Unitized energy storage system enclosure

• US 9,843,078 B2
• Filed: 02/12/2015
• Issued: 12/12/2017
• Est. Priority Date: 02/18/2014
• Status: Active Grant

• Current Assignee: Unique Electric Solutions Incorporated
• Original Assignee: DG Systems LLC
• Inventors: Ambrosio, Joseph Mario
• Primary Examiner(s): Apicella, Karie O'Neill
• Application Number:
  US14/620,436
• Publication Number:
  US 20150236311A1
• Time in Patent Office: 1,034 Days
• CPC Class Codes: H01G 11/18 against thermal overloads, e.g. heating, cooling or ventilating
• CPC Class Codes: H01G 11/78 Cases; Housings; Encapsulations; Mountings
• CPC Class Codes: H01G 11/84 Processes for the manufacture of hybrid or EDL capacitors, or components thereof
• CPC Class Codes: H01G 2/08 Cooling arrangements; Heating arrangements; Ventilating arrangements
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/6555 arranged between the cells
• CPC Class Codes: H01M 10/6557 arranged between the cells
• CPC Class Codes: H01M 10/6561 Gases
• CPC Class Codes: H01M 10/6567 Liquids
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H01M 50/213 adapted for cells having curved cross-section, e.g. round or elliptic H01M50/209, H01M50/216 take precedence
• CPC Class Codes: H01M 50/227 Organic material
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A thermally managed electrical energy storage device enclosure includes a monocoque body formed from a plastic material using a single batch process and at least one void defined by a circumferential inner wall of the monocoque body. The void is adapted to receive at least one electrical energy storage device with a compression interference fit between an entire outer circumferential surface of the electrical energy storage device and the circumferential inner wall. The circumferential inner wall exerts a uniform radial force on the electrical energy storage device received therein.

Claims

1. A thermally managed electrical energy storage device enclosure comprising:

a monocoque body formed from a thermally conductive plastic material using a single batch process; and

at least one void defined by a circumferential inner wall of said monocoque body;

said at least one void adapted to receive at least one electrical energy storage device with a compression interference fit between an entire outer circumferential surface of the electrical energy storage device and said circumferential inner wall defining said at least one void;

wherein said circumferential inner wall exerts a uniform radial force on the electrical energy storage device received therein.

2. The thermally managed electrical energy storage device enclosure according to claim 1, wherein said at least one void comprises a plurality of voids.

3. The thermally managed electrical energy storage device enclosure according to claim 2, wherein said plurality of voids are arranged symmetrically around a center of said monocoque body.

4. The thermally managed electrical energy storage device enclosure according to claim 1, wherein said at least one void has a cylindrical shape.

5. The thermally managed electrical energy storage device enclosure according to claim 1, wherein said entire outer circumferential surface of the electrical energy storage device is in direct contact with said circumferential inner wall defining said at least one void.

6. The thermally managed electrical energy storage device enclosure according to claim 1, further comprising a passageway extending through said monocoque body.

7. The thermally managed electrical energy storage device enclosure according to claim 6, further comprising at least one of an electrical signal conductor and a power conductor routed through said passageway.

8. The thermally managed electrical energy storage device enclosure according to claim 6, further comprising a retention rod disposed within said passageway.

9. The thermally managed electrical energy storage device enclosure according to claim 1, wherein said monocoque body comprises a substantially rectangular body, said at least one void comprises a plurality of voids arranged in an array and an integral control box is provided at an end of said substantially rectangular body.

10. The thermally managed electrical energy storage device enclosure according to claim 9, further comprising an access cover comprising an access plate covering said integral control box and a finned panel covering said array of voids.

11. The thermally managed electrical energy storage device enclosure according to claim 1, further comprising an auxiliary cooling system, said auxiliary cooling system comprising at least one of a liquid cooling system and an air cooling system.

12. A method of forming a thermally managed electrical energy storage device module, the method comprising the steps of:

a) fabricating a monocoque body enclosure from a thermally conductive plastic material using a single batch process, the monocoque body enclosure having least one void defined by a circumferential inner wall of the monocoque body enclosure; and

b) inserting an electrical energy storage device into the at least one void with a compression interference fit between an entire outer circumferential surface of the electrical energy storage device and the circumferential inner wall defining the at least one void;

wherein the circumferential inner wall exerts a uniform radial force on the electrical energy storage device received therein.

13. The method of forming a thermally managed electrical energy storage device module according to claim 12, wherein during the step of inserting the electrical energy storage device into the at least one void, the electrical energy storage device is provided at a first temperature and the monocoque body enclosure is provided at a second temperature which is different from the first temperature.

14. The method of forming a thermally managed electrical energy storage device module according to claim 12, wherein the at least one void comprises a plurality of voids.

15. The method of forming a thermally managed electrical energy storage device module according to claim 14, further comprising the step of arranging the plurality of voids symmetrically around a center of the monocoque body enclosure.

16. The method of forming a thermally managed electrical energy storage device module according to claim 12, further comprising the step of directly contacting an entire outer circumferential surface of the electrical energy storage device with the circumferential inner wall defining the at least one void.

17. The method of forming a thermally managed electrical energy storage device module according to claim 12, wherein the step of fabricating a monocoque body enclosure further comprises forming a passageway extending through the monocoque body enclosure.

18. The method of forming a thermally managed electrical energy storage device module according to claim 17, further comprising the step of routing at least one of an electrical signal conductor and a power conductor through the passageway.

19. The method of forming a thermally managed electrical energy storage device module according to claim 17, further comprising the step of inserting a retention rod through the passageway.