectional shapes: rectangular, circular, elliptical, square, or rhombus.

6. The assembly according to claim 5, wherein the insulating brick has an outer surface and an inner surface defined by the hollow inner region, and the cross-section of the inner surface has the same shape as the cross-section of the outer surface.

7. The assembly according to claim 5, wherein the insulating brick has an outer surface and an inner surface defined by the hollow inner region, and the cross-section of the inner surface has a different shape from the cross-section of the outer surface.

8. The assembly according to claim 4, wherein the conductive brick includes an outer surface and a hollow inner region, the inner surface is defined by the hollow inner region, and the cross-section of the inner surface has the same shape as the cross-section of the outer surface.

9. The assembly according to claim 1, wherein the insulating brick has an internal wall defined by the hollow internal region, and the internal wall includes at least one projection extending from the internal wall.

10. The assembly according to claim 1, wherein the conductive brick includes two or more intersecting conductive brick portions, and each of the two or more intersecting conductive brick portions has a rectangular cross-sectional shape.

11. The assembly according to claim 10, wherein the rectangular conductive bricks intersect to form one of the following shapes: "U", "N", "Z", or "2".

12. The assembly according to claim 9, wherein the conductive brick includes two or more intersecting conductive brick portions, each having a rectangular cross-sectional shape, and the two or more intersecting conductive brick portions are fitted to the at least one projection extending from the inner wall of the insulating brick.

13. The assembly according to claim 1, wherein the hollow internal region of the insulating brick includes a first protrusion and a second protrusion facing the first protrusion.

14. The assembly according to claim 1, wherein the hollow internal region of the insulating brick may include a first plurality of recesses and a second plurality of recesses facing the first plurality of recesses.

15. The assembly according to claim 1, wherein the hollow internal region of the insulating brick has an internal surface defined by the hollow internal region, and the internal surface includes a first semicircular portion and a second semicircular portion facing the first semicircular portion, and each of the first semicircular portion and the second semicircular portion is configured to receive a conductive brick having a circular cross-sectional shape.

16. The assembly according to claim 1, wherein the insulating brick has an internal surface defined by the hollow internal region, the internal surface has a rectangular cross-section, first and second triangular protrusions protruding from a first side of the internal surface with a first convex protrusion protruding between them, third and fourth triangular protrusions protruding from a second side of the internal surface facing the first side of the internal surface with a second convex protrusion protruding between them, and a conductive brick having a bow tie cross-section is disposed between the first side of the internal surface and the second side of the internal surface.

17. The assembly according to claim 1, wherein the hollow internal region of the insulating brick comprises a first portion having a first arched surface and a first open end facing the first arched surface, and a second portion having a second arched surface and a second open end facing the second arched surface, and each of the first portion and the second portion is configured to receive a different conductive brick.

18. An electrical resistance heating system configured to heat a material, wherein the system A surface configured to accept the aforementioned material, The brick structure comprises at least one brick structure including a plurality of electrically interconnected brick assemblies located near the surface, wherein each brick assembly is The non-hollow parts, hollow internal region and An insulating brick having, A conductive brick and Electrical resistance heating systems, including those mentioned above.

19. The electrical resistance heating system according to claim 18, wherein the at least one brick structure comprises a plurality of brick walls, each brick wall having a plurality of electrically interconnected brick assemblies arranged in close proximity to the surface.

20. The electrical resistance heating system according to claim 18, wherein the at least one brick structure comprises a brick floor including a plurality of electrically interconnected brick assemblies that form the surface.

21. The electrical resistance heating system according to claim 18, wherein the at least one brick structure comprises a brick ceiling including a plurality of electrically interconnected brick assemblies.

22. The electrical resistance heating system according to claim 18, comprising a housing having an internal region for receiving the at least one brick structure to form a furnace.

23. The electrical resistance heating system according to claim 22, wherein the material is not hollow.

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