Phase change material heat battery and method for applying thermal energy to a phase change material heat battery

Abstract

To provide an improved heat battery containing PCM which provides technical efficiency and benefit including flexibility for connecting to multiple charging heat sources.SOLUTION: Phase change material (PCM) battery designs which are heated are defined herein. More specifically, integrally and / or internally located heating devices (e.g., electrical heating devices) in a series of heat batteries containing PCM are described. Particularly described is a PCM heat battery comprising: a PCM enclosure capable of holding PCM; PCM located in the enclosure; an electronic control system for the PCM heat battery; and a heating device located in the PCM heat battery; where the heating device is capable of heating the PCM and / or charging the PCM with heat.SELECTED DRAWING: Figure 6a

Description

[Technical Field]

[0001] The present invention relates to an internally heated phase change material (PCM) battery design. More specifically, the present invention relates to a heating device (e.g., an electric heating device) that is integral with and / or internal to a series of thermal batteries that include a PCM. [Background technology]

[0002] Thermal batteries that include a PCM used to transfer and / or store heat are known. However, there are many problems with existing PCM battery technology.

[0003] In a standard heat battery containing a PCM, there are efficiency issues with connecting multiple heat storage sources, as well as issues in situations where the PCM heat battery needs to be charged by an externally located primary heat source.

[0004] A further problem is encountered in prior art systems when an internal heating device is used to heat the PCM in a controlled manner, as a very complex hydronics circuit is required. The complex hydronics circuit has been found to be very unreliable and prone to frequent failures. The complex hydronics circuit is also expensive and difficult to service.

[0005] It is an aim of at least one aspect of the present invention to avoid and / or mitigate at least one or more of the above problems.

[0006] It is a still further object of the present invention to provide an improved thermal battery including a PCM that offers technical efficiencies and benefits including the flexibility to connect to multiple thermal storage sources.

[0007] It is a still further object of the present invention to provide an improved thermal battery including a PCM that includes the ability to store heat in a controlled manner using an externally located primary heat source and / or an internal heating device without the need for complex hydronics circuitry. Summary of the Invention

[0008] According to a first aspect of the present invention, there is provided a PCM thermal battery having at least one, two or more, or a plurality of integral and / or internally disposed heating devices, for example electric heating devices.

[0009] According to a second aspect of the present invention, there is provided a PCM thermal battery including a PCM housing capable of holding a PCM, a PCM disposed in the housing, an electronic control system for controlling the PCM thermal battery, and at least one or more heating devices disposed in the PCM thermal battery, the at least one or more heating devices being capable of heating and / or storing heat in the PCM.

[0010] The present invention relates to an improved thermal battery design, for example a PCM thermal battery having at least one or more heating devices, which may be integral to and / or internal to the PCM battery.

[0011] A PCM thermal battery has the advantage of overcoming the requirement for complex hydronics circuitry in a thermal battery configuration, and any associated components and costs.

[0012] The PCM heat battery of the present invention provides an improved heat battery configuration and design that offers improved technical efficiency, benefits, and flexibility, especially with regard to connection to multiple heat storage sources.

[0013] Typically, the heating devices may be located within the PCM housing. Thus, in some embodiments, the heating devices may be in direct contact with and immersed within the PCM. A PCM thermal battery may include at least 1, 2, 3, 4, 5, or 6 heating devices.

[0014] Alternatively, the PCM thermal battery may include at least two or more, three or more, four or more, five or more, or six or more heating devices. The PCM thermal battery may include multiple heating devices.

[0015] The heating device may be described as being integrally and / or internally disposed within the PCM housing and thus the PCM thermal battery.

[0016] The heating devices may be located at different positions (i.e., depths or heights) within the PCM housing, and therefore may be located at different vertical positions within the PCM housing.

[0017] To eliminate the requirement for complex hydronics circuitry, the PCM heat battery may be charged with an external primary heat source. Thus, the PCM heat battery may be charged with both an external primary heat source and a heating device located within the PCM housing. Thus, the heating device of the present invention may be considered a secondary heat source for the PCM heat battery. Such a configuration allows for very precise control of the heat storage and / or temperature of the PCM. The PCM heat battery may include an external casing for the entire PCM heat battery.

[0018] A thermal insulating layer may be disposed within the outer casing of the PCM thermal battery, which may increase the thermal efficiency of the PCM thermal battery and retain heat within the PCM housing.

[0019] The PCM housing may be a container disposed inside the outer casing and the thermal insulation layer. The PCM housing may hold a PCM. Thus, the thermal insulation layer may form a covering thermal insulation layer around the PCM housing.

[0020] The PCMs used in the present invention can be adapted and modified to specific applications and energy needs, and thus any suitable type of PCM can be used for a range of applications, such as providing hot water, storing energy, and then releasing energy in both domestic and industrial applications.

[0021] The electronic control system may control the physical properties and / or temperature of the PCM by applying energy, such as heat, through a heating device.

[0022] The heating device may be any suitable element capable of providing energy and / or heat to the PCM. For example, the heating device may be an electric heating element that may be used to increase the temperature of the PCM by applying thermal energy to the PCM.

[0023] Thus, the heating device of the present invention may be integral to and / or internal to an electric heating device, and thus, in some embodiments, the heating device may be in direct contact with the PCM material.

[0024] Therefore, in some embodiments, the PCM can be directly heated, meaning that fluid circulation in the circuit within the battery is not required for the heat storage phase, but exists only for heat dissipation of the thermal battery. The present invention also overcomes the need for complex hydronics circuitry. In certain embodiments, the PCM thermal battery can be a dual-port thermal battery.

[0025] The PCM thermal battery may also include a heat exchanger, which may be, for example, a heat exchanger with a finned core, and may be located within the PCM housing.

[0026] The electronic control system of the present invention may include a low power circuit (LPC) and a high power circuit (HPC) that are used to provide electrical connections to the PCM thermal battery.

[0027] The electronic control system may also include an HPC input and an HPC output. There may also be an LPC input and an LPC output. The inputs and outputs may be located on the upper side, i.e., on the top surface, of the PCM thermal battery.

[0028] There may also be a battery controller. There may also be a battery heat storage status signal and a battery heat storage control signal. The PCM battery may be powered from the mains.

[0029] The PCM thermal battery may also include at least one or more sensors capable of monitoring the physical properties and / or temperature of the PCM and other portions of the thermal battery. For example, there may be an over-temperature safety cut-off thermostat S0. Additionally, there may be temperature sensors, e.g., temperature sensors S1, S2, S3. Sensors, e.g., temperature sensors, may be distributed throughout the thermal battery to obtain the temperature throughout the working medium.

[0030] The sensors can be placed at different vertical locations on the PCM, allowing the physical properties and temperature of the PCM to be monitored throughout the PCM housing. For example, sensors can be placed in the top half, near the center, and / or near the lower end of the PCM housing.

[0031] In any particular embodiment, the PCM thermal battery may be, for example, a dual port design with a heating device of the present invention in the form of a backup heater element, e.g., an electric heater element. There may be at least one or more backup heater elements.

[0032] The dual-port design of the present invention provides the technical advantage of being able to store heat in a thermal battery using non-potable water. Furthermore, the battery can store heat using simple, inexpensive, non-certified components. Heat can then be extracted using potable water. Thus, the thermal battery of the present invention is a significant improvement over the complex hydronics systems of the past.

[0033] In certain embodiments, the thermal battery may include a single or multiple heating devices, which may be, for example, standby electric heaters disposed in the PCM. The heating devices may be any form of electric heating device that may be disposed in the PCM. Thus, the heating devices may be described as electric heating devices immersed in, integral with, and / or internally disposed in the PCM. It is noted that the present invention may have at least one, two, or multiple heating devices disposed in the PCM.

[0034] It has been found that the location of the heating device in the PCM housing, and therefore in the PCM, is important. In certain embodiments, the heating device, e.g., an electric heater, may be located in the top half of the PCM housing. By top half, we mean the top vertical half of the PCM housing. The heating device may be immersed in the PCM.

[0035] The electronic control system may be or include a battery controller. The heating device may be connected to the battery controller. Thus, the heating device may be fully controlled and / or switched on and / or off when required. In addition, the amount of power and / or heating provided by the heating device may also be modified, i.e., adapted and changed. Thus, the amount of heating and heat storage provided may depend on sensor measurements and / or the power required for a particular application, such as providing hot water.

[0036] In certain embodiments, the heating device may be located in the top half, third, or top quarter of the PCM housing. It may be preferable for the heating device to be located at the top of the PCM housing so that the heating device can be used to heat the top of the PCM housing and the corresponding PCM therein. This allows only the PCMs in the top of the PCM housing to be heated, thus providing only a reduced capacity, but still providing enough heat to utilize the power available to the user. Thus, the heating device of the present invention may function as a fully compatible backup heating system.

[0037] A further advantage of the PCM battery of the present invention has been found to be the ability to input electrical heat via a heating device and then instantly extract the heat via a heat exchanger, without the need for electrical heat energy to be stored, as is the case in prior art systems such as instantaneous water heater systems.

[0038] In embodiments, the PCM thermal battery may include multiple electric heating devices located at different heights within the PCM housing. The advantage of doing so is that it is possible to select how much PCM material to heat, and therefore how much energy to store and / or release. By placing the electric heating devices at different heights, it is possible to heat different amounts (i.e., volumes) of PCM. Thus, the backup electric heater element function of the present invention is highly adaptable for a wide range of applications, such as, for example, dual-port systems.

[0039] In certain embodiments, the PCM thermal battery may include a heating device located in the top half of the PCM housing and a heating device located in the bottom half of the PCM housing. Thus, the PCM thermal battery may include two heating devices at different vertical locations. The top heating device may function as a backup heater, so that it can be activated if the primary heat source fails.

[0040] Alternatively, there may be a heating device located approximately in the top three-quarters of the PCM housing and a lower heating device located just above the bottom of the PCM housing. As noted above, the location of the heating devices may be adapted to allow for heating different amounts of the PCM. As noted above, the heating devices may be electric heaters / elements of any suitable form.

[0041] A heating device located on the bottom side of the PCM housing can allow substantially all of the PCM material in the battery to quickly store heat.

[0042] The advantage of placing the second heating device inside the PCM housing is that it allows the PCM in the thermal battery to store heat more quickly. The heating device located at the bottom of the PCM housing can function as the primary heat source for the thermal battery.

[0043] Thus, the present invention may have multiple heating devices integrally and / or internally located, such as electric heating devices at different heights in a battery, to provide different amounts of energy. Heating different amounts and volumes of PCM provides different amounts of energy, which can then be stored and / or distributed.

[0044] In further embodiments, there may be at least one or more heating devices that may be integral with and / or internally disposed in the PCM heat battery, e.g., immersed in the PCM below the heat exchanger. The PCM housing may also include, for example, a step structure, e.g., two step structures extending upward from the bottom of the PCM housing, disposed toward the lower end of the heat battery.

[0045] The tiered structure may provide an efficient housing for, for example, heater element terminals and safety cut-off structures. The tiered structure may also allow vacuum insulation panels to be used to insulate the PCM thermal battery.

[0046] These tiered structures 503 a also aid in positioning the heat exchanger 504 above the heating device 511 and positioning a quantity of PCM 505 below the heat exchanger 504 .

[0047] The heating device may be an electric heating device located at the lower end of the PCM housing. For example, the heating device may be tubular and integrated with a thermal battery. The heating device may be located below a heat exchanger. Thus, the heating device may be used to provide instantaneous heating to the PCM.

[0048] A heating device (e.g., a tubular electric heater) may penetrate the thermal battery case, for example, via a bulkhead connection. Such a configuration offers the advantage of being able to transfer heat from the tubular, elongated heating device to the PCM via a large surface area.

[0049] The heating device may be immersed and completely submerged in the PCM, so that the heating device is in direct contact with the PCM.

[0050] There may also be a heat exchanger located within the PCM thermal battery and inside the PCM housing. Typically, the heat exchanger has a finned core to improve thermal efficiency. The heat exchanger may have control circuitry.

[0051] Conduction and convection in the PCM can transfer heat to a heat exchanger, such as one with a finned core, which has been found to be an energy-efficient system.

[0052] In further embodiments, the PCM heat battery may include at least one or more thermal conductors, such as metal rods, that may be inserted substantially vertically into the heat battery case. The thermal conductors may be, for example, conductive rods or heat pipes. The thermal conductors may be positioned substantially vertically in the heat exchanger and extend into portions of the PCM, such as the upper end area of ​​the PCM. The thermal conductors may be used to dissipate and / or spread heat throughout the heat exchanger and / or PCM.

[0053] Thus, the thermal conductor may be immersed or at least partially immersed in the PCM. The thermal conductor may also extend or at least partially extend into the heat exchanger, for example, a heat exchanger core, which may be finned.

[0054] At least one or more heating devices may be disposed on a lower end side of the heat exchanger. The heating devices may be disposed on a bottom side of the PCM housing, substantially horizontally along the bottom.

[0055] In further embodiments, the PCM heat battery can include a heat plate (e.g., a conductive heat plate such as a metal plate) that can be integrated into the PCM heat battery design. The heat plate can extend or at least partially extend into a heat exchanger core (e.g., a heat exchanger finned core). The heat plate can extend below the heat exchanger or substantially below into the heated region of the heat battery.

[0056] For example, there may be two, three, four, or multiple heat plates. The heat plates may be arranged substantially vertically in the heat exchanger and may optionally extend through the heating device into the lower end area of ​​the PCM705. There may be any suitable number of heat plates that may be oriented in any suitable direction through the heat exchanger. It has been found that it is preferable that the heat plates be inserted substantially vertically to aid in the transfer of heat upward and cooling downward along the plates.

[0057] The thermal plate may be formed from any suitable heat-conducting material, such as a metal and / or alloy. The plate may be relatively thick to aid in heat transfer. The thermal plate may be substantially planar and oriented substantially vertically in the PCM heat battery.

[0058] The heat plate can be relatively thick, such as about 0.1 to 5 cm thick, about 0.1 to 2 cm thick, or about 0.1 to 0.5 cm thick.

[0059] In further embodiments, the PCM thermal battery may include a non-planar heating device, such as at least one or more substantially L-shaped electric heating devices embedded in a heat exchanger, such as a finned core heat exchanger.

[0060] A non-planar heating device (e.g., a substantially L-shaped heating device) may include a substantially vertically disposed portion that extends downward through the PCM. There may be one or more (e.g., three) substantially horizontally disposed portions that extend tangentially from the substantially vertical portion 811a. There may be any number of substantially vertically disposed portions and substantially horizontally disposed portions, such as single or multiple.

[0061] One substantially horizontally disposed portion may extend in the lower quarter of the heat exchanger core, a second horizontally disposed portion may extend through a substantially central portion of the heat exchanger core, and a third horizontally disposed portion may extend through the upper quarter of the heat exchanger core. The horizontally disposed portions may be located in any suitable area of ​​the heat exchanger core.

[0062] The substantially horizontally disposed portion may be embedded or at least partially embedded in the core of the heat exchanger (e.g., the finned core of a fin-tube heat exchanger), and the heat exchanger may preferably be fully or at least partially immersed in the PCM.

[0063] To provide better performance in terms of uniform heat storage, heat storage time, partial flushing, and expansion characteristics, the substantially horizontally positioned portion of the heating device may be positioned at a specific height within the heat exchanger core (e.g., finned core) depending on the footprint and aspect ratio of the thermal battery.

[0064] It has been found that the arrangement of the substantially horizontally arranged parts of the heating device alleviates the following problems: a) Excessive localized pressure that could damage the battery cell case b) Rapid overheating of the PCM beyond its safe operating limits c) Overheating of the heating device, resulting in a shortened lifespan or failure

[0065] It has been found that in PCM heat batteries it is preferable to have an interference fit between the heating element and portions of the heat exchanger core, such as the heat exchanger fins, which has surprisingly been found to provide an increased heat transfer surface with improved heat storage times.

[0066] It has been found that an "L" shaped heating device having a substantially horizontal portion also offers a number of advantages, including: 1) Relaxation of any expansion of the PCM during phase changes (melting and solidification) 2) Simple termination of cables required for thermal battery operation on top of the PCM thermal battery

[0067] In further embodiments, the PCM thermal battery may include at least one or more heating devices (e.g., electrically heated tubular heaters) that may be embedded in a heat exchanger core, which may optionally include metallic conductive elements (e.g., conductive tubing such as copper tubing).

[0068] The at least one or more heating devices may be electric heating devices. In particular, the heating device may include a portion of an electric heating device that may be disposed in an upper portion of the heat battery between the PCM housing and the heat exchanger core. In particular, at least one of the electric heating devices may be embedded in a manifold of the PCM heat battery.

[0069] The heating devices may also be embedded in circuits, for example skipped circuit rows, which may extend substantially horizontally across the heat exchanger core.

[0070] There may be any number of skip circuit rows extending across the heat exchanger core, for example, there may be a second skip circuit row extending substantially horizontally across the heat exchanger core.

[0071] Thus, the skip circuit rows may be embedded in the heat exchanger. There may also be passages, which may be, for example, tubes for heat exchange. The passages 920 may extend around the circuits, which may be, for example, skip circuit rows. There may be a heating device extending around the skip circuit rows. Thus, the electric heater may be embedded in the heat exchanger, in particular in the passages (i.e., tubes, which may be made of copper or any other suitable conductive material) that extend through the heat exchanger core. The heating device may be embedded in the heat exchanger core, and preferably not directly in the PCM, as appropriate. There are many different options for where to embed the heating device.

[0072] Thus, the heating device may be in direct contact with the heat exchanger, achieving improved and consistent heat transfer. Additionally, the heating device (e.g., heating element) may optionally not be in direct contact with the PCM in this embodiment and therefore may not need to be compatible with the PCM. This results in more heater options with reduced cost and increased reliability and robustness. The heater elements are accessible for servicing without service personnel being exposed to the PCM. Higher power elements may be used, and the PCM operating conditions are not subject to the heater's higher power surface load.

[0073] In further embodiments, the PCM thermal battery may include at least one or more heating devices that may be embedded in and / or disposed within a housing that includes a material capable of efficiently transferring and / or spreading heat, thus allowing for better transfer of heat from the heating device to the heat exchanger core and / or phase change material.

[0074] In this embodiment, a heating device (e.g., an electric heating device) may be located on the lower end side of the PCM housing and below the heat exchanger core (e.g., a heat exchanger finned core). There may be a first heat exchanger circuit (heat exchanger circuit 1) and a second heat exchanger circuit (heat exchanger circuit 2).

[0075] The heating device may also optionally be disposed between, and typically extend between, the two stage structures, which may be part of the PCM housing.

[0076] The heating device may be held within a housing that may be filled with a material / fluid capable of evenly transferring and / or spreading heat, which may be, for example, any suitable form of oil and / or thermal grease.

[0077] Typically, the heating device may be, for example, a tubular electric heating device that may be placed in a housing and surrounded by a material that can efficiently transfer and / or spread heat, and the housing may therefore be filled with oil and / or thermal grease.

[0078] The housing in some embodiments may be finned to improve heat transfer, while in other embodiments it may be unfinned depending on the particular thermal and energy requirements.

[0079] Thus, the heating device may be embedded in a housing that may be filled with a heat-conducting material capable of evenly transferring and / or spreading heat. The housing may preferably be integral with the PCM housing. The heating device typically does not contact the PCM.

[0080] The housing may be smooth or optionally may have fins which increase the surface area and increase heat transfer from the heater to the heat transfer material, housing and then to the PCM, but importantly reduce the surface loading of the heater resulting in a robust design with reduced service intervals. This is a significant technical advantage and has been found to increase the life of the PCM heat battery.

[0081] Utilizing an oil bath in the housing means that the heater does not need to have high fit tolerances within the housing, as is required with cartridge heaters. In many cases, both the heater and housing are preferably properly machined / specified to provide heat transfer (through an interference fit) and may be tapered to allow for easy removal of the heater, another advantage of this design.

[0082] This design of the heating device and housing means that the heating device can be easily removed and accessible to service personnel without exposing them to the PCM. A small amount of heat transfer material, such as oil, is replaced during service via an oil nipple in the housing. The heat battery can therefore be very easily serviced, which is a further technical advantage.

[0083] The fins on the housing may simply be elongated plates that act as heat dissipation areas to transfer and / or spread thermal energy by increasing the surface area.

[0084] In further embodiments, the PCM thermal battery may include at least one or more heating devices that may be located external to the PCM housing, such as a conductive block, in which a current may be induced via an external induction heater.

[0085] The heating device may be located on the lower end side of the PCM housing, typically below (i.e., substantially below) the heat exchanger core (e.g., heat exchanger finned core). Preferably, the heating device may be located outside the PCM housing and externally at or on the bottom side of the PCM housing. Thus, the heating device may be located between the bottom of the PCM housing and the bottom of the battery case. In certain embodiments, the heating device may be an induction heater.

[0086] Thus, the heating device may be described as being located external to the heat exchanger core and PCM, yet the heating device is internal to the PCM thermal battery.

[0087] A layer of conductive material may be disposed on or substantially on the heating device, inside the PCM housing, which may extend along or substantially along the bottom of the PCM housing. The function of the conductive material may be to inductively transfer heat from the heating device, which may be an induction heater. Thus, the conductive material may be in the form of a thermally conductive metal and / or alloy block in which an electric current may be induced to generate and / or transfer heat.

[0088] In further embodiments, the PCM thermal battery may include at least one or more removable cartridge heating devices that include a conductive block immersed therein.

[0089] The conductive block may be made from any suitable conductive material and may extend along the bottom of the PCM housing, optionally positioned below (ie, underneath) the heat exchanger core and PCM.

[0090] The conduction block may extend completely, substantially, or at least partially along one side of the PCM housing from one side to the other. The conduction block may be constructed of a conductive material, such as any suitable metal and / or alloy. The conduction block is thus intended to efficiently transfer heat from the inside of the bottom of the PCM housing, where a heating device may be located.

[0091] At least one, or a series of, cartridge heating devices, which may be removable, may be embedded within the conduction block and may extend substantially horizontally along, and preferably within, the block.

[0092] Thus, the cartridge heating device may be located inside the PCM housing, and thus may include a thermally conductive metal and / or alloy block capable of efficiently transferring heat.

[0093] Thus, the conduction block can function as a heat source embedded in the bottom and inside of the PCM housing. The conduction block typically has a large surface area compared to the embedded cartridge heating device.

[0094] A technical advantage of cartridge heaters is that they are externally accessible and therefore easily removable as they are not in contact with the PCM.

[0095] Preferably, the conduction block may be in the form of a heater block embedded in the bottom of the PCM housing.

[0096] In further embodiments, the PCM heat battery may additionally include an impeller agitator to mix the PCM and aid in heat transfer via forced convection. The addition of the impeller agitator therefore provides the following technical advantages:

[0097] ·Aids in heat transfer through forced convection. ·Stirring and mixing PCM and its constituents.

[0098] Thus, the PCM heat battery may additionally include an agitator, which may be any form of stirring device, such as a rotary agitator. The agitator may be located, for example, on the bottom side of the PCM housing and used to agitate the PCM to improve the efficiency of the heat battery and heat transfer.

[0099] In a further embodiment, the PCM thermal battery may include a heating device extending substantially vertically inside the PCM housing, which may be in the form of a network of heater elements.

[0100] The heating device in the form of a heater element network may be in the form of a grid-like pattern. Thus, there may be grid portions within which there may be tubular portions that provide efficient heat transfer. The tubular portions may be, for example, metal tubes, such as copper tubes.

[0101] The heating device may also include expansion members (e.g., fins) that may replace the typical fins found in heat exchangers. In certain embodiments, a positive temperature coefficient (PTC) heater may be used that may be slid onto a heat transfer tube, such as a copper tube, replacing the standard fins found in heat exchangers.

[0102] In a further embodiment, the PCM heat battery may include a heating device in the form of a substantially vertically oriented low power vertical heater, for example in the form of a heat pipe or conductive rod, to assist in the circulation of the PCM, which has been found to create a pumping action for the PCM material within the heat battery.

[0103] This configuration has been found to have many technical advantages, including: 1) Increase the heat transfer from the base of the thermal battery to the core in the upward direction, optimizing the heat storage time. 2) Create a path for the molten PCM to travel and relieve any pressure buildup caused by the phase change and expansion of the PCM.

[0104] The heating device may be disposed on the bottom side of the PCM housing, and may extend substantially across the bottom of the heat exchanger.

[0105] Typically, there may be a plurality of substantially vertically oriented low-power vertical heaters. The substantially vertically oriented heaters may be in the form of low-power heating devices or, alternatively, heat tubes. There may be any suitable number of substantially vertically oriented heaters.

[0106] A substantially vertically oriented heater may extend from the top surface of the PCM housing, through the PCM, and into the heat exchanger.

[0107] In further embodiments, the PCM heat battery may include louvered fins. The louvered fins may include a series of tubes (e.g., copper tubes) that can be used to transfer heat. The PCM material may flow through and around the tubes. The flow of the PCM material may be controlled using louvers in the fins. Thus, the fins may include louvers that can be substantially fully open. As such, they may be completely flat or may be converted into an angled configuration that can be used to control the flow of the PCM material. The louvered fin design may be incorporated into any of the embodiments and heat batteries described above.

[0108] In a third aspect of the present invention, a method of applying thermal energy to a PCM heat battery is provided, comprising the steps of providing a PCM housing capable of holding a PCM, providing a PCM disposed in the housing, providing an electronic control system for the PCM heat battery, and providing at least one or more heating devices disposed in the PCM housing and immersed in the PCM, the at least one or more heating devices being capable of heating and / or storing heat in the PCM.

[0109] The above features may be used in any combination with any of the embodiments described herein. The method may use any of the features described in the first and second aspects. [Brief explanation of the drawings]

[0110] By way of example only, embodiments of the present invention will now be described with reference to the following figures:

[0111] [Figure 1] 1 is a schematic diagram of a prior art dual-port thermal battery design;

[0112] [Figure 2] 1 illustrates a dual-port thermal battery according to an embodiment of the present invention, having a hydronics circuit for charging the thermal battery with an electric heater according to the present invention.

[0113] [Figure 3] 1 illustrates a thermal battery according to an embodiment of the present invention, with dual ports having backup electric heater elements.

[0114] [Figure 4] 1 shows a thermal battery according to a further embodiment of the invention, there is a dual port with an electrically heated thermal battery with two heating devices.

[0115] [Figure 5]1 shows a heat battery according to a further embodiment of the invention, where there is an electric heater integral with the heat battery, immersed in the PCM below the heat exchanger.

[0116] [Figure 6a] 1 illustrates a thermal battery according to a further embodiment of the present invention, in which a number of thermal conductors, such as thermally conductive rods or heat pipes, are inserted substantially vertically into the thermal battery case. [Figure 6b] 6b shows an enlarged cross-sectional view of the thermal conductor shown in FIG. 6a.

[0117] [Figure 7] 10 illustrates a heat battery according to a further embodiment of the present invention, wherein a conductive plate is integrated into the heat exchanger core, the conductive plate extending into the heated area of ​​the heat battery below the heat exchanger.

[0118] [Figure 8] 1 illustrates a further heat battery according to a further embodiment of the present invention, the heat battery comprising a substantially L-shaped electric heating device embedded in a heat exchanger;

[0119] [Figure 9] 1 illustrates a further thermal battery according to a further embodiment of the present invention, in which a heating device (e.g., an electrically heated tubular heater) is embedded in a heat exchanger core, which may include a conductive element, e.g., a metal tube such as a copper tube.

[0120] [Figure 10] 10 illustrates a further heat battery according to a further embodiment of the present invention, showing an arrangement for embedding skip rows in the heat exchanger;

[0121] [Figure 11a] 1 illustrates a further thermal battery according to a further embodiment of the present invention, with a heating device embedded and / or disposed in a housing comprising a material capable of efficiently transferring and / or dissipating heat.

[0122] [Figure 11b] 1 illustrates a further thermal battery according to a further embodiment of the present invention, having a heating device embedded and / or disposed in a housing comprising a material capable of efficiently transferring and / or dissipating heat, and having a fan extending downward from the entire housing.

[0123] [Figure 12] 1 illustrates a further thermal battery according to a further embodiment of the present invention, with a heating device located external to the PCM housing. Heating is provided by an externally located induction heater.

[0124] [Figure 13] 10 illustrates a further thermal battery according to a further embodiment of the present invention, with at least one or more removable cartridge heating devices disposed inside the conduction block.

[0125] [Figure 14] 1 illustrates a further thermal battery according to a further embodiment of the present invention, with at least one or more removable cartridge heating devices disposed inside the conduction block, and with a stirrer / agitator for mixing the PCM.

[0126] [Figure 15a] 1 illustrates a further embodiment of the present invention, in which a thermal battery is shown with heating devices in the form of a heating device network extending substantially vertically inside the PCM housing. [Figure 15b] Same as Figure 15a.

[0127] [Figure 16a] 1 represents a further embodiment of the present invention, in which a thermal battery is shown in which there is a heating device in the form of a substantially vertically oriented low power vertical heater, for example in the form of a heat pipe or conductive rod, to assist in the circulation of the PCM. [Figure 16b] Similar to Figure 16a.

[0128] [Figure 17] 10A-10C illustrate further embodiments of the present invention, and show cross sections of louvered fin designs that may be used in a thermal battery according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0129] Generally, the present invention relates to an improved thermal battery design, for example, a PCM thermal battery having at least one or more heating devices that may be disposed therein.

[0130] The heating device of the present invention may be integral to and / or located within an electric heating device, and thus in some embodiments the heating device may be in direct contact with the PCM material.

[0131] Therefore, in some embodiments of the present invention, the PCM can be directly heated, meaning that the circulation of fluid in the circuit within the battery is not necessary for the heat storage phase, but exists only for the heat dissipation of the thermal battery. The present invention also overcomes the need for complex hydronics circuits.

[0132] Figure 1 shows a prior art thermal battery design generally designated 100. The thermal battery 100 shown is a dual-port thermal battery.

[0133] As shown in Figure 1, there is a thermal battery case 101. Disposed within the thermal battery case 101 is a thermal insulator 102. Disposed within the thermal insulator 102 is a PCM housing 103 used to house the PCM of the thermal battery 100. The thermal insulator 102 forms a coating and insulating layer around the PCM housing 103.

[0134] Also shown in FIG. 1 is a low power circuit (LPC) 104 and a high power circuit (HPC) 105 that are used to provide electrical connections to the thermal battery 100 .

[0135] Also shown on top of the thermal battery 100 are an HPC input 106 and an HPC output 107. An LPC input 108 and an LPC output 109 are also shown.

[0136] FIG. 1 also shows that there is a battery controller 110, a main power supply (CC) 111, a battery heat storage status signal 112, and a battery heat storage control signal 113.

[0137] In the thermal battery 100 there is also an over-temperature safety cut-off thermostat S0, and temperature sensors S1, S2, and S3.

[0138] When the thermal battery 100 needs to be "heated / heat stored," the working fluid (water) circulates through the heat exchanger pipes to transfer thermal energy from the working fluid to the PCM located within the PCM housing 103. This requires an auxiliary hydronics assembly / circuit with pumps, temperature and flow sensors, etc. This is the technical solution used in the prior art and results in many drawbacks. The present invention addresses these issues and overcomes the need for such complex hydronics.

[0139] Therefore, there is a need in the art to provide improved thermal battery configurations and designs that offer improved technical efficiency, benefits, and especially flexibility for connecting to multiple heat sources for thermal storage. This includes the ability to use an external primary heat source and / or to still store heat with an internal heating device in a controlled manner without the need for a complex hydronics circuit. A conventional design with a complex hydronics circuit is shown schematically in Figure 2.

[0140] Figure 2 is a further thermal battery 200 design. Similar to the thermal battery 100 shown in Figure 1, there is a thermal battery case 201, a thermal insulator 202, a PCM housing 203, a low power circuit (LPC) 204, a high power circuit (HPC) 205, an HPC input 206, an HPC output 207, an LPC input 208, an LPC output 209, a battery controller 210, a main power supply (CC) 211, a battery heat storage status signal 212, and a battery heat storage control signal 213.

[0141] 2 also includes an electric heater 214 located on top of the battery 200. There is also a pump 215, an expansion relief valve (ERV) 216, an expansion vessel 217, and a system charging arrangement 218. Thus, the thermal battery 200 includes a hydronics loop 250.

[0142] Thus, the battery 200 shown in FIG. 2 is a dual port thermal battery hydronics electric heating configuration.

[0143] The independent hydronics circuit referred to above and shown in Figure 2 is suitable for batteries with single or multiple (dual) hydronics circuits. In situations where the thermal battery thermal storage circuit is designed for potable water, then the hydronics circuit and components in the circuit must be certified to water regulations, resulting in additional cost and complexity.

[0144] To avoid these types of hydronics circuits and any associated components, as well as the associated CAPEX and OPEX costs, configurations with integral and / or internally located heating devices (e.g., electric heating devices) are presented herein for a series of thermal batteries including a PCM.

[0145] Direct heating of the PCM therefore means that circulating fluid in any of the hydronics circuits is not required for the heat storage phase and is therefore only required for heat dissipation in the thermal battery. Direct heating of the PCM offers many technical advantages and overcomes many known problems with hydronics systems. 1. Scaling challenges: It has been found that scaling up the heater element in prior art thermal batteries can lead to thermal failure. 2. In conventional designs, controlling the heater has been found to be problematic, but in the present invention the heater is exposed to a PCM that can be controlled and made into any customized form for a specific set of requirements. 3. In conventional designs where the heater is in the working fluid flow, this has been found to add to the system pressure drop and can affect and hinder the flow rate for thermal storage. 4. The present invention uses a PCM that has a higher boiling point temperature than water used in conventional designs.

[0146] The thermal battery 200 shown in Figure 2 is an advancement from the thermal battery 100 shown in Figure 1. Thus, the thermal battery 200 advances from the older single port design due to its ability to store and / or dissipate heat in different circuits, which provides a very flexible solution.

[0147] The dual-port thermal battery design provides the ability to store heat in the thermal battery with non-potable water (using simple, inexpensive, non-certified components) and then extract heat with potable water without any additional components.

[0148] Each port in a "dual-port thermal battery" can be appropriately sized. For example, the thermal battery can be split 50%-50% or 70%-30%, allocating a larger proportion to heat dissipation compared to heat storage.

[0149] This allows for gradual heat storage over a longer period of time and the ability to dissipate heat at higher power and flow rates.

[0150] The present invention offers further improvements over the thermal battery shown in FIGS.

[0151] 3 depicts a thermal battery 300 according to the present invention. The thermal battery 300 is a dual-port design and has a backup heater element, e.g., an electric heater element. There can be at least one backup heater element, or multiple backup heater elements, as described in more detail below.

[0152] The dual-port design of the present invention provides the technical advantage of being able to store heat in a thermal battery with non-potable water. Furthermore, the battery can store heat with simple, inexpensive, non-certified components. The heat can then be extracted with potable water. Thus, the thermal battery of the present invention is a significant improvement over the complex hydronics systems of the past.

[0153] The thermal battery 300 includes a thermal battery case 301 that serves as an enclosure for all of the components of the thermal battery 300. Disposed within the thermal battery case 301 is an insulating layer 302. The insulating layer 302 acts as a thermal insulator to improve the efficiency of the thermal battery 300. The insulating layer 302 forms a thermal insulation coating. The insulating layer 302 may be made from any suitable insulating material.

[0154] Disposed within the insulating layer 302 is a PCM housing 303. Within the PCM housing 303 is a PCM. The particular PCM used can be adapted and customized for the particular purpose desired. Thus, the thermal battery 300 of the present invention is highly adaptable and modifiable for a wide range of applications.

[0155] FIG. 3 also shows that the thermal battery 300 includes a low power circuit (LPC) 304 and a high power circuit (HPC) 305 .

[0156] As shown in FIG. 3, the thermal battery 300 has an HPC input 306 and an LPC output 307 on its top surface.

[0157] Also on the top surface of the thermal battery 300 are an LPC input 308 and an LPC output 309 .

[0158] 3 also shows that there is a battery controller 310 connected to a main power supply (CC) 311. There is also a battery heat storage status signal 312 and a battery heat storage control signal 313.

[0159] Also shown is an overtemperature safety cutoff thermostat S0 and temperature sensors S1, S2, and S3. There may be at least one temperature sensor or multiple temperature sensors. Temperature sensors may be distributed throughout the thermal battery to obtain temperature throughout the working medium.

[0160] The thermal battery 300 also includes a heating device 314, which may be, for example, a standby electric heater, disposed in the PCM, as shown in FIG. 3. This feature represents a significant difference from the thermal batteries shown in FIGS. 1 and 2. The heating device 314 may be any form of electric heating device that may be disposed in the PCM. Thus, the heating device 314 may be described as an electric heating device that is immersed in, integral with, and / or internally disposed in the PCM. It should be noted that the present invention may have at least one, two, or multiple heating devices disposed in the PCM.

[0161] It has been found that the location of the PCM housing 303, and therefore the heating device 314 in the PCM, is important. The thermal battery 300 also includes a power source 315 for the heating device 314.

[0162] 3, the electric heater 314 is located in the top half of the PCM housing 303. By top half, we mean the top vertical half of the PCM housing 303. The electric heater 314 is also immersed in the PCM material.

[0163] The heating device 314 is connected to the battery controller 310. Thus, the heating device 314 can be fully controlled and / or switched on and / or off as required. Additionally, the amount of power and / or heating provided by the heating device 314 can also be modified and changed.

[0164] In a preferred embodiment, the heating device 314 is located in the top half, top third, or top quarter of the PCM housing 303. Preferably, the location of the heating device 314 is at the top of the PCM housing 313. This allows the heating device 314 to be used to heat the top and corresponding PCM in the top of the PCM housing 303. It only heats the PCM in the top of the PCM housing 303 and therefore provides only a reduced capacity, but still provides enough heat to utilize the power available to the user. Thus, the heating device 314 of the present invention can function as a fully adaptable backup heating system.

[0165] It has been found that a further advantage of the system shown in heat battery 300 is the ability to input electrical heat via heating device 314 and then instantly extract the heat via a heat exchanger. The advantage of this is that there is no need to store electrical heat energy, unlike in prior art systems such as instantaneous water heater systems.

[0166] Although not shown in FIG. 3 , the thermal battery 300 may include multiple electric heating devices located at different heights within the PCM housing 303. The advantage of doing so is that one can select how much PCM material to heat and, therefore, how much energy to store and / or release. By placing the electric heating devices at different heights, different amounts (i.e., volumes) of PCM can be heated. Thus, the backup electric heater element function of the present invention is highly adaptable for a wide range of applications, such as, for example, dual port systems.

[0167] The thermal battery 400 shown in Figure 4 is very similar to the thermal battery 300 shown in Figure 3. The difference is that the thermal battery 400 in Figure 4 has two heating devices, namely, heating device 414 and heating device 416.

[0168] The thermal battery 400 includes a thermal battery case 401, a thermal insulating layer 402, a PCM housing 403, a low power circuit (LPC) 404, a high power circuit (HPC) 405, an HPC input section 406, an HPC output section 407, an LPC output section 408, an LPC input section 409, a battery controller 410, a main power supply (CC) 411, a battery heat storage status signal 412, a battery heat storage control signal 413, an upper position electric heater 414, a power supply for the electric heater 415, and a lower position electric heater 416.

[0169] Also shown is an overtemperature safety cutoff thermostat S0 and temperature sensors S1, S2, S3.

[0170] Thus, the battery 400 includes a first heating device 414 located in the upper half of the PCM housing 403 and a second heating device 416 located in the lower half of the PCM housing 403 .

[0171] 4, heating device 414 is located approximately in the top three-quarters of the PCM housing 414, and lower-located heating device 416 is located just above the bottom of PCM housing 403. As noted above, the location of the heating devices can be adapted to allow for heating of different amounts of PCM. As noted above, the heating devices can be any suitable form of electric heater / element.

[0172] The upper positioned heating device 414 can function as a backup heater as described in Figure 3. Thus, the heating device 414 can be activated if the primary heat source fails.

[0173] The lower-located heating device 416 can be used in conjunction with a primary heating system. Because the heating device 416 is located on the bottom side of the PCM housing 403, it can rapidly heat up substantially all of the PCM material in the battery 400.

[0174] An advantage of having the second heating device 416 is that it allows for faster heat storage for the PCM in the thermal battery 400. The heating device 416, located at the bottom of the PCM housing 403, can serve as the primary heat source for the thermal battery 400.

[0175] Thus, in addition to the embodiment shown in Figure 4, the present invention may have multiple heating devices integrally and / or internally located, such as electric heating devices at different heights in the battery, to provide different amounts of energy. Heating different amounts and volumes of PCM provides different amounts of energy, which can then be stored and / or distributed.

[0176] It has been found that the embodiment shown in Figures 3 and 4 provides many technical benefits, including the ability to still charge the heat battery using an external primary heat source, eliminating the requirement for complex hydronics circuitry. It also provides the ability to charge the heat battery in a controlled manner with an external heat source and at least one or more internal heating devices. The at least one or more internal heating devices may be positioned at various vertical locations, providing the ability to heat different amounts of the PCM and, therefore, store and / or dissipate different amounts of energy.

[0177] Accordingly, the applicant has developed a thermal battery design in which an integral and / or internally disposed heating device, such as an electric heating device or multiple electric heating devices, provides many different technical advantages.

[0178] The thermal battery of the present invention with an integrated and / or internally located electric heating device or multiple integrated heating devices offers the following advantages: a) The thermal battery can still be charged by an external primary heat source (e.g. a boiler), and in this application the electric heater acts as a backup (secondary) heat source in case the primary heat source fails. b) Second, as shown in Figure 4, an integrated electric heater acts as the main / primary heat source and heats the battery directly, thereby eliminating the requirement for a complex hydronics circuit. c) The thermal battery can also be charged in a controlled manner by both external heat sources and internal heating devices, for example photovoltaics via electrical elements and supplemental heating by a boiler via a hydronics circuit. d) The heating device is surrounded by a PCM, i.e., an environment with constant and known parameters. In a hot water cylinder, the heating device is surrounded by potable water. Therefore, limescale accumulates on the heating element, causing hot spots and eventually leading to failure of the heating device. When the heating device is placed within a PCM, as in the present invention, these issues do not arise, thus extending the life of the heating device. e) Unlike a water cylinder, the thermal battery of the present invention with a heating device located at the bottom can store heat at different levels. For example, the heating device can be switched on only until, for example, 50% of the PCM is melted. Thus, the heat storage state can be controlled without using multiple elements at different heights.

[0179] Multiple variations / iterations were designed and evaluated, as described in detail below and shown schematically in Figures 5 through 15a and 15b. Each of the figures has a slightly different configuration of the device components, providing various technical benefits, which are described below.

[0180] 5 shows a heat battery 500 according to the present invention. There is a heating device immersed in the PCM, such as an electric heater, integrated into the heat battery, for example underneath a heat exchanger.

[0181] 5, there is a thermal battery case 501 with an insulating layer 502 disposed inside the thermal battery case 501. Disposed inside the insulating layer 502 is a PCM housing 503. The insulating layer 502 forms a coating around the PCM housing 503 which holds the PCM 505. Also present is a heat exchanger 504 and a heat exchanger core 520.

[0182] As shown in FIG. 5, the PCM housing 503 has two step structures 503 a that extend upward from the bottom of the PCM housing 503 and are disposed on the lower end side of the thermal battery 500 .

[0183] 5 also shows that there is a heat exchanger 504, which may have a finned core to improve thermal efficiency. Also shown are heat exchanger circuit 504a and heat exchanger circuit 504b. Inside the PCM housing 503 is located a PCM 505.

[0184] On the upper side of the PCM housing 503, an input section 506 (for example, input section circuit 1), an output section 507 (for example, circuit 1), an input section 508 (for example, circuit 2), and an output section 509 (for example, circuit 2) are arranged.

[0185] There are also sensors 510. As shown in Figure 5, there are preferably three sensors 510. A first sensor is located towards the upper end of the PCM housing 503, a second sensor is located near the centre of the PCM housing 503, and a further sensor is located towards the lower end of the PCM housing 503. Thus, multiple different sensors 510 can be located at different vertical positions in the PCM housing 503. This allows physical parameters such as the temperature of the PCM to be measured and / or recorded at different heights throughout the PCM material.

[0186] 5 also shows that a heating device 511, such as an electric heating device, is located at the lower end of the PCM housing 503. The heating device 511 may be tubular in form and may be integral with the thermal battery 500. The heating device 511 is located below the heat exchanger 504.

[0187] There is also a heat exchanger circuit 504a (heat exchanger circuit 1) and a heat exchanger circuit 504b (heat exchanger circuit 2). Thus, a heating device 511 can be used to provide instantaneous heating to the PCM 505.

[0188] As shown in FIG. 5, a heating device 511 (eg, a tubular electric heater) may penetrate the thermal battery case 501, for example, via a bulkhead connection.

[0189] Furthermore, the heating device 511 is immersed and completely submerged in the PCM 505. Thus, the heating device 511 is in direct contact with the PCM 505.

[0190] 5 provides the technical advantage of heat transfer from the heating device 511 to the PCM 505 via a large surface area. Conduction and convection in the PCM 505 transfer heat to the heat exchanger 504, for example, a heat exchanger with a finned core. This has been found to be a highly energy efficient system.

[0191] The step structures 503a are part of the PCM housing 503, for example on both sides of the PCM housing 503. Thus, there can be two step structures 503a, or any suitable number.

[0192] The tier structure 503a provides an efficient housing for, for example, heater element terminals and safety cut-off structures. The tier structure 503a may also allow vacuum insulation panels to be used to insulate the thermal battery 500.

[0193] These tiered structures 503 a also aid in positioning the heat exchanger 504 above the heating device 511 and a certain amount of PCM 505 below the heat exchanger 504 .

[0194] The inventors have also discovered the following aspect of the present invention: It has been found that when the thermal battery is at a low temperature (i.e., in heat dissipation mode), the PCM is in a solid state and has low thermal conductivity. In this condition, when the heating device is switched on, it melts the surrounding PCM (i.e., it forms an expanding liquid pool surrounded by the solid PCM), causing: a) Excessive localized pressure that could damage the battery cell case b) Rapid overheating of the PCM above its safe operating limits c) Overheating of the heating device, resulting in a shortened lifespan or failure.

[0195] To overcome these challenges, two main approaches have been investigated and deployed. a) Reduce the power input, i.e. slow down the heat transfer process to match the heat transfer characteristics of the PCM / heat exchanger core. This option was not pursued further as the battery heat storage time was unacceptable. b) As shown in Figure 6a below, a number of metal rods inserted vertically create a path for the expanding PCM to escape to the upper expansion space, thus preventing local pressure build-up and increasing convective heat transfer between the heating device and the heat exchanger / PCM core. This method was optimized to allow maximum power heat transfer. c) Rather than using metal rods as above, thin plates are integrated into the finned core of the heat exchanger design, which extends into the heated region of the thermal battery below the heat exchanger, as shown in Figure 6b. d) Using louvered fins to allow the PCM to move between the fins, aiding heat transfer through convection and allowing more channels for expansion of the PCM.

[0196] Figure 6a shows a thermal battery 600 in which a number of thermal conductors, for example metal rods, are inserted substantially vertically into the thermal battery case, as described below.

[0197] 6a, there is a thermal battery 600 having a thermal battery case 601 and a heat insulating layer 602 disposed inside the thermal battery case 601. There is also a PCM housing 603.

[0198] Figure 6a also shows that there can be a heat exchanger 604, which can be, for example, a heat exchanger finned core. The heat exchanger has a core 620. Figure 6a also shows that there is a heat exchanger circuit 604a (heat exchanger circuit 1) and a heat exchanger circuit 604b (heat exchanger circuit 2). Disposed inside the PCM housing 603 is a PCM 605.

[0199] On the upper side of the PCM housing 603, an input section 606 (for example, input section circuit 1), an output section 607 (for example, circuit 1), an input section 608 (for example, circuit 2), and an output section 609 (for example, circuit 2) are arranged.

[0200] There are also sensors 610. As shown in Figure 6a, there are preferably three sensors 610. A first sensor is located towards the top end of the PCM housing 603, a further sensor is located near the centre of the PCM housing 603, and a further sensor is located towards the bottom end of the PCM housing 603.

[0201] 6a also shows that a heating device 611 is disposed on the lower end side of the heat exchanger 604. The heating device 611 may be disposed on the bottom side of the PCM housing 603, substantially horizontally along it.

[0202] 6a further shows that there are four heating conductors 612, such as, for example, conductive rods or heat pipes, that are arranged substantially vertically in the heat exchanger 604 and extend from the heat exchanger core 620 into the upper end area of ​​the PCM 605.

[0203] Figure 6b is a cross section of the heating conduction rod or heat pipe 612 shown in Figure 6a. Figure 6b shows that heat travels up through the heat conduction rod or heat pipe and cooling travels down through the heat conduction rod or heat pipe.

[0204] Figure 7 relates to a heat battery 700 that does not use metal rods as in Figures 6a and 6b above. This embodiment relates to integrating a heat plate (e.g., a conductive heat plate such as a metal plate) into a heat exchanger core (e.g., a heat exchanger finned core). The plate extends into the heated region of the heat battery below the heat exchanger.

[0205] In the thermal battery 700 shown in Figure 7, there is a thermal battery case 701, an insulating layer 702, and a PCM housing 703. As shown in Figure 7, there is also a heat exchanger 704 and a heat exchanger core 720, which may preferably be a heat exchanger finned core.

[0206] FIG. 7 also shows that there is a heat exchanger circuit 704a (heat exchanger circuit 1) and a heat exchanger circuit 704b (heat exchanger circuit 2).

[0207] A PCM 705 is disposed in a PCM housing 703. On the top surface of the thermal battery case 701, an input unit 706 (e.g., input unit circuit 1), an output unit 707 (e.g., circuit 1), an input unit 708 (e.g., circuit 2), and an output unit 709 (e.g., circuit 2) are disposed.

[0208] There are also sensors 710. As shown in Figure 7, there are preferably three sensors 710. A first sensor is located towards the top end of the PCM housing 703, a further sensor is located near the center of the PCM housing 703, and a further sensor is located towards the bottom end of the PCM housing 703.

[0209] 7 also shows that the heating device 711 is positioned below the lower end of the heat exchanger 704. Thus, the heating device 711 is completely immersed in the PCM 705.

[0210] 7 further shows that there are, for example, four plates 712. The plates are arranged substantially vertically in the heat exchanger 704 and optionally extend through the heating device 711 and into the lower end area of ​​the PCM 705. There can be any suitable number of plates, which can be oriented in any suitable direction through the heat exchanger 704. It has been found that it is preferable for the plates 712 to be oriented substantially vertically to aid in the transfer of heat upward and cooling downward along the plates 712.

[0211] The plates 712 may be formed from any suitable heat-conducting material, such as a metal and / or alloy. The plates 712 may be relatively thick to aid in heat transfer. The plates 712 may be substantially planar and oriented substantially vertically in the thermal battery 700.

[0212] Plate 712 can be relatively thick, such as about 0.1-5 cm thick, about 0.1-2 cm thick, or about 0.1-0.5 cm thick.

[0213] Figure 8 relates to a further heat battery 800 according to the invention. The heat battery 800 comprises a substantially L-shaped electric heating device embedded in a heat exchanger, for example a heat exchanger finned core, as described below.

[0214] In Figure 8, there is a thermal battery 800 including a thermal battery outer case 801, a thermal insulation layer 802, and a PCM housing 803. There is also a heat exchanger 804 and a heat exchanger core 820 (e.g., a heat exchanger finned core). There is a heat exchanger circuit 804a (heat exchanger circuit 1) and a heat exchanger circuit 804b (heat exchanger circuit 2). Figure 8 also shows that there is a PCM 805 disposed within the PCM housing 803.

[0215] On the upper side of the PCM housing 803, an input section 806 (for example, input section circuit 1), an output section 807 (for example, circuit 1), an input section 808 (for example, circuit 2), and an output section 809 (for example, circuit 2) are arranged.

[0216] There are also sensors 810. As shown in Figure 8, there are preferably three sensors 810. A first sensor is located towards the upper end of the PCM housing 803, another sensor is located near the center of the PCM housing 803, and another sensor is located towards the lower end of the PCM housing 803 and PCM 805.

[0217] 8, the L-shaped electric heating device 811 includes a substantially vertically disposed portion 811a that extends downwardly through the PCM 805. Three substantially horizontally disposed portions 811b, 811c, and 811d extend tangentially from the substantially vertical portion 811a. There can be any number of substantially vertically disposed portions and substantially horizontally disposed portions, such as single or multiple.

[0218] One substantially horizontally disposed portion 811b may extend in the lower quarter of the heat exchanger core 820, horizontally disposed portion 811c may extend through substantially the middle of the heat exchanger core 820, and a third horizontally disposed portion 811d may extend through the upper quarter of the heat exchanger 804. The horizontally disposed portions may be located in any suitable area of ​​the heat exchanger core 820.

[0219] 8, in the thermal battery 800, the heating device 811, and in particular the substantially horizontally arranged portions 811b, 811c, 811d, are embedded in the core of the heat exchanger 814 (e.g., the finned core of a fin-tube heat exchanger). The heating device 811 is preferably at least partially immersed in the PCM 805.

[0220] It has been found that it is preferable to have an interference fit between the heating element 811 and parts of the heat exchanger core 820, such as the heat exchanger fins, in the thermal battery 800. Surprisingly, it has been found that this provides an increased heat transfer surface and improved heat storage time.

[0221] It has been found that an "L" shaped heating device having a substantially horizontal portion also offers a number of advantages, including: 1) Relaxation of any expansion of PCM805 during phase changes (melting and solidification) 2) Simple termination of the cables required for thermal battery operation on top of the thermal battery.

[0222] As shown in FIG. 8, to provide better performance in terms of uniform heat storage, heat storage time, partial flushing, and expansion characteristics, the substantially horizontally positioned portions 811b, 811c, 811d of the heating device 811 are positioned at specific heights within the heat exchanger core 804 (e.g., a finned core) depending on the footprint and aspect ratio of the thermal battery.

[0223] It has been found that the arrangement of the substantially horizontally arranged portions 811b, 811c, 811d of the heating device 811 alleviates the following problems. d) Excessive localized pressure that could damage the battery cell casing e) Rapid overheating of the PCM beyond its safe operating limits f) Overheating of the heating device, resulting in a shortened lifespan or failure.

[0224] The thermal battery 800 shown in Figure 8 has been found to be an ideal embodiment for a hybrid hot water heater that uses both stored heat and provided heating device power to instantly heat a domestic hot water supply.

[0225] FIG. 9 depicts a thermal battery 900 in which a heating device (eg, an electrically heated tubular heater) is embedded within a heat exchanger core, which may include a metallic conductive element, eg, a conductive tube such as a copper tube.

[0226] 9, there is a thermal battery case 901, a thermal insulating layer 902, and a PCM housing 903 that holds a PCM 905. There is also a heat exchanger 904 and a heat exchanger core 920.

[0227] On the upper side of the PCM housing 903, an input section 906 (for example, input section circuit 1), an output section 907 (for example, circuit 1), an input section 908 (for example, circuit 2), and an output section 909 (for example, circuit 2) are arranged.

[0228] There are also sensors 910. As shown in Figure 9, there are preferably three sensors 910. A first sensor is located towards the top end of the PCM housing 903, a further sensor is located near the center of the PCM housing 903, and a further sensor is located towards the bottom end of the PCM housing 903.

[0229] 9, the thermal battery 900 includes a heating device 911, such as an electric heating device. In particular, the heating device 911 includes an electric heating device 911a disposed in an upper portion of the thermal battery 900 between the PCM housing 903 and the heat exchanger core 920. In particular, the electric heating device 911a may be embedded in a manifold of the thermal battery 900.

[0230] 9 also shows that there are electric heating devices 911b, 911c embedded in passages 915 in the heat exchanger core 920. The passages 915 extend substantially horizontally across the heat exchanger core 920 and may bend in a "U".

[0231] FIG. 9 also shows that there is a second heating device 911c that extends substantially horizontally across the heat exchanger core 920.

[0232] Figure 10 shows a heating device 911b disposed in a passageway 915. In Figure 10, a PCM housing 903 and a PCM 905 are shown. A heat exchanger 904 is disposed within the PCM housing 903 and the PCM 905. The heat exchanger 904 may be a finned core heat exchanger.

[0233] Figure 10 shows that there is a passage 922, which may be, for example, a tube for heat exchanger 904. As shown in Figure 10, passage 922 may extend around passage 915, providing a "skip" configuration.

[0234] Thus, FIG. 10 relates to an embodiment in which the electric heater may be embedded within the heat exchanger, and in particular in a passageway (i.e., a tube which may be made from copper or any other suitable conductive material) extending through the heat exchanger core.

[0235] 9 and 10, the heating devices 911b, 911c are embedded within the heat exchanger core 904 and preferably are not optionally placed directly in the PCM 905. There are many different options for embedding the heating devices 911b, 911c. The heating devices 911b, 911c can be embedded in a number of ways, such as: As shown in the embodiment in Figure 9, the heaters 911b, 911c and passages 922 may provide an input extending from the working fluid, i.e., PCM 905. The heaters 911b, 911c may be recessed into larger diameter manifolds on the input for connection to smaller capillaries feeding through the heat exchanger finned core. This means that the heaters 911b, 911c are in the working fluid, and therefore heat storage is uniform throughout the battery. Operation of the heaters 911b, 911c is managed by a thermal battery controller, in coordination with auxiliary factory equipment. 10 shows where portions of the heat exchanger such as circuits 915 (e.g., skip row tubes) and the heat exchanger finned core (FIG. 10) are embedded. The skip rows in the heat exchanger finned core allow the "skip tubes" to be fed by multiple heaters at various locations throughout the finned block. The benefit of this is that the skip rows are extended into the finned block, providing better heat transfer from the tubes to the fins.

[0236] In both variations shown in Figures 9 and 10, the heater is in direct contact with the heat exchanger, so improved and consistent heat transfer is achieved. Additionally, the elements do not need to be compatible with the PCM because they are not in direct contact with the PCM. This reduces costs and creates more heater options with increased reliability and robustness. The heater elements are accessible for servicing without exposing service personnel to the PCM. Higher power elements can be used, and PCM operating conditions are not subject to the heater's higher power surface loading concerns.

[0237] 11a and 11b illustrate a further thermal battery according to the present invention, in which there is a heating device embedded and / or disposed in a housing comprising a material capable of efficiently transferring and / or spreading heat, thus allowing for better transfer of heat from the heating device to the heat exchanger core and / or phase change material, as will be explained in more detail below.

[0238] As shown in Figure 11a, there is a thermal battery 1000 having a thermal battery case 1001 and an insulating layer 1002 disposed inside the thermal battery case 1001. There is also a PCM housing 1003 and a PCM 1005. There is also a heat exchanger 1004 and a heat exchanger core 1020.

[0239] In FIG. 11a, on the upper side of the PCM housing 1003, an input section 1006 (e.g., input section circuit 1), an output section 1007 (e.g., circuit 1), an input section 1008 (e.g., circuit 2), and an output section 1009 (e.g., circuit 2) are arranged.

[0240] There are also sensors 1010. As shown in Figure 11a, there are preferably three sensors 810. A first sensor is located towards the top end of the PCM housing 1003, a further sensor is located near the centre of the PCM housing 1003, and a further sensor is located towards the bottom end of the PCM housing 1003.

[0241] As shown in Figure 11a, there is a heating device 1011 (e.g., an electric heating device) located below a heat exchanger core 1020 (e.g., a heat exchanger finned core) on the lower end side of the PCM housing 1003. There is a heat exchanger circuit 1004a (heat exchanger circuit 1) and a heat exchanger circuit 1004b (heat exchanger circuit 2).

[0242] The heating device 1011 is disposed between the two stage structures 1003a and 1003b and extends between these two stage structures 1003a and 1003b. The stage structures 1003a, 1003b are part of the PCM housing 1003.

[0243] The heating device is held within a housing 1030 which may be filled with a material / fluid capable of evenly transferring and / or spreading heat, which may be, for example, any suitable form of oil and / or thermal grease.

[0244] 11a, the heating device 1011 may be, for example, a tubular electric heating device that may be placed within a housing 1030 and surrounded by a material capable of efficiently transferring and / or dissipating heat. Thus, the housing 1030 may be filled with oil and / or thermal grease. In contrast to the embodiment seen in FIG. 11b, the housing 1030 is not finned.

[0245] 11a, the heating device 1011 is embedded in a housing 1030 filled with a heat-conductive material capable of evenly transferring and / or spreading heat. The housing 1030 is preferably integral with the PCM housing 1003. The heating device 1011 does not contact the PCM 1005.

[0246] The housing 1030 may be flat or optionally finned to increase the surface area and increase heat transfer from the heater to the heat transfer material, housing and PCM 1005, but importantly to reduce the surface loading of the heating device 1011, resulting in a robust design with reduced service intervals. This has been found to be a significant technical advantage and increases the lifespan of the thermal battery 1000.

[0247] Utilizing an oil bath in the housing 1030 means that the heating device 1011 does not need to have high fit tolerances within the housing 1030, as is required for cartridge heaters. In many cases, both the heating device 1011 and the housing 1030 are preferably properly machined / specified to provide heat transfer (through an interference fit) and may be tapered to allow for easy removal of the heating device 1011, which is a further advantage of the present design.

[0248] The design of the heating device 1011 and housing 1030 seen in Figure 11a means that the heating device 1011 is easily removable and accessible to service personnel without exposing them to the PCM 1005. A small amount of heat transfer material, such as oil, is replaced during service via an oil nipple in the housing. The thermal battery 1000 can therefore be very easily serviced, which is a further technical advantage.

[0249] Figure 11b shows an alternative embodiment in which the housing 1050 is similar to that seen in Figure 11a, but in this embodiment there are a series of fins 1052 extending downward from the entire housing 1050. The fins 1052 are simply elongated plates that act as heat dissipation areas to increase surface area and therefore the transfer and / or diffusion of thermal energy. Extending within and along at least a portion, or substantially all, of the interior length of the housing 1050 is a heating device 1054.

[0250] 12 shows a further thermal battery 1100 according to the invention. In this variant, the heating device is located outside the PCM housing. Inside is a conductive block, and current is induced via an external induction heater. This is explained in more detail below.

[0251] 12 shows that there is a thermal battery 1100 that includes a thermal battery case 1101 and an insulating layer 1102 disposed inside the thermal battery case 1101. There is also a PCM housing 1103 and a PCM 1105. There is also a heat exchanger 1104 and a heat exchanger core 1120.

[0252] In FIG. 12, on the upper side of PCM housing 1103, an input section 1106 (for example, input section circuit 1), an output section 1107 (for example, circuit 1), an input section 1108 (for example, circuit 2), and an output section 1109 (for example, circuit 2) are arranged.

[0253] There are also sensors 1110. As shown in Figure 12, there are preferably three sensors 1110. A first sensor is located towards the top end of the PCM housing 1103, a further sensor is located near the center of the PCM housing 1103, and a further sensor is located towards the bottom end of the PCM housing 1103.

[0254] There is a heat exchanger circuit 1104a (heat exchanger circuit 1) and a heat exchanger circuit 1104b (heat exchanger circuit 2).

[0255] As shown in Figure 12, there is a heating device 1111 located on the lower end side of the PCM housing 1103, below the heat exchanger core 1104 (e.g., heat exchanger finned core). In particular, in the thermal battery 1100 shown in Figure 12, the heating device 1111 is located outside the PCM housing 1103 and externally at the bottom of the PCM housing 1103. Thus, the heating device 1111 is located between the bottom of the PCM housing 1103 and the bottom of the battery case 1101. In certain embodiments, the heating device 1111 is an induction heater.

[0256] Thus, the heating device 1111 may be described as being externally located from the heat exchanger core 1104 and the PCM 1105 .

[0257] 12, disposed on or substantially on the heating device 1111 and inside the PCM housing 1103 is a layer of conductive material 1112 that extends along or substantially along the bottom of the PCM housing 1103. The function of the conductive material 1112 is to inductively transfer heat from the heating device 1111, which may be an induction heater. Thus, the conductive material 1112 may be in the form of a thermally conductive metal and / or alloy block in which an electric current may be induced to generate and / or transfer heat.

[0258] 13 depicts a further thermal battery 1200 according to the present invention. In this embodiment, the thermal battery 1200 includes at least one or more removable cartridge heating devices that include a conductive block immersed therein, as described in more detail below.

[0259] In the thermal battery 1200, there is a thermal battery case 1201 and an insulating layer 1202 disposed inside the thermal battery case 1201. There is also a PCM housing 1203 and a PCM 1205. There is also a heat exchanger 1204 and a heat exchanger core 1220.

[0260] In FIG. 13, on the upper side of PCM housing 1203, there are arranged input section 1206 (for example, input section circuit 1), output section 1207 (for example, circuit 1), input section 1208 (for example, circuit 2), and output section 1209 (for example, circuit 2).

[0261] There are also sensors 1210. As shown in Figure 13, there are preferably three sensors 1210. A first sensor is located towards the top end of the PCM housing 1203, a further sensor is located near the center of the PCM housing 1203, and a further sensor is located towards the bottom end of the PCM housing 1203.

[0262] There is a heat exchanger circuit 1204a (heat exchanger circuit 1) and a heat exchanger circuit 1204b (heat exchanger circuit 2).

[0263] 13, there is a block of material 1212 that extends along the bottom of the PCM housing 1203 and is disposed below the heat exchanger core 1220 and PCM 1205. The block 1212 may extend completely, substantially, or at least partially along the PCM housing 1203 from one side to the other. The block 1212 is composed of a conductive material, such as any suitable metal and / or alloy. Thus, the block 1212 is intended to efficiently transfer heat from the inside of the bottom of the PCM housing 1203, where the heating device is located.

[0264] Embedded internally within block 1212 are at least one, or a series of, cartridge heaters 1211, which may be removable. In Figure 13, three cartridge heaters 1211 are shown, but there may be any suitable number. The cartridge heaters 1211 extend substantially horizontally along block 1212.

[0265] Thus, the cartridge heating device 1211 is disposed internally within the PCM housing 1203. Thus, the cartridge heating device 1213 may include a thermally conductive metal and / or alloy block capable of efficiently transferring heat.

[0266] 13, there is a block 1212 that acts as a heat source embedded at the bottom inside of the PCM housing 1213. The block 1212 has a large surface area compared to the embedded cartridge heater 1213.

[0267] A technical advantage of the cartridge heaters 1211 is that they are externally accessible and therefore easily removable as they are not in contact with the PCM 1205. Therefore, the embodiment shown in Figure 13 and the thermal battery 1200 can be very easily serviced.

[0268] This variation uses a heater block embedded in the bottom of the PCM housing. This block has a large surface area compared to embedded cartridge heaters. The heater is externally accessible, so it is removable and does not come into contact with the PCM.

[0269] 14 depicts a further thermal battery 1300 in accordance with the present invention. In this embodiment, the thermal battery 1300 has at least one or more removable cartridge heating devices that include an internally immersed conductive block and also an impeller agitator that mixes the PCM 1315 and assists in heat transfer via forced convection. Thus, the addition of the impeller agitator provides the following technical advantages: ·Aids in heat transfer through forced convection Stirring and mixing PCM1305 and its components

[0270] The battery 1300 shown in FIG. 14 is described in more detail below.

[0271] The battery 1300 includes a thermal battery case 1301 and a thermal insulation layer 1302 disposed inside the thermal battery case 1301. There is also a PCM housing 1303 and a PCM 1305. There is also a heat exchanger 1304 and a heat exchanger core 1320.

[0272] In FIG. 14, on the upper side of PCM housing 1303, there are arranged input section 1306 (e.g., input section circuit 1), output section 1307 (e.g., circuit 1), input section 1308 (e.g., circuit 2), and output section 1309 (e.g., circuit 2).

[0273] There are also sensors 1310. As shown in Figure 14, there are preferably three sensors 1310. A first sensor is located towards the top end of the PCM housing 1303, a further sensor is located near the center of the PCM housing 1303, and a further sensor is located towards the bottom end of the PCM housing 1303.

[0274] There is a heat exchanger circuit 1304a (heat exchanger circuit 1) and a heat exchanger circuit 1304b (heat exchanger circuit 2).

[0275] 14, there is a block of material 1312 that extends along the bottom of the PCM housing 1303 and is disposed below the heat exchanger core 1320 and PCM 1305. The block 1312 may extend completely, substantially, or at least partially along from one side of the PCM housing 1303 to the other. The block 1312 is composed of a conductive material, such as any suitable metal and / or alloy. Thus, the block 1312 is intended to efficiently transfer heat from the inside of the bottom of the PCM housing 1303.

[0276] There is at least one or a series of cartridge heaters 1311, which may be removable, embedded internally in block 1312. In Figure 14, there are shown to be three cartridge heaters 1311, but there may be any suitable number.

[0277] Thus, the cartridge heating device 1311 is disposed internally within the PCM housing 1303. Thus, the cartridge heating device 1311 may include a thermally conductive metal and / or alloy block capable of efficiently transferring heat.

[0278] 14, there is a block 1312 that acts as a heat source embedded in the bottom and inside of the PCM housing 1303. The block 1312 has a large surface area compared to the embedded cartridge heater 1311.

[0279] Additionally, the heat battery 1300 includes an agitator 1315, which can be any form of agitation device, such as a rotary agitator. The agitator 1315 can be located, for example, on the bottom side of the PCM housing 1303 and can be used to agitate the PCM 1305 to improve the efficiency of the heat battery 1300 and heat transfer.

[0280] Figure 15a depicts a further embodiment of the invention in which there is shown a thermal battery 1400. In the thermal battery 1400 there is a heating device that extends substantially vertically inside the PCM housing. The heating device may be in the form of a heater element network, which is described in more detail below.

[0281] The battery 1400 includes a thermal battery case 1401 and a thermal insulation layer 1402 disposed inside the thermal battery case 1401. There is also a PCM housing 1403 and a PCM 1405. There is also a heat exchanger 1404 and a heat exchanger core 1420.

[0282] In FIG. 15a, on the upper side of the PCM housing 1403, an input section 1406 (for example, input section circuit 1), an output section 1407 (for example, circuit 1), an input section 1408 (for example, circuit 2), and an output section 1409 (for example, circuit 2) are arranged.

[0283] There are also sensors 1410. As shown in Figure 15a, there are preferably three sensors 1410. A first sensor is located towards the top end of the PCM housing 1403, a further sensor is located near the centre of the PCM housing 1403, and a further sensor is located towards the bottom end of the PCM housing 1403.

[0284] As shown in Figure 15a, there is a series of heating devices 1411 that extend substantially vertically in the PCM housing 1403. There can be any number of heating devices 1411, such as a single heating device or multiple heating devices. The embodiment shown in Figure 15a, which is merely an illustrative example, shows six heating devices 1411 arranged substantially vertically in the PCM housing 1403.

[0285] Figure 15b is an enlarged cross-sectional view of the heating device 1411. Figure 15b shows that the heating device 1411 includes a heating device network 1420 in a grid-like pattern. Within the grid section are tubular sections 1422 that provide efficient heat transfer. The tubular sections 1422 can be copper tubing. The heating device 1411 is in the form of fins 1430.

[0286] In the configuration shown in FIGS. 15a and 15b, during fabrication of the heat exchanger 1404, the normal fins are replaced with "heating fins," or heaters 1411. The location of the heating devices 1411 is determined, for example, by the aspect ratio, and the height of the heat battery 1400 and heating devices 1411 used can be selected to provide the desired power input depending on what thermal energy is required. The heating fins, in the form of the heating devices 1411, may be an integral part of the heat exchanger 1404 and therefore non-removable in certain embodiments. However, to ensure robustness of the heat battery, it is possible to install more extra heating fins, or heaters 1411, than are required for redundancy.

[0287] Due to the large heated surface area of ​​this design, the power density of each heating fin (ie, heating device 1411) is very low, improving the robustness and lifetime of the system.

[0288] Also, the density of the heater element network as shown in Figure 15b from the top to the bottom of the heating fins can be varied to optimize the heat storage and heat dissipation capabilities as suitable for the application.

[0289] 15a and 15b, a heating device 1411 may be used to replace the normal fins found in a heat exchanger. In certain embodiments, a positive temperature coefficient (PTC) heater may be used that may be slid onto a heat transfer tube, such as a copper tube, replacing the standard fins found in a heat exchanger.

[0290] Figure 16a shows a further embodiment of the invention in which there is shown a thermal battery 1500. In the embodiment shown in thermal battery 1500 there is a heating device in the form of a substantially vertically oriented low power vertical heater, for example in the form of a heat pipe or conductive rod, to assist in PCM circulation. This has been found to create a pumping action for the PCM material within the thermal battery.

[0291] The configuration shown in FIG. 15a has been found to have a number of technical advantages: 1) Increase the upward heat transfer from the base of the thermal battery to the core, optimizing the heat storage time. 2) Create a path for the molten PCM to travel and relieve any pressure buildup caused by the phase change and expanding PCM.

[0292] In the thermal battery 1500, there is a thermal battery case 1501 and an insulating layer 1502 disposed inside the thermal battery case 1501. There is also a PCM housing 1503 and a PCM 1505. There is also a heat exchanger 1504 and a heat exchanger core 1520.

[0293] In FIG. 16a, on the upper side of a PCM housing 1503, an input section 1506 (eg, input section circuit 1), an output section 1507 (eg, circuit 1), an input section 1508 (eg, circuit 2), and an output section 1509 (eg, circuit 2) are arranged.

[0294] There are also sensors 1510. As shown in Figure 16a, there are preferably three sensors 1510. A first sensor is located towards the upper end of the PCM housing 1503, a further sensor is located near the centre of the PCM housing 1503, and a further sensor is located towards the lower end of the PCM housing 1503.

[0295] There is a heat exchanger circuit 1504a (heat exchanger circuit 1) and a heat exchanger circuit 1504b (heat exchanger circuit 2).

[0296] 16a, a heating device 1511 is disposed on the bottom side of the PCM housing 1503. The heating device 1511 extends substantially across the bottom of the heat exchanger 1504.

[0297] 16a also shows that there are a plurality of substantially vertically oriented low-power vertical heaters 1512. The vertical heaters 1512 may be in the form of low-power heating devices or, alternatively, heat tubes. There may be any suitable number of vertical heaters 1512.

[0298] In the embodiment shown in thermal battery 1500 , there are four substantially vertically oriented heaters 1512 that extend from the top of PCM housing 1503 , through PCM 1505 , and into heat exchanger 1504 .

[0299] Figure 16b shows an enlarged cross-sectional view of a different type of vertical heater that may be used. On the left side of Figure 16b is a low-power heating device 1530. On the right side of Figure 16b is a heat tube 1540. Figure 16b shows that heat travels upward from the vertical heater and cooling flows downward through the vertical heater.

[0300] FIG. 17 illustrates a cross section of a louvered fin design generally designated 1600 in accordance with the present invention. The louvered fin design 1600 includes a series of tubes 1601 (e.g., copper tubes) that can be used to transfer heat. A PCM material flows through or around the tubes 1601. The flow of the PCM material is indicated by reference numeral 1603. As shown in FIG. 17, the flow of the PCM material can be controlled using louvers 1602a in the fins 1602. Thus, the fins 1602 can include louvers that can be substantially fully open. As such, they can be completely flat or can be switched to an angled configuration that can be used to control the flow of the PCM material. The louvered fin design 600 can be incorporated into any of the embodiments and thermal batteries described above.

[0301] While specific embodiments of the present invention have been described above, it should be understood that deviations from the described embodiments may still fall within the scope of the present invention. For example, any suitable type of housing may be used for the thermal battery. Additionally, any form of suitable PCM material and electronic control mechanism may be used. Furthermore, the heating device may be in any suitable form, such as electrically heated, or any other form of heating system contemplated within the scope of this application. Furthermore, any form of heat exchanger may be used in the thermal battery described in the present invention. Other possible claims (Item 1) a PCM thermal battery, a PCM housing capable of holding a PCM; a PCM disposed in the PCM housing; an electronic control system for controlling the PCM thermal battery; at least one or more heating devices disposed in said PCM thermal battery; Equipped with the at least one or more heating devices are capable of heating and / or storing heat in the PCM; PCM thermal battery. (Item 2) Item 1 , a PCM thermal battery according to item 1, wherein at least one or more heating device (e.g., electric heating) elements are integrally and / or internally disposed within the PCM battery. (Item 3) 3. The PCM thermal battery of any of items 1 or 2, wherein the at least one or more heating devices are disposed within the PCM housing and are therefore immersed in direct contact with the PCM. (Item 4) The PCM thermal battery of any of the preceding items, having at least 1, 2, 3, 4, 5, 6, or more heating devices. (Item 5) The PCM thermal battery of any of the preceding items, wherein the heating devices are positioned at different vertical positions within the PCM housing. (Item 6) A PCM thermal battery according to any of the preceding items, wherein the PCM thermal battery is charged with heat from an external primary heat source and the at least one or more heating devices are therefore secondary heat sources, allowing for very precise control of the heat charge and / or temperature of the PCM. (Item 7) The PCM thermal battery of any of the preceding items, wherein there is an outer casing for the entire PCM thermal battery and an insulating layer extending around the PCM housing. (Item 8) The PCM thermal battery of any of the preceding items, wherein the electronic control system controls the physical properties and / or temperature of the PCM by applying energy, such as heat, through the at least one or more heating devices. (Item 9) The PCM thermal battery according to any of the preceding items, wherein the PCM thermal battery is a dual-port thermal battery. (Item 10) The PCM thermal battery of any of the preceding items, wherein the PCM thermal battery includes a heat exchanger, which may optionally include fins, and the heat exchanger is disposed within the PCM housing. (Item 11) The PCM thermal battery of any of the preceding items, wherein the electronic control system includes a low power circuit (LPC) and a high power circuit (HPC) used to provide electrical connections for the PCM thermal battery. (Item 12) The PCM thermal battery of any of the preceding items, wherein the electronic control system includes an HPC input and an HPC output. (Item 13) The PCM thermal battery according to any of the preceding items, wherein there is a battery controller, along with a battery thermal storage status signal and a battery thermal storage control signal. (Item 14) The PCM thermal battery of any of the preceding items, wherein there is at least one or more sensors disposed in the PCM housing capable of monitoring physical characteristics and / or temperature of the PCM and other parts of the thermal battery. (Item 15) The PCM heat battery of any of the preceding items, including an overtemperature safety cutoff thermostat S0 and a series of temperature sensors distributed across different vertical positions of the heat battery to obtain temperatures throughout the working medium and across the PCM and / or heat exchanger. (Item 16) The PCM thermal battery of any of the preceding items, wherein the PCM thermal battery is a dual port design in which the heating device is in the form of a backup heater element, e.g., an electric heater element. (Item 17) The PCM thermal battery of any of the preceding items, wherein the heating device is disposed in the upper half of the PCM housing and immersed in the PCM. (Item 18) A PCM thermal battery as described in any of the above items, wherein the electronic control system includes a battery controller, allowing the heating device to be fully controlled and / or switched on and / or off when required, and the amount of power and / or heating provided by the heating device is also controlled (i.e., adapted and changed) in response to measurements of sensors located in the PCM housing and the PCM. (Item 19) The PCM heat battery of any of the preceding items, wherein there are multiple electric heating devices located at different heights within the PCM housing and / or PCM. (Item 20) The PCM thermal battery of any of the preceding items, wherein there is a first heating device disposed in the upper half of the PCM housing and a second heating device disposed in the lower half of the PCM housing, and both the first heating device and the second heating device are immersed in the PCM. (Item 21) The PCM heat battery of any of the preceding items, wherein there is at least one or more heating devices integral to and / or internally disposed in the PCM heat battery and immersed in the PCM below the heat exchanger. (Item 22) A PCM heat battery as described in any of the preceding items, wherein the PCM housing includes a step structure disposed on a lower end side of the heat battery and extending upward from the bottom of the PCM housing, the step structure providing a housing for heater element terminals and, optionally, a safety cutoff structure. (Item 23) A PCM thermal battery according to any of the above items, wherein the heating device is integrally arranged on the lower end side of the PCM housing, and the heating device is tubular in shape and arranged below the heat exchanger. (Item 24) The PCM thermal battery of any of the preceding items, wherein the heating device is a tubular, elongated heating device immersed in the PCM, the heating device being integrated into a bulkhead connecting ring to transfer heat to the PCM via a large surface area and provide instantaneous heating to the PCM. (Item 25) The PCM thermal battery of any of the preceding items, wherein there is a heat exchanger disposed within the PCM thermal battery and disposed inside the PCM housing and the PCM. (Item 26) The PCM heat battery of any of the preceding items, wherein there is at least one or more thermal conductors (e.g., metal rods or heat pipes) inserted substantially vertically into the heat battery and heat exchanger and extending into and immersed in at least a portion of the PCM. (Item 27) A PCM thermal battery according to any of the preceding items, wherein there is at least one or more heating devices arranged on a lower end side of the heat exchanger, the heating devices being arranged substantially horizontally along the bottom side of the PCM housing. (Item 28) A PCM heat battery as described in any of the preceding items, having a heat plate (e.g., a conductive heat plate such as a metal plate) that is substantially vertically oriented and extends or at least partially extends into the heat exchanger core (e.g., a heat exchanger finned core) and extends below the heat exchanger or substantially below into the heated region of the heat battery. (Item 29) The PCM heat battery of any of the preceding items, wherein there is at least one or more non-planar heating devices (e.g., substantially L-shaped electric heating devices) embedded in the heat exchanger core. (Item 30) 30. The PCM thermal battery of claim 29, wherein the non-planar heating device (e.g., a substantially L-shaped heating device) includes a substantially vertical portion extending downwardly through the PCM and has at least one or more substantially horizontally disposed portions extending substantially tangentially from the substantially vertical portion. (Item 31) Item 31. The PCM heat battery of item 30, wherein a first substantially horizontally disposed portion extends along a bottom quarter of the heat exchanger core, a second horizontally disposed portion extends substantially through a central portion of the heat exchanger core, and a third horizontally disposed portion extends through an top quarter of the heat exchanger core. (Item 32) 32. The PCM heat battery of any of items 30 or 31, wherein the substantially horizontally disposed portion is embedded or at least partially embedded within a heat exchanger core (e.g., a finned core of a fin-tube heat exchanger). (Item 33) The PCM thermal battery of any of the preceding items, wherein there is at least one or more heating devices (e.g., electrically heated tubular heaters) embedded in a heat exchanger core including a conductive element, e.g., a conductive tube such as a copper tube. (Item 34) 34. The PCM heat battery of any of claims 33, wherein the at least one or more electric heating devices are embedded in a manifold of the PCM heat battery. (Item 35) 34. The PCM thermal battery of claim 33, wherein the heating device is embedded in a circuit that extends substantially horizontally across the heat exchanger core. (Item 36) 36. The PCM thermal battery of claim 35, wherein the circuit is embedded in a heat exchanger. (Item 37) 37. The PCM thermal battery of any of items 35 and 36, wherein there is a passageway extending around the circuit, and at least one or more heating devices extend around the circuit. (Item 38) The PCM thermal battery of any of the preceding items, having at least one or more heating devices embedded and / or disposed in a housing comprising a material capable of efficiently transferring and / or dissipating heat. (Item 39) Item 39. The PCM thermal battery of item 38, wherein the material in the housing is oil and / or thermal grease. (Item 40) 40. The PCM thermal battery of any of items 38 and 39, wherein the housing is integral with the PCM enclosure and the heating device does not directly contact the PCM. (Item 41) 41. The PCM thermal battery according to any one of items 38 to 40, wherein the heating device is a tubular electric heater embedded in a housing filled with oil and / or thermal grease. (Item 42) The PCM thermal battery of any of the preceding items, wherein at least one or more heating devices are disposed outside the PCM housing, inside an outer casing for the PCM thermal battery. (Item 43) Item 43. The PCM thermal battery of item 42, wherein a conductive block is disposed within the PCM housing capable of inducing a current through an induction heater disposed substantially below and outside the PCM housing. (Item 44) 44. A PCM heat battery according to either item 42 or 43, wherein the heating device is positioned on the lower end side of the PCM housing, typically below (i.e., substantially below) the heat exchanger core (e.g., heat exchanger finned core). (Item 45) 45. The PCM thermal battery of any of items 42 to 44, wherein the heating device in the form of the conduction block is heated by an induction heater located externally, outside the PCM housing. (Item 46) Item 46. The PCM thermal battery of item 45, wherein the conduction block is disposed internally inside the PCM housing above or substantially above the induction heater. (Item 47) The PCM thermal battery of any of the preceding items, wherein there is an internally immersed conductive block integral to said thermal battery that is heated via at least one or more removable cartridge heaters. (Item 48) Item 48. A PCM thermal battery as described in item 47, having at least one or more removable cartridge heating devices disposed within an internally immersed conductive block, the conductive block being located within the PCM housing below the heat exchanger. (Item 49) 49. A PCM thermal battery according to any of items 47 and 48, wherein the conduction block is made of a thermally conductive material that extends along the bottom of the PCM housing and is positioned below (i.e., underneath) the heat exchanger core and the PCM. (Item 50) 50. The PCM thermal battery of any of claims 47 to 49, wherein the cartridge heater comprises a thermally conductive metal and / or alloy block disposed internally within the PCM housing and capable of efficiently transferring heat. (Item 51) The PCM heat battery of any of the preceding items, including an impeller agitator to mix the PCM and aid in heat transfer via forced convection. (Item 52) The PCM thermal battery of any of the preceding items, wherein the heating device is in the form of a heater element network. (Item 53) Item 53. The PCM thermal battery of item 52, wherein the heater element network includes a grid portion with a conductive tubular portion therein that provides efficient heat transfer. (Item 54) The PCM thermal battery of any of the preceding items, wherein the heating device includes an expansion member (e.g., fins) that aids in dissipating and / or transferring heat. (Item 55) The PCM thermal battery of any of the preceding items, wherein the heating device includes a positive temperature coefficient (PTC) heater that slides onto the heat transfer tube. (Item 56) 10. The PCM heat battery of claim 1, wherein the heating device is in the form of a substantially horizontally oriented low-power vertical heater that extends substantially across the bottom of the heat exchanger. (Item 57) The PCM thermal battery of any of the preceding items, wherein the heating device is in the form of a substantially vertically oriented low-power vertical heater. (Item 58) Item 58. The PCM heat battery of item 57, wherein the substantially vertically oriented low-power vertical heater is a heat pipe or conductive rod that aids in PCM circulation and creates a pumping action for the PCM material in the heat battery. (Item 59) 59. The PCM thermal battery of either item 57 or 58, wherein the substantially vertically oriented heater extends from a top surface of the PCM housing through the PCM to a heat exchanger. (Item 60) The PCM heat battery according to any of the preceding items, wherein the heat battery includes louvered fins. (Item 61) Item 61. The PCM thermal battery of item 60, wherein the louvered fins comprise a series of tubes (e.g., copper tubes) used to transfer heat, through which the PCM material flows and around which can be controlled using the louvers in the fins. (Item 62) 1. A method of adding thermal energy to a PCM thermal battery, comprising: providing a PCM housing capable of holding a PCM; providing a PCM disposed in the housing; providing an electronic control system for said PCM thermal battery; providing at least one or more heating devices disposed in the PCM housing and immersed in the PCM; Including, The method, wherein the at least one or more heating devices are capable of heating and / or storing heat in the PCM.

Claims

1. A phase change material thermal battery (PCM thermal battery), comprising: a PCM housing capable of holding a PCM; a PCM disposed in the PCM housing; a heat exchanger disposed within the PCM thermal battery and disposed inside the PCM housing and the PCM, the heat exchanger configured to transfer thermal energy between the PCM and a working medium; an electronic control system for controlling the PCM thermal battery; at least one or more heating devices disposed in the PCM thermal battery, the at least one or more heating devices being capable of heating and / or storing heat in the PCM; a plurality of sensors located at different vertical positions on the PCM housing of the PCM thermal battery capable of monitoring the temperature of the PCM and other portions of the PCM thermal battery; Equipped with the at least one or more heating devices are disposed within the PCM housing and are therefore immersed in direct contact with the PCM; at least one or more thermal conductors inserted substantially vertically into the PCM thermal battery and immersed or partially immersed in the PCM; the at least one or more heat conductors are disposed substantially vertically in the heat exchanger, extend into the PCM, and are not in direct contact with the at least one or more heating devices; the electronic control system controls the temperature of the PCM by applying heat directly to the PCM through the at least one or more heating devices based on measurements from the plurality of sensors. Phase change material thermal battery (PCM thermal battery).

2. The phase change material thermal battery (PCM thermal battery) of claim 1 , wherein there are heating devices located at different vertical positions within the PCM housing.

3. 3. The phase change material thermal battery (PCM thermal battery) of claim 1 or 2, further comprising a thermal insulation layer extending around the periphery of the PCM housing.

4. 4. A phase change material heat battery (PCM heat battery) according to any one of claims 1 to 3, wherein the heating device is a back-up heater element in the form of an electric heater element.

5. The phase change material thermal battery (PCM thermal battery) of claim 1 , wherein the heat exchanger comprises fins.

6. 6. A phase change material thermal battery (PCM thermal battery) according to any one of claims 1 to 5, wherein the heat exchanger comprises a first heat exchange circuit and a second heat exchange circuit, each including an input and an output.

7. 7. A phase change material heat battery (PCM heat battery) as described in any one of claims 1 to 6, wherein the heating device is integrally arranged on the lower end side of the PCM housing, the heating device is tubular in shape and is arranged below the heat exchanger.

8. The phase change material thermal battery (PCM thermal battery) of any one of claims 1 to 7, further comprising a battery controller configured to output a battery thermal storage status signal and a battery thermal storage control signal.

9. A phase change material thermal battery (PCM thermal battery) as described in any one of claims 1 to 8, wherein the multiple sensors are positioned throughout different vertical positions of the PCM thermal battery to obtain temperatures throughout the working medium, the PCM, and / or the heat exchanger.

10. 7. A phase change material thermal battery (PCM thermal battery) according to any one of claims 1 to 6, wherein the heating device is located in the top half of the PCM housing and immersed in the PCM.

11. 11. A phase change material thermal battery (PCM thermal battery) as claimed in any one of claims 1 to 10, wherein the electronic control system includes a battery controller and enables the heating device to be fully controlled and / or switched on and / or off when required, and the amount of power and / or heating provided by the heating device is also controlled depending on measurements of sensors located in the PCM housing and the PCM.

12. 12. A phase change material thermal battery (PCM thermal battery) according to any one of claims 1 to 11, wherein there are multiple electric heating devices arranged at different heights within the PCM housing and / or the PCM.

13. 13. A phase change material thermal battery (PCM thermal battery) as described in any one of claims 1 to 12, wherein there is at least one or more heating devices arranged on the lower end side of the heat exchanger, and the heating devices are arranged substantially horizontally along the bottom side of the PCM housing.

14. 1. A method of adding thermal energy to a phase change material thermal battery (PCM thermal battery), comprising: providing a PCM housing capable of holding a PCM; providing a PCM disposed in the PCM housing; providing a heat exchanger disposed within the PCM thermal battery and disposed inside the PCM housing and the PCM, the heat exchanger configured to transfer thermal energy between the PCM and a working medium; providing an electronic control system for controlling the PCM thermal battery; providing at least one or more heating devices disposed in the PCM housing and immersed in the PCM, the at least one or more heating devices being capable of heating and / or storing heat in the PCM; providing a plurality of sensors positioned at different vertical positions in the PCM housing of the PCM thermal battery capable of monitoring the temperature of the PCM and other portions of the PCM thermal battery; Including, the at least one or more heating devices are disposed within the PCM housing and are therefore immersed in direct contact with the PCM; at least one or more thermal conductors inserted substantially vertically into the PCM thermal battery and immersed or partially immersed in the PCM; the at least one or more heat conductors are disposed substantially vertically in the heat exchanger, extend into the PCM, and are not in direct contact with the at least one or more heating devices; the electronic control system controls the temperature of the PCM by applying heat through the at least one or more heating devices based on measurements from the plurality of sensors. method.

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