阅读说明：本技术 内部加热式相变材料热电池 (Internal heating type phase-change material thermal battery ) 是由 安德鲁·比塞尔 桑托克·加塔奥拉 乔纳森·尼克尔森 基兰·多克 于 2019-07-29 设计创作，主要内容包括：本文中限定了一种被加热式的相变材料(PCM)电池设计。更具体地,描述了在包含PCM的一系列热电池中一体地定位和/或内部地定位的加热装置(例如,电加热装置)。具体地,描述了一种PCM热电池,其包括：能够保持PCM的PCM封围件；定位在封围件中的PCM；用于PCM热电池的电子控制系统；定位在PCM热电池中的加热装置；其中,加热装置能够对PCM进行加热和/或充电。(A heated Phase Change Material (PCM) cell design is defined herein. More specifically, heating devices (e.g., electrical heating devices) are described that are integrally and/or internally located in a series of thermal batteries that contain a PCM. In particular, a PCM thermal battery is described, comprising: a PCM enclosure capable of holding PCM; a PCM positioned in the enclosure; an electronic control system for a PCM thermal battery; a heating device positioned in the PCM thermal battery; wherein the heating device is capable of heating and/or charging the PCM.)

1. A PCM thermal battery comprising:

a PCM enclosure capable of holding PCM;

a PCM positioned in the PCM enclosure;

an electronic control system for controlling the PCM thermal battery;

at least one or more heating devices positioned in the PCM thermal battery;

wherein the at least one or more heating devices are capable of heating and/or charging the PCM.

2. The PCM thermal battery of claim 1, wherein at least one or more heating devices (e.g. electrical heating elements) are integrally positioned and/or internally positioned within the PCM battery.

3. The PCM thermal battery of any of claims 1 or 2, wherein the at least one or more heating devices are positioned within the PCM enclosure and thus directly contact and are submerged in the PCM.

4. The PCM thermal battery according to any preceding claim, wherein at least one, two, three, four, five, six or more heating means are provided.

5. The PCM thermal battery of any preceding claim, wherein heating devices are located at different vertical levels within the PCM enclosure.

6. The PCM thermal battery according to any preceding claim, wherein the PCM thermal battery is charged with an external primary heat source and the at least one or more heating means are thus secondary heat sources, allowing the charging and/or temperature of the PCM to be controlled very precisely.

7. The PCM thermal battery of any preceding claim, wherein there is provided an outer casing for the entire PCM thermal battery and an insulating layer extending around the PCM enclosure.

8. The PCM thermal battery according to any preceding claim, wherein the electronic control system controls the physical properties and/or temperature of the PCM by applying energy, such as heat, via the at least one or more heating means.

9. The PCM thermal battery of any preceding claim, wherein the PCM thermal battery is a dual port thermal battery.

10. The PCM thermal battery of any preceding claim, wherein the PCM thermal battery comprises a heat exchanger, optionally possibly comprising fins, wherein the heat exchanger is positioned within the PCM enclosure.

11. The PCM thermal battery according to any preceding claim, wherein the electronic control system comprises a low power Loop (LPC) and a high power loop (HPC) for providing electrical connections for the PCM thermal battery.

12. The PCM thermal battery of any preceding claim, wherein the electronic control system comprises an HPC inlet and an HPC outlet.

13. The PCM thermal battery according to any preceding claim, wherein a battery controller is provided in connection with a battery charge state signal and a battery charge control signal.

14. The PCM thermal battery according to any preceding claim, wherein at least one or more sensors positioned in the PCM enclosure are provided, the at least one or more sensors being capable of monitoring physical properties and/or temperature of the PCM and other parts of the thermal battery.

15. The PCM thermal battery according to any preceding claim wherein there is provided an over-temperature safety cut-off thermostat S0 and a series of temperature sensors distributed across different vertical positions of the thermal battery to obtain the temperature across the entire working medium and the PCM and/or heat exchanger.

16. The PCM thermal battery according to any preceding claim, wherein the PCM thermal battery has a two port design, wherein the heating means is in the form of a backup heater element, such as an electric heater element.

17. The PCM thermal battery of any preceding claim, wherein the heating device is positioned in an upper half of the PCM enclosure and submerged in the PCM.

18. The PCM thermal battery according to any preceding claim, wherein the electronic control system comprises a battery controller allowing the heating means to be fully controlled and/or switched on and/or off when required, and wherein the power delivered and/or the amount of heating by the heating means is also controlled (i.e. adjusted and varied) in dependence of measurements of sensors positioned in the PCM enclosure and the PCM.

19. The PCM thermal battery of any preceding claim wherein a plurality of electrical heating devices are positioned at different heights within the PCM enclosure and/or the PCM.

20. The PCM thermal battery of any preceding claim wherein a first heating means is located in an upper half of the PCM enclosure and a second heating means is located in a lower half of the PCM enclosure, both the first and second heating means being immersed in PCM.

21. The PCM thermal battery according to any preceding claim, wherein at least one or more heating means are provided, which are integral with the PCM thermal battery and/or located inside the PCM thermal battery, and which are submerged in the PCM below a heat exchanger.

22. The PCM thermal battery of any preceding claim, wherein the PCM enclosure comprises a step feature located near a lower end of the thermal battery, extending upwardly from a bottom of the PCM enclosure, and wherein the step feature provides a housing for a heating element terminal and optionally a safety shut-off feature.

23. The PCM thermal battery of any preceding claim, wherein the heating means is integrally located proximate a lower end of the PCM enclosure and the heating means is in tubular form and is located below a heat exchanger.

24. The PCM thermal battery of any preceding claim wherein the heating means is a tubular elongate heating means immersed in the PCM and incorporated into a separator connecting ring, the heating means to transfer heat to the PCM via a larger surface area and provide immediate heating to the PCM.

25. The PCM thermal battery of any preceding claim, wherein a heat exchanger is provided positioned internally within the PCM thermal battery and positioned internally of the PCM enclosure and PCM.

26. The PCM thermal battery according to any preceding claim, wherein at least one or more thermal conductors (e.g. metal bars or thermal pipes) are provided, inserted substantially vertically into the thermal battery and heat exchanger and extending to and submerged in at least a part of the PCM.

27. The PCM thermal battery of any preceding claim, wherein at least one or more heating devices are located proximate a lower end of the heat exchanger and are located proximate and substantially horizontally along a bottom of the PCM enclosure.

28. The PCM thermal battery according to any preceding claim, wherein thermal plates (e.g. conductive thermal plates such as metal plates) are provided, which are substantially vertically oriented and which extend into or at least partially into a heat exchanger core (e.g. a heat exchanger finned sheet core) and into a heating zone of the thermal battery located below or substantially below the heat exchanger.

29. The PCM thermal battery according to any preceding claim, wherein at least one or more non-planar heating means (e.g. substantially L-shaped electrical heating means) are embedded in the heat exchanger core.

30. The PCM thermal battery of claim 29 wherein the non-planar heating means (e.g. substantially L-shaped heating means) comprises a substantially vertical portion extending downwardly through the PCM and is provided with at least one or more substantially horizontal locating portions extending substantially tangentially from the substantially vertical portion.

31. The PCM thermal battery of claim 30, wherein a first substantially horizontally positioned portion extends along a lower quarter of the heat exchanger core, a second horizontally positioned portion extends substantially through a middle portion of the heat exchanger core, and a third horizontally positioned portion extends through an upper quarter of the heat exchanger core.

32. The PCM thermal battery of any of claims 30 and 31, wherein the substantially horizontally positioned portions are embedded or at least partially embedded into a core of a heat exchanger (e.g. a finned sheet core of a fin-and-tube heat exchanger).

33. The PCM thermal battery according to any preceding claim, wherein at least one or more heating means (e.g. electrically heated tubular heaters) are provided embedded into a heat exchanger core comprising a conductive element, e.g. a conductive tube, such as a copper tube.

34. The PCM thermal battery of claim 33 wherein the at least one or more electrical heating devices are embedded in a manifold of the PCM thermal battery.

35. The PCM thermal battery of claim 33 wherein the heating means is embedded in a circuit extending generally horizontally across the heat exchanger core.

36. The PCM thermal battery of claim 35, wherein the circuit is embedded in a heat exchanger.

37. The PCM thermal battery according to any of claims 35 and 36, wherein a channel is provided extending around the circuit and at least one or more heating means are provided extending around the circuit.

38. The PCM thermal battery of any preceding claim, wherein at least one or more heating means are embedded and/or positioned in a housing containing a material capable of efficiently transferring and/or dissipating heat.

39. The PCM thermal battery of claim 38, wherein the material in the housing is oil and/or thermal paste.

40. The PCM thermal battery of any of claims 38 and 39 wherein the housing is integral with the PCM enclosure and the heating device is not directly engaged with the PCM.

41. The PCM thermal battery of any of claims 38 to 40, wherein the heating means is a tubular electric heater embedded into an oil and/or thermal paste filled housing.

42. The PCM thermal battery of any preceding claim wherein at least one or more heating devices are provided located externally of the PCM enclosure and internally of an external casing of the PCM thermal battery.

43. The PCM thermal battery of claim 42 wherein a conductive block is positioned within the PCM enclosure within which current can be induced via an induction heater positioned substantially below and outside of the PCM enclosure.

44. The PCM thermal battery of any one of claims 42 and 43 wherein the heating device is located proximate to a lower end of the PCM enclosure and generally below (i.e. substantially below) the heat exchanger core (e.g. heat exchanger finned sheet core).

45. The PCM thermal battery of any of claims 42 to 44 wherein the heating means in the form of the conductive block is heated by an externally positioned induction heater positioned externally of the PCM enclosure.

46. The PCM thermal battery of claim 45, wherein the conductive block is positioned internally above or substantially above the induction heater and inside the PCM enclosure.

47. The PCM thermal battery according to any preceding claim, wherein internally submerged conducting blocks are provided which are integral with the thermal battery, heated via at least one or several removable cartridge heaters.

48. The PCM thermal battery of claim 47 wherein at least one or more removable cartridge heating devices are located within an internally submerged conductive block, wherein the conductive block is located inside the PCM enclosure and below a heat exchanger.

49. The PCM thermal battery of any one of claims 47 and 48 wherein the conductive block is made of a thermally conductive material, the conductive block extending along a bottom of the PCM enclosure and positioned below (i.e., below) a heat exchanger core and the PCM.

50. The PCM thermal battery of any of claims 47 to 49 wherein the cartridge heater is located internally within the PCM enclosure and comprises a thermally conductive metal and/or alloy mass capable of efficiently transferring heat.

51. The PCM thermal battery of any preceding claim, wherein an impeller agitator is provided which mixes the PCM and assists heat transfer by forced convection.

52. The PCM thermal battery of any preceding claim, wherein the heating means is in the form of a network of heater elements.

53. The PCM thermal battery of claim 52 wherein the heater element mesh comprises a mesh section within which is disposed a conductive tubular section providing efficient heat transfer.

54. The PCM thermal battery of any preceding claim, wherein the heating means comprises expansion members (e.g. fins) which assist in dissipating and/or transferring heat.

55. The PCM thermal battery according to any preceding claim, wherein the heating means comprises a Positive Temperature Coefficient (PTC) heater slipped onto a heat transfer tube.

56. The PCM thermal battery of any preceding claim, wherein the heating means is in the form of a substantially horizontally oriented low power vertical heater extending substantially across the bottom of the heat exchanger.

57. The PCM thermal battery of any preceding claim, wherein the heating means is in the form of a substantially vertically oriented low power vertical heater.

58. The PCM thermal battery of claim 57 wherein the generally vertically oriented low power vertical heater is a thermal conduit or conductive rod that assists PCM cycling and produces a pumping action on the PCM material within the thermal battery.

59. The PCM thermal battery of any of claims 57 and 58 wherein the substantially vertically oriented heater extends from an upper surface of the PCM enclosure, through the PCM and into a heat exchanger.

60. The PCM thermal battery of any preceding claim, wherein the thermal battery comprises grid fins.

61. The PCM thermal battery of claim 60 wherein the grid fins comprise a series of tubes (e.g., copper tubes) for transferring heat, and PCM material flows inside and around the tubes and can be directed with the grids in the fins.

62. A method of applying thermal energy to a PCM thermal battery, comprising:

providing a PCM enclosure capable of holding a PCM;

providing a PCM positioned in the enclosure;

providing an electronic control system for the PCM thermal battery;

providing at least one or more heating devices positioned in the PCM enclosure and submerged in the PCM;

wherein the at least one or more heating devices are capable of heating and/or charging the PCM.

Technical Field

The invention relates to an internally heated Phase Change Material (PCM) battery design. More particularly, the present invention relates to heating devices (e.g., electrical heating devices) that are integrally and/or internally located in a series of thermal batteries containing PCMs.

Background

Thermal batteries comprising a PCM for transferring heat and/or storing heat are known. However, there are a number of problems with existing PCM battery technology.

In a standard thermal battery containing a PCM, there are problems in terms of efficiency and for connecting multiple charging heat sources. Furthermore, there are problems in the case where the PCM thermal battery must be charged using an externally located primary heat source.

It was found that prior art devices present other problems when charging the PCM in a controlled manner using an internal heating device, since charging the PCM in a controlled manner using an internal heating device requires a very complex fluid circulation loop. These complex fluid circulation loops have been found to be very unreliable and often subject to failure. These complex fluid circulation circuits are also expensive and difficult to maintain.

It is an object of at least one aspect of the present invention to obviate and/or mitigate at least one or more of the above-mentioned problems.

It is a further object of the present invention to provide an improved thermal battery containing a PCM that provides technical efficiencies and benefits, including flexibility in terms of connection to multiple sources of charged heat.

It is a further object of the present invention to provide an improved thermal battery containing a PCM, the improved thermal battery containing a PCM comprising the following capabilities: charged using an externally located primary heat source and/or charged in a controlled manner by an internal heating device without the need for a complex fluid circulation loop.

Disclosure of Invention

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 integrally and/or internally located heating means, such as electrical heating means.

According to a second aspect of the present invention, there is provided a PCM thermal battery comprising:

a PCM enclosure capable of holding PCM;

a PCM positioned in the PCM enclosure;

an electronic control system for controlling the PCM thermal battery;

at least one or more heating devices positioned in the PCM thermal battery;

wherein the at least one or more heating devices are capable of heating and/or charging the PCM.

The present invention relates to an improved thermal battery design, wherein the thermal battery is for example a PCM thermal battery having at least one or more heating means that may be integrally positioned and/or internally positioned within the PCM battery.

PCM thermal batteries have the advantage of overcoming the need for complex fluid circulation loops and any associated components and associated costs in thermal battery arrangements.

The PCM thermal battery of the present invention provides an improved thermal battery arrangement and design, which provides improved technical efficiency, benefits and flexibility, particularly in terms of connecting to multiple charging heat sources.

Typically, the heating device may be positioned within the PCM enclosure. In some embodiments, the heating device may thus be in direct contact with the PCM and immersed in the PCM.

The PCM thermal battery may comprise at least one, two, three, four, five or six heating devices.

Alternatively, the PCM thermal battery may comprise 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 comprise a plurality of heating devices.

The heating device may be described as being positioned integrally and/or internally within the PCM enclosure and thus within the PCM thermoelectric cell.

The heating means may be positioned at different levels (i.e. depth or height) within the PCM enclosure. Thus, the heating devices may be positioned at different vertical positions within the PCM enclosure.

PCM thermal batteries can be charged using an external primary heat source, thereby eliminating the need to have a complex fluid circulation loop. Thus, the PCM thermal battery can be charged both by an external primary heat source and by a heating device positioned in the PCM enclosure. The heating device of the present invention can therefore be considered as an auxiliary heat source for a PCM thermal battery. This arrangement allows the variation of the PCM and/or the temperature to be controlled very accurately.

The PCM thermal battery may comprise an outer casing for the entire PCM thermal battery.

An insulating layer may be positioned within the outer casing of the PCM thermal battery. The insulating layer may improve the thermal efficiency of the PCM thermal battery and retain heat within the PCM enclosure.

The PCM enclosure may be a storage container positioned inside the outer shell and the insulating layer. The PCM enclosure may hold PCM.

Thus, the insulating layer may form a sheath and an insulating layer around the PCM enclosure.

The PCM used in the present invention may be tailored and varied for specific applications and required energies. Thus, any suitable type of PCM may be used for a range of applications, such as providing hot water, storing energy and then transferring that energy in both domestic and industrial applications.

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

The heating means may be any suitable element capable of providing energy and/or heat to the PCM. For example, the heating device may be an electrical heating element, which may be used to apply thermal energy to the PCM and thereby increase the temperature of the PCM.

Thus, the heating device in the present invention may be an integrally positioned and/or internally positioned electrical heating device. Thus, in some embodiments, the heating device may be in direct contact with the PCM material.

Thus, in some embodiments, the PCM may be heated directly, which means that fluid circulation in the circuit in the battery is not necessary for the charging phase but only exists for the discharge of the thermal battery. The present invention also overcomes the need for complex fluid circulation loops.

In particular embodiments, the PCM thermal battery may be a dual port thermal battery.

The PCM thermal battery may also include a heat exchanger, which may be, for example, a heat exchanger having finned sheet cores. The heat exchanger may be positioned within the PCM enclosure.

The electronic control system of the present invention may include a low power Loop (LPC) and a high power loop (HPC) for providing electrical connections to the PCM thermal battery.

The electronic control system may also include an HPC inlet and an HPC outlet. An LPC inlet and an LPC outlet may also be provided. The inlet and outlet may be positioned on the upper, i.e. top, surface of the PCM thermal battery.

A battery controller may also be provided. There may also be a battery charge status signal and a battery charge control signal.

The PCM battery may be powered by a mains power supply.

The PCM thermal battery may also include at least one or more sensors capable of monitoring physical characteristics and/or temperature of the PCM and other portions of the thermal battery. For example, an overheat safety cut-off thermostat S0 may be provided. In addition, temperature sensors, such as temperature sensors S1, S2, and S3, may be provided. Sensors, such as temperature sensors, may be distributed throughout the thermal battery to obtain the temperature across the working medium.

The sensors may be positioned at different vertical locations in the PCM. This allows monitoring of the physical properties and temperature of the PCM throughout the PCM enclosure. For example, sensors may be provided which are positioned in the upper half of the PCM enclosure, and/or in about the middle of the PCM enclosure, and/or about close to the lower end of the PCM enclosure.

Any particular embodiment, PCM thermal battery, for example, may have a two port design, wherein the heating device of the present invention is in the form of a backup heater element, such as an electric heater element. At least one or more backup heater elements may be provided.

The dual port design of the present invention provides the technical advantage of being able to charge thermal batteries with non-potable water. Furthermore, the battery can be charged using simple and inexpensive, unauthenticated components. The drinking water can then be used to extract heat. Thus, the thermal battery of the present invention is a great improvement over previous complex fluid circulation systems.

In particular embodiments, the thermal battery may include a single or multiple heating devices, which may be, for example, backup electric heaters positioned in the PCM. The heating means may be any form of electrical heating means that may be positioned in the PCM. Thus, the heating device may be described as an integrally and/or internally positioned electrical heating device immersed in the PCM. It should be noted that the present invention may have at least one, two or more heating devices positioned in the PCM.

It has been found that the position of the heating means in the PCM enclosure is important, and thus the PCM. In particular embodiments, a heating device, such as an electric heater, may be positioned in the upper half of the PCM enclosure. The upper half refers to the vertical upper half of the PCM enclosure. The heating device may be immersed in the PCM.

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 can be fully controlled and/or switched on and/or off when required. In addition, the power and/or the amount of heat delivered by the heating device may also be modified, i.e. adjusted and varied. Thus, the amount of heat and charge delivered may depend on the measurements of the sensors and/or the power required for a particular application, such as supplying hot water.

In particular embodiments, the heating device may be positioned in the upper half, the upper third or the upper quarter of the PCM enclosure. The location of the heating means may preferably be in the upper section of the PCM enclosure, such that the heating means may be used to charge the top section and the respective PCM located in the top section of the PCM enclosure. Although this only heats the PCM in the upper section of the PCM enclosure and thus only provides a reduced capacity, it will still provide sufficient heat for the user to obtain a usable output. The heating device of the invention can thus be used as a fully adjustable backup heating system.

Another advantage of the PCM cell of the present invention is that it has been found possible to input electric heat via the heating means and then immediately remove the heat via the heat exchanger. This has the advantage that no electrical heat energy needs to be stored, unlike what is found in prior art systems such as instantaneous water heater systems.

In various embodiments, a PCM thermal battery may include several electrical heating devices positioned at different heights within a PCM enclosure. This has the advantage that it is possible to select how much of the PCM material is to be heated and thus how much energy is to be stored and/or released. Positioning the electrical heating devices at different heights allows different amounts (i.e., different volumes) of PCM to be heated. Thus, the function of the backup electric heater element of the present invention is to be highly adaptable to a wide range of applications such as, for example, a two-port system.

In certain embodiments, the PCM thermal battery may comprise a heating device positioned in an upper half of the PCM enclosure and a heating device positioned in a lower half of the PCM enclosure. The PCM thermal battery may thus comprise two heating devices at different vertical positions. The upper positioned heating device may be used as a backup heater. Thus, the heating device may be activated in case of failure of the primary heat source.

Alternatively, there may be provided a heating device positioned approximately three quarters up into the PCM enclosure and a heating device positioned only above the bottom of the PCM enclosure. As mentioned above, the position of the heating means may be adapted to allow different amounts of PCM to be heated. As previously mentioned, the heating means may be any suitable form of electric heater/element.

A heating device located near the bottom of the PCM enclosure may allow substantially all of the PCM material in the battery cell to be rapidly charged.

An advantage of having the second heating means positioned inside the PCM enclosure is that this enables the PCM in the thermal battery to be charged faster. The heating device positioned at the bottom of the PCM enclosure may be used as the primary heat source for the thermal battery.

Thus, the present invention may have a plurality of integrally and/or internally located heating devices, such as electrical heating devices located at different heights in the battery, to provide different amounts of energy. By heating different amounts and volumes of PCM, different amounts of energy are provided, which may then be stored and/or dispensed.

In further embodiments, at least one or more heating devices may be provided, which may be integral with and/or located inside the PCM thermal battery, and which may be submerged in the PCM, for example below the heat exchanger. The PCM enclosure may also include a step feature, e.g., two step features, located near the lower end of the thermal battery, extending upward from the bottom of the PCM enclosure.

The step feature may provide an effective housing for, for example, heating element terminals and safety shut-off features. The step feature may also allow the use of vacuum insulation panels to insulate the PCM thermal battery.

These step features 503a also help to position heat exchanger 504 above heating device 511 and to position PCM 505 volume below heat exchanger 504.

The heating means may be an electrical heating means located near the lower end of the PCM enclosure. The heating means may for example be in the form of a tube and may be integral with the thermal battery. The heating device may be positioned below the heat exchanger. Thus, the heating device may be used to provide instant heating to the PCM.

A heating device (e.g., a tubular electric heater) may penetrate the thermal battery enclosure, for example, via a separator connection. Such an arrangement provides the advantage of being able to transfer heat from the tubular elongated heating device to the PCM via a large surface area.

The heating device may be submerged and completely submerged in the PCM. Thus, the heating device may directly contact the PCM.

A heat exchanger positioned within the PCM thermoelectric cell and positioned inside the PCM enclosure and the PCM may also be provided. Typically, the heat exchanger may have a finned core to improve thermal efficiency. The heat exchanger may have a control circuit.

Conduction and convection in the PCM can transfer heat to a heat exchanger, such as a finned-core heat exchanger. This has been found to be a highly energy efficient system.

In another embodiment, the PCM thermal battery may include at least one or more thermal conductors, such as, for example, a metal rod that may be inserted substantially vertically into the thermal battery case. The thermal conductor may be, for example, a conductive rod or a thermal conduit. The thermal conductors may be positioned substantially vertically in the heat exchanger and extend into a portion of the PCM, such as for example an upper end region of the PCM. The thermal conductors may be used to dissipate and/or dissipate heat throughout the heat exchanger and/or PCM.

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, which may for example be a finned heat exchanger core.

At least one or more heating devices may be positioned proximate the lower end of the heat exchanger. The heating device may be positioned near and substantially horizontally along the bottom of the PCM enclosure.

In another embodiment, the PCM thermal battery may include thermal plates (e.g., conductive thermal plates such as metal plates) that may be incorporated into the PCM thermal battery design. The platens can extend into or at least partially into a heat exchanger core (e.g., a finned heat exchanger core). The platens may extend into a heating zone of the thermal battery that is located below or substantially below the heat exchanger.

For example, two, three, four or more hotplates may be provided. The platens may be positioned substantially vertically in the heat exchanger, and the platens may optionally extend into a lower end region of the PCM 705 and extend through the heating device. Any suitable number of thermal plates may be provided that may be oriented in any suitable orientation across the heat exchanger. It has been found that it is preferable that the hot plates be accessible substantially vertically to assist in the transfer of heat up the plates and cooling down.

The thermal plate may be formed of a thermally conductive material such as any suitable metal and/or alloy. The plates may be relatively thick to assist in heat transfer. The thermal plate may be substantially planar in the PCM thermal battery and may be substantially vertically oriented.

The hotplate can be relatively thick, such as about 0.1cm to 5cm thick, about 0.1cm to 2cm thick, or about 0.1cm to 0.5cm thick.

In another embodiment, the PCM thermal battery may include a non-planar heating device, such as, for example, at least one or more substantially L-shaped electrical heating devices embedded in a heat exchanger, such as a finned sheet core of a heat exchanger.

The non-planar heating means (e.g. the substantially L-shaped heating means) may comprise a substantially vertically oriented portion extending downwardly through the PCM. One or more (e.g., three) generally horizontally oriented portions extending tangentially from the generally vertical portion 811a may be provided. Any number such as single or multiple substantially vertically and substantially horizontally positioned portions may be provided.

One generally horizontally oriented portion may extend in the lower quarter of the heat exchanger core, a second generally horizontally oriented portion may extend through a middle portion of the heat exchanger core, and a third generally horizontally oriented portion may extend through the upper quarter of the heat exchanger core. The horizontally positioned portion may be positioned in any suitable area of the heat exchanger core.

The generally horizontally positioned portion may be embedded or at least partially embedded into a core of a heat exchanger (e.g., a finned sheet core of a fin-and-tube heat exchanger). The heat exchanger may preferably be fully or at least partially submerged in the PCM.

A generally horizontally oriented portion of the heating device may be positioned at a particular height within the heat exchanger core (e.g., finned sheet core) depending on the thermal battery footprint) and aspect ratio to produce better performance with respect to uniform charging, charging time, localized extraction, and expansion characteristics.

It has been found that the positioning of the substantially horizontally oriented portion of the heating means alleviates the following problems:

a) excessive localized pressure that can damage the battery cell casing;

b) rapid overheating of the PCM beyond the PCM safe operating limit; and

c) overheating of the heating device which leads to a shortened service life or to a malfunction of the heating device.

It has been found that in PCM thermal batteries it is preferable to have an interference fit between the heating element and parts of the heat exchanger core, such as the heat exchanger fins. It has surprisingly been found that this provides an increased heat transfer surface and an improved charging time.

It has also been found that an "L" shaped heating device having a substantially horizontal portion provides a number of advantages, such as:

1) mitigating any expansion of the PCM during phase change (melting and solidification) of the PCM; and

2) the cables required for the operation of the thermal battery are simply terminated at the top of the PCM thermal battery.

In another embodiment, the PCM thermal battery may comprise at least one or more heating devices (e.g. electrically heated tubular heaters) embedded into a heat exchanger core, which may optionally comprise a metal conductive element, e.g. a conductive tube, such as a copper tube.

The at least one or more heating devices may be electrical heating devices. In particular, the heating means may comprise the following parts of the electric heating means: this portion may be positioned in the upper portion of the thermal battery between the PCM enclosure and the heat exchanger core. In particular, at least one of the plurality of electric heating devices may be embedded in a manifold of the PCM thermal battery.

The heating device can also be embedded in the circuit, for example in a jump circuit row. The circuit may extend substantially horizontally across the heat exchanger core.

Any number of jump circuit rows extending across the heat exchanger core may be provided. For example, a second row of skip circuits may be provided that extends generally horizontally across the heat exchanger core.

Thus, the jumped circuit rows may be embedded in the heat exchanger. Channels may also be provided, which may be tubes for heat exchange, for example. The channel 920 may extend around a loop, which may be, for example, a jumped loop row. Heating means may be provided extending around the row of jumped loops. Thus, the electric heater may be embedded into the heat exchanger, and in particular into a channel (i.e., a tube that may be made of copper or any other suitable conductive material) extending through the heat exchanger core. The heating device may be embedded in the heat exchanger core, and the heating device is preferably and optionally not directly embedded in the PCM. There are many different options for embedding the heating means.

Thus, the heating device may be in direct contact with the heat exchanger and thus an improved and consistent heat transfer is achieved. Further, in this embodiment, the heating devices (e.g., heating elements) may optionally never be in direct contact with the PCM, and thus these heating devices need not be PCM compatible. This provides a heater with more options of reduced cost, improved reliability and robustness. The heater elements will be accessed for repair and maintenance without the maintenance personnel being exposed to the PCM. Higher power elements may be used and PCM operating conditions are independent of the higher power surface loading of the heater.

In another embodiment, the PCM thermal battery may include at least one or more heating devices that may be embedded and/or positioned in a housing containing a material capable of efficiently transferring and/or dissipating heat. Thus, the material allows for a better transfer of heat from the heating device to the heat exchanger core and/or the phase change material.

In this embodiment, a heating device (e.g., an electrical heating device) may be positioned proximate to the lower end of the PCM enclosure and below the heat exchanger core (e.g., heat exchanger finned sheet core). A first heat exchanger circuit (heat exchanger circuit 1) and a second heat exchanger circuit (heat exchanger circuit 2) may be provided.

The heating device may also optionally be positioned between and generally extend between two step features. The step feature may be part of the PCM enclosure.

The heating device may be held within a housing, which may be filled with a material/fluid capable of uniformly transferring and/or dissipating heat. The material/fluid is for example a suitable oil and/or thermal paste in any form.

In general, the heating device may be, for example, a tubular electric heating device that may be positioned within a housing and surrounded by a material capable of efficiently transferring and/or dissipating heat. Thus, the housing may be filled with oil and/or thermal paste.

In some embodiments, the housing may be finned to improve heat transfer, and in other embodiments, the housing may be finned out according to particular thermal and energy requirements.

Thus, the heating device may be embedded in a housing which may be filled with a thermal material capable of evenly transferring and/or dissipating heat. The housing may preferably be integral with the PCM enclosure. The heating device is typically not engaged with the PCM.

The housing may be flat or, alternatively, finned to increase surface area and enhance heat transfer from the heater to the hot material to the housing and then to the PCM, but it is important to reduce the surface loading of the heating device, resulting in a robust design and reduced maintenance intervals. This has been found to be a significant technical advantage and increases the life of PCM thermal batteries.

The use of an oil bath in the housing means that the heating means does not need to have a high tolerance fit within the housing as required by cartridge heaters. In general, both the heating device and the housing preferably may be suitably machined/designated to provide heat transfer (by interference fit) and both the heating device and the housing are tapered to enable the heating device to be easily removed. This is yet another advantage of the present design.

The design of the heating means and the housing means that the heating means can be easily removed and can be accessed by service personnel without being exposed to the PCM. A smaller volume of hot material, such as oil, is replaced during service intervals via an oil nozzle in the housing. Thus, the thermal battery is very easy to service, which is another technical advantage.

The fins on the housing may simply be extended elongated plates that serve as heat dissipation areas to increase the surface area and thus transfer and/or dissipate thermal energy.

In another embodiment, the PCM thermal battery may comprise at least one or more heating devices that may be positioned outside the PCM enclosure. Furthermore, for example, a conductive block can be provided in which an electric current can be induced via an external induction heater.

The heating device may be positioned near the lower end of the PCM enclosure and is typically positioned below (i.e., substantially below) the heat exchanger core (e.g., heat exchanger finned sheet core). Preferably, the heating device may be positioned externally to the PCM enclosure and at or near the bottom of the PCM enclosure. Thus, the heating device may be positioned in between the bottom of the PCM enclosure and the bottom of the battery case. In a particular embodiment, the heating device may be an induction heater.

Thus, the heating device may be described as being positioned outside of the heat exchanger core and the PCM. The heating device is still positioned inside the PCM thermal battery.

A layer of conductive material positioned above or substantially above the heating means and inside the PCM enclosure may be provided, which may extend along the bottom or substantially along the bottom of the PCM enclosure. The function of the conductive material may be to transfer heat inductively 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 within which an electrical current may be induced to generate and/or transfer heat.

In another embodiment, the PCM thermal battery may have at least one or more removable cartridge heating devices comprising internally submerged conductive blocks.

The conductive block may be made of any suitable conductive material, and the conductive block may extend along the bottom of the PCM enclosure and may optionally be positioned below (i.e., below) the heat exchanger core and the PCM.

The conductive block may extend completely or substantially or at least partially along the PCM enclosure from one side to the other. The conductive block may be composed of a conductive material such as any suitable metal and/or alloy. Thus, the conductive block means that heat is efficiently transferred from within the bottom of the PCM enclosure where the heating means are located.

At least one or a series of cartridge heating devices may be provided which may be removably internally embedded within the conductive block. The cassette heating means may extend substantially horizontally along the block and preferably within the block.

Thus, the cartridge heating device may be positioned internally within the PCM enclosure. Thus, the cassette heating device may include a thermally conductive metal and/or alloy block capable of efficiently transferring heat.

Thus, the conductive block may serve as a heat source embedded at the bottom and inside of the PCM enclosure. The conductive block typically has a larger surface area than the embedded cartridge heating device.

A technical advantage of the cassette heating device is that the cassette heating device can be externally accessed and can therefore be easily removed since the cassette heating device is not in contact with the PCM.

Preferably, the conductive block may be in the form of a heater block embedded at the bottom of the PCM enclosure.

In another embodiment, the PCM thermal battery may further comprise an impeller agitator that mixes the PCM and assists heat transfer by forced convection. Thus, the addition of an impeller agitator provides the following technical advantages:

auxiliary heat transfer via forced convection;

stirring and mixing the PCM and its constituents.

In addition, the PCM thermal battery may therefore comprise a stirrer, which may be any form of stirring device such as a rotary agitator. An agitator may be positioned, for example, near the bottom of the PCM enclosure, and the agitator may be used to agitate the PCM to improve the efficiency of the thermal battery and heat transfer.

In another embodiment, the PCM thermal battery may comprise a heating device extending substantially vertically inside the PCM enclosure. The heating means may be in the form of a network of heater elements.

The heating means in the form of a network of heater elements may be in the form of a grid-like pattern. Thus, a mesh section may be provided, within which a tubular section providing efficient heat transfer may be provided. The tubular section may be, for example, a metal tube, such as a copper tube.

The heating device may also include an expansion member (e.g., fins) that may replace the usual fins found in heat exchangers. In certain embodiments, Positive Temperature Coefficient (PTC) heaters may be used that can be slid onto heat transfer tubes, such as copper tubes, in place of the standard fins found in heat exchangers.

In another embodiment, the PCM thermal battery may comprise the following heating means: the heating means is in the form of a low power vertical heater oriented substantially vertically, for example in the form of a heat pipe or conductive rod to assist in PCM circulation. This has been found to produce a pumping action on the PCM material within the thermoelectric cell.

This arrangement has been found to have a number of technical advantages, such as:

1) increasing the heat transfer from the base of the thermal battery to the core, thereby optimizing the charging time; and

2) a path is created for the melted PCM to travel, mitigating any pressure build-up due to the phase change and expanded PCM.

The heating device may be positioned near the bottom of the PCM enclosure. The heating means may extend substantially across the bottom of the heat exchanger.

Typically, a plurality of substantially vertically oriented low power vertical heaters may be provided. The substantially vertically oriented heater may be in the form of a low power heating device or alternatively in the form of a heat pipe. Any suitable number of generally vertically oriented heaters may be provided.

A generally vertically oriented heater may extend from an upper surface of the PCM enclosure, through the PCM, and into the heat exchanger.

In another embodiment, the PCM thermal battery may include cascade fins. The grid fins may comprise a series of tubes (e.g., copper tubes) that may be used to transfer heat. The PCM material may flow within and around the tube. The flow of PCM material may be directed using louvers in the fins. Thus, the fin comprises such louvers: the louvers are in fact fully open so that the louvers are fully planar or are converted into an angled form so that the louvers may be used to direct the flow of PCM material. The louvered fin design may be incorporated into any of the embodiments and heating cells described above.

According to a third aspect of the present invention there is provided a method of applying thermal energy to a PCM thermal battery, the method comprising:

providing a PCM enclosure capable of holding a PCM;

providing a PCM positioned in the enclosure;

providing an electronic control system for the PCM thermal battery;

providing at least one or more heating devices positioned in the PCM enclosure and submerged in the PCM;

wherein the at least one or more heating devices are capable of heating and/or charging the PCM.

The features described above may be used with any of the embodiments described in this application in any combination.

The method may use any of the features described in the first and second aspects.

Drawings

Embodiments of the present invention will now be described, by way of example only, with reference to the following drawings, in which:

FIG. 1 is a schematic diagram of a two-port thermal battery design according to the prior art;

FIG. 2 shows a two-port thermal battery according to an embodiment of the present invention having a fluid circulation loop for charging the thermal battery by an electric heater according to the present invention;

FIG. 3 illustrates a thermal battery according to an embodiment of the present invention in which a dual port with a backup electric heater element is provided;

FIG. 4 shows a thermal battery according to another embodiment of the present invention, wherein a dual port with an electrically heated thermal battery having two heating devices is provided;

FIG. 5 illustrates a thermal battery according to another embodiment of the present invention, wherein an electric heater is provided, which is incorporated into the thermal battery and immersed in the PCM below the heat exchanger;

FIG. 6a shows a thermal battery according to another embodiment of the present invention, wherein a plurality of heat transfer bodies, such as heat transfer conductive rods or heat pipes, are inserted substantially vertically into the thermal battery housing;

FIG. 6b shows an enlarged cross-sectional view of the thermal conductor shown in FIG. 6 a;

FIG. 7 shows a thermal battery according to another embodiment of the present invention in which a conductive plate is incorporated into the heat exchanger core and extends into a heating zone of the thermal battery below the heat exchanger;

FIG. 8 illustrates another thermal battery in accordance with another embodiment of the present invention, wherein the thermal battery includes a generally L-shaped electrical heating device embedded in a heat exchanger;

FIG. 9 shows another thermal battery according to another embodiment of the present invention, wherein a heating device (e.g., an electrically heated tubular heater) is embedded in a heat exchanger core, which may include a conductive element, such as a metal tube, e.g., a copper tube;

FIG. 10 illustrates another thermal battery according to another embodiment of the present invention, showing a configuration for embedding jump rows into a heat exchanger;

FIG. 11a shows another thermal battery according to another embodiment of the present invention wherein there is provided a heating device embedded and/or positioned into a housing containing a material capable of efficiently transferring and/or dissipating heat;

fig. 11b shows another thermal battery according to another embodiment of the present invention, wherein there is provided a heating device embedded and/or positioned into a housing containing a material capable of efficiently transferring and/or dissipating heat, and wherein there is provided fins extending along the length of the housing.

FIG. 12 shows another thermal battery according to another embodiment of the present invention in which a heating device is provided that is positioned outside the PCM enclosure and heating is provided by an externally positioned induction heater;

FIG. 13 illustrates another thermal battery according to another embodiment of the present invention in which at least one or more removable cartridge heating devices positioned within the conductive block are provided;

FIG. 14 shows another thermal battery according to another embodiment of the present invention, wherein at least one or more removable cartridge heating devices are provided positioned within the conductive block, and wherein an agitator is also provided to mix the PCM;

fig. 15a and 15b show a further embodiment of the invention, in which a thermal battery is shown in which heating means in the form of a network of heating means extending substantially vertically within the PCM enclosure are provided;

figures 16a and 16b illustrate another embodiment of the invention in which a thermal battery is shown in which heating means are provided to assist in the form of a low power vertical heater oriented substantially vertically, for example in the form of a heat pipe or conducting rod; and

FIG. 17 shows another embodiment of the present invention and shows a cross section of a cascade plate fin design that can be used in a thermal battery according to the present invention.

Detailed Description

In general, the present invention relates to an improved thermal battery design, wherein the thermal battery is a PCM thermal battery having at least one or more heating devices, which may be located internally, for example.

The heating means in the present invention may be an integrally positioned or internally positioned electrical heating means. Thus, the heating device may in some embodiments be in direct contact with the PCM material.

In the present invention, therefore, in some embodiments, the PCM may be heated directly, which means that the circulation of the fluid in the circuit in the battery is not necessary for the charging phase but only exists for the discharge of the thermal battery. The present invention also overcomes the need for complex fluid circulation loops.

Fig. 1 shows a prior art thermal battery design, generally designated 100. The illustrated thermal battery 100 is a two-port thermal battery.

As shown in fig. 1, a heat battery case 101 is provided. An insulating material 102 is provided inside the thermal battery case 101. Disposed within the insulating material 102 is a PCM enclosure 103 for containing the PCM of the thermal battery 100. The insulating material 102 forms a sheath and an insulating layer around the PCM enclosure 103.

Also shown in fig. 1, a low power Loop (LPC)104 and a high power loop (HPC)105 are provided for providing electrical connections to the thermal battery 100.

At the top of the thermal battery 100, an HPC inlet 106 and an HPC outlet 107 are also shown. Also shown are an LPC inlet 108 and an LPC outlet 109.

Fig. 1 also shows a battery controller 110, a mains power supply (CC)111, a battery charge status signal 112 and a battery charge control signal 113.

In the thermal battery 100, an overheat safety cut-off thermostat S0 and temperature sensors S1, S2, and S3 are also provided.

In case it is desired to "heat/charge" the thermal battery 100, a working fluid (water) is circulated through the tubes of the heat exchanger, thereby transferring thermal energy from the working fluid to the PCM positioned within the PCM enclosure 103. This requires a supplemental fluid circulation assembly/circuit with pumps, temperature sensors, flow sensors, etc. This is the technical solution used in the prior art and brings with it a number of disadvantages. The present invention addresses these problems and overcomes the need for these complex fluid circulations.

Accordingly, there is a need in the art to provide an improved thermal battery device and design that provides improved technical efficiency, benefits, and flexibility, particularly in terms of connecting multiple charging heat sources. This includes the ability to still utilize an external main heat source and/or be charged in a controlled manner by internal heating means without the need for complex fluid circulation loops. A prior art design with a complex fluid circulation loop is schematically shown in fig. 2.

FIG. 2 is another thermal battery 200 design. Similar to the thermal battery 100 shown in fig. 1, there are provided a thermal battery case 201, an insulating part 202, a PCM enclosure 203, a Low Power Circuit (LPC)204, a High Power Circuit (HPC)205, an HPC inlet 206, an HPC outlet 207, and LPC inlet 208 and LPC outlet 209, a battery controller 210, a mains power supply (CC)211, a battery charge status signal 212, and a battery charge control signal 213.

The battery 200 shown in fig. 2 also includes an electric heater 214 positioned at the top of the battery 200. A pump 215, an Expansion Relief Valve (ERV)216, an expansion vessel 217 and a system fill arrangement 218 are also provided. Thus, the thermal battery 200 includes a fluid circulation loop 250.

Thus, the cell 200 shown in fig. 2 is a two-port thermal cell fluidic-cycling electrical heating arrangement.

The independent fluid circulation loops mentioned above and shown in fig. 2 are suitable for batteries with single or multiple (dual) fluid circulation loops. Then, in the case of designing a thermal battery charging circuit for potable water, this fluid circulation circuit and the components in the circuit must be subject to water code certification, thereby adding cost and complexity.

In order to eliminate these types of fluid circulation circuits, as well as any associated components and associated capital expenditure/operating costs, it is therefore proposed in the present application to provide an arrangement of integrally or internally located heating devices (e.g. electrical heating devices) for a range of thermal batteries containing PCM.

Thus, directly heating the PCM means that the circulating fluid in either fluid circulation loop is not necessary for the charging phase and is therefore only needed for the discharge of the thermal battery. By directly heating the PCM, a number of technical advantages are provided and a number of known problems of fluid circulation systems are overcome:

1. fouling problem-fouling of heater elements in prior art thermal batteries has been found to lead to heating failures.

2. In the prior art, it has been found that there is a problem with the design of the control of the heater, whereas in the present invention the heater is exposed to any custom-made form of PCM that can be controlled and made for a range of specific requirements.

3. In prior art designs, where the heater is in the working fluid stream, this has been found to increase the system pressure drop. It may also affect the amount of charging currents and hinder them.

4. The present invention uses a PCM with a higher boiling temperature than the water used in the prior art designs.

The thermal battery 200 shown in fig. 2 takes one step forward from the thermal battery 100 shown in fig. 1. Thus, the thermal battery 200 takes a step forward from the old single port design due to the ability to charge and/or discharge the different circuits. This gives a very flexible solution.

The dual port thermal battery design provides the ability to charge the thermal battery with non-potable water (using simple, inexpensive, non-certified components) and then extract heat with the potable water without the need for additional components.

Each of the ports in the "two-port thermal battery" may be appropriately sized. For example, the thermal battery may be divided into 50% -50% or 70% -30% so that a larger proportion may be allocated for discharging than for charging.

This enables slow charging over a longer period of time, but discharging at higher power and higher flow.

The present invention provides a further improvement over the thermal batteries shown in fig. 1 and 2.

Fig. 3 shows a thermal battery 300 according to the present invention. The thermal battery 300 has a two port design with a backup heater element, such as an electric heater element. At least one or more backup heater elements may be provided. This is described in more detail below.

The dual port design of the present invention provides the technical advantage of being able to charge thermal batteries with non-potable water. Also, the battery can be charged using simple and inexpensive unauthenticated components. The drinking water can then be used to extract heat. Thus, the thermal battery of the present invention is greatly improved over previous complex fluid circulation systems.

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. An insulating layer 302 is provided within the thermal battery case 301. The insulating layer 302 serves as a thermal insulator to improve the efficiency of the thermal battery 300. The insulating layer 302 forms an insulating sheath. The insulating layer 302 may be made of any suitable insulating material.

A PCM enclosure 303 is provided within the insulating layer 302. The PCM enclosure 303 has PCM disposed therein. The particular PCM used may be tailored and tailored to the particular purpose desired. Thus, the thermal battery 300 of the present invention is highly adaptable and can be modified for a wide range of applications.

Fig. 3 also shows that thermal battery 300 includes a low power Loop (LPC)304 and a high power loop (HPC) 305.

On the upper surface of the thermal battery 300 and as shown in fig. 3, there is provided an HPC inlet 306 and an LPC outlet 307.

An LPC inlet 308 and an LPC outlet 309 are also provided on the upper surface of the thermal battery 300.

Fig. 3 also shows that a battery controller 310 is provided which is connected to a mains supply (CC) 311. A battery charge status signal 312 and a battery charge control signal 313 are also provided.

Also shown are an overheat safety cut-off thermostat S0 and temperature sensors S1, S2, S3. At least one temperature sensor or a plurality of temperature sensors may be provided. The temperature sensors may be distributed throughout the thermal battery to obtain the temperature across the entire working medium.

The thermal battery 300 also includes a heating device 314, and the heating device 314 may be, for example, a backup electric heater positioned in the PCM as shown in fig. 3. This feature relates to a significant difference from the thermal battery shown in fig. 1 and 2. The heating device 314 may be any form of electrical heating device that may be positioned in the PCM. Thus, the heating device 314 may be described as an integrally and/or internally located electrical heating device immersed in the PCM. It should be noted that the present invention may have at least one, two or more heating devices positioned in the PCM.

It has been found that the position of the heating means 314 in the PCM enclosure 303 is important and thus the PCM is found to be important.

The thermal battery 300 also includes a power supply 315 for the heating device 314.

As shown in fig. 3, the electric heater 314 is positioned in the upper half of the PCM enclosure 303. The upper half refers to the vertically upper half of the PCM enclosure 303. The electric heater 314 will also be immersed in the PCM material.

Heating device 314 is connected to battery controller 310. Thus, the heating device 314 may be fully controlled and/or switched on and/or off when required. Additionally, the power delivered by the heating device 314 and/or the amount of heating may also be modified and varied.

In a preferred embodiment, the heating means 314 is positioned in the upper half, third or quarter of the PCM enclosure 303. The position of the heating device 314 is preferably in the upper section of the PCM enclosure 313, so that the heating device 314 may be used to charge the top section and the corresponding PCM located in the top section of the PCM enclosure 303. Although this only heats the PCM located in the upper section of the PCM enclosure 303 and thus only provides a reduced capacity, it will still provide sufficient heat for the user to obtain a usable output. Thus, the heating device 314 of the present invention may be used as a fully adaptable backup heating system.

Another advantage of the system shown in thermal battery 300 is that it has been found that electrical heat can be input via heating device 314 and immediately taken away via a heat exchanger. This has the advantage that no electrical heat energy needs to be stored, unlike what is found in prior art systems such as instantaneous water heater systems.

Although not shown in fig. 3, the thermal battery 300 may comprise several electrical heating devices positioned at different heights within the PCM enclosure 303. This has the advantage that it is possible to select how much of the PCM material is to be heated and thus how much energy is to be stored and/or released. Disposing the electrically heating material at different heights allows for heating different amounts (i.e., different volumes) of PCM. Thus, the functionality of the backup electric heater element of the present invention is highly adaptable to a wide range of applications, such as, for example, a two-port system.

The thermal battery 400 shown in fig. 4 is very similar to the thermal battery 300 shown in fig. 3. The difference is that the thermal battery 400 in fig. 4 has two heating devices: heating means 414 and heating means 416.

The thermal battery 400 includes: a thermal battery case 401; an insulating layer 402; a PCM enclosure 403; a low power Loop (LPC) 404; high power loop (HPC) 405; an HPC inlet 406; an HPC outlet 407; an LPC outlet 408; an LPC inlet 409; a battery controller 410; a mains power supply (CC) 411; a battery charge status signal 412; battery charge control signal 413; an upper positioned electric heater 414; a power supply 415 for the electric heater and a lower positioned electric heater 416.

Also shown are an overheat safety cut-off thermostat S0 and temperature sensors S1, S2, S3.

Thus, the battery cell 400 includes a first heating device 414 positioned in the upper half of the PCM enclosure 403 and a second heating device 416 positioned in the lower half of the PCM enclosure 403.

As shown in fig. 4, the heating means 414 is positioned approximately three quarters up in the PCM enclosure 414, and the lower positioned heating means 416 is positioned just above the bottom of the PCM enclosure 403. As mentioned above, the position of the heating means may be adapted to allow different amounts of PCM to be heated. As previously mentioned, the heating means may be any suitable form of electric heater/element.

The upper positioned heating device 414 may be used as a backup heater as described in fig. 3. Thus, if the primary heat source fails, the heating device 414 may be activated.

The lower positioned heating device 416 may be used with the primary heating system. This allows substantially all of the PCM material in the battery cell 400 to be charged quickly, as the heating device 416 is positioned near the bottom of the PCM enclosure 403.

The advantage of having the second heating means 416 is that this enables the PCM in the thermal battery 400 to be charged more quickly. The heating device 416 positioned at the bottom of the PCM enclosure 403 may be used as the primary heat source for the thermal battery 400.

Thus, with the embodiment shown in fig. 4, the present invention may have multiple integrally and/or internally located heating devices, such as electrical 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 that may then be stored and/or dispensed.

It has been found that the embodiments shown in fig. 3 and 4 provide a number of technical benefits, including the ability of the thermal battery to still be charged using an external primary heat source, thereby eliminating the need to have a complex fluid circulation loop. This also provides the ability for the thermal battery to be charged in a controlled manner by an external energy 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 positions, which provides the ability to heat different amounts of PCM and thus store and/or release different amounts of energy.

The applicant of the present application has therefore developed a thermal battery design whereby an integrally positioned and/or internally positioned heating device, such as an electrical heating device or a plurality of electrical heating devices, provides a number of distinct technical advantages.

The thermal battery of the present invention with an integrated and/or internally positioned electric heating means or a plurality of integrated heating means provides advantages such as:

a) the thermal battery can still be charged by an external primary heat source (e.g. a water heater) and in this application the electric heater is used as a backup (auxiliary) heat source if the primary heat source fails.

b) Second, as shown in fig. 4, an integral electric heater serves as the primary/primary heat source and directly heats the battery, thereby eliminating the need for a complex fluid circulation loop.

c) The thermal battery may also be charged in a controlled manner by both an external heat source and an internal heating device. For example, supplemental heating is performed by solar photovoltaic via ab electrical elements and by a water heater via a fluid circulation loop.

d) The heating device is surrounded by a PCM, i.e. an environment with constant and known parameters. In hot water tanks, the heating device is surrounded by drinking water and thus scale forms on the heating element, leading to the formation of hot spots and ultimately to the failure of the heating device. When the heating means are positioned in the PCM as in the present invention, these problems do not arise and therefore the heating means will have a long service life.

e) Unlike a water vat, the thermal battery of the present invention with the heating device positioned at the bottom can be charged to different levels. E.g. only switching on the heating means until 50% of the PCM melts and so on. Therefore, the state of charge can be controlled without using a plurality of elements located at different heights.

As described in detail below and schematically illustrated in fig. 5-15, several variations/comparative types have been designed and evaluated. Each of the figures has a slightly different configuration for the components of the apparatus, thereby bringing various technical benefits. As will be discussed below.

Fig. 5 shows a thermal battery 500 according to the invention, wherein a heating means, such as an electric heater, is provided, which is integrated with the thermal battery and/or positioned inside the thermal battery and submerged in the PCM, for example below the heat exchanger.

As shown in fig. 5, a thermal battery case 501 is provided, the thermal battery case 501 having an insulating layer 502 positioned within the thermal battery case 501. Within the insulating layer 502 is a PCM enclosure 503. An insulating layer 502 forms a sheath around the PCM enclosure 503 to hold the PCM 505.

A heat exchanger 504 and a heat exchanger core 520 are also provided.

As shown in fig. 5, the PCM enclosure 503 has two step features 503a located near the lower end of the thermal battery 500, the two step features 503a extending upward from the bottom of the PCM enclosure 503.

Fig. 5 also shows a heat exchanger 504, and the heat exchanger 504 may have a finned core to improve thermal efficiency. Also shown are heat exchanger circuit 504a and heat exchanger circuit 504 b.

A PCM 505 is disposed within the PCM enclosure 503.

On the upper side of the PCM enclosure 503, an inlet 506 (e.g., inlet circuit 1), an outlet 507 (e.g., circuit 1), an inlet 508 (e.g., circuit 2), and an outlet 509 (e.g., circuit 2) are provided.

A sensor 510 is also provided. As shown in fig. 5, three sensors 510 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 503, a second sensor is positioned in about the middle of the PCM enclosure 503, and another sensor is positioned near the lower end of the PCM enclosure 503. Thus, a plurality of different sensors 510 positioned at different vertical positions in the PCM enclosure 503 may be provided. This allows measuring and/or recording physical parameters, such as the temperature of the PCM, at different heights and throughout the entire body of PCM material.

Importantly, fig. 5 also shows that a heating means 511, such as an electrical heating means, is provided which is located close to the lower end of the PCM enclosure 503. The heating device 511 may be in the form of a tube and may be integrated with the thermal battery 500.

The heating device 511 is positioned below the heat exchanger 504.

A heat exchanger circuit 504a (heat exchanger circuit 1) and a heat exchanger circuit 504b (heat exchanger circuit 2) are also provided.

Thus, heating device 511 may be used to provide instantaneous heating to PCM 505.

As shown in fig. 5, a heating device 511 (e.g., a tubular electric heater) may be connected through the thermal battery enclosure 501 via, for example, a separator.

Further, the heating device 511 is immersed and completely submerged in the PCM 505. Thus, the heating device 511 directly contacts the PCM 505.

Fig. 5 provides a technical advantage in that heat is transferred from heating device 511 to PCM 505 via a larger surface area. Conduction and convection in the PCM 505 transfer heat to the heat exchanger 504, for example, a heat exchanger having finned core. This has been found to be a highly effective system.

The step feature 503a is a part of the PCM enclosure 503 and exists, for example, on both sides of the PCM enclosure 503. Thus, two step features 503a or any suitable number of step features 503a may be provided.

The step feature 503a provides an effective housing for the heating element terminals and safety shut-off feature, for example. The step feature 503a may also allow the thermal battery 500 to be insulated using a vacuum insulation panel.

These step features 503a also help to position heat exchanger 504 above heating device 511 and to position PCM 505 volume below heat exchanger 504.

The inventors of the present application have also found the following aspects according to the present invention. It has been found that when the thermal battery is cooled (i.e. in discharge mode), the PCM is in a solid state and has a low thermal conductivity. In this case, if the heating device is switched on, the PCM surrounding the heating device will be melted (i.e. this will form an expanding fluid pool surrounded by solid PCM), resulting in:

a) excessive localized pressure that can damage the battery cell casing;

b) rapid overheating of the PCM beyond the PCM safe operating limit; and

c) overheating of the heating device which leads to a shortened service life or to a malfunction of the heating device.

To overcome these problems, two main approaches have been studied and pursued:

a) the power input is reduced, i.e. the heat transfer process is slowed down to match the heat transfer characteristics of the PCM/heat exchanger core. This option is not further adopted because the battery charge time is not acceptable;

b) a plurality of metal rods inserted vertically as shown below in fig. 5a create a path for expanding the PCM volume to escape towards the top expansion space and thus prevent local pressure build-up and also increase convective heat transfer between the heating device and the heat exchanger/PCM core. The method has been optimized to enable full power heat transfer;

c) instead of using metal rods as described above, thin plates are incorporated into the finned core of the heat exchanger design, which extend into the heating zone of the thermal battery below the heat exchanger as shown in FIG. 5 b; and

d) the use of grid fins enables the PCM to be transferred between the fins, thereby facilitating heat transfer by convection and allowing more channels for PCM expansion.

Fig. 6a shows a thermal battery 600, in which thermal battery 600 a plurality of thermal conductors, such as, for example, metal rods, are inserted approximately vertically into a thermal battery housing. This is described below.

As shown in fig. 6a, a thermal battery 600 is provided, the thermal battery 600 having a thermal battery case 601 and an insulating layer 602 positioned within the thermal battery case 601. A PCM enclosure 603 is also provided.

Fig. 6a also shows a heat exchanger 604 which may be, for example, a finned plate core of a heat exchanger. The heat exchanger has a core 620. Fig. 6a also shows a heat exchanger circuit 604a (heat exchanger circuit 1) and a heat exchanger circuit 604b (heat exchanger circuit 2).

Within the PCM enclosure 603 is disposed a PCM 605.

On the upper side of the PCM enclosure 603, an inlet 606 (e.g., inlet circuit 1), an outlet 607 (e.g., circuit 1), an inlet 608 (e.g., circuit 2), and an outlet 609 (e.g., circuit 2) are provided.

A sensor 610 is also provided. As shown in fig. 6a, preferably three sensors 610 are provided. A first sensor is positioned near the upper end of the PCM enclosure 603, another sensor is positioned in approximately the middle of the PCM enclosure 603, and another sensor is positioned near the lower end of the PCM enclosure 603.

Fig. 6a also shows a heating device 611 located close to the lower end of the heat exchanger 604. The heating device 611 may be positioned near the bottom of the PCM enclosure 603 and substantially horizontally along the bottom of the PCM enclosure 603.

Fig. 6a also shows four heating conductors 612, such as, for example, conductive rods or heat pipes. The heating conductor 612 is positioned substantially vertically in the heat exchanger 604 and extends from the heat exchanger core 620 into the upper end region of the PCM 605.

Fig. 6b is a cross-section of a thermally conductive rod or thermal conduit 612 as shown in fig. 6 a. Figure 6b shows that heating travels up the heat conducting rod or heat pipe and cooling travels down the heat conducting rod or heat pipe.

Fig. 7 relates to a thermal battery 700 in which, rather than using a metal bar as shown in fig. 6a and 6b above, this embodiment relates to incorporating a thermal plate (e.g., a conductive thermal plate such as a metal plate) into a heat exchanger core (e.g., a heat exchanger finned sheet core). These plates extend into the heating zone of the thermal battery below the heat exchanger.

In the thermal battery 700 shown in fig. 7, a thermal battery case 701, an insulating layer 702, and a PCM enclosure 703 are provided. As shown in fig. 7, there is also provided a heat exchanger 704 and a heat exchanger core 720 which preferably may be a finned sheet core of a heat exchanger.

Fig. 7 also shows that a heat exchanger circuit 704a (heat exchanger circuit 1) and a heat exchanger circuit 704b (heat exchanger circuit 2) are provided.

Within the PCM enclosure 703 is disposed a PCM 705. An inlet 706 (e.g., inlet loop 1), an outlet 707 (e.g., loop 1), an inlet 708 (e.g., loop 2), and an outlet 709 (e.g., loop 2) are provided on the upper surface of the thermal battery case 701.

A sensor 710 is also provided. As shown in fig. 7, three sensors 710 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 703, another sensor is positioned in about the middle of the PCM enclosure 703, and another sensor is positioned near the lower end of the PCM enclosure 703.

Fig. 7 also shows that a heating device 711 is provided which is positioned below the lower end of the heat exchanger 704. Thus, the heating device 711 is completely submerged in the PCM 705.

Fig. 7 also shows that e.g. four plates 712 are provided. The plates are positioned substantially vertically in the heat exchanger 704 and optionally extend into the lower end region of the PCM 705 and through the heating means 711. Any suitable number of plates may be provided that may be oriented in any suitable orientation through the heat exchanger 704. It has been found that it is preferable that the plate 712 enter substantially vertically to aid in heat transfer up the plate 712 and cooling down the plate 712.

The plate 712 may be formed of a thermally conductive material, such as any suitable metal and/or alloy. The plate 712 may be relatively thick to assist in heat transfer. The plate 712 may be substantially planar and oriented substantially vertically in the thermal battery 700.

The plate 712 may be relatively thick, such as about 0.1cm to 5cm thick, about 0.1cm to 2cm thick, or about 0.1cm to 0.5cm thick.

Fig. 8 relates to another thermal battery 800 according to the present invention. The thermal battery 800 includes a generally L-shaped electrical heating device embedded in a heat exchanger, such as a finned sheet core of a heat exchanger. This is described below.

In fig. 8, a thermal battery 800 comprising a thermal battery outer case 801, an insulating layer 802, and a PCM enclosure 803 is provided. A heat exchanger 804 and a heat exchanger core 820 (e.g., a finned sheet core) are also provided. A heat exchanger circuit 804a (heat exchanger circuit 1) and a heat exchanger circuit 804b (heat exchanger circuit 2) are provided.

Fig. 8 also shows that there is provided a PCM 805 positioned within the PCM enclosure 803.

On the upper side of the PCM enclosure 803, an inlet 806 (e.g., inlet circuit 1), an outlet 807 (e.g., circuit 1), an inlet 808 (e.g., circuit 2), and an outlet 809 (e.g., circuit 2) are provided.

A sensor 810 is also provided. As shown in fig. 8, three sensors 810 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 803, another sensor is positioned in about the middle of the PCM enclosure 803, and another sensor is positioned near the lower ends of the PCM enclosure 803 and the PCM 805.

As shown in fig. 8, the L-shaped electric heating device 811 includes a substantially vertically positioning portion 811a extending downward through the PCM 805. Three substantially horizontal positioning portions 811b, 811c and 811d extend tangentially from the substantially vertical portion 811 a. Any number, such as single or multiple, of generally vertically and generally horizontally positioned portions may be provided.

One generally horizontally oriented portion 811b may extend in the lower quarter of the heat exchanger core 820, a horizontally oriented portion 811c may extend generally across the middle portion of the heat exchanger core 820, and a third horizontally oriented portion 811d may extend across the upper quarter of the heat exchanger 804. The horizontally positioned portions may be positioned in any suitable area of the heat exchanger core 820.

As shown in fig. 8, in the thermal battery 800, the heating device 811 and in particular the substantially horizontally positioned portions 811b, 811c, 811d are embedded into the core of the heat exchanger 814 (e.g., finned sheet core of a finned tube heat exchanger). The heating means 811 is preferably at least partially submerged in the PCM 805.

It has been found that in thermal battery 800, it is preferable to have an interference fit between heating element 811 and a component of heat exchanger core 820, such as a heat exchanger fin. It has surprisingly been found that this provides an increased heat transfer surface and an improved charging time.

It has also been found that an "L" shaped heating device having a substantially horizontal portion provides several advantages, such as:

1) mitigating any expansion of the PCM 805 during phase change (melting and solidification) of the PCM 805; and

2) the cables required for operation of the thermal battery are simply terminated at the top of the thermal battery.

As shown in fig. 8, generally horizontally positioned portions 811b, 811c, 811d of heating device 811 are disposed at specific heights within heat exchanger core 804 (e.g., finned sheet core) according to thermal battery footprint and aspect ratio to produce better performance with respect to uniform charging, charging time, local extraction and expansion characteristics.

It has been found that the positioning of the substantially horizontal positioning portions 811b, 811c, 811d of the heating means 811 alleviates the following problems:

d) excessive localized pressure that can damage the battery cell casing;

e) rapid overheating of the PCM beyond the PCM safe operating limit;

f) overheating of the heating device which leads to a shortened service life or to a malfunction of the heating device.

It has been found that the thermal battery 800 shown in fig. 8 is an ideal embodiment for a hybrid hot water heater that both uses stored heat and provides heating device power to instantaneously heat a domestic hot water supply.

Fig. 9 shows a thermal battery 900, in which thermal battery 900 a heating device (e.g., an electrically heated tubular heater) is embedded in a heat exchanger core, which may include a metallic conductive element, e.g., a conductive tube, such as a copper tube.

In a thermal battery 900 shown in fig. 9, a thermal battery case 901, an insulating layer 902, and a PCM enclosure 903 holding a PCM 905 are provided. A heat exchanger 904 and a heat exchanger core 920 are also provided.

On the upper side of the PCM enclosure 903, an inlet 906 (e.g., inlet circuit 1), an outlet 907 (e.g., circuit 1), an inlet 908 (e.g., circuit 2), and an outlet 909 (e.g., circuit 2) are provided.

A sensor 910 is also provided. As shown in fig. 9, three sensors 910 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 903, another sensor is positioned in about the middle of the PCM enclosure 903, and another sensor is positioned near the lower end of the PCM enclosure 903.

In fig. 9, the thermal battery 900 comprises a heating device 911, such as an electric heating device. In particular, the heating device 911 comprises an electric heating device 911a, the electric heating device 911a being positioned in an upper portion of the thermal battery 900 between the PCM enclosure 903 and the heat exchanger core 920. In particular, the electrical heating device 911a may be embedded in the manifold of the thermal battery 900.

Fig. 9 also shows that there are provided electrical heating means 911b, 911c embedded in the channels 915 in the heat exchanger core 920. The channels 915 may extend generally horizontally across the heat exchanger core 920 and turn in a "U" shape.

Fig. 9 also shows that a second heating device 911c is provided which passes substantially horizontally through the heat exchanger core 920.

Figure 10 is a diagram illustrating the heating device 911b positioned in the channel 915. In fig. 10, a PCM enclosure 903 and a PCM 905 are shown. The heat exchanger 904 is positioned within the PCM enclosure 903 and PCM 905. The heat exchanger 904 may be a finned core heat exchanger.

Fig. 10 shows that channels 922 are provided, the channels 922 being for example tubes for the heat exchanger 904. As shown in fig. 10, channel 922 may extend around channel 915, providing a "jump" arrangement.

Thus, fig. 10 relates to an embodiment in which an electric heater is provided that is embedded into the heat exchanger and in particular into a channel (i.e. a tube that may be made of copper or any other suitable conductive material) extending through the heat exchanger core.

In the embodiment shown in fig. 9 and 10, the heating means 911b, 911c are embedded into the heat exchanger core 904, and preferably and optionally not directly into the PCM 905. There are a number of different options for embedding the heating devices 911b, 911 c. The heating devices 911b, 911c may be embedded in various ways, such as:

as shown in the embodiment in fig. 9, the heating devices 911b, 911c and the channel 922 may provide an inlet extending from the working fluid, i.e. the PCM 905. The heating devices 911b, 911c may be embedded on the inlet in a manifold connected to smaller capillaries feeding through finned cores of the heat exchanger. This means that the heating devices 911b, 911c are within the working fluid and therefore the charging is uniform throughout the battery. The operation of the heating devices 911b, 911c is linked to auxiliary plant equipment and managed by the thermal battery controller.

Fig. 10 shows the position where the circuit 915 (e.g., skip bank pipe) and a portion of the heat exchanger, such as a heat exchanger finned core (fig. 10), are embedded. By skipping rows in the finned sheet core of the heat exchanger, the "runout tubes" can be occupied by several heaters at various locations throughout the finned sheet. The advantage is that the skip rows extend into the finned blocks, resulting in excellent heat transfer from the tubes to the fins.

In both variants shown in fig. 9 and 10, the heating device is in direct contact with the heat exchanger and thus an improved and consistent heat transfer is achieved. In addition, these elements are never in direct contact with the PCM, and therefore they need not be PCM compatible. This provides a heater with more options of reduced cost, improved reliability and robustness. The heater elements will be accessed for repair and maintenance without the maintenance personnel being exposed to the PCM. Higher power elements may be used and PCM operating conditions are independent of the higher power surface load of the heater.

Fig. 11a and 11b show another thermal battery according to the present invention. In the thermal battery, a heating device is provided which is embedded and/or positioned in a housing, wherein the housing contains a material which is capable of efficiently transferring and/or dissipating heat. Thus, the material allows for a better transfer of heat from the heating device to the heat exchanger core and/or the phase change material. This will be explained in more detail below.

As shown in fig. 11a, a thermal battery 1000 is provided having a thermal battery case 1001 and an insulating layer 1002 positioned within the thermal battery case 1001. A PCM enclosure 1003 and a PCM 1005 are also provided. A heat exchanger 1004 and a heat exchanger core 1020 are also provided.

In fig. 11a, an inlet 1006 (e.g., inlet circuit 1), an outlet 1007 (e.g., circuit 1), an inlet 1008 (e.g., circuit 2), and an outlet 1009 (e.g., circuit 2) are provided on the upper side of the PCM enclosure 1003.

A sensor 1010 is also provided. As shown in fig. 11a, preferably three sensors 810 are provided. A first sensor is positioned near the upper end of the PCM enclosure 1003, another sensor is positioned in about the middle of the PCM enclosure 1003, and another sensor is positioned near the lower end of the PCM enclosure 1003.

As shown in fig. 11a, a heating device 1011 (e.g., an electric heating device) is provided which is positioned near the lower end of the PCM enclosure 1003 and below the heat exchanger core 1020 (e.g., a heat exchanger finned sheet core). A heat exchanger circuit 1004a (heat exchanger circuit 1) and a heat exchanger circuit 1004b (heat exchanger circuit 2) are provided.

The heating device 1011 is positioned between the two step features 1003a, 1003b and extends between the two step features 1003a, 1003 b. The step features 1003a, 1003b are part of the PCM enclosure 1003.

The heating device is held within a housing 1030 that may be filled with a material/fluid capable of uniformly transferring heat and/or dissipating heat. The material/fluid may be, for example, any form of suitable oil and/or thermal paste.

In fig. 11a, heating device 1011 may be, for example, a tubular electric heating device that may be positioned within housing 1030 and surrounded by a material capable of efficiently transferring and/or dissipating heat. Thus, housing 1030 may be filled with oil and/or thermal paste. In contrast to the embodiment of fig. 11b, the housing 1030 is not finned.

In the arrangement shown in fig. 11a, the heating device 1011 is therefore embedded in a housing 1030 filled with a thermal material capable of uniformly transferring and/or dissipating heat. The housing 1030 is preferably integral with the PCM enclosure 1003. The heating means 1011 is not bonded to the PCM 1005.

The housing 1030 may be flat or optionally finned to increase surface area and enhance heat transfer from the heater to the hot material to the housing and then to the PCM 1005, but it is important to reduce the surface loading of the heating device 1011, resulting in a robust design and reduced service intervals. This has been found to be a significant technical advantage and increases the life of the thermal battery 1000.

The use of an oil bath in the housing 1030 means that the heating means 1011 need not have a high tolerance fit within the housing 1030 as required by cartridge heaters. In general, both the heating device 1011 and the housing 1030 preferably may be appropriately machined/designated to provide heat transfer (by an interference fit), and the heating device 1011 and the housing 1030 are tapered to enable the heating device 1011 to be easily removed. This is yet another advantage of the present design.

The design of the heating means 1011 and the housing 1030 shown in fig. 11a means that the heating means 1011 can be easily removed and can be accessed by service personnel without being exposed to the PCM 1005. A smaller volume of hot material, such as oil, is replaced during service intervals via an oil nozzle in the housing. Thus, another technical advantage is that the thermal battery 1000 can be very easily serviced.

Fig. 11b shows an alternative embodiment in which the housing 1050 is similar to that of fig. 11a, but in which a series of fins 1052 are provided extending along the length of the housing 1050. The fins 1052 are simply extended elongated plates that serve as heat dissipation areas to increase surface area and thus transfer and/or dissipate heat. A heating device 1054 is provided, the heating device 1054 extending into the housing 1050 along at least a portion of or substantially all of the interior length of the housing 1050.

Fig. 12 shows another thermal battery 1100 according to the present invention. In this variant, the heating means are positioned outside the PCM enclosure. A conductive block is provided inside, and a current is induced via an external induction heater. This will be discussed in more detail below.

Fig. 12 shows that a thermal battery 1100 is provided that includes a thermal battery case 1101 and an insulating layer 1102 positioned within the thermal battery case 1101. A PCM enclosure 1103 and a PCM 1105 are also provided. A heat exchanger 1104 and a heat exchanger core 1120 are also provided.

In fig. 12, an inlet 1106 (e.g., inlet circuit 1), an outlet 1107 (e.g., circuit 1), an inlet 1108 (e.g., circuit 2), and an outlet 1109 (e.g., circuit 2) are provided on an upper side of the PCM enclosure 1103.

A sensor 1110 is also provided. As shown in fig. 12, three sensors 1110 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 1103, another sensor is positioned in about the middle of the PCM enclosure 1103, and another sensor is positioned near the lower end of the PCM enclosure 1103.

A heat exchanger circuit 1104a (heat exchanger circuit 1) and a heat exchanger circuit 1104b (heat exchanger circuit 2) are provided.

As shown in fig. 12, a heating device 1111 is provided that is positioned near the lower end of the PCM enclosure 1003 and below the heat exchanger core 1104 (e.g., heat exchanger finned sheet core). In particular, in the thermal battery 1100 shown in fig. 12, the heating device 1111 is positioned externally to the PCM enclosure 1103 and at the bottom of the PCM enclosure 1103. Thus, the heating device 1111 is positioned between the bottom of the PCM enclosure 1103 and the bottom of the battery enclosure 1101. In a particular embodiment, the heating device 1111 is an induction heater.

Thus, the heating device 1111 may be described as being positioned external to the heat exchanger core 1104 and the PCM 1105.

As shown in fig. 12, there is provided a layer of conductive material 1112 positioned above or substantially above the heating device 1111 and inside the PCM enclosure 1103, the conductive material 1112 extending along the bottom of the PCM enclosure 1103 or substantially along the bottom of the PCM enclosure 1103. The function of the conductive material 1112 is to transfer heat inductively 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 within which an electrical current may be induced to generate and/or transfer heat.

FIG. 13 illustrates another thermal battery 1200 according to the present invention. In this embodiment, at least one or more removable cartridge heating devices comprising internally submerged conductive blocks are provided in the thermal battery 1200. This will be described in more detail below.

In the thermal battery 1200, a thermal battery case 1201 and an insulating layer 1202 positioned inside the thermal battery case 1201 are provided. A PCM enclosure 1203 and PCM 1205 are also provided. A heat exchanger 1204 and a heat exchanger core 1220 are also provided.

In fig. 13, an inlet 1206 (e.g., inlet circuit 1), an outlet 1207 (e.g., circuit 1), an inlet 1208 (e.g., circuit 2), and an outlet 1209 (e.g., circuit 2) are provided on an upper side portion of the PCM enclosure 1203.

A sensor 1210 is also provided. As shown in fig. 13, three sensors 1210 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 1203, another sensor is positioned in approximately the middle of the PCM enclosure 1203, and another sensor is positioned near the lower end of the PCM enclosure 1203.

A heat exchanger circuit 1204a (heat exchanger circuit 1) and a heat exchanger circuit 1204b (heat exchanger circuit 2) are provided.

As shown in fig. 13, a block of material 1212 is provided that extends along the bottom of the PCM enclosure 1203 and is positioned below the heat exchanger core 1220 and the PCM 1205. The block 1212 may extend fully or substantially or at least partially along from one side to the other side of the PCM enclosure 1203. The block 1212 is constructed of a conductive material such as any suitable metal and/or alloy. Thus, block 1212 means efficient transfer of heat from within the bottom of the PCM enclosure 1203 where the heating means are located.

At least one or a series of cartridge heating devices 1211 are provided which may be removably internally embedded within the block 1212. In fig. 13, although three cassette heating devices 1211 are shown, any suitable number of cassette heating devices 1211 may be provided. The cartridge heating device 1211 extends generally horizontally along the block 1212.

Thus, the cartridge heating device 1211 is positioned internally within the PCM enclosure 1203. Thus, the cartridge heating device 1213 may comprise a thermally conductive metal and/or alloy mass capable of efficiently transferring heat.

Thus, in the embodiment shown in fig. 13, a block 1212 is provided, the block 1212 serving as a heat source embedded at the bottom of the PCM enclosure 1213 and inside the PCM enclosure 1213. The block 1212 has a larger surface area than the embedded cartridge heating device 1213.

A technical advantage of the cassette heating devices 1211 is that they are externally accessible and can therefore be easily removed, since they are not in contact with the PCM 1205. Thus, the embodiment and the thermal battery 1200 shown in fig. 13 can be very easily repaired.

The modification uses a heater block embedded at the bottom of the PCM enclosure. The block has a larger surface area than the embedded cartridge heater. The heater may be externally accessible and thus can be removed and not in contact with the PCM.

Fig. 14 shows another thermal battery 1300 according to the present invention. In this embodiment, at least one or more removable cartridge heating devices comprising an internally submerged conductive block and an impeller agitator that mixes the PCM 1315 and assists heat transfer via forced convection are provided in the thermal battery 1300. Thus, the addition of an impeller agitator provides the following technical advantages:

assist heat transfer via forced convection.

The PCM 1305 and its constituent components are agitated and mixed.

The battery 1300 shown in fig. 14 is described in more detail below.

The battery 1300 includes a thermal battery case 1301 and an insulating layer 1302 positioned within the thermal battery case 1301. A PCM enclosure 1303 and PCM 1305 are also provided. A heat exchanger 1304 and a heat exchanger core 1320 are also provided.

In fig. 14, an inlet 1306 (e.g., inlet circuit 1), an outlet 1307 (e.g., circuit 1), an inlet 1308 (e.g., circuit 2), and an outlet 1309 (e.g., circuit 2) are provided on the upper side of the PCM enclosure 1303.

A sensor 1310 is also provided. As shown in fig. 14, three sensors 1310 are preferably provided. A first sensor is positioned near the upper end of the PCM enclosure 1303, another sensor is positioned in about the middle of the PCM enclosure 1303, and another sensor is positioned near the lower end of the PCM enclosure 1303.

A heat exchanger circuit 1304a (heat exchanger circuit 1) and a heat exchanger circuit 1304b (heat exchanger circuit 2) are provided.

As shown in fig. 14, a block of material 1312 is provided that extends along the bottom of PCM enclosure 1303 and is positioned below heat exchanger core 1320 and PCM 1305. The block 1312 may extend completely or substantially or at least partially along the length from one side of the PCM enclosure 1303 to the other. Block 1312 is comprised of a conductive material such as any suitable metal and/or alloy. Thus, block 1312 means efficient heat transfer from within the bottom of the PCM enclosure 1303.

Internally embedded within block 1312 is at least one or a series of cartridge heating devices 1311, which may be removable. In fig. 14, although three cassette heating devices 1311 are shown, any suitable number of cassette heating devices 1311 may be provided.

Thus, the cartridge heating device 1311 is positioned internally within the PCM enclosure 1303. The cartridge heating device 1311 may thus comprise a thermally conductive metal and/or alloy block capable of efficiently transferring heat.

Thus, in the embodiment shown in fig. 14, a block 1312 is provided, the block 1312 serving as a heat source embedded at the bottom of the PCM enclosure 1303 and inside the PCM enclosure 1303. The block 1312 has a larger surface area than the embedded cartridge heating device 1311.

In addition, the thermal battery 1300 includes an agitator 1315, and the agitator 1315 may be any form of agitation device, such as a rotary agitator. An agitator 1315 may be positioned near the bottom of the PCM enclosure 1303, for example, and may be used to agitate the PCM 1305 to improve the efficiency of the thermal battery 1300 and heat transfer.

FIG. 15a shows another embodiment of the present invention, in which a thermal battery 1400 is shown. A heating device is provided in the thermal battery 1400 extending substantially vertically within the PCM enclosure. The heating means may be in the form of a network of heater elements. This will be described in more detail below.

The battery 1400 includes a thermal battery case 1401 and an insulating layer 1402 positioned within the thermal battery case 1401. A PCM enclosure 1403 and a PCM 1405 are also provided. A heat exchanger 1404 and a heat exchanger core 1420 are also provided.

In fig. 15a, an inlet 1406 (e.g., inlet circuit 1), an outlet 1407 (e.g., circuit 1), an inlet 1408 (e.g., circuit 2), and an outlet 1409 (e.g., circuit 2) are provided on an upper side of the PCM enclosure 1403

A sensor 1410 is also provided. As shown in fig. 15a, preferably three sensors 1410 are provided. A first sensor is positioned close to the upper end of the PCM enclosure 1403, another sensor is positioned in about the middle of the PCM enclosure 1403, and another sensor is positioned close to the lower end of the PCM enclosure 1403.

As shown in fig. 15a, a series of heating devices 1411 are provided which extend substantially vertically within the PCM enclosure 1403. Any number of heating devices 1411 may be provided, such as a single heating device or multiple heating devices. The embodiment shown in fig. 15a, merely as a specific example, shows six heating devices 1411 positioned substantially vertically within the PCM enclosure 1403.

Fig. 15b is an enlarged cross-sectional view of the heating device 1411. Fig. 15b shows that the heating device 1411 includes a heating device web 1420 in a grid-like pattern. Within the mesh section is disposed a tubular section 1422 that provides efficient heat transfer. The tubular section 1422 may be a copper tube. The heating device 1411 is in the form of fins 1430.

In the arrangement shown in fig. 15a and 15b, and during manufacture of the heat exchanger 1404, the conventional fins are replaced with "heating fins", i.e., heating devices 1411. The location of the heating device 1411 is determined by, for example, the aspect ratio and height of the thermal battery 1400, and the heating device 1411 used can be selected to produce the desired power input based on the thermal energy required. In certain embodiments, the heating fins in the form of heating device 1411 are an integral part of heat exchanger 1404 and therefore will not be removable. However, more additional heating fins than are required, i.e. heating devices 1411, may be placed in place for redundancy to ensure robustness of the thermal battery.

Due to the large heating surface area of this design, the power density of each heating fin (i.e., heating device 1411) is very low and will improve the robustness and longevity of the system.

The density of the heater element mesh from the top to the bottom of the heating fins, such as shown in fig. 15b, can also be varied to optimize the charging and discharging capabilities to meet the application.

In the thermal battery 1400 shown in fig. 15a and 15b, the heating device 1411 can therefore be used instead of the ordinary fins found in heat exchangers. In certain embodiments, Positive Temperature Coefficient (PTC) heaters may be used that can be slid onto heat transfer tubes, such as copper tubes, in place of the standard fins found in heat exchangers.

FIG. 16a shows another embodiment of the present invention, in which a thermal battery 1500 is shown. In the embodiment shown, the following heating devices are provided in the thermal battery 1500: the heating means is in the form of a low power vertical heater oriented substantially vertically, for example in the form of a heat pipe or conductive rod to assist the PCM circulation. This has been found to produce a pumping action on the PCM material within the thermoelectric cell.

The arrangement shown in fig. 15a has been found to have a number of technical advantages, such as:

1) increasing the heat transfer from the base of the thermal battery to the core, thereby optimizing the charging time; and

2) a path is created for the melted PCM to travel, mitigating any pressure build-up due to the phase change and expanded PCM.

In the thermal battery 1500, a thermal battery case 1501 and an insulating layer 1502 positioned inside the thermal battery case 1501 are provided. A PCM enclosure 1503 and PCM 1505 are also provided. A heat exchanger 1504 and a heat exchanger core 1520 are also provided.

In fig. 16a, an inlet 1506 (e.g., inlet circuit 1), an outlet 1507 (e.g., circuit 1), an inlet 1508 (e.g., circuit 2), and an outlet 1509 (e.g., circuit 2) are provided on an upper side of the PCM enclosure 1503.

A sensor 1510 is also provided. As shown in fig. 16a, three sensors 1510 are preferably provided. A first sensor is positioned close to the upper end of the PCM enclosure 1503, another sensor is positioned in about the middle of the PCM enclosure 1503, and another sensor is positioned close to the lower end of the PCM enclosure 1503.

A heat exchanger circuit 1504a (heat exchanger circuit 1) and a heat exchanger circuit 1504b (heat exchanger circuit 2) are provided.

As shown in fig. 16a, a heating device 1511 is provided which is positioned near the bottom of the PCM enclosure 1503. The heating device 1511 extends substantially over the bottom of the heat exchanger 1504.

Figure 16a also shows that a plurality of generally vertically oriented low power vertical heaters 1512 are provided. The vertical heater 1512 may be in the form of a low power heating device or alternatively in the form of a heat pipe. Any suitable number of vertical heaters 1512 may be provided.

In the embodiment shown, four generally vertically oriented heaters 1512 are provided in the thermal battery 1500, the four generally vertically oriented heaters 1512 extending from the upper surface of the PCM enclosure 1503, through the PCM 1505, and into the heat exchanger 1504.

Figure 16b shows an enlarged cross-sectional view of a different type of vertical heater that may be used. On the left side of fig. 16b is a low power heating means 1530. The heat pipe 1540 is shown on the right side of fig. 16 b. Fig. 16b shows heat traveling up the vertical heater and the cooling flow down through the heater.

FIG. 17 shows a cross-section of a louvered fin design, generally indicated at 1600, in accordance with the present invention. Cascade fin design 1600 includes a series of tubes 1601 (e.g., copper tubes) that can be used to transfer heat. PCM material flows within the tubes 1601 and around the tubes 1601. The flow of PCM material is shown by reference numeral 1603. As shown in fig. 17, the flow of PCM material may be directed using louvers 1602a in fins 1602. Thus, the fin 1602 includes louvers: the louvers may be fully open in nature such that the louvers are fully planar or are converted into an angled form such that the louvers may be used to direct the flow of PCM material. The grid fin design 600 may be incorporated into any of the embodiments and heating cells described above.

While particular embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the invention. For example, any suitable type of enclosure may be used for the thermal battery. In addition, any form of suitable PCM material and electronic control mechanism may be used. Furthermore, the heating means may be in any suitable form as contemplated within the scope of the present application, such as an electrical heating type or any other form of heating system. Furthermore, any form of heat exchanger may be used in the thermal battery described in the present invention.