Systems and methods for transferring temperature

Abstract

The energy storage system includes a plurality of energy storage nodes, each of which includes a battery storage element, at least one cold plate, and a coolant manifold coupled to at least one cold plate. The coolant manifold divides the flow of cooling water into a bidirectional configuration at the front and inside of the cold plate. A method for assembling the energy storage cooling system is also provided.

Description

Technical Field

[0001] Cross - reference to Related Applications This application claims priority under 35 U.S.C.§120 to U.S. Patent Application No. 63 / 531,430, filed on August 8, 2023, entitled "System and Method For Transferring Temperature", the entire disclosure of which is incorporated herein by reference.

[0002] This subject matter relates to exemplary systems and methods for cooling an array of battery cells within a battery module of a battery energy storage system.

Background Art

[0003] Battery energy storage systems, hybrid energy storage systems, and some energy provisioning systems have extensive problems related to heat generation. The dissipation or removal of this generated heat is of utmost importance for the success of a battery energy storage system. Improved heat transfer capabilities improve the lifespan and safety of the components in a battery energy storage system that generate heat and those that receive heat.

[0004] Furthermore, the size of modern battery modules within a battery energy storage system causes unique problems for cooling the battery cells. Thermally regulating the temperature uniformly across the entire battery module and the battery cells that make it up is important for the lifespan of the entire battery module and the battery cells that compose it. The lifespan of a battery cell depends on maintaining the battery cell within a specific temperature range. Additionally, for the battery cells to wear evenly, the temperature range between cells must also be within reasonable parameters. The larger the area of the battery cells within a battery module, the more difficult it becomes to use only a single cold plate to maintain the temperature range of individual cells within certain limits and the temperature range between cells within certain fluctuations.

[0005] Therefore, there is a need for a system and method for uniformly regulating the temperature of battery cells within a battery module of a battery energy storage system. [Overview of the project]

[0006] In the first example, the energy storage system 101 includes a plurality of energy storage nodes 105A to N, each of which includes battery storage elements 106A to N, at least one cold plate 500, and a coolant manifold 600 coupled to at least one cold plate 500. The coolant manifold 600 is configured to divide the coolant flow in a bidirectional configuration between the front and the interior of the cold plate 500.

[0007] In the second example, a method for assembling the energy storage system 101 includes providing a plurality of energy storage nodes 105A to N, each of which contains battery storage elements 106A to N; connecting at least one cold plate 500 to each of the plurality of energy storage nodes 105A to N; and connecting a coolant manifold 600 to at least one cold plate 500. The coolant manifold 600 is configured to divide the coolant flow in a bidirectional configuration between the front and interior of the cold plate 500.

[0008] The additional purposes, advantages, and novel features of the example are described in part in the following description and in part may become apparent to those skilled in the art by examining the following and the accompanying drawings, or by generating or manipulating the example. The purposes and advantages of this disclosure are realized and achieved by the methods, means, and combinations specifically indicated in the accompanying claims.

[0009] The figures in the drawings illustrate one or more embodiments of the present concept, not as limitations, but merely as examples. In the figures, similar reference numerals refer to identical or similar elements. [Brief explanation of the drawing]

[0010] [Figure 1] This refers to systems including energy storage systems, energy systems, and electrical applications. [Figure 2] Figure 1 shows the first energy storage node of a group of energy storage nodes in an energy storage system coupled to an electrical application. [Figure 3] This is a cutaway diagram of the first energy storage node among multiple energy storage nodes, showing details of multiple battery storage elements. [Figure 4] This is a thermal gradient diagram of a conventional cold plate installed on a battery module. [Figure 5] This is a flowchart of a preferred coolant flowing across a cold plate to reduce temperature fluctuations between battery cells within a battery module. [Figure 6] This is an isometric view of a cold plate manifold configured to improve temperature fluctuations between battery cells within a battery module. [Figure 7] Figure 6 is an isometric view of the cold plate manifold brazed to the cold plate, with arrows indicating the flow of coolant across the cold plate. [Figure 8] Figure 7 is a top view of the cold plate, showing the flow path of the coolant at the junction between the cold plate and the cold plate manifold. [Figure 9] Figure 7 is a longitudinal cross-sectional view of the cooling plate, showing the coolant inflow and outflow channels. [Figure 10] This is a flowchart showing a method for assembling an energy storage system according to one embodiment. [Explanation of Symbols]

[0011] 100 Systems 101 Energy Storage Systems 102 Energy Systems 103 Electrical Applications 104 Power conversion system 105A~N Energy storage nodes 106,106A~N Battery storage elements 107 Power conversion subsystem 108 Transformer 109 Energy source 110 Control subsystem 115 Control system 120 Physical space 125 Power bus 205 Power inverter 210 Rectifier 215 DC-DC converter 300 Enclosure 400, 500, 700 Cold plates 402, 602 Coolant inlet 404, 604 Coolant outlet 405A~Z, 505A~Z Battery cells 600 Coolant manifold 612 Inflow groove 614 Outflow groove 702 End part of cold plate 704 Start part of cold plate 712A~D Inlet channels 714A~D Outlet channels 800 Method

Best Mode for Carrying Out the Invention

[0012] In the following embodiments for carrying out the invention, numerous specific details are set forth in order to provide a thorough understanding of the related teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such specific details. In other instances, well-known methods, procedures, components, transfer functions, and / or circuits are described at a relatively high level without detail in order to avoid unnecessarily obscuring aspects of the present teachings.

[0013] Unless otherwise indicated, any embodiment can be combined with any other embodiment. In particular, Figures 1-10 and the related text are all combinable with each other.

[0014] As used herein, the term “coupled” means any logical, physical, electrical, or optical connection, link, etc., through which signals or light generated or supplied by one system element are transferred to another coupled element. Unless otherwise stated, coupled elements or devices are not necessarily directly connected to one another and may be separated by intermediate components, elements, or communication media that can modify, manipulate, or carry light or signals.

[0015] The orientations of the system 100 incorporating battery storage elements 106A-N, such as batteries, energy storage system 101, energy storage nodes 105A-N, associated components, and / or any complete device, as shown in any of the drawings, are given for illustrative and explanatory purposes only. During operation of a particular energy storage application, the energy storage nodes 105A-N may be oriented in any other direction suitable for the particular application of the energy storage system 101, e.g., upright, sideways, or any other orientation. Also, to the extent used herein, any orientation terms such as left, right, front, back, rear, end, up, down, top, bottom, and side are used for illustrative purposes only and are not limited to any orientation or orientation of any energy storage system 101 or energy storage nodes 105A-N, or to any components of an energy storage system 101 or energy storage nodes 105A-N constructed as otherwise described herein.

[0016] Unless otherwise specified, any coupled electrical components may be connected in series or parallel. In the case of energy storage nodes 105A~N or battery storage elements 106A~N, components may be linked in series, parallel, or a combination thereof, depending on the state of the switch or submodule.

[0017] Here, we will refer in detail to the example shown in the attached diagram and described below.

[0018] Figure 1 shows a system 100 including an energy storage system 101, an energy system 102, and an electrical application 103. For example, the energy storage system 101 may be a battery energy storage system (BESS). The energy storage system 101 is coupled with the energy system 102 and the electrical application 103. The energy storage system 101 may include a power conversion system 104, a number of energy storage nodes 105A-N, an optional transformer 108, and a control system 115. The components of the energy storage system 101 can be located in a physical space 120, either outdoors or indoors, for example, inside a building, container, or other structure.

[0019] The power conversion system 104 is coupled to multiple energy storage nodes 105A~N. The power conversion system 104 is coupled to the energy system 102 and the electrical application 103 to provide the necessary power flow to the electrical application 103 by discharging the multiple energy storage nodes 105A~N, or to provide the necessary power flow from the energy system 102 to charge the multiple energy storage nodes 105A~N. The power conversion system 104 can be coupled to an optional transformer 108. The optional transformer 108 can step up or step down the necessary power flow to and from the electrical application 103, such as AC voltage.

[0020] The energy system 102 may include any suitable system for generating electrical energy from the energy source 109. The energy system 102 may be a renewable energy system that can replenish the energy source 109. Such renewable energy sources 109 may include solar power, wind power, geothermal power, biomass, and hydropower. For example, the renewable energy system 102 may be implemented as an array of photovoltaic modules. Photovoltaic (PV) modules may include crystalline silicon, amorphous silicon, copper-indium gallium selenide (CIGS) thin films, cadmium telluride (CdTe) thin films, and concentrating photovoltaic cells that focus sunlight into small but highly efficient multi-junction solar cells using lenses and curved mirrors. In another example, the energy system 102 may include a wind turbine or a gas turbine. In some examples, the energy system 102 may be a non-renewable energy system in which the energy source 109 includes non-renewable energy sources such as fossil fuels.

[0021] Electrical application 103 may include distribution networks such as transmission grids, or smaller local loads such as backup power systems for facilities such as hospitals, manufacturing plants, homes, or other suitable facilities. Electrical application 103 may deliver AC or DC power for on-grid or off-grid applications, including commercial, industrial, or residential use. Electrical application 103 may deliver power to buildings, electric vehicle charging stations, and other locations that include various electrical loads consuming AC or DC power. Electrical application 103 may be a front-of-the-meter system owned or operated by a utility company, or a behind-the-meter system that directly supplies electricity to buildings and homes.

[0022] Energy source 109 can be renewable energy sources such as solar and wind power, which are intermittent and potentially less reliable compared to fossil fuels. To improve resilience, energy storage system 101 can store energy from energy system 102 when production from energy source 109 is high. Later, energy storage system 101 can dispatch energy to electrical application 103 when demand is high or when production from energy source 109 is not keeping up with demand. Furthermore, events may occur when the connected load or operating demand load of electrical application 103 is excessive, or when the power grid is unstable, for example, during extreme weather. By storing energy from energy source 109 and then dispatching that energy during such events, energy storage system 101 can continue to dispatch the necessary power flow to electrical application 103.

[0023] Energy storage nodes 105A-N include battery storage elements 106A-N. Battery storage elements 106A-N can be (1) a single battery cell, (2) a cell grouping including several battery cells in a parallel configuration, (3) a battery submodule or module including several battery cells in parallel and series configurations, (4) a battery string including several battery modules in series, (5) a battery bank including several battery strings in parallel, (6) other known energy storage elements, and / or (7) a combination thereof. For example, battery storage elements 106A-N may include, but are not limited to, multiple batteries of any existing or future reusable battery technology that can be used in a battery energy storage system (BESS), including, for example, lithium-ion or flow batteries, or mechanical storage such as flywheel energy storage, compressed air energy storage, pump storage of hydroelectric energy, gravitational potential energy, or hydraulic accumulators.

[0024] Figure 2 shows the first energy storage node 105A of the multiple energy storage nodes 105A-N of Figure 1 coupled to the electrical application 103. The energy storage nodes 105A-N may include a battery storage element 106, a power conversion subsystem 107, and a control subsystem 110, or a combination thereof. The energy storage system 101 can control the electrical application 103 to be satisfied while distributing the dispatch of the power flow required across the multiple battery storage elements 106A-N, according to the control system 115's recognition of specific battery conditions, including the charge state, temperature, and other physical phenomena occurring within the battery storage elements 106A-N.

[0025] The power conversion system 104 may include a power inverter 205, a rectifier 210, a DC-DC converter 215, other power conversion elements, or a combination thereof. The power inverter 205 may be configured to convert DC power from battery storage elements 106A~N, etc., into an AC waveform. The rectifier 210 may be configured to convert AC power from energy systems 102 or electrical applications 103, etc., into DC for battery storage elements 106A~N. The DC-DC converter 215 may be configured to convert DC power from battery storage elements 106A~N, etc., into different DC power characteristics.

[0026] If the energy source 109 is wind power, the power conversion system 104 can convert the generated AC electricity into DC power for storage in multiple energy storage nodes 105A-N via the rectifier 210. If the energy source 109 is solar energy, the power conversion system 104 can convert the DC electricity to different voltage levels via the DC-DC converter 215. The power inverter 205 can convert the required power flow from the energy storage system 101 from DC power to AC power during dispatch to the electrical application 103. For example, the power inverter 205 can be configured to convert power on the power bus 125 for use by the electrical application 103. For example, the power inverter 205 converts the DC power stored in the energy storage nodes 105A-N into AC power for consumption by the electrical load of the electrical application 103.

[0027] The power conversion subsystem 107 includes hardware and software similar to that of the more centralized power conversion system 104. The power conversion subsystem 107 is more locally distributed across each of the energy storage nodes 105A-N. The control subsystem 110 can be configured for local computation, processing, and control of the battery storage elements 106A-N and the power conversion subsystem 107. The control system 115 can be configured for more centralized computation, processing, and control of the energy storage system 101, the energy system 102, the electrical application 103, and the entire power conversion system 104. Both the control subsystem 110 and the control system 115 can include single-board computers, application-specific integrated circuits (ASICs), microcontrollers, digital signal processors (DSPs), field-programmable gate arrays (FPGAs), or a combination thereof.

[0028] Figure 3 is a cutaway view of the first energy storage node 105A of a plurality of energy storage nodes 105A-N, showing details of the plurality of battery storage elements 106A-N. As shown, the energy storage node 105A includes an enclosure 300, such as a physical housing, for storing the plurality of battery storage elements 106A-N. The battery storage elements 106A-N may be assemblies of one or more batteries, such as a plurality of battery strings or battery banks organized logically, physically, and electrically.

[0029] In the example in Figure 3, the battery storage elements 106A-N may include battery racks (e.g., 6 shown) that hold each stack of battery modules (e.g., 17 shown). A battery module may include an array of prisms, pouches, or cylindrical battery cells packaged together to increase voltage, amperage, or both. In some examples, a battery module may include an electric vehicle battery pack, e.g., an assembly of lithium-ion battery cells packaged together.

[0030] Energy storage nodes 105A-N may be similar to the features presented in the energy storage system described in international application PCT / US2021 / 30551, “Energy Storage System with Removable, Adjustable, and Lightweight Plenums,” filed on 4 May 2021, which is incorporated herein by reference in its entirety.

[0031] Figure 4 is a top-down view of the thermal gradient of the cold plate 400 installed on the battery module element 106A. The cold plate 400 is generally installed along the bottom of the battery storage element 106A. This is because the battery cells 405A to Z are generally not stacked, and all of the battery cells 405A to Z are in contact with the bottom of the battery storage element 106A. The installation of the cold plate 400 along the bottom of the battery storage element 106A ensures that each of the battery cells 405A to Z is in contact with the cold plate 400.

[0032] The low-temperature coolant flows in from the coolant inlet 402, disperses across the cold plate 400 and battery cells 405A-Z, and finally flows out from the coolant outlet 404. The coolant flow is not directed, and as a result, the coolant forms a temperature gradient. The gradient can generally be described as being warmest on the cold plate 400 furthest from the coolant inlet 402, such as battery cell 405C, and coldest on the cold plate 400 closest to the coolant inlet 402, such as battery cell 405B. Battery cell 405B may also receive the least warmed coolant circulating from the rest of the cold plate 400 and is therefore the coldest of the battery cells 405A-Z. The pressure of the low-temperature coolant flowing in from the coolant inlet 402 prevents the warmer coolant from recirculating towards the corner where battery cell 405B is located. Battery cell 405D is warmer than battery cell 405B. This is because the coolant flowing from the coolant inlet 402 across the cold plate 400 is heated as it passes the battery cells 405E-Z through the center of the cold plate 400. Battery cell 405A is also warmer than battery cell 405B and is closer to the coolant outlet 404, which is the intended path for heat dissipation from the cold plate 400, so it can be predicted to be the warmest of the battery cells 405A-Z on the cold plate 400. However, since battery cell 405A is also very close to the coolant inlet 402, battery cell 405A is also cooled by the coolant that enters immediately. In fact, the thermal gradient diagram shows that the coolant flows through the coolant inlet 402 and cools immediately at the coolant outlet 404, ultimately not cooling any of the battery cells 405A-Z, thus limiting the effectiveness of the cold plate 400 in functioning as a cold plate. A temperature difference of approximately 10 degrees Celsius was observed between battery cell 405B and battery cell 405C, which is substantially higher than the ideal maximum temperature difference of 3 degrees Celsius.

[0033] Figure 5 is a top view flowchart of a preferred coolant flowing across a cold plate 500 to reduce temperature fluctuations between battery cells 505A-Z within the battery storage element 106A. The cold plate 500 is oriented and constructed similarly to the cold plate 400, but the cold plate 500 has means for gradually flowing all of the cold coolant from the coolant inlet 402 to the battery cells 505A-Z, and then gradually flowing the coolant, which has been heated at the far end of the cold plate 500, across the battery cells 505A-Z toward the coolant outlet 404.

[0034] The design implements the principle of Cold Plate 500, so that the first battery cells in each row (e.g., battery cells 505A-D) are exposed to the coldest and hottest coolants, respectively, resulting in an averaged coolant flow rate. Similarly, the last battery cells in each row (e.g., battery cells 505H-K) receive the same amount of cooling as battery cells 505A-D, as well as the same amount of cooling as the hottest cold coolant and the coldest hot coolant, resulting in an averaged coolant flow rate. Therefore, since battery cells 505A-D in the first row and battery cells 505H-K in the last row all use coolant at the same average temperature, by mathematical induction, the intermediate battery cells (e.g., battery cells 505E-G) are also all exposed to coolant at the average temperature.

[0035] Figure 6 is an isometric view of the cold plate manifold 600 configured to improve temperature fluctuations between battery cells within the battery storage element 106A. To achieve the uniform temperature distribution shown in Figure 5, the coolant flow distribution needs to be decomposed into a two-pass system running in the Y direction of the cold plate. However, a two-pass system cannot be effectively realized without a design that allows the coolant to return to the front of the cold plate. Therefore, the coolant manifold 600 divides the coolant flow into a bidirectional (up / down) configuration at the front and inside of the cold plate.

[0036] The cold coolant enters the coolant manifold 600 at the coolant inlet 602, travels along the inlet groove 612, and then enters the channels of the cold plate. Once the heated coolant is circulated through the cold plate, it is returned to the outlet groove 614, where the heated coolant flows toward the coolant outlet 604. The inlet groove 612 is configured to be higher than the outlet groove 614, thereby allowing the cooling water to flow from the inlet groove 612, over the cold plate, and into the outlet groove 614.

[0037] Figure 7 is an isometric view of the cold plate manifold of Figure 6 coupled to the cold plate 700, with arrows indicating the flow of coolant across the cold plate 700. For example, the cold plate manifold 600 can be brazed or welded to the cold plate 700 by, for example, soldering or melting a filler metal or a copper-zinc alloy at high temperatures.

[0038] The cold plate 700 includes a plurality of inlet channels 712A-D and a plurality of outlet channels 714A-714D. In the embodiment shown in Figure 7, each of the plurality of inlet channels 712A-D and the plurality of outlet channels 714A-D includes at least four sets of inlet channels 712A-D and at least four sets of outlet channels 714A-714D. However, the embodiment is not limited to at least four sets of inlet channels 712A-D and outlet channels 714A-D, and any other number of sets of inlet channels 712A-D and outlet channels 714A-D may be used, as long as at least one set of inlet channels 712A-D and at least one set of outlet channels 714A-D are present for each battery cell 505A-Z.

[0039] The inlet channels 712A to D are located at the same elevation level (for example, on the same plane) as the outlet channels 714A to D.

[0040] The inlet channels 712A-712D may be adjustable. For example, the size and / or design of the inlet channels 712A-712D can be changed during the design of the cold plate 700.

[0041] The cold plate manifold 600 shown in Figure 7 forms a flow path through which coolant flows in from the coolant inlet 602 and passes through the inlet groove 612. This coolant inlet path branches out and flows into the lower parts of each of the four sets of inlet channels 712A to D. The coolant flowing in from the coolant inlet 602 passes through the inlet groove 612, branches out and flows down into each of the multiple inlet channels 712A to D, and flows toward the end 702 of the cold plate 700 (for example, relative to the coolant inlet 602). When the coolant reaches the end 702 of the cold plate 700, the coolant descends and flows backward along each of the four sets of outlet channels 714A to D toward the beginning 704 of the cold plate 700. Next, the coolant descends again from the outlet channels 714A to D into the outlet groove 614, where it flows into the coolant outlet 604, is recooled, and recycled throughout the system.

[0042] In the example shown in Figure 7, each set of inlet channels 712A-D is paired with an adjacent set of outlet channels 714A-D. Battery cells are located above both the set of inlet channels 712A and the set of outlet channels 714A-D. For example, battery cells can be positioned above an equal number of at least four sets of inlet channels 712A-D and at least four sets of outlet channels 714A-D. Thus, the cooling water flowing back through the outlet channels 714A-D primarily transfers the heat it picked up while flowing through the inlet channels 712A-D, provided by the battery cells positioned directly above the inlet channels 712A-D and outlet channels 714A-D associated with the same battery cells.

[0043] Each of the inlet channels 712A to D can be indiscriminately connected to at least one (e.g., an adjacent) outlet channel of the outlet channels 714A to D, which may result in the mixed coolant flowing back towards the outlet channel 614.

[0044] The battery cells can, for example, span above multiple sets of inlet channels 712A-D and above multiple sets of outlet channels 714A-D, depending on the size of the battery cells. It is preferable that the battery cells span above an equal number of sets of inlet channels 712A-D and outlet channels 714A-D in order to balance thermal distribution.

[0045] A consideration for making the heat dissipation system shown in Figure 7 effective is that within the battery storage element 106A, battery cells can relatively easily induce heat transfer within themselves, resulting in an average temperature that is very close to the sampled temperature at a random location within the battery cell. However, because the battery cells within the battery storage element 106A have a relatively low ability to induce heat transfer from one another, the average temperature of all battery cells within the battery storage element 106A may not particularly represent the randomized sampled temperature within the battery storage element 106A. Therefore, to achieve temperature uniformity throughout the battery cells, intracellular heat transfer is generally not prioritized, and intercellular heat transfer can be concentrated by the cooling system within the battery module of the battery energy storage system.

[0046] Figure 8 is a top view of the cold plate of Figure 7, showing the coolant flow path at the junction of the cold plate 700 and the cold plate manifold 600. The coolant can be seen flowing into the inlet groove 612. A stepped section, depicted by a shadow in the figure, indicates a drop to the inlet channels 712A-B. The coolant flows over the stepped section and flows along the drop into the inlet channels 712A-B. Next, the coolant flows through the inlet channels 712A-B, reaches the terminal section 702, and flows back into the outlet channel 714A. Another stepped section, depicted by a shadow in Figure 8, indicates another drop from the outlet channel 714A to the hidden outlet groove 614. Thus, the coolant drops twice: from the inlet groove 612 to the inlet channels 712A-B, and from the outlet channel 714A to the outlet groove 614. An additional drop may be provided between the inlet channel 712A and the outlet channel 714A to prevent backflow of the coolant. Alternatively, if the coolant pressure is sufficient and sustained, the step between the inlet channel 712A and the outlet channel 714A may not be necessary.

[0047] Figure 9 is a longitudinal section of the cooling plate 700 of Figure 7, showing the coolant inlet channels 712A-B and outlet channel 714A. As shown in Figure 9 and explained with reference to Figure 7, the inlet channels 712A-B are located at the same elevation level (e.g., in the same plane) as the outlet channel 714A.

[0048] However, the embodiments are not limited to this configuration. For example, in an alternative design, the outlet channel 714A may be positioned lower than the inlet channels 712A-B to reduce coolant backflow while maintaining the coolant flow velocity.

[0049] In certain embodiments, multiple (e.g., two or more) cold plates 500, 700 may be coupled to battery storage elements 106A, 700 of energy storage nodes 105A, 700. For example, separate cold plates 500, 700 may be coupled to each battery storage element 106A, 700 of energy storage nodes 105A, 700.

[0050] Figure 10 is a flowchart showing a method 800 for assembling the energy storage system 101.

[0051] Starting in step 802, method 800 includes providing a plurality of energy storage nodes 105A-N, each of which includes battery storage elements 106A-N (Figure 2). Energy storage nodes 105A-N may include a battery storage element 106, a power conversion subsystem 107, and a control subsystem 110 for receiving battery data 111A-N from the battery storage element 106, the power conversion subsystem 107, or a combination thereof.

[0052] Proceeding to step 804, method 800 further includes connecting at least one cold plate 500, 700 to each of the multiple energy storage nodes 105A~N.

[0053] Proceeding to step 806, method 800 further includes connecting a coolant manifold 600 to at least one cold plate 500, 700. The coolant manifold 600 is configured to divide the coolant flow into a bidirectional configuration between the front and interior of the cold plates 500, 700.

[0054] Although not shown in Figure 8, prior to step 804, method 800 may further include the step of arranging a plurality of inlet channels 712A-D and a plurality of outlet channels 714A-D on at least one cold plate 500, 700. The plurality of inlet channels 712A-D and the plurality of outlet channels 714A-D may be arranged at the same elevation level.

[0055] Although not shown in Figure 8, prior to step 804, method 800 may further include the step of placing at least one battery cell 505A-Z of the energy storage element 106A-N on both at least one of the multiple inlet channels 712A-D and at least one of the multiple outlet channels 714A-D of at least one cold plate 500, 700. At least one battery cell 505A-Z is placed above an equal number of multiple inlet channels 712A-D and multiple outlet channels 714A-714D of at least one cold plate 500, 700.

[0056] The thermal control technology disclosed herein enables the flow of coolant as evenly as possible across a cold plate having a surface area exceeding 700 mm × 500 mm, for example, approximately 1000 mm × 700 mm, to cool approximately 50 battery cells. The cold plates described herein may have dimensions of approximately 700 mm to 1000 mm × 500 mm to 700 mm. For example, a cold plate may have dimensions of 963 mm × 698 mm, accommodating mounting of 52 battery cells and enabling the flow of coolant to cool as evenly as possible across the entire cold plate.

[0057] Furthermore, battery cells cooled by the thermal control techniques disclosed herein can be cooled within a range of ±3 degrees Celsius or less.

[0058] The thermal control designs disclosed herein allow for narrow inlet and outlet spaces to increase energy density and optimize coolant flow.

[0059] The thermal control designs disclosed herein enable space savings by separating the inlet and return of the cooling system by utilizing the upper and lower collection areas of the separation manifold.

[0060] The thermal control technologies disclosed herein can achieve better heat transfer from battery cells to cooling media, thereby improving the lifespan and overall power flow of battery energy storage systems to provide power flow for electrical applications. Improved lifespan and power flow can reduce operating costs and enhance operational safety.

[0061] The terms and expressions used herein shall be understood to have the ordinary meanings given to such terms and expressions in relation to the respective areas of the corresponding investigations and studies, unless a specific meaning is otherwise explained herein. Relative terms such as first and second, or obvious and alternative, may be used solely to distinguish one entity or action from another, and do not necessarily require or imply any actual relationship or order between such entities or actions. The terms “comprises,” “comprising,” “includes,” “including,” or any other variation thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises or includes a list of elements or steps may include other elements or steps that are not explicitly listed or are specific to such process, method, article, or apparatus, rather than including only those elements or steps. The element preceded by “a” or “an” does not, unless further constraints apply, exclude the presence of additional identical elements in a process, method, article, or apparatus that comprises that element.

[0062] Unless otherwise specified, all measurements, values, ratings, locations, sizes, angles, and other designations described herein, including in the following claims, are approximate and not strict. Such quantities are intended to have a reasonable range that is consistent with the function to which they relate and with what is customary in the art to which they relate. For example, unless expressly specified otherwise, parameter values, etc., may vary by approximately ±5% or ±10% from the stated quantities. The terms “approximately” and “substantially” mean that parameter values, etc., may vary by up to ±10% from the stated quantities.

[0063] Furthermore, in the modes for carrying out the invention described above, it can be understood that various features are grouped together in various examples in order to rationalize this disclosure. This method of disclosure should not be interpreted as reflecting an intention that the claimed examples require more features than are explicitly stated in each claim. Rather, as reflected in the following claims, the subject matter to be protected is not all of the features of any single disclosed example. Thus, the following claims are incorporated here into the modes for carrying out the invention, and each claim is based on itself as separately claimed subject matter.

[0064] While the best forms and / or other examples have been described above, it will be understood that various modifications are possible, that the subject matter disclosed herein can be implemented in various forms and examples, and that these may apply to numerous applications, of which only a portion are described herein. The following claims are intended to claim all possible modifications and variations that fall within the true scope of the Concept.

[0065] The scope of protection is limited solely by the claims that follow this specification, which, when interpreted in light of this specification and the following application history, is intended and should be interpreted to encompass all structural and functional equivalents, insofar as it is consistent with the ordinary meaning of the language used in the claims. Nevertheless, none of the claims are intended, nor should they be interpreted, to encompass subject matter that does not meet the requirements of Sections 101, 102, or 103 of the Patent Act. Any unintended inclusion of such subject matter is disallowed herein.

[0066] Except as stated immediately prior to this, nothing described or illustrated, whether or not it is described in the claims, is intended, nor should it be construed, to give to the public any component, step, feature, purpose, benefit, advantage, or equivalent.

Claims

1. An energy storage system, A plurality of energy storage nodes, each of which includes an energy storage element, At least one cold plate, The system comprises a coolant manifold coupled to at least one of the cold plates, The energy storage system wherein the coolant manifold is configured to divide the flow of cooling water in a bidirectional manner between the front and the interior of the cold plate.

2. The energy storage system according to claim 1, wherein the at least one cold plate comprises a plurality of inlet channels and a plurality of outlet channels.

3. The energy storage system according to claim 2, wherein the plurality of inlet channels are arranged at the same elevation level as the plurality of outlet channels.

4. The energy storage system according to claim 2, wherein the plurality of inlet channels are adjustable.

5. The energy storage system according to claim 2, wherein the energy storage element comprises at least one battery cell positioned above both at least one of the plurality of inlet channels and at least one of the plurality of outlet channels.

6. The energy storage system according to claim 2, wherein the plurality of inlet channels comprises at least one set of inlet channels, and the plurality of outlet channels comprises at least one set of outlet channels.

7. The energy storage system according to claim 6, wherein the at least one battery cell is positioned above the same number of at least one set of inlet channels and the at least one set of outlet channels.

8. The energy storage system according to claim 2, wherein the coolant manifold comprises a coolant inlet and an inlet groove, and the coolant flowing in from the coolant inlet passes through the inlet groove, divides the coolant inlet passage, and moves downward toward the end of the cold plate into each of the plurality of inlet channels.

9. The energy storage system according to claim 8, wherein the coolant manifold comprises a coolant outlet and an outlet groove, and after the coolant reaches the terminal portion of the cold plate, the coolant inlet descends and flows backward along each of the plurality of outlet channels toward the starting portion of the cold plate.

10. The energy storage system according to claim 9, wherein each of the plurality of inlet channels is connected to at least one of the plurality of outlet channels, and the mixed coolant flows back toward the outlet groove.

11. The energy storage system according to claim 10, wherein the plurality of outlet channels are provided with stepped portions leading to the outflow groove, and the coolant flows from each of the plurality of outlet channels to the stepped portions leading to the outflow groove.

12. The energy storage system according to claim 1, wherein in the bidirectional configuration, the coolant flows toward the end of the cold plate and flows backward from the end of the cold plate in the same plane.

13. The energy storage system according to claim 1, wherein in the bidirectional configuration, the coolant manifold separates the flow of the coolant in both the vertical and horizontal directions.

14. The energy storage system according to claim 13, wherein the coolant manifold separates the coolant flow in both the vertical and horizontal directions while maintaining the flow velocity of the coolant by using the set of inlet channels, the set of outlet channels, and the upper and lower collection areas of the cold plate.

15. The energy storage system according to claim 1, wherein the coolant manifold is brazed to the at least one cold plate.

16. A method for assembling an energy storage system, wherein the method is To provide a plurality of energy storage nodes, wherein each of the plurality of energy storage nodes includes a battery storage element, Connecting at least one cold plate to each of the plurality of energy storage nodes, The coolant manifold is connected to at least one of the cold plates, The method wherein the coolant manifold is configured to divide the flow of coolant in a bidirectional manner between the front and the interior of the cold plate.

17. The method according to claim 16, wherein the at least one cold plate comprises a plurality of inlet channels and a plurality of outlet channels.

18. The method according to claim 17, further comprising the plurality of inlet channels and the plurality of outlet channels being located at the same elevation level.

19. The method according to claim 17, further comprising positioning at least one battery cell of the battery storage element above at least one of the plurality of inlet channels and at least one of the plurality of outlet channels.

20. The method according to claim 19, wherein the at least one battery cell is positioned above the same number of inlet channels and the plurality of outlet channels.

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