Modular battery power storage and generation system

A power storage and generation system is modular, portable, stackable, electrically connectable, interchangeable, and customizable with respect to interconnections among one another. The electrical connections are arranged in such a manner that they are not exposed to the user when in use, thus preventing accidental short circuits or electrical shocks. The power storage and generation systems can be used together or separately to provide both D/C power then converts to A/C power supply for electrical equipment at remote locations. Different configurations allow for the adaptation of the system to different voltage and amperage requirements for various applications.

BACKGROUND OF THE INVENTION

The present invention relates to energy storage systems, and more particularly to a modular rechargeable battery power system.

Conventional lead acid battery or rechargeable battery packs for providing power to electric vehicles, electrical devices, and accessories have many limitations. First, the lead acid solutions that are currently being used for most utility electric vehicles are very inefficient in term of space and weight. Lead acid batteries require many times more raw material than lithium-ion to achieve the same energy storage, making a much larger negative impact on the environment and are highly hazardous to human health. On the other hand, lithium iron phosphate batteries offer significant advantages, including improved discharge and charge efficiency, longer life span, and the ability to deep cycle while maintaining performance.

When high capacity and voltage is required, the conventional lead acid battery or rechargeable battery packs are made up from multiple cells or batteries connected to one another by cable and clamp connectors partially exposed, which may present shock and/or short circuit hazards. Also, the size and weight of the batteries will greatly increase making it very difficult and inconvenient for the user to install, maintain, and transport. Furthermore, most of the batteries are for single-purpose usage. In most cases, this is D/C to D/C application only, which limits the use of the battery for other applications that require A/C power. In order to provide A/C power to electrical equipment at remote locations without access to the power grid or in the event of natural disasters or extreme weather emergencies such as hurricanes, earthquakes, fires, ice storms, or other conditions leading to power outage, fuel generators are most commonly used during these events. These types of generators require frequent maintenance and are costly to maintain. Additionally, fuel generators are very loud, require toxic fuels, and are environmentally hazardous.

To become energy independent and off the grid, there is a desire and need to provide an improved power storage and generation system that is a more reliable power source wherever electricity is needed; a power storage and generation system that is modular and thus allows quick and easy connection and disconnection from its base charging station, transport, and reconnect to a portable charger inverter to directly power electronic equipment or recharge batteries for other consumer electronics; a power storage and generation system able to charge and recharge using a wall outlet (grid), solar power or other power sources; and a power storage and generation system that is modular, portable, stackable, electrically connectable, interchangeable, and expandable to provide the desired power voltage and capacity for various applications. Further, a system that does not provide exposed electrical connections is desired and needed to maintain safety for the system's users.

It is apparent that a need exists for an improved power storage and generation system that overcomes the disadvantages of the prior art. The present invention is directed toward providing such system and method that its predecessors do not provide.

BRIEF SUMMARY OF THE INVENTION

The present invention provides solutions to these problems by providing a power storage and generation system that is modular, portable, stackable, electrically connectable, interchangeable, and customizable with respect to interconnections among one another. The electrical connections are arranged in such a manner that they are not exposed to the user when in use, thus preventing accidental short circuits or electrical shocks. In certain embodiments, the power storage and generation systems can be used together or separately to provide both D/C power for utility electric vehicles (UEVs) such as a battery-powered scooter, bike, and golf cart, and most portable electronics, then converts to A/C power supply for electrical equipment at remote locations without access to the power grid or in the event of natural disasters or extreme weather emergencies such as hurricanes, earthquakes, fires, ice storms, and other causes of power outages.

In certain embodiments, the stackable, interchangeable, and modular nature of the invention provides features of allowing the power storage system to easily disconnect from UEVs to reconnect to a base charger and charge the battery system with the capability to add-on additional battery systems to maximize or increase the capacity of the system for other applications. The power storage and generation systems can be charged and recharged by a regular wall outlet, solar, or other renewable power sources. The power storage and generation systems are able to connect to one or more adjacent power systems' top and bottom caps from above or below, respectively, with associated electrical connectors connecting the internal circuitry to transfer current from one system to another system to provide the desired power voltage and capacity for various applications. The systems' endcaps and connectors permit it to be installed in any orientation, such that the systems may be used standing upright, lying sideways at ninety degrees, or any other increments, and the components will still reliably connect. The endcaps are designed to inherently shield the electrical connections from inadvertent contact. Also, the special connectors feature allows the systems to easily be disconnected, transported to where power is needed, and then reconnected. The power storage and generation system is capable of providing either D/C or A/C power and it can be customizable and expandable to provide the desired power voltage and capacity for various applications. The power storage and generation system may in certain embodiments include voltage or power status indicators, a convenient on/off switch, and remotely access and control to power on/off in order to minimize unintentional drain on the systems.

In certain embodiments, a number of additional features may be included. The battery bottom and bottom covers with an associated electrical connector construction may be identical with other battery, charger, inverter, or power systems. The battery module can be stacked below or on top of the power systems' associated electrical connector. The first battery module may be parallel connected to independently charge and discharge the second or other battery modules. The systems top and bottom covers design and construction may allow the battery to work independently, replacing the need to increase or decrease the energy capacity without interruption or discontinuing the modular power storage and generation system while in operation. The battery modules may include fire extinguisher modules that automatically act to prevent an overheating condition within the battery from causing a fire.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

All numbers used in the specification and claims are to be understood as being or may be modified, unless otherwise indicated. Accordingly, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending at least upon the specific analytical technique, the applicable embodiment, or other variations according to the particular configuration of the systems. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, details, changes and omissions may be made in the design, operating configuration and arrangement of the present, preferred and other exemplary embodiments may be made without departing from what is covered in the appended claims.

In general, the modular power storage and generation system100comprises a power storage system200, which is an energy storage or battery module with internal components and electrical circuitry that are able to store electrical energy; power generation system300, which is a power control module with internal circuitry, including A/C and D/C input and output connectors supplying both an A/C and D/C electrical power supply; and system docking station400, which is a base that is electrically connected to charge and discharge multiple power storage systems200in place of power generation system300.

With reference toFIGS. 1-3D, a first embodiment of the present invention may be described. The overall power storage and generation system100consists of one or more power storage modules200and power generation modules300. The modular nature of the system allows for various custom configurations to be created in order to power a desired load, and then readily disconnected and then reconnected in a different configuration to power another load application. The modular nature of the individual power storage systems200permit the power generation system300to be disconnected from power storage systems200into individual modules that are each more readily transported to a desired location and conveniently reconnected as desired. The power storage system200features multiple D/C input and output terminals205A that recess so the power storage system200can easily connect or dock to a power generation system300or docking station400. Connectors305A on power generation system300provide for the D/C interconnection between a power storage system200and a power generation system300, such that D/C current passes between connectors205A and305A. In the case where two power storage systems200are stacked vertically, D/C power may be transferred between connectors205A on the top side of a power storage system200and connectors203A on the bottom side of a power storage system200. Because of the design and arrangement of connectors205A and305A, it may be seen that when a power storage system200and power generation system300are connected, the connection is not exposed such that there is no risk of an inadvertent short circuit by contact with a conductor in the area or shock due to a person touching the system when in use. Likewise, when two power storage systems200are connected, the interconnection between corresponding connectors205A at the top of one power storage system200and connectors203A at the bottom of the next power storage system200provides a shielded connection preventing inadvertent short circuit or shock.

The power generation system300may have inlet sockets312and outlet sockets315or other connector terminals that can be charge from the wall outlet or other renewable energy sources such as solar, wind, or any other source. The power storage system200as shown inFIGS. 1-2Cincludes an outer casing201uniquely designed with top and bottom caps202and203, respectively, with associated connectors as described above that make it easier to transport, assemble and disassemble, electrically connecting to one another. Various embodiments of the invention will be described in detail with reference to the accompanying drawings.

The power storage system200comprises an outer casing201with a latch slot201A and USB slot201B to lock the top and bottom caps into place; a top cap202with associated carrying handle204, top cap slot202A, terminal slot202B, and power button slot202C; a bottom cap203having bottom cap latches203A and terminal slot203B; terminals205including terminal housing205A and power contact205B that may fastened in place with retainer pins208; ON/OFF power switch or button206A, which may have a LED indicator206B indicating the power or operating status; the battery cells209D held together with cell holders209C and connector tubes209B; electrically connecting to alloy plate209E, alloy or copper bar211B, and alloy cable wire211A; battery management system (BMS)210B; USB ports207; and PCB module210A, which are separated and secured in place by fastener209A, insulator plate209F and cover209G.

The power generation system300comprises an outer casing301having latch slot301A and vent slot314to lock the top and bottom caps into place; top cap302with associated carrying handle304, top cap latch302A, terminal slot302B, and power button slot302C; bottom cap303having bottom cap latches303A and terminal slot303B; terminals305including terminal housing305A and power contact305B that may fastened in place with retainer pins308; ON/OFF power switch or button306A, which may have a LED indicator306B indicating the power or operating status; secondary power switch or bottom306C; PCB module310A; power board310D; control board310E; LCD board310F; UBS ports307; mounting panel316with USB slot316A and power button slot316B; cooling fan313; wiring311A; screw309A; and inlet312and outlet sockets315.

The docking station400, as shown inFIGS. 5-5E, comprises a base with one or more receptor terminals405A including terminal housing404A and power contact405B with a similar design construction as the systems so the docking station and power storage system may easily disconnect or connect as shown inFIG. 6-8C. The docking station400can charge or discharge the power storage system200when connected. The system may discharge power from the power storage system200by transferring power from the power storage system200by either providing D/C power for utility electric vehicles (UEVs) such as a battery-powered scooter, bike, golf cart, or the like, or most portable electronics with terminals204directly or terminals connecting to the docking station400.

The power generation system300or docking station400may discharge the power from the power storage system200by transferring power from the power storage system200to power generation system300providing both 5 VDC USB ports307and 100-220 AC315outlet socket or output terminals to supply power for most electrical equipment. Stacking multiple power storage systems200provides an expandable and flexible source of power supply and power storage for utility electric vehicles as desired. If the user requires additional power, he or she may choose to add one or more power storage systems200, while a user whose power needs are relatively lower may choose to reduce the number of power storage systems200in the overall system.

The power storage and generation system100include top cap ends202and302, which are male receptacles; and bottom cap ends203and303, which are female receptacles. The outer casings feature identical top and bottom caps of the power storage system200and power generation system300that form male and female receptacles. The system endcaps and connectors permit the power storage system100to be connected in either direction. The systems may either be used standing upright, at 180 degrees, or lying side way 90 degrees, or other increments, and the systems will still connect; the unique connectors feature allows the power generation system200to easily connect and disconnect to one or more power storage systems200, such as shown inFIG. 3A-D. The power storage system200may either connect to the top or bottom of the power generation system300by the top and/or bottom caps that house the terminals205and305with associated electrical connectors connects to the internal electrical components to permit the power generation system300to charge the power storage system200from an A/C wall power outlet, solar, or other power sources. The identical top and bottom caps with connectors allowing the power storage and generation systems100able to connect to one or more adjacent systems from above or below, as shown inFIGS. 3C and 3D. The terminals205and305with associated electrical connectors connecting the internal circuitry to transfer current from one system to another system to provide the desired power voltage and capacity for various applications. The complementary nature of the connections for power storage system200and power generation system300allow any configuration of multiples of these components, as desired by the user. For example,FIG. 3Aillustrates a power storage system200connected on top of a power generation system300;FIG. 3Billustrates a power generation system300connected on top of a power storage system200;FIG. 3Cillustrates an arrangement similar toFIG. 3Abut with an additional power storage system200′ installed on top of the first power storage system200; andFIG. 3Dillustrates an arrangement similar toFIG. 3Bbut with an additional power storage system200′ installed on top of power generation system300.

As shown, for example, inFIG. 2A, the power storage system200and power generation system300terminals use an associated electrical connector power contact205B and305B that interlock in place when connected to one or more adjacent systems. The power storage and generation systems100are capable of operating at either D/C or A/C voltage. PCB boards310A include an inverter with the internal charge-and-discharge electrical components. The power generation system300further includes a heat sink connected to the inverter on the power board310D. The power storage and generation system100may include a voltage or power status indicator306, and convenient on/off switch306A, with remotely access and control to power on/off to minimize unintentional drain on the systems. The system may also include an internal battery management system (BMS)210B and electrical circuit board that enable the system to be connected via Bluetooth or Wi-Fi access to monitor the status of the battery module. The BMS may have either Bluetooth or/and Wi-Fi capabilities.

The power storage system200comprises multiple lithium ion phosphate battery cells109D that are connected either in series, parallel, or a combination of both. However, according to other alternative embodiments, other battery materials and sizes may be used. A wide variety of capacities and voltages may be configured depending on the desired application. Battery cell holders109C may be used, which can easily access and/or replace a damaged individual battery cell109D without disassembly of the entire battery pack. The user may simply disconnect the appropriate cable, wiring, and welder joints to remove or replace the damaged cell. Connection between battery cells to/from the electrical circuitry may be different depending on the battery size and voltage configurations (series, parallel, or combination of both). Depending on the different configurations, some cells109D may be grouped in a series connection, and others in parallel. A system200may produce 12V, 24 V, 36V, 48V, 60V, 72V and 5, 10, 15, 20 Ah, respectively, when hours fully charged, although other voltage, capacity, settings and configurations may be used. The system200may have a capacity of 480 watt-hours (48V 10 Ah), and other embodiments of the system, for example, may have a capacity of 960 watt-hours (48V 20 Ah), and each system comprises a lithium ion phosphate battery cell material. However, according to alternative embodiments, other battery materials and chemistries may be used, and a wide variety of capacities and voltages may be provided depending on the configuration for variety of applications.

The power generation and storage system100in may independently charge from each storage system200. The systems may be electrically connected to the storage system through a terminal with associated power connectors and contacts. In other cases the module300of one storage system200may be electrically connected to module300and the battery200of another storage system200′. The power module300may be connected to independently charge and discharge to both storage system200and200′ simultaneously.

The power storage and generation systems100may include electronic components including an input protection circuit, an output protection circuit, a charge controller, a display controller and a temperature controller, which may be configured on power controller circuit board310E. The input protection circuit may include an input port that will shut down when the temperature exceeds a predetermined level to protect the battery from being overcharged, overheated or otherwise damaged. The output protection circuit may include output connection ports and other suitable electronic components for delivering appropriate electrical power from the battery to the outlet ports. The input and output ports are protected by a readily accessible fuse having a suitable rating. The power controller circuit board310E regulates the charge and discharge to the power storage system200. The LCD display310F circuit detects the voltage of the battery and controls the LCD display that indicates the real-time charge of the battery module. The temperature controller includes a temperature detector that monitors D/C and A/C inputs and outputs, such that when the temperature sensed by the detector exceeds a predetermined set point, it will automatically cut power off. Casing301may be made of a heat conductive metal, thus allowing heat transfer between the internal part and the external part to facilitate operation at the most desirable temperature and conditions.

The system may use pins308to secure components in place. These may be manually inserted and removed in order to reconfigure the system. The top and bottom cap ends are made from a resilient, tacky, or other non-slip material whose properties or characteristics to help minimize relative movement of components when connected together as an assembly.

In certain embodiments a fire retardant/extinguisher capsule217, as shown for example inFIG. 2C, is employed to protect the battery from fire in the case of an overheat condition. In normal use, a lithium ion battery remains at a temperature of below 40° C. Overheating can result from various causes, such as damage to the battery, a short circuit, overcharging, application of reverse polarity, or exposure to a high ambient temperature. The circuitry in power storage system200will, in certain embodiments, turn off power storage system200when the temperature reaches an unsafe level, such as 55° C. in one example.

If the circuitry fails to turn off power storage system200and temperature continues to increase, then capsule217may be activated in one of two ways. First, there are positive and negative leads into capsule217, which are separated by a polymer fiber material (polymorph). Polymorph is a non-toxic, biodegradable polyester with a low melting temperature of about 60° C. Other materials may be used, with melting temperatures between 55° C. and 65° C. When the polymorph separating the leads melts due to a signal being sent across the leads, then electrical contact is made between them. This contact ignites an explosive material within capsule217. The explosion that results sends flame retardant material through the interior of power storage system200to extinguish the fire. The flame-retardant materials used in capsule217may include phosphorous, carbon dioxide, powdered graphite, copper powder, and/or sodium carbonate, as non-limiting examples.

If this first method does not function due to failure of the control circuitry or damage to the leads, then capsule217has a casing that is also constructed of the micrometer-sized polymorph fibers that together form a heat-sensitive polymer coating. In the presence of sufficient heat, the polymorph fibers in the coating of capsule217will melt. With the interior of capsule217thus exposed to the heat, this then ignites a fuse within capsule217, which is in communication with the explosive that is then ignited. Again in this case, the flame-retardant material is sent throughout the power storage system200by the explosion, thereby extinguishing the fire and preventing any further fire or electrocution hazard that results from the overheat condition.

FIGS. 4A-4Cillustrate one or two power storage systems200interconnecting with an enclosure500. An enclosure of this type may be employed, for example, on a powered vehicle such as a moped in order to securely house power storage systems200while the vehicle is in motion. The high walls of enclosure500serve to prevent the power storage systems200from becoming dislodged during movement of the vehicle, and also serve to prevent any contact with the electrical connections by a conductor or the user while the system is in use.

FIGS. 5-5Eillustrate a docking station400that allows the side-by-side mounting of up to four power storage systems200. Alternative embodiments of docking station400may allow for fewer or more power storage systems200to dock. Docking station400includes a top cap402to receive the power storage systems200that fits onto terminal housing404A. Endcaps404B provide support for docking station400. Electrical interconnection with power storage systems200occurs at receptor terminals405A, which mate with power contacts205B. Docking station400further includes secondary power switch406C, USB ports407, inlet412, vent slots414for cooling, and outlet socket415.

FIGS. 6-7Billustrate a configuration with four power storage systems200connected directly to a docking station400.FIGS. 8-8Aillustrate a configuration with eight power storage systems200connected to a docking station400, with four of the power storage systems200attached directly to the docking station400, and each the other four power storage systems200attached at the top of one of the other four power storage systems200.FIGS. 8B-8Cshow a similar configuration with twelve power storage systems200arranged in three layers of four each. These non-limiting examples are provided to demonstrate the flexibility of the system in terms of storage capacity and other system parameters as set forth above.

Unless otherwise stated, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, a limited number of the exemplary methods and materials are described herein. It will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein.

All terms used herein should be interpreted in the broadest possible manner consistent with the context. When a grouping is used herein, all individual members of the group and all combinations and subcombinations possible of the group are intended to be individually included. When a range is stated herein, the range is intended to include all subranges and individual points within the range. All references cited herein are hereby incorporated by reference to the extent that there is no inconsistency with the disclosure of this specification.