Energy storage devices and methods

Abstract

An energy storage device comprising a heat storage module configured to receive a heat transfer medium, a packed thermal bed positioned within the heat storage module, a first plenum defined in the heat storage module at one end of the heat storage module, and a second plenum defined in the heat storage module at another end of the heat storage module is disclosed. The packed thermal bed comprising a layer of material comprising concrete.

Description

Patent ApplicationAttorney Docket No. WEC-2024-158-PCTTITLEENERGY STORAGE DEVICES AND METHODSFIELD

[0001] The present disclosure is generally related to energy storage devices and methods, more particularly, is directed toward to facilitating the storage of energy using a thermal bed to store heat from a heat transfer medium.CROSS-REFERENCE TO RELATED APPLICATION

[0002] This application claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Application Serial No. 63 / 733,911, entitled ENERGY STORAGE DEVICES AND METHODS, filed December 13, 2024, the disclosure of which is incorporated by reference herein in its entirety.BACKGROUND

[0003] The creation of energy storage to levelize power on the electrical grid, avoiding the need for large amounts of spinning reserve, has been an extreme challenge. Due to an ever-increasing deployment of non-dispatchable renewable energy devices, like solar photovoltaic cells and wind turbines, grid stability has suffered. Traditional energy storage solutions, such as pumped storage and batteries, have either exhausted their capacity or are prohibitively difficult to cite due to environmental concerns. By storing energy as heat, either from a heat pump arrangement or from the sources of heat used to generate electricity, created just prior to the generation of electricity, rather than the storing of electricity, relatively low-cost storage may be achieved and utilized by a reactor in a nuclear power plant. Thermal storage in and of itself is not new, but what has been elusive is a design that can efficiently store energy in relatively low-cost reservoirs using common materials, rather than expensive salts or geologic formations, which may not exist everywhere. Accordingly, there may be a need to provide a low-cost, scalable energy storage device that is constructed from common, easily acquired materials.

[0004] Example energy storage devices are described in U.S. Patent No. 11,248,851 and U.S. Patent No. 11,692,778, the entirety of both of these are hereby incorporated by reference herein in their entirety.SUMMARY

[0005] The following summary is provided to facilitate an understanding of some of the innovative features unique to the aspects disclosed herein, and is not intended to be a full description. A full appreciation of the various aspects can be gained by taking the entirePatent ApplicationAttorney Docket No. WEC-2024-158-PCT specification, claims, and abstract as a whole.

[0006] In various aspects, an energy storage device comprising a heat storage module configured to receive a heat transfer medium, a packed thermal bed positioned within the heat storage module, a first plenum defined in the heat storage module at one end of the heat storage module, and a second plenum defined in the heat storage module at another end of the heat storage module is disclosed. The packed thermal bed comprises a layer of material comprising concrete. The energy storage device is configured to operate in one of a charging mode of operation or a discharging mode of operation. The charging mode of operation is characterized by receipt, by the first plenum, of the heat transfer medium from a source and distribution of the heat transfer medium through the layer of material, an exit of the heat transfer medium from the heat storage module through the second plenum to a storage location, and a transfer of a portion of heat in the heat transfer medium to the layer of material in the charging mode of operation of the energy storage device. The discharging mode of operation is characterized by receipt, by the second plenum, of the heat transfer medium from the storage location and distribution of the heat transfer medium through the layer of material, an exit of the heat transfer medium from the heat storage module through the first plenum to the source, and a transfer of a portion of heat in the layer of material to the heat transfer medium in the discharging mode of operation of the energy storage device.

[0007] In various aspects, a method of storing thermal energy comprising directing a heat transfer medium over a face of and through a plurality of heat transfer layers of a heat storage module, wherein at least one layer of the plurality of heat transfer layers comprises concrete packed together to form a packed thermal bed, and wherein the heat storage module defines a first plenum at one end and a second plenum at another end is disclosed. The method of storing thermal energy comprising transferring heat from one of the heat transfer medium to the heat transfer layers upon entry of the heat transfer medium into the heat storage module through the first plenum and exiting the heat transfer medium from the heat storage module through the second plenum in a charging mode of operation, or the heat transfer layers to the heat transfer medium upon entry of the heat transfer medium into the heat storage module through the second plenum and exiting the heat transfer medium from the heat storage module through the first plenum in a discharging mode of operation.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Various features of the aspects described herein are set forth with particularity in the appended claims. The various aspects, however, both as to organization and methods of operation, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

[0009] FIG. 1 is a perspective view of an energy storage device, in accordance with atPatent ApplicationAttorney Docket No. WEC-2024-158-PCT least one aspect of the present disclosure;

[0010] FIG. 2 is a cross section view of the energy storage device of FIG. 1, in accordance with at least one aspect of the present disclosure;

[0011] FIG. 3 is a perspective view of a plurality of superellipsoids packed together, in accordance with at least one aspect of the present disclosure;

[0012] FIG. 4 is a cross section view of another energy storage device, depicting accumulators and pumps for use with the energy storage device, in accordance with at least one aspect of the present disclosure; and

[0013] FIG. 5 is a cross section view of a portion of a plate formed of concrete, in accordance with at least one aspect of the present disclosure.

[0014] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate various aspects of the disclosure, in one form, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.DETAILED DESCRIPTION

[0015] Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the aspects as described in the disclosure and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the aspects described in the specification. The reader will understand that the aspects described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims. Furthermore, it is to be understood that such terms as "forward", "rearward", "left", "right", "upwardly", "downwardly", and the like are words of convenience and are not to be construed as limiting terms.

[0016] Before explaining various aspects of the methods and devices for energy storage in detail, it should be noted that the illustrative examples are not limited in application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative examples may be implemented or incorporated in other aspects, variations, and modifications, and may be practiced or carried out in various ways. Further, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative examples for the convenience of the reader and are not for the purpose of limitation thereof. Also, it will be appreciated that one or more of the following-described aspects, expressions of aspects, and / or examples, can be combined with any one or more of the other following-described aspects, expressionsPatent ApplicationAttorney Docket No. WEC-2024-158-PCT of aspects, and / or examples.

[0017] FIGS. 1 and 2 illustrates an energy storage device 100, or high temperature reservoir, for storing energy. The energy storage device 100 includes a vessel 110. In one embodiment, the vessel 110 is a large, double-walled tank. In various embodiments, the vessel 110 is externally insulated. A heat storage module 120 (e.g., heat transfer reservoir) is positioned within the vessel 110 and a thermal bed 130 is positioned within the heat storage module 120. In various embodiments, the thermal bed 130 includes one or more than one layer 131 of material.

[0018] In one embodiment, one of the one or more than one layer 131 of material is a layer of manufactured, or engineered, concrete 132. In various embodiments, the engineered concrete is in the form of a plurality of individual pieces of concrete, each of the individual pieces manufactured with a specific shape designed to increase the random order packing fraction. The engineered concrete 132 is placed into the vessel 110 to form a layer of material of the thermal bed 130. In various embodiments, individual pieces of engineered concrete are compressed, or packed, together to form a packed thermal bed. As discussed in greater detail below, the engineered concrete may be of various sizes, shapes, configurations, and / or packed in different manners.

[0019] In an alternative embodiment, one of the one or more than one layer 131 of material is a slab, or plate 200. Referring to FIG. 5, the plate 200 includes a base 210 and a plurality of protrusions 220 extending from the base 210. The protrusions 220 may be substantially cubic in shape with filleted edges 222. In some embodiments, the protrusions 220 may be a different shape than cubic. For example, the protrusions may be cylindrical or they may be a combination of different cylindrical sizes. In one embodiment, outer most edges 240 of the plate 200 may terminate in a square profile (e.g., an irregular pentagon). Further, each protrusion 220 is separated from an adjacent protrusion by a channel 230 defined by the plate 200. In one embodiment, the plate 200 may be an approximately two foot by two foot plate that is approximately 0.75 inch to 1.5 inch thick. In one embodiment, the plate 200 may be manufactured by hydraulicly pressing concrete material together to form the plate 200. In one embodiment, the plate 200 may be manufactured using a wet casting operation. The channels 230 may be formed as part of the hydraulic pressing operation or the wet casting operation to form an ordered packing arrangement of thermal mass with the channels 230 providing for flow of a medium around the individual protrusions 220.

[0020] In various embodiments, a plurality of the plates 200 are stacked together vertically during manufacture / packaging and then coarse sand (e.g., fine aggregate) may be positioned or forced into the channels 230 to further reduce void fraction and increase convective heat transfer. When stacked vertically, the protrusions 220 extend verticallyPatent ApplicationAttorney Docket No. WEC-2024-158-PCT relative to the vessel with the channels 230 extending horizontally relative to the vessel and ground, for example. Further, the stacked plates 200 may be wrapped in a wire containment to tightly bind and hold the plates 200 and sand together. To load the plates 200 and sand into the vessel 110, the plurality of the plates 200 wrapped in the wire containment may be flipped on their side (e.g., oriented horizontally to the ground) such that the channels 230 are oriented vertical relative to the vessel 110. In one embodiment, after the plates 200 are loaded into the vessel 110, they may be packed together to form a packed thermal bed comprised of the plurality of plates 200 and sand. In one embodiment, the base 210 of each plate 200 is a thin layer formed during the casting I hydraulic pressing of the plate 200. In one embodiment, the base 210 acts as a cast-in-place form. In various aspects, the protrusions 220 may break away from the base 210 during loading or packing of the plates 200 within the vessel 110. The protrusions 220 breaking away from the base 210 may permit slight movement of the protrusions 220 relative to each other. As such, once the plurality of the plates 200 are loaded into the vessel 110, the protrusions 220 may break away from the base 210 resulting in a highly ordered bed as compared to a randomly ordered bed, for example. In one embodiment, after the protrusions 220 break away from the base 210, the protrusions 220, bases 210, and sand may be packed together by tamping or vibrating the materials within the vessel 110.

[0021] Referring to FIG. 2, in one embodiment, the engineered concrete 132 has a higher random order packing fraction than a natural crushed aggregate. In one embodiment, the engineered concrete 132 comprises ultra-high performance concrete. In various embodiments, the engineered concrete 132 is manufactured using one or more than one water-reducing add mixtures. In at least one embodiment, the engineered concrete layer can be directly submerged in a heat transfer medium, thus greatly reducing the effective cost of the thermal interface. By the use of engineered concrete, such as the types described herein, a specific shape and surface finish is permitted that gives lower oil fraction (reducing costs), near 100% oil wetting, low-to-no porosity, and consistent, desirable, and engineered (high performance) properties. In one embodiment, the engineered concrete is comprised of a plurality of superellipsoids 139 packed together. In one embodiment, the superellipsoids 139 are positioned together and tightly bound with a wire containment 140. A representation of a plurality of superellipsoids packed together, such as they would be within the layer of engineered concrete 132 of the thermal bed 130, is illustrated in FIG. 3. The super-ellipsoid approximates both elements of a sphere and cube, while having no flat surfaces, thus maximizing heat transfer area. In one embodiment, the superellipsoids are defined by the following equation:Patent ApplicationAttorney Docket No. WEC-2024-158-PCT

[0022] In the above equation m is the shape parameter, and a, b, and c, are the semimajor axis lengths as described in “The packing properties of superellipsoids” authored by G. W. Delaney and P. W. Cleary which was published in the EPL A letters Journal Exploring the Frontiers of Physics in February 2010 which is attached as Appendix A. In one embodiment, each of the superellipsoids 139 is defined by the above equation with m greater than or equal to 4 and less than or equal to 6 and a = 1. In one embodiment, m = 5 and a = 1, for example.

[0023] Further to the above, in one embodiment, the employment of finer interstitial fills may be used, to further reduce void fraction. For example, the thermal bed 130 may include additional pieces, fragments, or granules of crushed concrete, and / or natural aggregates of concrete 138 intermixed within the layer of engineered concrete 132. In one embodiment, the crushed concrete and / or natural aggregates of concrete 138 are smaller (e.g., finer in size) than the individual pieces that form the layer of engineered concrete 132. In at least one embodiment, the packing fraction of a thermal bed including the engineered concrete 132 and the crushed concrete and / or natural aggregates of concrete 138 has a higher random order packing faction than a thermal bed having the engineered concrete 132 that does not include crushed concrete and / or natural aggregates of concrete 138.

[0024] Further to the above, in one embodiment, the thermal bed 130 includes a first, or upper layer of material 134 and a second, or lower layer of material 136 with the layer of material 131 positioned between the upper layer of material 134 and the lower layer of material 136. In an alternative embodiment, only one additional layer 134, 136 may be positioned above or below the first layer of material 131 which may be the layer of engineered concrete 132 or the plurality of stacked plates 200. In one embodiment, the upper layer of material 134 and the lower layer of material 136 may be comprised of a different material than the layer of material 131. In one embodiment, the upper layer of material 134 and the lower layer of material 136 may comprise the same material and / or the same mixture of materials. In an alternative embodiment, the upper layer of material 134 and the lower layer of material 136 are different. In one embodiment, the upper layer of material 134 and / or the lower layer of material 136 are comprised of a material having a heat transfer capability that is greater than a heat transfer capability of the layer of engineered concrete 132 and / or the heat transfer capability of the plurality of stacked plates 200.

[0025] Further to the above, in various embodiments, the energy storage devices 100Patent ApplicationAttorney Docket No. WEC-2024-158-PCT may include one or more than one layer of the thermal bed 130 having an encapsulated phase change material, with the characteristic of a constant temperature heat exchange. The one or more than one layer with encapsulated phase change material can reduce thermocline degradation across multiple cycles and aim to reduce total overbuild and, thus, cost of the energy storage devices 100. In various embodiments, the upper layer of material 134 and / or the lower layer of material 136 comprise a plurality of capsules. The plurality of capsules contain one or more than one phase change material configured to melt at a predetermined temperature to release stored energy when raised above the predetermined temperature. In one embodiment, the predetermined temperature is the temperature of a heat transfer medium that flows through the upper layer 134 and / or the lower layer 136 of material around the phase change capsules positioned therein.

[0026] Further to the above, in various embodiments, the upper layer of material 134 and / or the lower layer of material 136 comprise a plurality of metallic granules. In one aspect, the metallic granules are thermally conductive. In various embodiments, the metallic granules have a higher thermal conductivity than the engineered concrete 132 and / or the crushed concrete and / or the natural aggregates of concrete 138.

[0027] Further to the above, the energy storage device 100 includes a first plenum 112 defined in the heat storage module 120 at one end of the heat storage module 120, and a second plenum 114 defined in the heat storage module 120 at another end of the heat storage module 120. In one embodiment, the first plenum 112 is above the second plenum 114, and the plenums 112, 114 are positioned on opposite sides of the heat storage module 120 directly across from each other. In an alternative embodiment, the plenums 112, 114 may not be positioned directly across from each other. The heat storage module 120 is configured to receive a heat transfer medium, initially, through the first plenum 112 from a source 150. In one embodiment, the heat transfer medium moves through the heat storage module 120 and exits the heat storage module 120 through the second plenum 114 to a storage location 160.

[0028] Further to the above, in one embodiment, the heat transfer medium is a nontoxic, non-hazardous heat transfer fluid (HTF). In various aspects, the HTF has a high autoignition point (e.g., well above any operational temperature of the energy storage device 100) and / or a high fire point (e.g., 306 degrees Celsius). In one embodiment, the heat transfer medium is an oil, or similar.

[0029] Referring to FIG. 4, an energy storage device 100’ is illustrated. The energy storage device 100’ is similar to the energy storage device 100, except for the differences discussed herein. The energy storage device 100’ includes a first accumulator 155 and a first pump 157 positioned between the source 150 of the heat transfer medium and the first plenum 112. Further, the energy storage device 100’ includes a second accumulator 165Patent ApplicationAttorney Docket No. WEC-2024-158-PCT and a second pump 167 positioned between the storage location 160 and the second plenum 114. In one embodiment, the first accumulator 155 and the second accumulator 165 are storage tanks configured to store an accumulation of the heat transfer medium which can then be pumped, by way of respective pumps 157, 167 into the heat storage module 120 bi-directionally. In one embodiment, only one of the accumulators 155, 165 and pumps 157, 167 is employed for use with the heat storage module 120.

[0030] Further to the above, the energy storage devices 100, 100’ are configured to operate in one of a charging mode of operation or a discharging mode of operation. In an alternative, embodiment, the energy storage devices 100, 100’ are configured to operate in both the charging mode of operation and the discharging mode of operation. In any event, in the charging mode of operation, the first plenum 112 receives the heat transfer medium from the source 150 and distributes the heat transfer medium through the one or more than one layer of material of the thermal bed 130, and the heat transfer medium exits the heat storage module 120 through the second plenum 114 to the storage location 160. In the charging mode of operation, the heat transfer medium flows in direction FDi. A portion of heat in the heat transfer medium is transferred to the layer of material in the charging mode of operation of the energy storage devices 100, 100’. Further, in the discharging mode of operation, the second plenum 114 receives the heat transfer medium from the storage location 160 and distributes the heat transfer medium through the one or more than one layer of material of the thermal bed 130, and the heat transfer medium exits the heat storage module 120 through the first plenum 112 to the source 150. In the discharging mode of operation, the heat transfer medium flows in direction FD2. A portion of heat in the one or more than one layer of material of the thermal bed 130 is transferred to the heat transfer medium in the discharging mode of operation of the energy storage device 100, 100’.

[0031] In various embodiments, in the charging mode of operation, the source 150 initially supplies the heat transfer medium to the heat storage module 120 and the heat transfer medium is eventually stored in the storage location 160. Further, in the discharging mode of operation, the storage location 160 initially supplies the heat transfer medium to the heat storage module 120 and the heat transfer medium is eventually received, or stored, in the source 150. As such, in various embodiments, the source 150 may act as storage location for the heat transfer medium in the discharging mode of operation and the storage location 160 may act as a source of the heat transfer medium in the charging mode of operation.

[0032] As discussed above, the energy storage device 100’ includes the first and second accumulators 155, 165 and the first and second pumps 157, 167. In one embodiment, the accumulators 155, 165 accumulate and store the heat transfer medium prior to the heat transfer medium entering the heat storage module 120. In such instances, the pumps 157,Patent ApplicationAttorney Docket No. WEC-2024-158-PCT167 are configured to pulse the flow of the heat transfer medium through the heat storage module 120. For example, in the charging mode of operation, the first accumulator 155 accumulates the heat transfer medium and the first pump 157 pulses the flow of the heat transfer medium into the heat storage module 120 and through the one or more than one layer of material of the thermal bed 130. Similarly, in the discharging mode of operation, the second accumulator 165 accumulates the heat transfer medium and the second pump 167 pulses the flow of the heat transfer medium into the heat storage module 120 and through the one or more than one layer of material of the thermal bed 130. In at least one embodiment, the average flow rate across the heat storage module 120 of the energy storage device 100’ is the same as the average flow rate across the heat storage module 120 of the energy storage device 100. In other words, the pumps 157, 167 are configured to pulse the flow of the heat transfer medium across the heat storage module 120 of the energy storage device 100’ such that the average flow rate of the heat transfer medium across the heat storage module 120 of the energy storage device 100’ is the same as the average flow rate of the heat transfer medium across the heat storage module 120 of the energy storage device 100 which does not include the pumps 157, 167.

[0033] Further to the above, in one embodiment, the heat storage module 120 of the energy storage device 100’ includes a circulator pump 180 fluidly connected to the vessel 110 intermediate the first plenum 112 and the second plenum 114. The circulator pump 180 is configured to circulating the heat transfer medium within the heat storage module 120.

[0034] As discussed above, the heat transfer medium flow is bi-directional such that a “thermal wave” can be moved through the thermal bed 130. In various aspects, this is done in a manner such that the natural thermocline of the heat transfer medium is also complementary to the thermal profile of the thermal bed 130. In various aspects, during the charging mode of operation, hot heat transfer medium is pumped into the top of the vessel 110 and heats the thermal bed 130 in a top-down manner. This lowers the temperature of the heat transfer medium such that it exits the vessel 110 (e.g., through the second plenum 114) at a low-point temperature. As the elements of the thermal bed 130 saturate in temperature and the thermal wave reaches close to the bottom of the vessel 110, the outlet temperature starts to trend upwards. This can signify the end of charging. The discharge mode of operations is a reverse of charging mode of operation process, where cold heat transfer medium is pumped into the bottom of the vessel 110 and hot heat transfer medium leaves from the top of the vessel 110. The vessel 110 may be designed such that two-walled construction provides part of the insulating value and also serves as primary containment for a heat transfer medium leak in the walls of the vessel 110. In various embodiments, the energy storage devices 100, 100’ can include a series of platforms and ladders to permit inspection at a low-temperature maintenance condition. In one embodiment, the vessel 110Patent ApplicationAttorney Docket No. WEC-2024-158-PCT of the energy storage devices 100, 100’ may be inerted and leak detection is installed.

[0035] Further to the above, in one embodiment, concrete mixes and materials of various construction may be engineered together to control differential expansion rates. Further, the use of layered walls, employing foam glass or similar insulation in a sandwich, within the wall of the vessel 110 can limit the vessel 110 wall expansion due to thermal expansion relative to the thermal bed 130. In such instances, thermal ratcheting may be reduced and / or eliminated. In various embodiments, internal cage-like structures may also be employed to limit direct contact between the thermal bed 130 and the vessel 110 wall.

[0036] Further to the above, in various embodiments, the energy storage devices 100, 100’ may include a non-cementitious layer or region in the thermal bed 130. In at least one embodiment, the non-cementitious layer may include an encapsulated phase change material such as those described herein. In various embodiments, the use of the non- cementitious layer in the thermal bed 130 may reduce the size of the vessel 110 and increase the performance of the energy storage device 100, 100’ across the full charge or discharge event. In various aspects, the non-cementitious layer may include a material that has a better heat transfer properties, e.g., a higher thermal conductivity, than the layer of engineered concrete 132. In at least one embodiment, the non-cementitious layer may be steel and / or another metallic material (e.g., iron ores, etc.). In various embodiments, the non- cementitious layer would flatten transients as the thermal bed 130 fills (increasing outlet temperatures) or empties (decreasing outlet temperatures). In various embodiments, one or more than one layer of the thermal bed 130 may comprise a plurality of non-cementitious superellipsoids and / or non-cementitious spherical balls. In various embodiments, the non- cementitious superellipsoids and / or non-cementitious spherical balls may be metal. In various embodiments, the non-cementitious superellipsoids and / or non-cementitious spherical balls have a higher thermal conductivity than the engineered concrete 132 and / or the crushed pieces of concrete and / or natural aggregates of concrete 138

[0037] Various aspects of the present disclosure include, but are not limited to, the aspects listed in the following numbered clauses.

[0038] Clause 1 - An energy storage device comprising a heat storage module configured to receive a heat transfer medium, a packed thermal bed positioned within the heat storage module, a first plenum defined in the heat storage module at one end of the heat storage module, and a second plenum defined in the heat storage module at another end of the heat storage module. The packed thermal bed comprises a layer of material comprising concrete. The energy storage device is configured to operate in one of a charging mode of operation or a discharging mode of operation. The charging mode of operation is characterized by receipt, by the first plenum, of the heat transfer medium from a source and distribution of the heat transfer medium through the layer of material, an exit ofPatent ApplicationAttorney Docket No. WEC-2024-158-PCT the heat transfer medium from the heat storage module through the second plenum to a storage location, and a transfer of a portion of heat in the heat transfer medium to the layer of material in the charging mode of operation of the energy storage device. The discharging mode of operation is characterized by receipt, by the second plenum, of the heat transfer medium from the storage location and distribution of the heat transfer medium through the layer of material, an exit of the heat transfer medium from the heat storage module through the first plenum to the source, and a transfer of a portion of heat in the layer of material to the heat transfer medium in the discharging mode of operation of the energy storage device.

[0039] Clause 2 - The energy storage device of clause 1 , wherein the layer of material is engineered concrete comprising a higher random order packing fraction than natural crushed aggregate.

[0040] Clause 3 - The energy storage device of clause 2, wherein the engineered concrete comprises a plurality of superellipsoids.

[0041] Clause 4 - The energy storage device of clause 2 or 3, wherein the engineered concrete comprises ultra-high performance concrete.

[0042] Clause 5 - The energy storage device of clauses 2, 3, or 4, wherein the packed thermal bed comprises an interstitial fill that is more fine in size than the engineered concrete.

[0043] Clause 6 - The energy storage device of clauses 2, 3, 4, or 5, wherein the layer of material comprises a natural aggregate of concrete intermixed with the engineered concrete, and wherein the natural aggregate of concrete is more fine in size than the engineered concrete.

[0044] Clause 7 - The energy storage device of clauses 1, 2, 3, 4, 5, or 6, further comprising an accumulator and a pump to pulse the flow of the heat transfer medium into the heat storage module.

[0045] Clause 8 - The energy storage device of clauses 1, 2, 3, 4, 5, 6, or 7, wherein the heat storage module further comprises a pump to aid in circulating the heat transfer medium within the heat storage module.

[0046] Clause 9 - The energy storage device of clauses 1 , 2, 3, 4, 5, 6, 7, or 8, wherein the layer of material is a first layer of material and the packed thermal bed comprises an upper layer of material and a lower layer of material, wherein the first layer of material is positioned between the upper layer of material and the lower layer of material, and wherein the upper layer of material and the lower layer of material are different from the first layer of material.

[0047] Clause 10 - The energy storage device of clause 9, wherein the upper layer of material or the lower layer of material comprises a material having a heat transfer capability that is greater than a heat transfer capability of the first layer of material.Patent ApplicationAttorney Docket No. WEC-2024-158-PCT

[0048] Clause 11 - The energy storage device of clause 9, wherein the upper layer of material or the lower layer of material comprises a plurality of capsules containing a phase change material configured to melt at a predetermined temperature to release stored energy in response to a portion of heat transferred from the heat transfer medium.

[0049] Clause 12 - The energy storage device of clause 9, wherein the upper layer of material or the lower layer of material comprises a plurality of metallic granules or a non- cementitious material.

[0050] Clause 13 - The energy storage device of clauses 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, or 13, wherein the layer of material comprises a plurality of plates stacked together, wherein each one of the plurality of plates includes a base and a plurality of protrusions extending from the base, wherein the plurality of protrusions are separated by a plurality of channels defined by the plate, and wherein each channel is filled with sand or fine aggregate based on the plurality of stacked plates being positioned in the heat storage module.

[0051] Clause 14 - A method of storing thermal energy comprising directing a heat transfer medium over a face of and through a plurality of heat transfer layers of a heat storage module, wherein at least one layer of the plurality of heat transfer layers comprises concrete packed together to form a packed thermal bed, and wherein the heat storage module defines a first plenum at one end and a second plenum at another end. The method of storing thermal energy comprising transferring heat from one of the heat transfer medium to the heat transfer layers upon entry of the heat transfer medium into the heat storage module through the first plenum and exiting the heat transfer medium from the heat storage module through the second plenum in a charging mode of operation, or the heat transfer layers to the heat transfer medium upon entry of the heat transfer medium into the heat storage module through the second plenum and exiting the heat transfer medium from the heat storage module through the first plenum in a discharging mode of operation.

[0052] Clause 15 - The method of clause 14, further comprising pumping the heat transfer medium through the first plenum or the second plenum into the heat storage module by pulsing the flow of the heat transfer medium by way of a pump.

[0053] Clause 16 - The method of clause 15, further comprising accumulating the heat transfer medium in an accumulator tank prior to pumping the heat transfer medium into the heat storage module.

[0054] Clause 17 - The method of clauses 14, 15, or 16, further comprising circulating the flow of the heat transfer medium within the heat storage module by way of a pump positioned intermediate the first plenum and the second plenum.

[0055] Clause 18 - The method of clauses 14, 15, 16, or 17, wherein the plurality of heat transfer layers comprises one or more than one layer of capsules having a phase change material therein.Patent ApplicationAttorney Docket No. WEC-2024-158-PCT

[0056] Clause 19 - The method of clauses 14, 15, 16, 17, or 18, wherein the plurality of heat transfer layers comprises one or more than one layer of non-cementitious material.

[0057] Clause 20 - The method of clauses 14, 15, 16, 17, 18, or 19, wherein the packed thermal bed comprises naturally crushed cement intermixed within the layer of engineered concrete.

[0058] All patents, patent applications, publications, or other disclosure material mentioned herein, are hereby incorporated by reference in their entirety as if each individual reference was expressly incorporated by reference respectively. All references, and any material, or portion thereof, that are said to be incorporated by reference herein are incorporated herein only to the extent that the incorporated material does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as set forth herein supersedes any conflicting material incorporated herein by reference and the disclosure expressly set forth in the present application controls.

[0059] The present disclosure has been described with reference to various exemplary and illustrative aspects. The aspects described herein are understood as providing illustrative features of varying detail of various aspects of the disclosed disclosure; and therefore, unless otherwise specified, it is to be understood that, to the extent possible, one or more features, elements, components, constituents, ingredients, structures, modules, and / or aspects of the disclosed aspects may be combined, separated, interchanged, and / or rearranged with or relative to one or more other features, elements, components, constituents, ingredients, structures, modules, and / or aspects of the disclosed aspects without departing from the scope of the disclosed disclosure. Accordingly, it will be recognized by persons having ordinary skill in the art that various substitutions, modifications or combinations of any of the exemplary aspects may be made without departing from the scope of the disclosure. In addition, persons skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the various aspects of the disclosure described herein upon review of this specification. Thus, the disclosure is not limited by the description of the various aspects, but rather by the claims.

[0060] Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the followingPatent ApplicationAttorney Docket No. WEC-2024-158-PCT appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.

[0061] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”

[0062] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although claim recitations are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are described, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” or other past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

[0063] It is worthy to note that any reference to “one aspect,” “an aspect,” “anPatent ApplicationAttorney Docket No. WEC-2024-158-PCT exemplification,” “one exemplification,” and the like means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in one aspect,” “in an aspect,” “in an exemplification,” and “in one exemplification” in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more aspects.

[0064] As used herein, the singular form of “a”, “an”, and “the” include the plural references unless the context clearly dictates otherwise.

[0065] Directional phrases used herein, such as, for example and without limitation, top, bottom, left, right, lower, upper, front, back, and variations thereof, shall relate to the orientation of the elements shown in the accompanying drawing and are not limiting upon the claims unless otherwise expressly stated.

[0066] The terms “about” or “approximately” as used in the present disclosure, unless otherwise specified, means an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain aspects, the term “about” or “approximately” means within 1, 2, 3, or 4 standard deviations. In certain aspects, the term “about” or “approximately” means within 50%, 200%, 105%, 100%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

[0067] In this specification, unless otherwise indicated, all numerical parameters are to be understood as being prefaced and modified in all instances by the term “about,” in which the numerical parameters possess the inherent variability characteristic of the underlying measurement techniques used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0068] Any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of “1 to 100” includes all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 100, that is, having a minimum value equal to or greater than 1 and a maximum value equal to or less than 100. Also, all ranges recited herein are inclusive of the end points of the recited ranges. For example, a range of “1 to 100” includes the end points 1 and 100. Any maximum numerical limitation recited in this specification is intended to include all lower numerical limitations subsumed therein, and any minimum numerical limitation recited in this specification is intended to include all higher numerical limitations subsumed therein.Accordingly, Applicant reserves the right to amend this specification, including the claims, toPatent ApplicationAttorney Docket No. WEC-2024-158-PCT expressly recite any sub-range subsumed within the ranges expressly recited. All such ranges are inherently described in this specification.

[0069] Any patent application, patent, non-patent publication, or other disclosure material referred to in this specification and / or listed in any Application Data Sheet is incorporated by reference herein, to the extent that the incorporated materials is not inconsistent herewith. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

[0070] The terms "comprise" (and any form of comprise, such as "comprises" and "comprising"), "have" (and any form of have, such as "has" and "having"), "include" (and any form of include, such as "includes" and "including") and "contain" (and any form of contain, such as "contains" and "containing") are open-ended linking verbs. As a result, a system that "comprises," "has," "includes" or "contains" one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that "comprises," "has," "includes" or "contains" one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

Claims

Patent ApplicationAttorney Docket No. WEC-2024-158-PCTWHAT IS CLAIMED IS:1 . An energy storage device, comprising: a heat storage module configured to receive a heat transfer medium; a packed thermal bed positioned within the heat storage module, the packed thermal bed comprising a layer of material comprising concrete; a first plenum defined in the heat storage module at one end of the heat storage module; and a second plenum defined in the heat storage module at another end of the heat storage module, wherein the energy storage device is configured to operate in one of: a charging mode of operation wherein the charging mode of operation is characterized by: receipt, by the first plenum, of the heat transfer medium from a source and distribution of the heat transfer medium through the layer of material; an exit of the heat transfer medium from the heat storage module through the second plenum to a storage location; and a transfer of a portion of heat in the heat transfer medium to the layer of material in the charging mode of operation of the energy storage device; or a discharging mode of operation, wherein the discharging mode of operation is characterized by: receipt, by the second plenum, of the heat transfer medium from the storage location and distribution of the heat transfer medium through the layer of material; an exit of the heat transfer medium from the heat storage module through the first plenum to the source; and a transfer of a portion of heat in the layer of material to the heat transfer medium in the discharging mode of operation of the energy storage device.

2. The energy storage device of claim 1 , wherein the layer of material is engineered concrete comprising a higher random order packing fraction than natural crushed aggregate.

3. The energy storage device of claim 2, wherein the engineered concrete comprises a plurality of superellipsoids.

4. The energy storage device of claim 2, wherein the engineered concrete comprises ultra-high performance concrete.Patent ApplicationAttorney Docket No. WEC-2024-158-PCT5. The energy storage device of claim 2, wherein the packed thermal bed comprises an interstitial fill that is more fine in size than the engineered concrete.

6. The energy storage device of claim 2, wherein the layer of material comprises a natural aggregate of concrete intermixed with the engineered concrete, and wherein the natural aggregate of concrete is more fine in size than the engineered concrete.

7. The energy storage device of claim 1, further comprising an accumulator and a pump to pulse the flow of the heat transfer medium into the heat storage module.

8. The energy storage device of claim 1, wherein the heat storage module further comprises a pump to aid in circulating the heat transfer medium within the heat storage module.

9. The energy storage device of claim 1, wherein the layer of material is a first layer of material and the packed thermal bed comprises an upper layer of material and a lower layer of material, wherein the first layer of material is positioned between the upper layer of material and the lower layer of material, and wherein the upper layer of material and the lower layer of material are different from the first layer of material.

10. The energy storage device of claim 9, wherein the upper layer of material or the lower layer of material comprises a material having a heat transfer capability that is greater than a heat transfer capability of the first layer of material.

11. The energy storage device of claim 9, wherein the upper layer of material or the lower layer of material comprises a plurality of capsules containing a phase change material configured to melt at a predetermined temperature to release stored energy in response to a portion of heat transferred from the heat transfer medium.

12. The energy storage device of claim 9, wherein the upper layer of material or the lower layer of material comprises a plurality of metallic granules or a non-cementitious material.

13. The energy storage device of claim 1, wherein the layer of material comprises a plurality of plates stacked together, wherein each one of the plurality of plates includes a base and a plurality of protrusions extending from the base, wherein the plurality of protrusions are separated by a plurality of channels defined by the plate, and wherein eachPatent ApplicationAttorney Docket No. WEC-2024-158-PCT channel is filled with sand or fine aggregate based on the plurality of stacked plates being positioned in the heat storage module.

14. A method of storing thermal energy, comprising: directing a heat transfer medium over a face of and through a plurality of heat transfer layers of a heat storage module, wherein at least one layer of the plurality of heat transfer layers comprises concrete packed together to form a packed thermal bed, and wherein the heat storage module defines a first plenum at one end and a second plenum at another end; and transferring heat from one of: the heat transfer medium to the heat transfer layers upon entry of the heat transfer medium into the heat storage module through the first plenum and exiting the heat transfer medium from the heat storage module through the second plenum in a charging mode of operation; or the heat transfer layers to the heat transfer medium upon entry of the heat transfer medium into the heat storage module through the second plenum and exiting the heat transfer medium from the heat storage module through the first plenum in a discharging mode of operation.

15. The method of claim 14, further comprising: pumping the heat transfer medium through the first plenum or the second plenum into the heat storage module by pulsing the flow of the heat transfer medium by way of a pump.

16. The method of claim 15, further comprising: accumulating the heat transfer medium in an accumulator tank prior to pumping the heat transfer medium into the heat storage module.

17. The method of claim 14, further comprising: circulating the flow of the heat transfer medium within the heat storage module by way of a pump positioned intermediate the first plenum and the second plenum.

18. The method of claim 14, wherein the plurality of heat transfer layers comprises one or more than one layer of capsules having a phase change material therein.

19. The method of claim 14, wherein the plurality of heat transfer layers comprises one or more than one layer of non-cementitious material.Patent Application Attorney Docket No. WEC-2024-158-PCT20. The method of claim 14, wherein the packed thermal bed comprises naturally crushed cement intermixed within the layer of engineered concrete.

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