Patent Application
20250075943
It should be noted that the figures are not drawn to scale and that elements of similar structures or functions are generally represented by like reference numerals for illustrative purposes throughout the figures. It also should be noted that the figures are only intended to facilitate the description of the preferred embodiments. The figures do not illustrate every aspect of the described embodiments and do not limit the scope of the present disclosure.
Some versions of a heat pump water heater (often called a “hybrid” water heater) can utilize a combination of a heat pump along with one or more resistive elements to heat domestic water. The heat pump in some examples draws around 400 watts and provides a slow but efficient means of heating the water in the tank. Because instantaneous demand for hot water may be greater than what the heat pump can itself replenish in some examples, the one or more resistive elements can offer a boost. Such resistive elements can draw 5000 watts in some examples (e.g., limited by a 240V 30 amp circuit) and in various embodiments may be used sequentially instead of simultaneously.
In various embodiments as discussed in more detail herein, a heat pump water heater architecture can be configured to run off a much smaller branch circuit (e.g. 110V, 15 A) by powering resistive elements of the water heater from an integrated battery. In some embodiments, the battery can be configured to power the resistive elements alone, but in some embodiments such a battery can be configured to power resistive elements and a heat pump of the water heater. Accordingly, some embodiments can allow a water heater to operate even if incoming power from a receptacle that the water heater is plugged into becomes unavailable (e.g., a blackout scenario).
Resistive elements in various embodiments can be made to operate directly on high voltage DC power provided by the battery in contrast to some examples using an inverter to create AC power. A heat pump compressor of various examples can be driven in one or more ways: from 120V AC power; from DC power via an inverter driven heat pump; from 240 VAC power via a modest step up transformer; and the like. In some embodiments, driving a heat pump compressor from 120V AC power can be desirable because in some examples such a configuration can provide a simple and/or low cost option. In some embodiments, driving a heat pump compressor from DC power via an inverter driven heat pump can be desirable because in some examples such a configuration can provide efficient operation of the heat pump by leveraging the advantages of inverter driven units. In some embodiments, driving a heat pump compressor from 240 VAC power can be desirable because it can allow for use of 240 VAC heat pump components.
Some embodiments of 120V capable water heaters lack resistive elements. This can mean that some such water heaters are only applicable to households with limited hot water usage who also live in warm environments. A battery enabled 120V water heater of various embodiments that includes one or more resistive elements can be desirable in various examples and can provide the same convenience and low installation costs of a 120V water heater that lacks resistive elements. Various embodiments include a tanked hot water heater that can operate on 120V or 240V, either hardwired or plugged into a standard 120V 15 AMP outlet.
When gas hot water heaters are banned in 2028, there will be homeowners whose gas hot water heaters break and need replacement. Electricians are in short supply, and will be in shorter supply after this change. Many homes will require or should upgrade their electrical service when adding a replacement electric hot water heater. For most homeowners, going without hot water is not acceptable, but it may be acceptable in some examples to have less hot water or lower temperature hot water.
Various embodiments include an electrically-heated, tanked hot water heater that can immediately replace a failed natural gas tanked hot water heater. Various examples can be plugged into an outlet or extension cord to provide lower temperature or lower volume hot water while the home is upgraded with either a new branch circuit, new load center, or new service from the utility. Once 240V 30 AMP service is available, the hot water heater can use this service for more hot water or higher temperature water. However, in some embodiments, an electrically-heated, tanked hot water heater can be configured to be a suitable permanent replacement for a gas water heater that operates off standard 120V power.
Various examples separate the plumbing and electrical aspects of installing an electric hot water heater. Various embodiments give the homeowner control of the trade-off between lower temperature/high-normal volume hot water vs. higher temperature/low volume hot water (e.g., via a mixing or control valve). In some examples, homeowners can opt for this solution to have some hot water while they wait for electrical upgrades in some examples. The hot water heater has an optional battery in some embodiments to enable faster recovery.
A battery of some embodiments can be installed or removed by the homeowner without specialized tools or knowledge. This can allow homeowners in some examples to rent the battery for the period of time until their electrical upgrade is complete, or can allow other similar business models, for example, the plumber who installed the tank owns the battery and rents it to the homeowner.
A hot water heater of various embodiments optionally has two 120V 15 A inputs, and can be operated at the equivalent of 120V 30 A by utilizing two separate circuits in the home (not just two separate plugs in various embodiments). The hot water heater of various embodiments has integrated smart control of one or more heating elements to allow one or more of the following and more in some examples: battery management; time-of-use electricity rates; domestic scheduling and automated learning (e.g., heat water in the tank above target temperature immediately before an anticipated heavy usage such as morning showers); current control of the heating elements to support various configurations of electricity supply (e.g., single 120V 15 A, dual 120V 15A, 240V 30 A, 120V at lower amperage for safe use of extension cords, and the like).
In some examples household of four uses about 19 therms of natural gas per month, which can be 556 kWh or 750 watts continuously. In various embodiments, a water heater running off 120V at 15 A can support this, but recovery can be slow in some examples. However, with a battery to aid in recovery and some knowledge about assuage patterns, in various embodiments operating from 120V 15 A power with a battery can be sufficient such that many homeowners who would otherwise need to upgrade the electrical service to support 240V 30 A may never actually do it and can suitably operate their battery integrated water heater off 120V 15 A power.
In some instantiations, the incoming domestic water line can be used to keep the battery in an acceptable temperature range (e.g., cooling or heating the battery depending on the relative temperature of the air and domestic water). In various cases, the battery will be warmer than the incoming water. In addition to keeping the battery in a safe temperature range, this architecture in various examples harvests heat that would otherwise be wasted, increasing the overall efficiency.
In some instantiations, the storage water tank can be a closed volume of water. In some examples, incoming domestic water can run through a heat exchanger to accept heat from the storage tank, rather than running into the tank itself. In some such cases, the storage tank temperature can be much hotter than the desired domestic water temperature without requiring the use of a mixing valve. This can allow the storage tank to store more energy for a smaller volume in some examples. In addition, this architecture may benefit from reduced scaling in some examples.
As discussed in more detail herein, in various embodiments load sources 200 can be respectively associated with a battery 305 and/or load source system 300 (See e.g.,
While
Also, while the example of
As shown in
In various embodiments, the water heater 140 can comprise a housing 350, a water tank 360, a heat pump 370 having one or more fans 372 a water heater interface 380 having a screen 382, and plumbing 390 that comprises a water-in line 392A and a water-out line 392B. As discussed herein in more detail, various elements can be a part of or associated with the load source system 300, such as heating elements of a load source system 300 being configured to generate heat in a volume of water in the water tank 360. In various embodiments, the water heater 140 can be a heat pump water heater that includes a heat pump 370; however, in further embodiments a water heater 140 can be any suitable type of water heater 140, which may or may not include a heat pump 370, such as a heat exchanger water heater, an electric resistance water heater (e.g., Electric Storage Element (ESE)). heat pump water heater, tankless water heater (e.g., on-demand or instantaneous water heater), or the like.
In one preferred embodiment, a water heater 140 has a water tank 360 with 30 gallon capacity. Further embodiments can include a water tank 360 with a capacity of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90 gallons, or the like, or a range between such example values. However, in some embodiments, a water tank 360 can be absent.
In various embodiments, a heat pump 370 of a heat pump water heater 140 transfers heat from the surrounding air to the water in the tank 360, which in some examples can make a heat pump water heater (HPWH) more energy-efficient than an electric resistance water heater. A heat pump water heater 140 can comprise an evaporator comprising a coil of tubing with refrigerant inside, and as warm air from the surrounding environment is drawn over the evaporator, the refrigerant can absorb heat and evaporate into a gas. A heat pump water heater 140 can further comprise a compressor that pressurizes the gaseous refrigerant, which can cause temperature of the gaseous refrigerant to rise significantly. A heat pump water heater 140 can further comprise a condenser comprising another coil, that in various examples can be wrapped around the water tank 360 or placed inside the water tank 360. The hot, pressurized refrigerant can flow through the condenser, transferring heat from the pressurized refrigerant to water in the water tank 360.
After the refrigerant has cooled by transferring heat from the refrigerant to the water, the refrigerant can pass through an expansion valve that causes sudden expansion of the refrigerant, which in turn causes the refrigerant to cool rapidly, preparing it to absorb heat again in the evaporator. A fan 372 can be configured to draw air over the evaporator coil to facilitate heat absorption.
The heat pump 370 in various embodiments can operate in a cycle within the heat pump water heater 140, which can include a thermostat detecting that a temperature of water within the water tank 360 has dropped below the set point. The fan 372 can activate, drawing warm air over the evaporator. The refrigerant in the evaporator can absorb heat from this air and can evaporate. The compressor can then pressurize this gas, raising the temperature of the gas further. This hot, high-pressure gas can move to the condenser, where the high-pressure gas transfers heat of the high-pressure gas to the water in the water tank 360. As the refrigerant cools, the refrigerant can condense back into a liquid and then passes through the expansion valve, which rapidly cool the refrigerant before returning to the evaporator to begin the cycle again. This process continues until the water in the water tank 360 is determined to have reached a desired temperature. However, it should be clear that in further embodiments a heat pump 370 can be absent or a heat pump 370, or the like, can include any suitable elements, so the present examples should not be construed as being limiting.
In some embodiments, one or more batteries 305 and/or battery systems 300 can be integrated into a load source 200 (e.g., into an appliance housing) at the factory where the load source is manufactured or can be integrated into a load source aftermarket. For example, load sources 200 (e.g., appliances) can be specifically designed to allow integration of the appropriate quantity of batteries 305 and/or other elements of a load source system 300 within their normal housing. This can allow for such load sources 200 or appliances to be placed within a residence without any change to how they are integrated into standardized fixturing. In various embodiments, electrical connections to batteries 305 and/or other elements of a load source system 300 are made in the factory and fully integrated into the appliance circuit. This can allow for load sources 200 such as appliances that utilize DC current (e.g., a water heater 140) to pull power directly from the one or more batteries 305 without the added cost of a high-power inverter.
In some embodiments, batteries 305 can be designed to be integrated into load sources 200 (e.g., appliances) in an aftermarket factory setting. For example, a company that is not the original equipment manufacturer of an appliance buys new appliances, installs the load source system 300 in their own facility, and re-sells the appliance as new. The retrofitter in some examples installs one or more batteries 305 and/or elements of the load source system 300 within the housing of the appliance, wiring them directly into the integral electrical system of the appliance. This can be desirable in some embodiments if high-voltage connections are required given the danger of such high-voltage connection if not being handled by a professional. Also, in some embodiments where a load source 200 (e.g., an appliance) has an internal rectification circuit that is converting 60 Hz AC current to DC, it can be desirable in some examples to connect the load source system 300 directly into the internal circuitry of the load source (e.g., to avoid costly addition of high-power inversion).
In some embodiments, batteries 305 and elements of a load source system 300 are designed to nest with load sources (e.g., appliances), either as a footing, or a backing, etc. Such nesting can be done by the customer in various examples. Batteries 305 and/or elements of a load source system 300 can be designed to nest directly external to the appliance, such as by taking into consideration the shape and intended location of the appliance within a house 105. One or more batteries 305 and elements of a load source system 300 (e.g., power control stage) are packaged in such a way in various examples such that they can be placed directly alongside the appliance. The appliance can be plugged into the load source system 300 and the load source system 300 is then plugged into the wall.
Additionally, it should be clear that a powered building system 100 can include any suitable number and type of battery systems 300 including one or more of the battery systems 300 shown herein. However, in some examples one or more of the battery systems 300 shown herein can be specifically absent.
A load source system 300 can comprise various suitable elements. For example,
For example, in some embodiments, a load source system 300 can comprise a computing device which can be configured to perform methods or portions thereof discussed herein. The memory 420 can comprise a computer-readable medium that stores instructions, that when executed by the processor 410, causes the load source system 300 to perform methods or portions thereof discussed herein, or other suitable functions. The clock 430 can be configured to determine date and/or time (e.g., year, month, day of the week, day of the year, time, and the like) which as discussed in more detail herein, can in some examples be used to configure the power storage and/or power discharge of the battery 305 based on time.
The control system 440 in various embodiments can be configured to control power storage and/or power discharge of the battery 305 based on instructions from the processor, or the like. Additionally, in some embodiments, the control system 440 can determine various aspects, characteristics or states of the battery 305 such as a charge state (e.g., percent charged or discharged), battery charge capacity, battery health, battery temperature, or the like. For example, in various embodiments, a load source system 300 can comprise various suitable sensors to determine such aspects, characteristics or states of the battery 305 or aspects, characteristics or states of other elements of a building system 100 which can include environmental conditions such as temperature, humidity, or the like, internal to or external to a building 105.
In some embodiments, the control system 440 can be configured for various features such as: maintaining a data pipeline to the cloud or another wireless device (e.g., by way of CANBus communication between peripherals and a Wi-Fi, Bluetooth, or Cellular module) to remotely log system data and manage firmware updates; interpreting the states/positions of user interface controls (e.g., knobs, buttons, switches, touchscreens, or the like) and carrying out corresponding actions within the device; providing feedback control to heating operations of the load source system 300 via temperature and current sensing; and the like. The control system 440 may additionally be used in enabling and facilitating various operating modes and features (e.g., water heating features, safety features, power storage features, and the like).
In various embodiments, the communication system 450 can be configured to allow the load source system 300 to communicate via one or more communication networks as discussed in more detail herein, which in some embodiments can include wireless and/or wired networks and can include communication with devices such as one or more other battery systems 300, user device, server, or the like.
The interface 460 can include various elements configured to receive input and/or present information (e.g., to a user). For example, in some embodiments, the interface can comprise a touch screen, a keyboard, one or more buttons, one or more knobs, one or more lights, a speaker, a microphone, a haptic interface, and the like. In various embodiments, the interface 460 can be used by a user for various suitable purposes, such as to configure the load source system 300, view an aspect, characteristic or state of the load source system 300, configure network connections of the load source system 300, or the like. In some embodiments, the interface 460 can comprise a water heater interface 380 having a screen 382 as shown in the example of
The electrical power bus 470 can be configured to obtain electrical power from one or more sources and/or provide electrical power to one or more load sources 200. For example, in various embodiments, the electrical power bus 470 can obtain power from one or more power receptacles 165 (see, e.g.,
In various embodiments, the AC/DC conversion module 480 (e.g., in a water heater 140) can be configured for transforming the alternating current (AC) such as from a standard household outlet into direct current (DC) suitable for powering various elements of the load source system 300 (e.g., parts of a water heater 140). The AC/DC conversion module 480 of various examples can include a rectifier circuit, which converts the AC voltage into a pulsating DC voltage, followed by a filter that smooths out the fluctuations to produce a steady DC output. Additionally, the AC/DC conversion module 480 of various embodiments can include voltage regulation circuitry to ensure the output remains within a specific voltage range, accommodating the precise needs of the elements of the load source system 300 such as electronic controls, water heater 360, heat pump 370, and the like. The AC/DC conversion module 480 of some examples not only powers heating elements but also supplies DC power to auxiliary components such as a control panel, sensors, and the like. Example embodiments of an AC/DC conversion module 480 and components thereof are discussed in more detail herein.
Any suitable sensors 490 can be used in a load source system 300. For example, various suitable sensors can be used for sensing temperature (e.g., for generating an over-temperature cut-off response) can including thermal fuses, thermostats, thermocouples, thermistors, PTC (Positive Temperature Coefficient) devices, RTDs (Resistance Temperature Detectors), bimetallic switches, IC temperature sensors, thermal cut-out switches, infrared sensors, and the like.
In further embodiments, sensors can include pressure sensors configured to monitor the water pressure within the water tank 460 to ensure it remains within safe operating limits. If the pressure becomes too high, in various embodiments a pressure sensor can trigger a safety mechanism to release excess pressure or shut down the system to prevent damage or potential hazards.
Some water heaters 140 can include flow sensors to detect water usage patterns, which in some examples can help optimize energy efficiency by predicting hot water demand and adjusting heating cycles accordingly. In heat pump water heaters 140, for example, ambient temperature sensors may be used to measure the surrounding air temperature, allowing the system to determine when it is more efficient to use the heat pump versus backup electric resistance elements, or the like.
Humidity sensors can be present in some examples of heat pump water heaters 140, as they can help monitor the moisture levels in the air. This information can be used in various embodiments to prevent excessive dehumidification of the surrounding space, which can be a side effect of operation of a heat pump 370. Additionally, some water heaters 140 employ leak detection sensors, which in various examples can be placed near the base of the water heater 140, to alert users of potential water leaks before such leaks cause significant damage.
For water heaters 140 with anodes to prevent corrosion, anode depletion sensors may be used to indicate when the anode rod needs replacement. Such sensors can monitor the electrical current flowing through the anode, which can change as the anode deteriorates over time. Some examples can include water quality sensors to detect impurities or mineral buildup in the water of the water tank 360 or other location(s), which can help to maintain the efficiency and longevity of a water heater 140, or the like. A load source system 300 can comprise a thermostat, which can measure the water temperature inside a water tank 360 of a water heater 140, or the like. A thermostat in various examples can comprise a thermistor or thermocouple that provides feedback to the control system 440, enabling the control system 440 to maintain a desired or set water temperature by activating or deactivating heating elements, heat pump, or the like as needed.
The one or more batteries 305 can be any suitable system configured to store and discharge energy. For example, in some embodiments, the one or more batteries 305 can comprise rechargeable lead-acid, nickel-cadmium (NiCd), nickel-metal hydride (NiMH), lithium-ion (Li-ion), LiFePO4 (Lithium Iron Phosphate), lithium-ion polymer (LiPo), rechargeable alkaline batteries, Sodium-ion (Na-ion), Lithium Titanate (LTO), Lithium Sulfur (Li—S), Nickel-Zinc (Ni—Zn), Zinc-Air, Solid-state lithium, Flow batteries (e.g., Vanadium Redox Flow Batteries), or the like.
In some embodiments, a battery 305 of a load source system 300 can be configured to generate various suitable voltages, including 80V, 90V, 100V, 110V, 120V, 130V, 140V, 150V, 160V, 170V, 180V, 190V, 200V, 210V, 220V, 230V, 240V, 250V, 260V, 270V and the like, or a range between such example values. Some preferred embodiments can comprise a battery 305 having a voltage of between 180V-230V. A battery 305 in various examples can comprise a plurality of cells, which in some examples can have a nominal voltage 3.0V, 3.1V, 3.2V, 3.3V, 3.4V, 3.5V. In one example, a battery 305 can comprise 72 cells in series, which can generate a voltage of ˜260 VDC (e.g., between 230 VDC and 270 VDC). In another example, a battery 305 can comprise 64 cells in series, which can generate a voltage of ˜240 VDC (e.g., between 230 VDC and 250 VDC).
In various embodiments, components of the load source system 300, such as the water tank 470, heat pump 480, and the like can be configured to operate at different input voltages such as 120V, 130V, 140V, 150V, 160V, 170V, 180V, 190V, 200V, 210V, 220V, 230V, 240V, 250V, 260V, 270V, and the like, or a range between such example values. For example, such an input voltage can be based on power from one or both of a receptacle 165 (e.g., 120V receptacle) and battery 305.
As discussed herein, rechargeable in various embodiments can be defined as having the ability to store and discharge energy multiple times without substantial degradation of the ability to store and discharge energy for at least a plurality of cycles (e.g., 5, 10, 50, 100, 500, 1000, 10k, 100k, 1M, 10M, 100M, or the like). While various preferred embodiments can include chemical storage of electrical energy, in further embodiments one or more batteries 305 can be configured to store energy in various suitable ways, such as mechanical energy, compressed fluid, thermal energy, and the like.
In some embodiments, the one or more batteries 305 can contain or be defined by removable cartridges that allow the one or more batteries 305 to scale or be replaced. Battery packs in some examples can be composed of small sub-packs that can be easily removed. This can allow for old or faulty cells to be replaced in some examples. Additionally, in some examples such a configuration allows for the fine tuning of pack size within a network of load source systems 300 as discussed herein. For example, one or more batteries 305 can be initially sized and colocated with an expected load source 200.
Turning to
In various embodiments, the electrical input 505 can comprise a power cord 310 with a plug 315 configured to couple with an electrical power receptacle 165 of a power distribution system 150 (see, e.g.,
In various embodiments, the charger 510 can comprise a power converter or a battery charger that manages a flow of electrical energy from the electrical input 505 to the battery 350, computer 515, controller 525, transformer 530, heat pump 370, water tank 360, heating elements 362A, 362B, or the like. For example, in some embodiments, the charger 510 can convert an AC voltage (e.g., 120 VAC or 240 VAC) from a wall outlet into a suitable DC voltage required to charge the battery 305, which can involve rectification (converting AC to DC) and regulation (ensuring the DC output is stable and suitable for the battery). In some examples, an AC/DC regulator in an AC/DC conversion module of the charger 510 may be used to transform the power input from the electrical input 505. The charger 510 in various embodiments can monitor and control the charging process of the battery 305 to ensure it is charged efficiently and safely, preventing overcharging or overheating, and can manage the charging current and voltage according to the specifications of the battery 305.
In various embodiments, the charger 510 and/or battery 305 can supply DC power to one or more of the computer 515, controller 525, transformer 530, heat pump 370, water tank 360, heating elements 362A, 362B, or the like. For example, in various embodiments, one or more of such elements can be configured to be powered only by the charger 510; powered only by the battery 305; and/or powered by both the charger 510 and the battery 305 at the same time. As discussed herein, such powering capabilities can be desirable in various examples to allow for operation of the water heater 140 or portions thereof via power from the battery 305 while power from the electrical input 505 is unavailable or undesirable such as when there is a power outage or when power obtained from the electrical input 505 is undesirably expensive (e.g., when such power obtained from a power grid is expensive). Such powering capabilities can be desirable in various examples to allow for a combination of power from the electrical input 505 and battery 305 to be used, which can allow for greater power to heating elements 362, water tank 360, or the like, than would be available from the electrical input 505 alone, which can allow a water heater 140 to perform near, at, or above the capability of a water heater 140 powered by 240 VAC, even though the water heater 140 is powered by only 120 VAC via the electrical input 505. Such powering capabilities can be desirable in various examples to allow for a combination of power from the electrical input 505 and battery 305 to be used, which can allow for a reduced amount of power consumed from the electrical input 505, which may be desirable when power obtained from the electrical input 505 is unstable, inconsistent, or undesirably expensive (e.g., when such power obtained from a power grid is expensive) or when it is desirable to draw less power from the electrical input 505 (e.g., where a circuit does not support drawing full power because of other appliances on the circuit). Such powering capabilities can be desirable in various examples to allow for one or more of the computer 515, controller 525, transformer 530, heat pump 370, water tank 360, heating elements 362A, 362B, or the like to be powered via the electrical input 505, when it is undesirable to use power from the battery 305, when the battery 305 is out of power, when the battery 305 is malfunctioning, when the battery 305 is overheating, when power from the electrical input 505 is obtained from a renewable source (e.g., solar), or the like. As discussed herein, various additional and/or alternative elements can be powered via DC power from the charger 510 and/or battery 305, so the example elements discussed herein should not be construed to be limiting.
For example, the load source system 300 may additionally or alternatively power status indicators (e.g., LEDs, displays, audio systems), user interface displays, external-facing USB ports (and their devices), speakers, externally daisy-chained high-voltage DC devices, and the like. Some of these elements may require a DC/DC regulator or a DC/AC inverter downstream (e.g., of a battery's 240 VDC) in order to operate. Some of these elements may be enabled via manual control, while others may be enabled via autonomous software control (e.g., via the control system 440).
In various embodiments the computing device 515 can be configured to implement methods discussed herein (e.g., for energy efficiency, learn usage patterns, or adjust heating based on time-of-use electricity rates) via elements such as a processor 410, memory 420 and the like. The computing device 515 in various embodiments can comprise a communication system 440 which may allow the computing device to connect to the internet, allow remote control, remote monitoring, integration with smart home systems, and the like. The communication system can operate via Wi-Fi, LTE, or the like. The computer in various embodiments can obtain data and/or input form various sources such as an interface 460, one or more sensors 490, or the like.
In various embodiments, the controller 525, can be configured to operate the heating elements 362A, 362B of the water tank 360. In some embodiments, the controller 525 can comprise a thermostat to measure water temperature within the water tank 360, safety mechanisms (e.g., thermal cutoffs), elements to maintain water temperature within a set range by activating or deactivating the heating elements 362 as needed, and the like.
In various embodiments, the transformer 530 can be configured to transfer electrical energy between two or more circuits through electromagnetic induction (e.g., the electrical input 505 and heat pump 360). The transformer 530 in various embodiments can operate with alternating current (AC) and can be used primarily to change the voltage level of the current flowing through it. For example, transformation of voltage can be achieved in various examples without altering the frequency of the AC, which allows for either an increase (step-up) or decrease (step-down) in voltage depending on what is desired or necessary. In some embodiments, the transformer 530 can be absent from a load source system 300.
Additionally, or alternatively, one or more additional or alternative power inputs may be used as a power source, which may be AC and/or DC. For example, in some embodiments the electrical input 505 can be DC power. In some embodiments, there can be one or more additional DC power inputs in addition to an AC electrical input 505.
DC power (e.g., nominally 240 VDC) from the charger 510 may be provided to the battery 305 by way of a safety relay in various examples. Current from the battery 305 can be provided to various elements of the load source system 300 by way of a safety relay and can serve as a source for powering elements such as a processor and/or safety triggers of the load source system 300 by way of a DC/DC regulator, or the like.
The AC power input 505 may connect (e.g., with a cord and plug) to an electrical receptacle (e.g., common receptable with 120 VAC 15A, 20 A, or the like or an appliance outlet with 230 VAC with 20 A, 30 A, 50 A, or the like) to provide outside power to the load source system 300. In some embodiments, an AC/DC conversion module can use the AC power input from the power input 505 to charge the battery 305 source, used to charge supplementary battery systems or directly power various systems or elements.
In some variations, the amount of current drawn from the power input 505 may be limited in some embodiments (e.g., through a configuration setting). For example, the limit may be set below 10A, 15A, 20 A, 30 A, 50 A, or the like. For example, where a water heater 140 is located with other appliances, there may be insufficient circuit capacity to operate all appliances at once so a water heater 140 having a load source system 300 can be configured to draw less power. For example, a washer and drier might be on the same circuit as a water heater 140 having a load source system 300 and the water heater 140 can be configured to a lower maximum charging rate to facilitate operation of all appliances on the circuit.
In some embodiments, a load source system 300 can include a monitoring system that monitors incoming AC voltage of a shared branch circuit. During times of high use, the voltage can sag, and the load source system 300 can automatically lower charging current of the load source system 300 to accommodate (e.g., to avoid tripping the circuit breaker). Because the sensing and/or control can be part of the load source system 300, techniques like synchronous source detection may be used in some examples to calibrate out differences in grid voltage and for other applications.
An AC/DC conversion module of some embodiments may output a DC power output (e.g., nominally 240 VDC), which as described may be provided to a battery 305 by way of a safety relay in some examples. Power from the charger 510 and/or the battery 305 may be provided to elements of the system load source system 300 by way of a safety relay and may serve in some examples as the main source for powering one or more processors and/or safety triggers by way of a DC/DC regulator. In some embodiments, DC power may primarily be used to directly power the high-load elements of the load source system 300 such as the water tank 360 and/or heat pump 370.
As discussed, the load source system 300 in various embodiments can include one or more supplementary battery systems, which may be used as a backup to the battery 305. In some variations, such a supplementary battery system may be or include a battery-equipped Uninterruptible Power Supply (UPS); for example, in the event of a grid blackout and/or dead or disabled battery 305, to maintain some level of continuous processor operation (e.g., to continue logging events), the battery-equipped UPS can keep the processor(s) powered.
In order to satisfy a suitable safety standard (e.g., meet UL standards), in some embodiments there may be a series of redundant controls that can independently (e.g., without software) disable/disengage some or all potentially hazardous aspects of the load source system 300; for example, power to the charger 510; the output of high-voltage batteries; some or all connections powered off high-voltage batteries, and the like. Such a control scheme may include thermal fuses, current fuses, insulation fault detectors, or some combination thereof, whereby one tripped fuse can disconnect the trigger signal to the normally controlled relays that control the pathways and/or subsystems. Temperature fuses in some examples may be configured to trip/trigger at determined temperature points and may be oriented inside or near one or more heating element 362, water tank 362, heat pump 370, battery 305, and the like. Current fuses may be integrated inside the battery 305 (e.g., integral to a battery management system (BMS)). Additional safety measures may include Ground Fault Protection between the one or both terminals of a DC signal (e.g., 240 VDC) and the systems chassis (e.g., water heater chassis), and a Ground Fault Protection between an auxiliary AC power outlet 540 and the chassis of the water heater.
Some variations of a load source system 300 and/or a method implemented by a load source system 300 can be configured to boost heating capabilities of a water tank 360 or other heating element, and the like. The load source system 300 may be configured to implement process of a method that includes using the battery 305 to provide high instantaneous power output. This may be used to enable a “boost” mode for use during water heating or in other situations. Because a battery enabled water heater 140 of various embodiments can output higher instantaneous power than a conventional wired water heater, this boost mode can be made to be quite powerful.
The use of a DC input in some examples can reduce the size of components used in driving a water heater 140. In AC-driven systems, bulky ripple capacitors may be used which are both expensive and large. Ripple capacitors can also reduce the overall efficiency of the circuit and reduce the power factor. Some AC-driven systems can require a PFC circuit and/or EMI/RFI circuits, which may be eliminated or simplified in the system when powering from a line-isolated DC battery. The system's DC input to a water tank 360, avoiding the need for such components, may result in a more energy efficient load source system 300 in some embodiments.
In some variations, the load source system 300 may include cascaded DC and AC relays. The load source system 300 may include a single DC relay to control a plurality of AC relays in some examples. By using a DC relay to switch first, in some embodiments the AC relays can be switched in a dry state to minimize or reduce contact arcing issues that can be associated with AC relays. This may also help to prolong the life of the contacts and reduce maintenance costs. Additionally, a single DC relay can be used to control multiple AC relays, which can simplify the wiring and control systems, and reduce the overall cost of the load source system 300.
In some variations, a DC powered approach of the load source system 300 or method implemented by the load source system 300 may enable usage of Metal-Oxide-Semiconductor Field-Effect Transistors (MOSFETs) to switch power to high powered loads. For example, MOSFETs may be used to switch 230 VDC 20 A power to power one or more heating elements 362 in some embodiments. MOSFETs may have increased switching life over other switching elements that can be used in AC operated water heaters 140. This may result in increased life, easier maintenance, and/or more accurate temperature control because of an ability to rapidly switch between power states. As one potential benefit, a system variation using FET control with faster cycling may provide more latitude to control when each of the heating elements 362A, 362B are on, to coordinate the power draw of each in order to limit the total power draw of the water heater 140.
In some variations, the load source system 300 may include a maximum power point tracker (MPPT) which may function to enable the load source system 300 to accept power generated locally by a solar panel, wind turbine, or other source of power generation. This solar powered solution may be more generally applied as part of a general energy storage equipped (ESE) appliance, which may be a water heater 140 as described herein but could be any suitable type of appliance. In some variations, the ESE could be a water heater or heat pump or other suitable load source 200 as described herein.
In one example, energy can be generated by a solar panel, and pass through the MPPT into the battery 305 of the ESE appliance. This energy in various embodiments can augment power received from a receptacle 165 to the ESE appliance and can limit the total amount of power drawn from a home's power distribution system 150 by the ESE appliance. In some variations, the load source system 300 may be configured to avoid “backfeeding” of the home's electrical system or the grid, which may mean this kind of installation can take place without permission of a utility in some examples, thereby leading to simplified installation.
In one variation, a load source system 300 and/or method implemented by the load source system 300 may include a slow heat mode, which can function to preserve energy stored by the battery 305. A control system may be used to manage operations of the device to adjust for stored power availability, predicted power availability from an AC power input 505 or some other power source in coordination with predicted usage of the appliance (e.g., time of day, cooking habits, showering habits, bathing habits, etc.). In some embodiments, a load source system 300 and/or method implemented by the load source system 300 may use time and/or usage-based charging profiles. Charging of the battery 305 and the heating capabilities of a water heater 140 may be adjusted to meet expected requirements. Some examples of such methods are disclosed in related U.S. patent application Ser. No. 17/692,714, filed Mar. 11, 2022, entitled “APPLIANCE LEVEL BATTERY-BASED ENERGY STORAGE,” which is incorporated herein by reference.
In another variation, a load source system 300 and/or method implemented by the load source system 300 may include detecting circuit breaker (for shared branch circuit) overdraw by measuring voltage sag from wall. In another variation, a load source system 300 and/or method implemented by the load source system 300 may use special heating modes.
In another variation, a load source system 300 and/or method implemented by the load source system 300 may operate to manage power storage of the battery 305 based on external data sources. In one such example, the load source system 300 may charge the battery 305 when emissions intensity is below a threshold, based on external data.
In another variation, a load source system 300 and/or method implemented by the load source system 300 may use various sensing approaches. A load source system 300 and/or method implemented by the load source system 300 may use multi-probe water tank temperature sensing. This may involve sensing and detecting uniformity of heat, and if a large enough temperature difference is detected, the load source system 300 can run a pump for mixing.
In some variations, the load source system 300 may include battery fixturing that may facilitate moving or accessing a battery 305. This may be useful to enable cleaning, maintenance, and the like. The battery 305 may include feet of a material with low resistance (e.g., Delrin, Teflon, etc.) to enable the battery 305 to slide without loading attachment points to the water heater 140. In another variation, the battery 305 may be attached to the water heater 140 but have rolling feet. The load source system 300 in some examples may include design features to facilitate installation and servicing accessibility. The battery 305 and/or associated components may use connectors and fixturing mechanisms for ease of connecting power plugs and accessing the components of the battery 305 and/or associated components.
The battery 305 may be a detachable unit in some examples, which may enable the battery 305 to be supplied separately. This may be useful to allow for changing of a battery 305 and installation of the battery 305 into a previously set up appliance, swapping of a battery 305, or the like.
The battery 305 in various embodiments may include safety features to ensure that the battery 305 is used when the battery 305 is properly installed and in a safe operating condition. A battery control system that may be part of an auxiliary power source system may measure and record the state of the battery 305 through one or more sensors, which may include but is not limited to accelerometers, switches, thermometers, and the like.
In some variations, the battery 305 may include a protective casing or layer, which can be a component encasing the battery 305 in a protective material to ensure protection from fire. This may be designed to provide the battery 305 with at least 60 minutes or at least 120 minutes of protection in a building fire, or the like. For example, gypsum or similar fire retardant or phase-change material may be used. The load source system 300 in some embodiments may include a battery cooling system which in some examples can be a special cooling fan that activates only when needed to cool battery.
A load source system 300 and/or method implemented by the load source system 300 may include an integrated safety system for addressing possible electrical safety issues. In the case of a water heater 140, possible issues that may be mitigated can include detection of a water tank over-temperature event, detection of a battery over-temperature event, and detection of an electrical hazard (e.g., insulation fault, incorrect installation, damaged battery, DC isolation fault, AC hazard, and the like).
In some embodiments, a method of safety system activation can comprise a determination that there is an heating element over-temperature event present, a water tank over-temperature event present, a heat pump over-temperature event present, that a battery over-temperature event is present, or that an electrical hazard event is present (e.g., by a control system 480 based on data from one or more sensors 490). In response, a safety system (e.g., safety circuit) can cause a suitable response, which can include a battery cut-out, a charger cut-out, grounding, ground fault circuit interruption (CFCI), and the like. In various examples, an over-temperature event can be determined based at least in part on data or physical response from a temperature sensor indicating a temperature (e.g., of water in a water tank 360 and/or components of the water tank 360) being above a given threshold for an amount of time.
In some embodiments, a safety system may enable safe operation of a water heater 140, with the battery 305 in close proximity to the water tank 360 and/or heating elements 362. In some examples, over-temperature of the battery 305 can cut off the water tank 360, and over-temperature of the water tank 360 can cut off the battery 305, to ensure both are operating safely. Similar methods can be applied to other appliances or elements of a water heater 140.
In some embodiments, the same set of relays may be used to perform activation of a plurality of safety measures (e.g., not multiple independent pairs of relays), with such safety measures including one or more of responding to a determined heating element over-temperature event, water tank over-temperature even, heat pump over-temperature event, responding to a determined battery over-temperature event, and responding to a determined electrical hazard event.
In some examples, a string of over-temperature cut-offs can be associated with various heat sources generally or specifically such as the battery 305, heating elements 362, and the like. In some embodiments such a string may have redundant over-temperature cutoffs for some or all such heat source locations. In some embodiments, two or more independent strings can have just one over-temperature cut-off at some or all such heat source locations. Various suitable sensors can be used for sensing temperature and generating an over-temperature cut-off response including thermal fuses, thermostats, thermocouples, thermistors, PTC (Positive Temperature Coefficient) devices, RTDs (Resistance Temperature Detectors), bimetallic switches, IC temperature sensors, thermal cut-out switches, and the like.
Redundant relays in some embodiments can be configured to stop some or all heating of the load source system 300 by cutting off the battery 305 and/or by cutting off the charger 510, or the like. Such a cutoff can be configured to de-power one or more heating elements 362, a heat pump 370 or other elements, including heat sources and non-heat sources. In some embodiments, at least some non-heat sources can remain active after such a cutoff such as an interface 460, screen 382, processor 410, control system 440, communication system 450, auxiliary electrical output, and the like.
In some embodiments, the same or different cut-off relays can be configured to respond to electrical hazards, such as electrical hazards posed by insulation, isolation faults of the battery system, and the like. In some embodiments, a sensor string can have additional sensors or relays as part of the sensor string, which can be configured to open when an electrical fault is detected, thus triggering power cut-off relays.
In some embodiments, relays that perform a battery cut-off can be disposed within a battery enclosure, and in some examples can be configured to perform a safety function of preventing the battery from energizing unless it is correctly installed into the product (e.g., in an embodiment where the battery is removable). For example, in some embodiments, a string of sensors cannot be completed without the battery 305 correctly installed into the load source system 300, such that with a battery 305 not installed or incorrectly installed (e.g., battery connections improperly or incompletely seated), cut-off relays disabling battery power cannot turn on unless the battery 305 is installed into the load source system 300.
In some embodiments, a tankless on-demand water heater can be a type of water heating system 140 that heats water directly as needed, without the use of a water tank 360. It can operate in some examples by passing cold water through a heating element, which rapidly heats the water to the desired temperature before delivering it to a faucet, shower or the like. This design in various embodiments can eliminate the need for a bulky water storage tank 360, provides a continuous supply of hot water, and/or can be more energy-efficient than traditional water heaters by eliminating standby heat loss.
Utilizing a DC battery to power one or more internal component of a tankless water heater can allow for off-grid operation in various embodiments, making it suitable for applications where access to AC power is limited or unavailable in some examples. This can be particularly useful in remote locations or during power outages.
Removing the need for AC-dependent components and utilizing DC-compatible components can simplify the system design in some embodiments by eliminating components related to Power Factor Correction (there may be no AC noise or phase shifting to filter and/or compensate for) and bulky transformer components used for AC power conversion. This streamlined design in some embodiments can result in easier installation, reduced complexity, and potentially lower maintenance requirements.
Furthermore, the elimination of combustion-based heat generation can have several benefits to the longevity and performance of various embodiments by eliminating the byproducts of the combustion. The impacts of such byproducts can be one or more of:
Corrosion: Water vapor produced during combustion can contribute to the formation of condensation within the tankless water heater. If not properly managed, in some examples this moisture can lead to corrosion of internal components and reduce the lifespan of the unit.
Scaling: Some tankless water heaters may experience scaling on the heat exchanger or other internal components due to mineral deposits present in the water supply. Scaling can reduce the efficiency of the unit and increase energy consumption over time.
Buildup of Combustion Byproducts: Inadequate ventilation or improper combustion can lead to the accumulation of combustion byproducts in various examples, including carbon monoxide, within the appliance. This buildup can not only impact the performance but also pose safety risks to occupants if not adequately vented.
Reduced Efficiency: Incomplete combustion or inefficient combustion processes can lead to a lower efficiency rating for the tankless water heater in some examples, resulting in higher energy consumption and increased utility costs.
Performance Issues: If combustion is not occurring optimally, in various examples it can affect the water heater's ability to heat water efficiently and deliver a consistent supply of hot water.
One challenge with some instant water heaters is that they can consume a lot of power. For example, a 11 kW instant water heater of some embodiments can provide enough hot water for about two standard showers simultaneously and uses up to 46 Amp. This can occupy significant breaker space in a home's main distribution panel. A battery-assist tankless water heater can be made in some examples to consume only 15 amps and service many simultaneous standard showers without occupying as much breaker space.
A charger 510 and the battery 305 enclosed in a water heater can be liquid cooled in some embodiments to allow for silent operation and/or increased efficiency by transferring waste heat back into the water.
Utilizing a DC battery 305 in some embodiments allows the system to use lower voltage DC heating elements (e.g., typically 120V or 240V). This can be beneficial in lowering the number of battery cells in series and can afford various examples of the system greater flexibility in battery and water heater form factor.
Various embodiments of a water heater can be equipped with wireless communication ability, allowing monitoring of battery and time-of-use (TOU) arbitrage. Accessories like a wireless switch can be installed in bathrooms to signal to the water heater to turn on a recirculation pump. When the light on the switch turns on a few seconds later, the user knows that the shower is ready to deliver hot water immediately. This can save households money by not wasting water waiting for the shower water to get hot. This switch can also be programmed in some examples to trigger shower routines (e.g., preset and user-programmable). For example, hot water for 20 seconds, then cold water for 35 seconds, then hot again for 15 seconds, and the like.
In some households, space constraints make the inclusion of a large storage tank water heat with a heat pump difficult. This includes not just the eight million households that currently utilize instantaneous gas water heaters, but also the many households that currently have a small gas tank water heater, but not enough room to get a tanked heat pump water heater.
One approach to address this challenge in some examples can be to incorporate a water heater into a mini-split utilized for space heating. The compressor of a mini-split can produce a significant amount of heat in various examples, which during the cooling season can be a waste product. During the heating season this may not be a waste product, but the incremental cost of upsizing the mini-split can be much lower in various examples than installing an entire separate heat pump system for water heating. In some examples, the discharge temperature after the compressor should be approximately 100 degrees F. above the ambient outdoor temperature.
For example,
Heat can be transferred from a compressor of the heat pump 370 to the water in the water tank 360 in various suitable ways. For instance, a water jacket system can claim waste heat from the compressor and direct it to a water storage tank 360 in some examples. In some examples, a refrigerant line between the compressor and the condenser can be redirected to run through the water storage tank 360 to heating the water. Such a water tank 360 can be integral to an enclosure of the heat pump 370 in some examples. Alternatively, the water tank 360 in some examples can be made into the foundation for the heat pump 370, which in some examples can require concrete block foundations for stability and vibration isolation. In some instantiations, the heat pump 370 can use conventional refrigerant lines to drive the interior HVAC unit. In some examples, the same domestic hot water line can be used to drive an interior hydronic radiator or forced air unit. In various embodiments, such a water heater 140 can also comprise heating elements 362 (see e.g.,
Such a system in various embodiments can allow households without the room for a heat pump water heater to enjoy the cost savings and energy reductions of a heat pump. Such houses currently having an instantaneous gas water heater may already have water lines running to the exterior of the house, making installation of such a system easier in some examples.
A battery-integrated water heater of various embodiments can also accept power directly from a solar array, for instance by utilizing an integrated maximum power point tracking system. In various examples, the water heater is located at a location like a basement or garage that is easy to run wiring from the solar array. Because some or all solar can be consumed by the appliance and/or integrated battery in various examples, such a configuration in various embodiments would not require an interconnection agreement with a utility, and construction could be significantly simplified. Further, for houses with a conventional rooftop solar array, often a limiting constraint is the rating of the bus bars in the breaker box (often called the 120% rule), rather than available roof space or space on a favorable surface. In some such cases, direct integration of solar with an appliance of various embodiments can allow a household to utilize more solar energy than conventionally possible.
For example,
In the case of replacing a gas water heater, in various embodiments the flue/chimney can provide a viable path for wiring for a solar installation. Because the combustion has been eliminated, this chimney is no longer needed, and can be converted to a path for electrical conduit in various examples.
Various embodiments can comprise an inverter on a DC bus and/or motor-driven mechanisms in place of other systems (e.g., heat pump vs. resistive heaters). In the pursuit of improved efficiency and reduced noise, good speed control of electric motors can be desirable in various embodiments. The complexity of a motor and driver system can been concentrated into the driver half of the system in some examples via solid-state power electronics, which may reduce the motor to a simple externally-commutated device.
In order to modulate the speed of an externally commutated motor, in some examples it can be desirable to modulate the frequency of the applied voltage waveform. This can require unlinking the incoming AC waveform from the outgoing motor waveform in some embodiments, which can be done in various examples by rectifying the incoming AC to DC, and then inverting the DC back to AC in the motor driver.
In some examples, power conversion electronics can be expensive or impossible to build, so only small loads such as control and communication modules can be run on DC using a small AC-DC converter, and the bulk of the power electronics can be operated directly on the incoming AC power with no intermediate power conversion.
However, with the large loads using DC inputs in some embodiments, various examples can rectify the incoming AC to DC immediately, for further distribution to both large and small loads. This can require there to be a high-power DC bus in some examples to which some or all the loads can be independently attached in various embodiments.
Various embodiments of power technologies such as batteries and PV cells can operate as DC devices. This can provide an opportunity in some examples to attach not only loads to the DC bus, but sources as well, with minimal or no intervening power conversion. For example, if an appliance is designed to operate at 300 VDC, then a 300 VDC (peak) battery can be attached directly to the DC bus of the appliance in various embodiments (e.g., with only a charge current limiter). In some examples, solar panel or wind turbine can be attached to the DC bus to provide power to the appliance load and/or battery. Since the performance characteristics of the load of such a closed system can be well characterized per appliance in various embodiments, the performance and other characteristics of each device attached to the DC bus can be carefully chosen to maximize economic value in some examples. Similarly, since such a system in various embodiments can be characterized as a production appliance rather than a bespoke installation, in some examples the engineering and regulatory burden can be defrayed across some, or the entire, production fleet, minimizing the economic overhead of the installation.
For example,
As shown in the example of
In various embodiments, a water heater can be implemented with a phase change material used for energy storage. For example, phase change materials (PCM) can be used to store energy and minimize the footprint of a full scale domestic water heater in some embodiments. In this way, a portion, or the total energy storage of some examples can be the combination of water thermal storage, battery chemical storage, and phase change thermal storage.
In some embodiments, a PCM heat storage system has a tank with two heat exchangers in it (e.g., one input heat exchanger and one output heat exchanger). For example, a heat pump coolant loop can be run through the input heat exchanger and to the heat pump, and a cold supply can be run through the output heat exchanger and to a domestic hot water supply (DHW). Various heat pumps can provide 1-10 kw output heat, and various PCM tanks can store a few to several kwh (e.g., 80 gallons at an input temperature of 32 F can be about 15 kwh, and doing that in an hour can be about 15 kW thermal). In various embodiments, providing hot water to two showers in a home can require 18 kW at 77 F inlet temp, 25 kW at 65 F inlet temp, 36 kW at 47 F inlet temp, and the like.
In various embodiments a PCM system can be configured to operate in a plurality of different operating configurations. For example, a normal configuration can include the PCM system heating slowly via an input loop and drawing small loads from an output loop. In various embodiments, a heat pump can run at 100, 200, 300, 400 watts, or the like, and additional headroom can be used to charge a battery. In some embodiments, a high demand configuration can include reconfiguring the PCM system so the cold supply goes to the heat pump, then to the thermal storage, then to the domestic hot water supply (DHW). In various examples, in such a high demand configuration, the heat pump can be run hard and above the AC electrical input capacity and can be supported by the battery. In one example, a 5 kwh battery can supply about 15-20 kwh of heat at a Coefficient-of-performance (COP) of 3-4, which may be similar to an 80 gallon equivalent with an input temp of 32 F. In some examples, such heating can require about 15 kW of thermal power, which in some embodiments can be shunted through PCM material to boost the total thermal power and stabilize output temperatures simultaneously, which may allow for use of a smaller heat pump compared to embodiments where thermal power is not shunted through the PCM material.
In various embodiments water heater 130 and load source system 300 can be configured to operate in a plurality of different operating configurations. For example, a low demand mode can include the system heating slowly via an input loop and drawing small loads from an output loop. In various embodiments, a heat pump can run at less than maximum capacity and additional capacity can be used to charge the battery 305. In some embodiments, a high-demand mode can include reconfiguring the system so the cold supply line 392A goes to the heat pump 370, then to the first and second PCM heat exchangers 1120, then to the hot water output line 392B. In other words, in some examples of a high-demand mode, the heat pump 370 and first and second PCM heat exchangers 1120 can contribute to hot water output, whereas in some examples of a low-demand mode, the first PCM heat exchanger 1120A can be reserved for small loads, the second PCM heat exchanger 1120B can be used for low-power heating, and the heat pump 370 can run at low power with a circulation pump (e.g., below 1500 W in total). In various examples, in such a high-demand mode, the heat pump 370 can be run hard and above the AC electrical input capacity (e.g., above 110 VAC) and can be supplemented with additional power from the battery 305. In various embodiments, of a high-demand mode, the circulation pump can be bypassed. In various embodiments, such a system can comprise resistive heating.
Various embodiments can include an all-in-one heat pump washer-dryer-water heater where architecture of a water heater is combined with a heat pump washer-dryer in a single device. In some examples, a heat pump in the washer-dryer can be used to dry the clothes, but also to heat water stored in an insulated tank (e.g., in the lower part of the appliance). Because the washer-dryer of various embodiments can require plumbing connections to a domestic hot and cold water line of a building, such an appliance in some examples can also function as a water heater to distribute hot water through existing lines. This can be advantageous for some examples of smaller houses that previously did not have a washer or dryer due to space constraints. In some embodiments, such an appliance can take up the space that a water heater would be in or used to be in, which can allow for small households to have in-unit laundry.
In some examples of a heat pump dryer or heat pump washer-dryer, the heat pump sits idle most of the time and is only used when laundry is being processed. However, in some examples of an all-in-one heat pump washer-dryer-water heater, the same heat pump can be used more regularly to provide the domestic hot water needs of a household.
For example,
In some embodiments, operating an all-in-one heat pump washer-dryer-water heater 1200 can comprise a plurality of operating configurations. For example, in a normal laundry mode, air can be taken from the drum 1210, run over the evaporator 1220 to cool the air and remove humidity, and then the air can be run over the condenser 1230 to reheat it. The air can then be returned to the drum 1210 to collect more moisture from the drying clothes. During a water heating operating configuration, water can be cycled from the water tank 360 over the condenser 1230 to heat the water and returned to the water tank 360. In some embodiments, the evaporator 1220 can be simultaneously cooled by a duct fan blowing ambient air over the evaporator 1220. In some embodiments, one or more batteries 305 can run or provide supplementary power to various elements of the all-in-one heat pump washer-dryer-water heater 1200; however, in some embodiments, batteries 305 can be absent.
Energy can be stored in the water tank 360 in various embodiments by running the heat pump water heater 1200 while the clothes are washing. When the time comes to dry the clothes, the heat stored in the water tank 360 can be used to augment the power of the heat pump 370, which can speed drying times in various examples by applying additional heat to the condenser 1230. In some embodiments, external air exchange can also be used to provide additional heat sinking to the evaporator 1220.
In some instantiations, resistance heating elements can be used to boost the performance of the heat pump 360 for water heating, which can enable a smaller storage tank to provide more hot water to the house. In some instantiations, resistance heating elements can be used to boost the performance of the heat pump 370 for drying clothes, which can shorten the drying cycle time. The length of a drying cycle can often be a complaint about some heat pump dryers and washer-dryers, so using resistance elements to augment drying can improve customer experience in various examples. In some instantiations, an onboard battery 305 can be used to provide high power output to such resistance elements without requiring high electrical power input (e.g., operating on 120V 15 amps rather than on 240V 30-50 amps).
In some instantiations with resistance elements in the dryer, the heat used to dry the clothes can be reclaimed by the heat pump 370 and delivered to the water tank 360, which can increase the efficiency of the all-in-one heat pump washer-dryer-water heater 1200. In some instantiations, the thermal energy of hot water during a hot wash cycle can be reclaimed by the heat pump 370, rather than dumped down a drain. This can be accomplished in various examples by circulating hot water through an evaporator 1220 with a heat exchanger, while circulating water from the tank through a condenser 1230.
In some examples, the weight of the water tank 360 can provide stability during a (e.g., fast) spin drying cycle. The shipping weight can stay low for convenience of installation and then after installation the water tank 360 can be filled to weigh it down. In some instantiations with one or more batteries 305, incoming cold water (e.g., via and input line 392A) can be used to cool the one or more batteries 305. In the case of thermal runaway, in various examples the incoming water can automatically be used to control the event before a fire starts. In some instantiations, a phase change material (PCM) can be used as thermal storage in place of or in addition to the water tank 360, which can increase the amount of stored energy.
In various embodiments of a water heating configuration, such an appliance 1200 can provide air conditioning to the space the appliance occupies. If desired (e.g., in the winter), this cold air can also be vented to the outdoors in some examples. If the appliance 1200 is replacing a conventional washer/dryer, such a vent may already be available in various examples. In some instantiations with batteries 305, such batteries 305 can also be used to reheat cold exhaust air to avoid cooling the room.
In various embodiments a water heater 140 or other appliance can be configured to operate in one or more blackout configurations when a blackout (e.g., loss of power from a receptacle) is identified. For example, a temperature limiter during blackout configuration can be configured to extend battery life during a blackout by the water heater being configured to limit the maximum water temperature to a threshold (e.g., flatly or gradually as battery level decreases). Such a threshold can be set automatically, configured by a user (e.g., via an app, interface, or the like).
In various embodiments, where a blackout or limited power availability is identified, usage recommendations can be provided to a user. For example, a water heater 140 can track and learn average usage patterns (e.g., amount of energy used daily, duration of showers, preferred temperatures, and the like) and in the event of a blackout, a user can be informed about how long they can keep their behaviors before the battery runs out or the system goes into a battery savings mode. In one example, a determination can be made regarding how many showers the user can take before the battery runs out or the system goes into a battery savings mode, which in some examples can be based on a determined average shower time of the user determined based on average shower times over a period of time such as a week, month, year, or the like. In some embodiments, a determination can be made regarding a number of dishwashing sessions, clothes washing sessions, bath sessions, or the like, which can be based on information regarding hot water used by a dishwasher, hot water used by a clothes washer, average amount of hot water used by a user when washing dishes, average amount of hot water used when taking a bath, and the like.
Various embodiments can include a configuration that provides thermoelectric standby power. For example, in various embodiments, the backend electronics of a water heater 140 can need a low level amount of power (e.g., ‘always-on’/standby power) in order to, for example, monitor the safety state of the system, maintain a minimum level of data communication, or the like. In various embodiments, standby power can be sourced from either a battery and/or wall AC, whichever is available, such as via a diode or circuit. Using a thermoelectric generator, the residual heat from a water heater 140, tank-based or otherwise, can be used in some examples as a third source of power (e.g., as a third branch in a diode, circuit, or the like) to keep the backend electronics powered. This can be desirable not only as an additional fail-safe in some examples, but can be desirable to reduce/conserve the amount of standby power supplied by the battery in the event of a blackout or other power failure.
Some embodiments can include Time-of-Use (TOU) water monitoring. For example, some jurisdictions can impose pricing schedules around water usage, which may include monitoring water usage during a blackout. In various embodiments, a water heater 140 can adjust flow rate and limit total usage during a blackout based on blackout water rates. By having a network of connected water heaters 140 with a community in some examples, water usage “restrictions” can be intelligently coordinated according to total demand. In some embodiments, by implementing intelligent water conservation efforts, water shortages can be less frequent and the cost of water can decrease.
In various embodiments, a water heater 140 can using thermochemical energy storage (TCES) to augment or improve the performance of a 120 Volt AC heat pump water heater 140. For example, to further enhance the efficiency and/or recovery rate of a 120-volt AC heat pump water heater 140, thermochemical energy storage (e.g., using desiccating salts) can be incorporated as an additional energy source. Some such embodiments can leverage the high-energy density and reversible absorption/desorption reactions of compounds (e.g., of desiccating salts, such as calcium chloride, or the like) to store thermal energy and release it on demand. The integration of TCES can allow a water heater 140 of some embodiments to maintain or even increase hot water output without relying on high-power resistive heating elements.
In some embodiments, a method of operating a water heater 140 with thermochemical energy storage (TCES) can include an absorption/charging phase and a desorption/discharge phase. For example, during periods of low hot water demand, a heat pump 370 of a water heater 140 can operate as usual by slowly heating the water in the tank. In various embodiments, a portion of the heat generated by the heat pump can be directed to drive a desorption process in a TCES unit, where desiccating salts are dehydrated and thermal energy is stored in the form of potential energy within the desiccating salt. When a high demand for hot water is detected such as being over a volume threshold, rate threshold for a period of time, or the like, (e.g., multiple showers running), the TCES unit can be activated for energy discharge, where energy stored in the desiccating salts is released by reabsorbing moisture, an exothermic process that generates heat. This heat in some embodiments can be transferred directly to water in a storage tank or through a heat exchanger, which can rapidly increase the temperature of the water without the need for the high-power resistive elements or with reduced need for resistive elements.
In various embodiments, a TCES unit can operate with a system that comprises a battery and heat pump. For example, a TCES unit of some embodiments can work in tandem with an integrated battery to manage energy flow efficiently. The battery can power a heat pump and/or other components during periods of high demand, grid outages, or the like, while the TCES can provide a thermal energy boost, which can allow the system in various examples to recover temperature faster. For example, where the battery is low or discharged below a threshold or depleted, the TCES can provide critical support to meet hot water needs without overloading a 120-volt AC circuit that the system is operating on.
A TCES unit can provide various benefits to a water heater 140 or other appliance or system. For example, a TCES unit can provide an additional heat source, which can reduce the reliance on slow heat pump cycles or high-power resistive elements and can provide an enhanced recovery rate. In another example, by utilizing waste heat from a heat pump to charge the TCES unit, the overall system efficiency is improved and/or can reduce the cycling of resistive elements, which can lower energy consumption of the system. In a further example, during power outages, the combination of a TCES unit and battery storage can allow the water heater 140 to maintain a supply of hot water, which can provide resilience and comfort to homeowners along with grid independence. In one example, a TCES unit can be designed to fit within the existing footprint of a water heater 140, making it a desirable solution for space-constrained homes and the modular nature of the TCES unit in various embodiments can allow for scalability depending on the hot water demand of a household.
In some embodiments, a TCES unit can be disposed within the housing of a water heater 140, as an external module connected to the water heater 140 via (e.g., insulated) pipes, or the like. In various examples, a system can include smart controls to optimize when to charge the TCES unit based on electricity rates, available solar energy, anticipated hot water usage patterns, or the like. By integrating thermochemical energy storage with a 120-volt AC heat pump water heater 140, some embodiments can provide homeowners with a more efficient and responsive hot water solution, such as in various examples where electrical service is limited or during transitions away from gas-powered water heaters.
In various embodiments, a phase change material (PCM) can be used to augment or enhance a 120 Volt AC heat pump water heater 140, which may provide for improved efficiency, recovery and performance of the heat pump water heater 140. For example, PCMs can have the ability to absorb and release large amounts of latent heat during their phase transitions (e.g., from solid to liquid and vice versa), making them a desirable thermal storage medium in various embodiments. Integration of a phase change material (PCM) in some embodiments can provide an additional energy source to help the water heater 140 recover its temperature faster, operate more efficiently, and preheat the water before the water enters the heat pump cycle. In various examples, a PCM can allow the systems to operate without relying on high-power resistive heating elements, operate with less reliance on resistive heating elements, or the like.
In various embodiments, a PCM-based thermal storage unit can be integrated into a water heater system 140, such as within a storage tank 360 of the water heater 140, as a separate module that interfaces with the storage tank 360 of the water heater 140, or the like. In some examples, a PCM can be selected to have a melting point close to a desired hot water temperature, which may include 40° C., 45° C., 50° C., 55° C., 60° C., 65° C., 70° C., 75° C., 70° C., or the like, or a range between such example values. In various embodiments, a PCM can include paraffin wax, salt hydrates, other organic/inorganic compounds designed for thermal energy storage, or the like.
In some embodiments, a method of operating a water heater 140 with a (PCM) can include an absorption/charging phase and a desorption/discharge phase. For example, during periods of low hot water demand or when excess energy is available (e.g., during off-peak electricity hours or when supplemented by renewable power), the heat pump can be configured to gradually heat water in a tank of the water heater. The PCM can be in direct or indirect thermal contact with the water in some examples and can absorb excess heat and can melt, which can store the energy as latent heat. In various embodiments, such an absorption/charging phase can ensure that the PCM is adequately or fully charged and ready to release stored energy when needed.
In various embodiments, when there is a sudden demand for hot water, the PCM can begin to solidify, which can release latent heat stored in the PCM back into the water. This process can rapidly increase the temperature of the water, which can assist the heat pump by providing an immediate thermal boost, which can reduce the load on the system and can shorten recovery time of the system. Such an immediate release of energy by the PCM can preheat the water in some examples before the water is heated by the heat pump, which can enhance the efficiency of the system.
In various embodiments, a PCM unit can be part of a system comprising a heat pump and battery. For example, the battery can power the heat pump during peak demand or outages, while the PCM can provide thermal energy necessary to meet hot water demands quickly and efficiently. In some examples, smart controls of a water heater 140 can be configured to optimize when to charge the PCM based on electricity rates, anticipated hot water usage, available renewable energy, or the like, which in various examples can ensure that the PCM is ready to release energy when needed or desired.
Incorporating a PCM unit into a water heater 140 or other load source can provide various suitable benefits in some embodiments. For example, latent heat stored in a PCM can provide a quick thermal response, allowing the water heater 140 to recover temperature faster than relying on the heat pump alone. In another example, by preheating the water with stored thermal energy from the PCM, the heat pump can require less energy to reach the desired water temperature, which can increase energy efficiency and reduce overall electricity consumption. In a further example, in the event of a power outage, the combination of PCM and battery storage can allow a water heater 140 to maintain a supply of hot water, which can enhance comfort and convenience for homeowners and provide improved grid resilience. In one example, by reducing reliance on resistive heating elements and decreasing the load on the heat pump of a system, the overall lifespan of the heat pump components can be extended and improve the working life of the heat pump.
In some embodiments, a PCM can be encapsulated in containers or panels that line the inside of a water tank 360 of a water heater 140, can be placed in a dedicated compartment adjacent to the water heater tank 360, or the like. Such containers can be designed in various examples to maximize surface area for efficient heat transfer between the water and the PCM. In some embodiments, a PCM can be housed in an external module (e.g., that can be plumbed into the water heater system 140). Such a module in various examples can preheat incoming cold water using stored thermal energy before the incoming cold water enters the main tank for further heating by the heat pump.
In various embodiments, a water heater 140 or other load source can comprise a smart control system to manage the PCM's charging and discharging cycles, which in some examples can ensure that the system operates optimally based on the hot water usage patterns, energy availability, energy cost, and the like.
By incorporating phase change materials (PCMs) into the design of a 120-volt AC heat pump water heater 140, in various embodiments the system can be configured to deliver enhanced performance, greater energy efficiency, faster recovery times, and the like, which can provide a superior hot water solution for homeowners, (e.g., in scenarios where electrical service is limited, during the transition away from gas-powered water heaters, or the like).
In some examples, it can be advantageous and more cost effective to augment an existing gas water heater with a battery attached resistive heating element that replaces an anode rod. Some such examples can allow the battery to trickle charge when electricity is abundant, lower carbon, dump that energy into water that would otherwise be heated by gas without the cost and complexity of replacing the whole water heater, and the like.
Various embodiments can include a heat pump water heater 140 with high thermal mass materials. For example, to enhance the efficiency and recovery rate of a heat pump water heater 140, in some embodiments the water tank can be (e.g., partially) filled with high thermal mass materials such as granite spheres, metal spheres, encapsulated phase-change materials (PCMs), or the like. Such materials in various embodiments can serve as thermal energy reservoirs, which can retain heat and can reduce the recovery time required to bring the water back to a desired temperature after hot water is used.
In various embodiments, high thermal mass materials (e.g., spheres) within the tank can have a high surface area, which in some examples can allow for rapid heat exchange with surrounding water. When the heat pump raises the water temperature, such materials can absorb and retain heat, act as thermal buffers, and the like. Additionally, in various embodiments, when cold water enters the water tank, the new cold water can mix with pre-heated material rather than displacing a volume of warm water. The retained thermal energy in such materials in various examples can quickly raise the temperature of the incoming water, leading to a much faster recovery time compared to some embodiments of water heaters 140 that rely solely on water without high thermal mass materials. Encapsulated phase-change materials (e.g., within spheres) in various examples can absorb excess heat during periods of low demand and release thermal energy during peak usage, which can smooth out temperature fluctuations and improve the consistency of hot water supply.
While the inclusion of such materials can reduce the total volume of water the tank can hold, a trade-off can be an increase in efficiency and recovery rate. This configuration in various embodiments can be beneficial in scenarios where rapid hot water replenishment is more critical than total water volume. In various embodiments, maintaining a more consistent temperature within the tank and reducing the frequency of temperature drops, wear and tear on the heat pump components can be reduced and can extend the lifespan of the system. In some examples, the type, size, and quantity of the materials used can be customized based on the specific needs of the household or application, allowing for a tailored approach to balancing water volume and recovery speed.
The choice of materials (e.g., granite, metal, PCM, or the like) can depend in some examples on factors such as thermal conductivity, heat capacity, durability, cost, and the like. The encapsulation of phase-change materials can include use of materials that can withstand repeated heating and cooling cycles without degradation. The internal design of the tank may be adjusted in some embodiments to accommodate characteristics of the materials, which in various examples can help ensure that such materials are evenly distributed and do not interfere with water flow, heat pump operation, or the like.
Smart controls can be integrated in some examples to manage a heating cycle, which in various embodiments can ensure that the thermal storage materials are utilized effectively during periods of high demand, low energy availability, or the like. By filling a heat pump water heater 140 with high thermal mass materials, in various embodiments the system can provide a more efficient and responsive hot water solution, which in some examples can be desirable for households that prioritize rapid recovery times over maximum hot water volume. Such an approach in various examples can reduce energy consumption by leveraging stored thermal energy to maintain water temperature, which can offer a practical solution in the transition to more energy-efficient and sustainable home heating systems.
In various embodiments, electronic components of a load source system 300 can be disposed in various locations relative to a water tank 360 and/or heat exchanger 370, such as on top, on the front of, behind, split up on a plurality of sides of, or the like.
In some embodiments, a load source system 300 of a water heater 140 can comprise an auxiliary electrical output configured to output electrical power, which may come from the battery 305 and/or electrical input 505. An auxiliary electrical output in various embodiments can comprise a standard electrical receptacle (e.g., 120 VAC receptacle) disposed on a housing of a load source 200 (e.g., a water heater 140) that allows various other appliances, tools, or the like to be plugged into and powered by the load source system 300. In various embodiments, the electrical input 505 and/or battery 305 can directly or indirectly supply AC power to the auxiliary electrical output. For example, in various embodiments, electrical output can be configured to be powered only by the electrical input 505; powered only by the battery 305; and/or powered by both the electrical input 505 and the battery 305 at the same time. As discussed herein, such powering capabilities can be desirable in various examples to allow for auxiliary power from the battery 305 while power from the electrical input 505 is unavailable or undesirable such as when there is a power outage or when power obtained from the electrical input 505 is undesirably expensive (e.g., when such power obtained from a power grid is expensive). Such powering capabilities can be desirable in various examples to allow for a combination of power from the electrical input 505 and battery 305 to be used, which can allow for greater power to the auxiliary electrical output than would be available from the electrical input 505 alone, which can allow the auxiliary electrical output to perform near, at, or above the capability of a water heater 140 powered by 240 VAC, even though the load source system 300 is externally powered by only 120 VAC via the electrical input 505. Such powering capabilities can be desirable in various examples to allow for a combination of power from the electrical input 505 and battery 305 to be used, which can allow for a reduced amount of power consumed from the electrical input 505, which may be desirable when power obtained from the electrical input 505 is unstable, inconsistent, or undesirably expensive (e.g., when such power obtained from a power grid is expensive) or when it is desirable to draw less power from the electrical input 505 (e.g., where a circuit does not support drawing full power because of other appliances on the circuit). Such powering capabilities can be desirable in various examples to allow for the auxiliary electrical output to be powered via the electrical input 505, when it is undesirable to use power from the battery 305, when the battery 305 is out of power, when the battery 305 is malfunctioning, when the battery 305 is overheating, when power from the electrical input 505 is obtained from a renewable source (e.g., solar), or the like. In some embodiments, the electrical input 505 (e.g., 120 VAC from a wall receptable) provides power to a dedicated, external-facing ‘auxiliary power’ inverter, which can function as a default passthrough for preserving the battery state of charge and avoiding power conversion losses (and the associated noise from fans).
One or more auxiliary electrical output may be integrated into the load source system 300 in a convenient accessible location such as on the front of a water heater 140 near the floor, behind a cover on the top of the water heater 140, in a reachable location on the back of the water heater 140, affixed with a small whip to allow the user to move the outlet to a counter near the water heater 140, on the top of the water heater 140 with a fluids cover, and/or in any suitable location.
The auxiliary electrical output may comprise a NEMA 5-15 or NEMA 5-20 plug in some examples. The auxiliary power port in some examples may provide standardized AC power (e.g., 120 VAC power). DC auxiliary power ports in some alternative form (e.g., a USB port) may additionally or alternatively be included. The auxiliary electrical output can be powered in some embodiments by a DC battery and may connect to an internal inverter to convert the power from DC to AC.
An auxiliary power port in some embodiments can be ‘full power’ or provide the max available power of 2400 w (nema 5-20) or 1800 w (nema 5-15), or the like. An auxiliary electrical output in some examples can alternatively or dynamically provide less power, such as 1000 w, 500 w or 300 w, or the like.
The auxiliary electrical output in some embodiments may be integrated into the load source system 300 as a passthrough system whereby a device could be plugged into the auxiliary electrical output and the power may by default be supplied via the AC power input, but then during a power outage or during other suitable situations, the load source system 300 can switch over to providing power via the battery 305.
The load source system 300 in some embodiments can additionally or alternatively include a DC auxiliary electrical output. This may provide a DC power rail in some examples. The DC auxiliary electrical output may be used in various ways including to power an additional appliance, tool, light or the like, that may be plugged into the water heater. In another variation, a DC auxiliary electrical output may be used to power an external inverter which could be used to provide AC power to a high-power device like an air fryer, a dishwasher, washer, dryer, and the like. In some variations, a DC auxiliary electrical output may be used to connect an external battery, which could be used as additional power storage capacity.
A load source 200 that comprises a load source system 300 can have various suitable form factors, which may include conventional form factors or novel form factors such as shown in
Systems and methods for battery enhanced appliances described in various embodiments discussed herein can function to provide various solutions and enhanced functionality for a modern appliance. In particular, the systems and methods of some examples can provide an energy storage equipped water heater 140 (or other type of appliance) that uses an electrical architecture and configuration that ensures safety and provides DC power to high-load heating elements 362 of a water heater 140, or the like.
The systems and methods of some embodiments may include components and/or operational processes to facilitate conversion from an alternating current power source (e.g., from a wall outlet) to DC power used to drive various elements of the water heater 140 (e.g., high-load elements such as one or more heating elements 362, water tank 360, heat pump 370, or the like) and charge an auxiliary power source, which may also supply DC power. In some variations, the DC power matches voltage of the auxiliary power source (e.g., storage battery voltage) such that the high-load elements of an appliance may be powered directly from the auxiliary power source without further voltage conversion.
The systems and methods of various embodiments may include or be implemented through an AC power input, an AC/DC conversion module, and one or more heating modules/elements. The system may additionally include an auxiliary power source that can be managed and used as a backup or as a supplement to power delivered through the AC power input.
The components of various embodiments are integrated into an appliance system such as a cooking range, an oven, a cooktop, a clothes dryer, water heater, heat pump, washer, dryer or the like. Depending on the capabilities and features of such an appliance, the exact architecture of the appliance may be adjusted. For example, the system and methods discussed herein can be embodied in a water heater or other appliance configured to heat water or other fluids and/or any suitable type of appliance for heating a fluid.
In some variations, a battery enhanced appliance may be used in connection with a network of other appliances. These can be other appliances in the same house, which may also be battery enhanced appliances or may be other types of electrical appliances without battery or power storage. In some variations, the systems and methods of some examples may be used with a powered building system and electric power distribution system such as the one described in U.S. patent application Ser. No. 17/692,714, filed Mar. 11, 2022, entitled “APPLIANCE LEVEL BATTERY-BASED ENERGY STORAGE,” which is incorporated by reference.
As one potential benefit, the systems and methods of some examples can enable use of a line power source (i.e., a wall outlet power source) with a battery power source to augment capabilities of an electric water heater 140. The systems and methods of some examples can preserve functionality and capabilities of more traditional natural gas ranges while enabling a transition to electrical power. Enabling use of an electrical power source can have many benefits as the world transitions to more sustainable power sources.
As one potential benefit, the system and method of some examples may lower the requirements of a building's existing electrical system when using an electrical appliance, thereby enabling wider adoption of electrical appliances. Common residential electrical outlets (e.g., “120V standard outlet”) can have insufficient power capacity for many appliances, typically requiring installation of a higher voltage and higher power outlet (e.g., “240V appliance outlet”). By augmenting an appliance with the systems and methods of some embodiments (e.g., an integral or attached energy storage system such as a battery), a standard 120V electrical outlet may be used with the systems and methods of various examples to supply a much higher power level to the appliance in a non-continuous-use application. In some embodiments, this can be an equivalent power level to a traditional 240V appliance outlet.
In some variations, such as an on-demand hot water heater, even a single 240V appliance outlet can be insufficient for the appliance, and by using some embodiments herein, sufficient power can be provided to the appliance in various examples, which might otherwise require a multi-circuit and/or hard-wired electrical installation, or might exceed the capacity of the entire load center.
As another potential benefit, the systems and methods of some embodiments may enable use of a hot water heater 140 and/or other appliance type during varying power availability. For example, some variations described herein may allow for use of the hot water heater 140 during power blackouts, during increased grid use (e.g., when electrical costs are high), and/or when using other electrical appliances at the same time.
As another potential benefit, systems and methods of various embodiments can avoid limitations and problems that occur with AC-based heating appliances. This may include audible and tactile vibrations that can make the water heating experience less pleasurable. Furthermore, some variations of the systems and methods discussed herein may enable customization of the sound and feel of water heating to make the water heating experience more pleasurable and/or safe. For example, some auditory and/or vibrational sensations may be actively enabled when heating water as a form of feedback that water is heating up. These auditory and tactile cues could be varied based on conditions.
As another potential benefit, the systems and methods of some examples may enable a reduction in usage of various components used in AC appliances. For example, the systems and methods of various embodiments may avoid or reduce the number of filter capacitors/inductors, rectification systems. In particular, the systems and methods of some examples may eliminate or reduce the need for a PFC circuit and/or EMI/RFI circuits, which may be required for an AC-powered device. The firmware may similarly be simplified in some embodiments. The resulting systems and methods of various embodiments may enable an appliance that can be less heavy, smaller, cheaper and quieter.
As another potential benefit, the systems and methods of some embodiments can decouple device performance from limitations of outlet capacity and/or inverter capacity. The systems and methods of various examples comprise a battery 305 that can enable capacity and power capabilities to be based on the battery 305.
In one example, a system variation can include a battery charger that can draw up to 15 A from a standard 120V wall outlet, charging the battery with a nominal 230 VDC and 5 k Wh capacity. Once fully charged, the system in various embodiments can supply, for example, approximately 7 kW for one hour to an appliance (5 kW from the battery+1.875 kW from the standard wall outlet), after which the battery may need re-charging. In a scenario of some examples, the battery 305 charges whenever the appliance is not in use, or in use at a low power level, such that it is fully charged when needed or desired. The specific battery voltage can be adjusted in various embodiments based on the internal design of the appliance load elements. The battery capacity (kWh) can be adjusted in various embodiments based on a desired usage profile of the appliance, cost, or other factors. In another example, the charger may draw 30 A from a standard 240V appliance outlet, charging a battery 305 with a nominal 230 VDC and 10 k Wh capacity. Once fully charged, the system of some embodiments can provide approximately 30 kW for 20 minutes, as might be utilized in some examples by an on-demand hot water heater which may require 2× or 3× the capacity of a standard 240V appliance outlet.
One example embodiment includes a first battery system that is an integral component of and disposed within a housing of a first load source of the plurality of load sources, the first load source comprising a first power cord plugged into a first receptable of the plurality of receptacles, the first battery system comprising a first battery configured to obtain and store power from the first receptacle, the first load source being configured to be fully powered by power stored by the first battery and configured to be fully powered by power obtained from the first receptacle and configured to be partially powered by both the first battery and power obtained from the first receptacle.
Various embodiments can eliminate significant upgrade costs required to replace fossil fuel appliances. Many electric appliances (e.g., hot water heaters, induction ranges and electric dryers) require dedicated high-capacity circuits to be installed, but only draw their full capacity for short periods of time. This electrical work can significantly increase the cost of such an upgrade, providing a large barrier to entry, and can negate any value proposition the increased efficiency of these more advanced appliances may provide. As an example, a four-burner induction cooktop with oven on its own runs from $1,000-$2,000, and (in the lucky case where an appropriate 240V circuit is already available) can be installed by the homeowner or a general contractor for $150-$200. If a stove of some embodiments is replacing a natural gas stove, however, the likelihood that an appropriate, unused circuit is available at the correct location is very low, and the cost to install the required 30-40 amp appliance circuit is roughly $800-1,000, with an additional $380-$460 required if the routing from the circuit breaker to the stove is long or inconvenient. Further, in most cases the available electrical service was designed assuming fossil fuel use and is insufficient for this large additional circuit. Upgrading the service panel in this situation can add an additional $1,500-$4,000 on top of the project cost, making the total cost of replacing the natural gas stove a factor of 2-6 higher than the underlying new appliance cost. Similar issues can be present with installing or replacing a water heater 140.
In various embodiments, appliances with integrated or associated batteries as discussed herein can eliminate the need to upgrade electrical service, as they can supply the required high current during use, while only drawing meager average power from an existing 110V electrical outlet to recharge. In the case of the induction stove, the overwhelming majority of dinnertime cooking needs can be met by a 0.75-1.5 kWh integrated battery 305. This battery can add a mere $100-$200 to the appliance cost if installed in the factory at current EV prices, and less as the scale of this industry continues to bring costs down. As a result, the total project cost to the homeowner to eliminate this source of residential emissions remains predictable and low, and the night time hot water heating, which can occur largely outside the productive window for solar, can be cost-effectively shifted to be powered by renewables.
Additionally, centralized main home batteries can require large, dedicated inverters to supply AC power, even when appliances (e.g., water heaters 140) use internal rectification to convert the power back to DC. Placing batteries at these points of load can allow direct DC powering of the appliance, with only modest AC draw from the electrical outlet in various embodiments. On a systemic level, in various embodiments this can eliminate the inversion-rectification cycle on power drawn and deferred from the grid, and significantly reduce the power requirements on an inverter supplying power from a rooftop solar array. The result can be a reduction in system cost, and an efficiency increase due to eliminated power conversions.
Also, large battery packs that may be required for main home batteries are often spoiled by a single bad cell. In contrast, a ˜1 kWh commoditized pack that can be used to power a home appliance can be easier to manage than centralized batteries, and in various embodiments can be made easier to replace in the event of failure. Having fewer cells under a battery management system (BMS) can allow, in some embodiments, better control over charge cycle, mechanical, and thermal stress and more robust health diagnostics, leading to longer battery life. Battery management systems and supporting power electronics can be at a price point such that an increased number of them does not present a cost barrier. As an additional benefit to this approach, in some embodiments smaller battery packs used for point of load storage can be more appropriate for second-life applications of plug-in EV batteries-supply of which is expected to grow rapidly in the next 10 years. Even after use in an EV, such cells are expected to have 70% of their initial capacity and be viable for another 10 years in their second-life application.
In various embodiments, a load source system 300 such as a water heater 140 can be configured to operate in different operating modes depending on state of the battery 305. For example, a load source system 300 can be configured to operate a water heater 140 in a full power mode or in one or more limited power mode (e.g., when the battery 305 is dead or when it is desirable to conserve power stored in the battery 305 and/or being drawn from a receptacle 165).
In various embodiments, a benefit of having a load source system 300 such as a water heater 140 that comprises a battery 305 can be that the water heater 140 can be operated even when the power from the grid and/or renewable sources is out, intermittent or limited. To facilitate uninterrupted use of a water heater 140 under such condition, in some examples, an interface 460 can be configured to alert a user about the charge status of the battery 305 and/or the remaining energy left in the battery 305 so the user can make informed decisions on how much energy to use while heating water, such as delays in regaining power delivery from a utility or renewable sources; when the cost of energy from the grid is expensive; or the like.
A display or other presentation of energy consumption can be visualized in various suitable ways (e.g., to suit user preferences), such as an absolute percentage of battery capacity remaining, quantity of energy stored in kWh or Wh, an estimated time of exhaustion based on the current energy draw, an average of the last X number of minutes of water heating, and the like. In some embodiments, the load source system 300 can determine energy consumption using a machine learning approach based on a water heating training dataset (e.g., including data amassed over the life of the water heater 140, a moving window of time therein, or the like).
In the case where the battery 305 is depleted, the user can be notified via the interface 460, such as via a display 384, another visual indicator, an audio indicator, or the like. The interface 460 in various examples can indicate that the water heater 140 will function at limited capacity based on the amount of energy coming from a receptacle 165 the water heater 140 is connected to. In some embodiments, when limited power is available based on lack of power from the battery 305 or receptacle 165, the water heater 140 can be configured to still have a functional water tank 360, but in some examples, the water heater 140 can take longer to reach temperature due to operating at lower than full power. In some embodiments, when limited power is available based on lack of power from the battery 305 or receptacle 165, the water heater 140 can be configured to operate with a reduced number of heating elements 362 and/or with less than max power output on one or more heating elements 362, or the like.
In various environments, a load source system 300 of a water heater 140 can be configured to operate in any suitable number of power configurations, including one, two, three, four, five, ten, twelve, or the like. For example, some embodiments can include a full power operating configuration and a minimal operating power configuration, where the minimal operating power configuration provides less operating capacity than the full power operating configuration. Some embodiments can include a full power operating configuration, a first reduced operating power configuration that provides less operating capacity than the full power operating configuration, and a second reduced operating power configuration that provides less operating capacity than the first reduced operating power configuration and full power operating configuration.
Full and reduced or minimum operating power configurations of a water heater 140 can provide more or less operating capacity in various suitable ways. For example, in embodiments where a water heater 140 comprises one or more heating elements 362, a full power operating configuration can allow the one or more heating elements 362 of the water tank 360 to operate at 100% power capacity, and one or more reduced operating power configurations can limit the water tank 360 and/or heating element(s) 262 to operating at equal to or less than 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%, 5%, or the like, or a range between such example values. One embodiment can include a full power operating configuration that can allow the one or more heating elements 362 of the water tank 360 to operate at 100% power capacity and a minimum operating power configuration that limits the one or more heating elements 362 of the water tank 360 to operating at 50% power or less. Another embodiment can include a full power operating configuration can allow the one or more heating elements 362 of the water tank 360 to operate at 100% power capacity, a first reduced operating power configuration that limits the one or more heating elements 362 of the water tank 360 to operate at 65% power or less, and a second reduced operating power configuration that limits the one or more heating elements 362 of the water tank 360 to operating at 35% power or less.
In some embodiments, where a water heater 140 comprises a water tank 360 with a plurality of heating elements 362 of (e.g., 2, 3, 4, 5 separate heating elements 362, or the like), different power configurations can limit the total number of heating elements 362 that are able to function at the same time. For example, where a water tank 360 consists of four heating elements 362, a full power operating configuration can allow up to all four heating elements 362 to operate simultaneously and one or more reduced operating power configuration can limit the maximum heating elements 362 operating simultaneously to three, two or one at a time. In some examples, such a limitation can be on specific heating elements 362 or can apply to any sets of two, three or four heating elements 362 of the four heating elements 362.
In various embodiments, once power from a previously unavailable or unused source becomes available, the water heater 140 can switch from a limited operation configuration to a fully operational configuration. For example, after operating in a limited operation configuration from only power from the receptacle 165, as a result of the battery 305 being depleted or below a minimum charge threshold, once the battery 305 has charged to a minimum change state (e.g., defined by a set charge percentage or historical data for how the water heater 140 has been used), the water heater 140 can return to a fully operational configuration based on power from the battery 305 and receptable 165. Such a configuration change can be presented via an interface 460 in various suitable ways.
In another example, after operating in a limited operation configuration from only power from the battery 305 as a result of the power from the receptacle 165 being unavailable or unused, the water heater 140 can return to a fully operational configuration based on power from the battery 305 and receptable 165 once power from the receptacle 165 becomes available or usable (e.g., after a power outage; once the cost of power from the grid is below a cost threshold making it desirable to use; once renewable power becomes available via the receptacle 165 at a sufficient amount such as to provide full power instead of grid power; or the like).
In various embodiments, the load source system 300 can determine or predict a time to achieve different operational capabilities. For example, where a water heater 140 is operating in a limited capability mode due to the battery 305 being depleted or having insufficient power, a determination or prediction can be made regarding how long it will take for the battery 305 to charge to a level where the water heater 140 will be able to operate at a greater operational capacity and/or a full operational capacity. For example, where a minimum charge of 10% is required for the water heater 140 to operate at full power, a determination can be made regarding the time it will take for the battery 305 to charge to 10% capacity. Such a determination can be made based on data such as current charging rate, current power use by the water heater 140, predicted power use by the water heater 140, current charging current, current charging voltage, stages of a charging protocol, and the like.
Similarly, in some embodiments, where a water heater 140 is operating in a full operating configuration or a greater than minimum operating configuration, a determination or prediction can be made regarding how long the battery 305 has sufficient charge to operate at such a level and until the water heater 140 will switch to a minimum or lower operating configuration. For example, where a minimum charge of 10% is required for the water heater 140 to operate at full power, a determination can be made regarding the time it will take for the battery 305 to be depleted to below or equal to 10% capacity. Such a determination can be made based on data such as current charging rate, current power use by the water heater 140, predicted power use by the water heater 140, current charging current, current charging voltage, stages of a charging protocol, and the like.
In some embodiments, an interface 460 of the load source system 300 can include a timer counting down to when the water heater 140 is predicted to be able to operate at a full capacity configuration; is predicted to be able to operate at greater than a minimum capacity configuration; is predicted to be required to operate at a minimum operating configuration, is predicted to be required to operate at below a maximum operating configuration; and the like. In various examples, an ability of a load source system 300 to provide information about energy consumption, battery status, and switching between normal and one or more limited modes can enhance the user experience by empowering the user to make informed decisions about their usage of the enhanced water heater 140, thereby optimizing energy usage and user satisfaction. In various embodiments, a load source system 300 can automatically switch between one or more operational power modes without user interaction, such as when battery charge reaches or exceeds one or more threshold, when battery charge reaches or falls below one or more threshold, or the like. In some embodiments, operational power modes can be configured by a user, such as via an interface 460 of a load source system 300.
Turning to
In various embodiments, load source use data can include data regarding elements of a load source 200 being used, such as an heating elements 362 of a water tank 360, heat pump 370, and the like. For example, use data can include the identity of one or more heating elements 362 of a water tank 360, a power level that a heating element 362 is set at, an amount of power being consumed by a heating element 362, a mode of a heating element 362, a power level that the tank 360 is set at, an amount of power being consumed by the tank 360, a mode of the tank 360, an amount of power being consumed by an auxiliary electrical output, a mode of an auxiliary electrical output, and the like.
In various embodiments, power availability data can include an indication of whether power is available from a battery 305, an amount of power available from a battery 305, voltage and/or current available from a battery 305, an indication of whether power is available from a receptacle 165, an amount of power available from a receptacle 165, voltage and/or current available from a receptacle 165, one or more source of power coming from the receptacle 165, cost of power coming from the receptacle 165, and the like.
In various embodiments, determining an operating configuration can be based at least in part on whether power is available from the battery 305 and/or receptacle 165. For example, where a determination is made that power from the receptacle 165 has become unavailable, but power from the battery 305 remains available, a determination can be made that an operating configuration should be changed to a reduced power configuration from a full power configuration. In another example, where a determination is made that power from the battery 305 has become unavailable, but power from the receptacle 165 remains available, a determination can be made that an operating configuration should be changed to a reduced power configuration from a full power configuration. In another example, where a determination is made that power from both the receptacle 165 and battery 305 are available after one being unavailable, then a determination can be made that an operating configuration should be changed from a reduced power configuration to a full power configuration.
In various embodiments, power from the battery 305 may be unavailable due to the battery 305 lacking charge, lacking charge above a threshold minimum amount, being broken, being absent from the load source system 300, being improperly installed in the load source system 300, where using power from the battery 305 is undesirable, or the like. In various embodiments, power from the receptacle 165 may unavailable due to a power outage of an electrical grid, lack power generated by a renewable source (e.g., solar, or wind), or where using power from the receptacle 165 is undesirable due to cost, being from a non-renewable source, or the like.
For example, in some embodiments, a determination can be made to change to a reduced power configuration from a full power configuration when the cost of power from an electrical grid obtained via the receptacle 165 is above a cost threshold, which may be based on price data, time of day, a selection by a user, or the like. In some embodiments, a determination can be made to change to a full power configuration from a reduced power configuration when the cost of power from an electrical grid obtained via the receptacle 165 is below a cost threshold, which may be based on price data, time of day, a selection by a user, or the like.
In some embodiments, a determination can be made to change to a reduced power configuration from a full power configuration when power from a renewable source becomes available, when power from a renewable source becomes available at an amount above a threshold, or the like. In some embodiments, a determination can be made to change to a full power configuration from a reduced power configuration when power from a renewable source becomes unavailable, when power from a renewable source becomes unavailable at an amount below a threshold, or the like.
In various embodiments, an operating configuration can be selected based on a mode of the load source system 300, which in some examples can be selected by a user, set based on a timer, set based on obtained data, and the like. In some embodiments, a mode can include a battery charging priority mode; a renewable energy mode that prioritizes use of renewable energy sources in powering the load source and/or charging the battery 305; a cost saving mode that prioritizes use of free energy sources such as renewable energy and/or when cost of power from the grid is more affordable; or a performance mode that prioritizes higher functionality of the load source 200 over battery charging, use of renewable energy, cost of power from the grid, or the like.
In some embodiments, a determination can be made to change to a reduced power configuration from a full power configuration when a user switches from a performance mode to a battery charging priority mode. In some embodiments, a determination can be made to change to a full power configuration from a reduced power configuration when a user switches from a battery charging priority mode to a performance mode.
In some embodiments, a determination can be made to change to a reduced power configuration from a full power configuration when a user switches from a performance mode to a cost saving or renewable energy priority mode. In some embodiments, a determination can be made to change to a full power configuration from a reduced power configuration when a user switched from a cost saving or renewable energy priority mode from a performance mode.
In some embodiments, a reduced power configuration can include limiting, stopping or preventing operation of one or more elements of a load source system 200, and for a water heater 140 can include limiting, stopping or preventing operation of one or more of an tank 360, heating elements 363 of a heat pump 370, and an auxiliary electrical output.
In some embodiments, such a method 1400 of
As discussed herein, determining an output configuration can be for various suitable purposes, such as to maximize use of renewable energy sources (e.g., solar panels 115); to maximize storage of power from renewable energy sources; to maximize storage of power from a power grid 110 when such power is at a low or lower cost; to maximize performance of a load source 200; to maximize energy efficiency of a load source; to maximize energy storage by one or more batteries 305; to minimize charging time for one or more batteries 305; and the like. For instance, a shorter nighttime hot water heating session can be completely covered in some examples by an on-board or associated battery 305, charged during the day with ample solar resources, while a longer, more demanding nighttime water heating sessions could be powered jointly by the battery 305 and low-capacity outlet (e.g., receptacle 165). In this way, the charge and discharge control laws of the system and/or network can maximize the use of renewable-generated electricity, in some examples, without impacting the experience of the user.
In various embodiments a load source system 300 can include settings that enable a user (e.g., via interface 460) to control functional and usability related aspects of the load source system 300, which in some examples can include a selection of a charging mode, such as based on user preferences, based on external factors, or the like. One embodiment can include a charging mode configured to charge the battery 305 via a receptacle 165 during off-peak hours for lower cost and less grid strain. For example, such a charging mode can be based on the time of day, day of the week, month, time of the year, or the like, which can be set by a user, based on historical patterns, or the like. In some examples, such a charging mode can be based on electricity pricing data (e.g., obtained from a utility company), with charging occurring when price drops below a threshold.
Another example charging mode can be configured to keep the battery 305 topped up all the time in preparation for utility power interruption or other desired use of the battery 305. Yet another example charging mode can be configured to charge the battery 305 during times when the electricity supplied to the receptacle 165 comes from a renewable resource such as solar or that at least prioritizes charging when renewable power is being supplied to the receptacle (e.g., only charging the battery 305 via renewable power unless the battery 305 reaches or is below a charge threshold). In various examples, such a charging mode can be based on data obtained regarding power sources, which can include a house server providing information on an amount of power being generated by one or more renewable sources and/or being provided by an electrical power grid 110.
To provide a user with information about such one or more charging modes, an interface 460 of the load source system 300 may display such charging modes on a digital display, along with a short description for each charging mode. In this way, the user can be informed about the options available to them and can choose the charging mode that best suits their needs or preferences.
In a home that has multiple appliances that have built-in batteries 305 that are networked together, one or more of the appliances may include an integrated control interface. An integrated control interface may be used, for example, to set global energy policies for the network of appliances such as charging after 9 μm or staying charged all the time in case of a blackout. In one example, it can be desirable to instruct a connected mini-split air conditioner to turn off from your stove because the stove is downstairs from the air conditioner, and you are already cooking on the stove. The ability to control appliances from other appliances can allow for embodiments of such appliances that do not have their own interface and rely on other nodes in the appliance network to control them.
For example, a method of heating water in a water tank 360 can include obtaining data from a plurality of temperature sensors and determining whether a difference between one or more detected temperature is above a threshold difference, and if so, automatically turning on a mixer of the water tank 360. If a difference between one or more detected temperature is not above a threshold difference, then the mixer can be automatically turned off or not turned on. Sampling of data from temperature sensors can occur at any suitable interval.
In some embodiments, a method of power allocation for a localized power grid that includes a battery supplemented appliance includes: in response to an appliance activation, providing power to the appliance, which may include providing battery power to the appliance; in response to external power usage, providing power to the external power usage, which may include providing battery power to the external power usage; and in response to battery depletion, providing power to the battery.
The method in various examples can provide dynamic power allocation for a local energy grid connected to a high-power consumption load source 200 such as a water heater 140 comprising an energy storage device (e.g., a battery 305). The method may function with a load source system 300 as described herein but may additionally or alternatively be incorporated with any applicable system. Example use cases for such a method can include office buildings, local households, residential type buildings (e.g., apartment complexes, hotels), local communities (e.g., HOAs, condominium communities, gated communities, etc.), data farms, and/or any other type of local energy grid.
Providing power to the load source 200 can enable function of the load source 200 by providing power to the load source 200 once the load source 200 has been activated. In some embodiments, the load source 200 can comprise a high-power consumption water heater 140 that may not be able to function powered directly by the local power grid (e.g., a 220V appliance, such as a water heater 140, connected to a 110V receptacle 165). In some embodiments, the load source 200 can comprise a high-power consumption water heater 140 that may not be able to fully function powered directly by the local power grid; for example, a 220V appliance, such as a water heater 140, connected to a 110V receptacle 165 that is configured to fully function with 220V power; configured to fully function with greater than 110V power; configured to operate at a limited power configuration at 110V; configured to operate at a minimal power configuration at 110V; and the like.
In other words, some embodiments can include a load source 200 such as a water heater 140 comprising a load source system 300 that is inoperable to operate in a full power configuration based on power from a receptacle 165 that the load source 200 is plugged into. In some embodiments, such a load source 200 may be inoperable to operate solely via power from the receptacle 165 that the load source 200 is plugged into and may require a combination of power from the receptacle 165 and a battery 305 of the load source system 300 to operate in a full power configuration (e.g., greater than 110V, at 220V, or the like). In some embodiments, such a load source 200 may be inoperable to operate in a full power configuration solely via power from the receptacle 165 that the load source 200 is plugged into and may require a combination of power from the receptacle 165 and a battery 305 of the load source system 300 to operate in a full power configuration (e.g., greater than 110V, at 220V, or the like), but may be able to operate in a reduced, low or minimal power configuration solely via power from the receptacle 165 that the load source 200 is plugged into. In some embodiments, the load source system 300 may be able to operate in a first reduced power configuration solely via power from the receptacle 165 that the load source 200 is plugged into; able to operate in a second reduced power configuration solely via power from the battery 305 of the load source 200; able to operate in a third reduced power configuration via a combination of power from the receptacle 165 that the load source 200 is plugged into and via power from the battery 305; and able to operate in a full power configuration via power from the receptacle 165 that the load source 200 is plugged into and from power from the battery 305. In various embodiments, the first, second and third reduced power configurations can have reduced operating capability of the load source 200 compared to the full power configuration. In various embodiments, the first and second reduced power configurations can have reduced operating capability of the load source 200 compared to the third power configuration.
In various examples, such embodiments can be desirable for providing operability of a load source 200 when power from the battery 305 is unavailable or undesirable to use; when power from the receptacle 165 is unavailable or undesirable to use; and/or when power from both the receptacle 165 and the battery 305 are available and desirable to use.
In various embodiments, providing power from the battery 305 to the load source 200 can function to provide supplementary power to the load source 200 in addition to or as an alternative to power from the receptacle 165, such that the load source 200 may operate in one or more power configuration. In some variations, not all load source 200 functionalities may require supplementary power, thus power from the battery 305 may be provided in some examples only when additional power is necessary for the load source 200 to function.
In some variations, a method may be implemented with a system that includes multiple battery integrated load sources 200. In some such variations, power may be provided to each load source 200 separately, wherein providing battery power to the load source 200 can function individually for each load source 200. For example, a battery 305 integrated with a single load source 200 may provide supplementary power for function of that single load source 200.
Providing power to the external power usage can function to provide electrical power to a device connected to the local power grid. Providing power to the external power usage in various examples can provide sufficient power to the device to enable the device to function within device specifications. Some examples can provide power to multiple devices, and in some household energy grid implementations, can function in allocating power to dozens of devices/operations as necessary or desired.
Providing power to the external power usage may include providing power from the battery 305 to the external power usage. Providing battery power to the external power usage may in some examples be dependent on the amount of external power usage and level of battery charge (e.g., current amount of power stored in the battery 305). Providing battery power to the external power usage may allow for supplementary power for the external power usage when more power is being used, and the battery 305 is sufficiently charged. Additionally, where the battery 305 is incorporated with the load source 200, providing battery power to the external power usage in some examples can be reserved for times when the load source 200 is not activated, and the battery 305 is not providing (e.g., supplementary) power to the load source 200. Thus, providing battery power to the external power usage can function in various examples to provide supplementary power for general power usage on the local grid during times of increased power need and/or when the load source 200 has reduced or no power need.
In some variations that include multiple batteries 305 integrated with multiple load sources 200, each battery 305 may have a separate call for providing battery power to the external power usage, wherein each non-activated load source 200 may have its integrated battery 305 provide power for external power usage, while each activated load source 200 may have its integrated battery 305 provide power for use of each activated load source 200.
Providing power to the battery 305 can function to charge the battery 305 from external power. Although providing power to the battery 305 may occur in various examples any time the battery 305 needs to be charged, in some examples charging the battery 305 can be initiated in times of low power consumption of the local power grid, (e.g., during times that the load source 200 is not in use and there is less than normal external power usage). For example, for a household power grid this may occur during the night.
In some embodiments, a load source 200 can comprise a water heater 140 with a load source system 300 that operates on a standard 120V, 20-amp receptable 165, while still providing the functionality and quality of a water heating experience available in a water heater 140 that operates plugged into a standard 240V, 20-amp, 30-amp or 50-amp receptacle 165. Various embodiments can comprise a water heater 140 with a load source system 300 that does not require electrical upgrades (e.g., installing a new 220V receptacle in place of a 110V receptacle) or skilled labor beyond that needed to perform a standard water heater 140 replacement, allowing the water heater 140 to be installed in occupied apartments with limited resident disruption.
In various embodiments, a load source 200 (e.g., a water heater 140) can be configured to pass one or more of the following standards: UL 2595: Standard for Safety for General requirements for battery-powered appliances; UL 1642: Standard for Lithium Batteries (Cells); UL 2054: Standard for Household and Commercial Batteries; UL/IEC 62133-2: Standard for Safety for Secondary Cells and Batteries containing Alkaline or Other Non-Acid Electrolytes-Safety Requirements for Portable Sealed Secondary Cells & for Batteries Made From Them for Use in Portable Application; UL 1973: Standard for Batteries for Use in Stationary, Vehicle Auxiliary Power and Light Electric Rail (LER) Applications; UL 9540A: Standard for Test Method for Evaluating Thermal Runaway Fire Propagation in Battery Energy Storage Systems; and the like.
It should be clear that the embodiments discussed herein are only some example embodiments of a load source system 300 and that load source systems 300 having fewer or more elements or having more or less complexity are within the scope and spirit of the present disclosure. For example, one or more of the elements of
Additionally, in some embodiments, on-board or network control laws can be adaptive to patterns of use, which can allow a given battery capacity to adapt to expected demands. Further, these laws in various embodiments can be configured to adapt to local time-of-use rates, allowing behind-the-scenes energy arbitrage. Implementation of these control laws can be based on reinforcement learning and controls techniques, accompanied by best practice user interfaces allowing homeowner monitoring and tuning.
Various embodiments can be configured for managing the thermal requirements of the battery 305 of the load source 200. Due to the high-energy density, thermal runaway of lithium batteries can be a safety concern and should be prevented in various examples. Additionally, on a less catastrophic level, operating batteries at elevated temperatures can impact lifetime of the battery. Because of these factors, a battery management system 760 can have integrated temperature sensing and thermal interlocking. Accordingly, various embodiments can comprise a battery management system 760 along with careful thermal design to isolate battery compartments from regions of the appliance or local environment with unsafe operating temperatures. For instance, an effective design strategy for thermal management in various embodiments is building high aspect ratio packs adjacent to the ambient environment. Another strategy can be to incorporate fire suppression at the appliance level in the individual load source system 300. For example, in some embodiments a load source system 300 can include a fire suppression system that comprises sensors operable to determine whether a fire is occurring in the battery, and if so, execute fire-suppression measures such as releasing foam, liquid, gas, generating a vacuum, or the like to extinguish the fire.
Some embodiments can be configured for obtaining adequate safety certifications by placing batteries directly into appliances and obtaining sufficient buy-in from appliance manufacturers to adopt this technology. Mitigation strategies may include one or more of the following. First, some embodiments can include data analytics and software modeling to estimate the most effective appliance targets and quantify value propositions. For instance, some examples can include localized estimates of the value per watt-hour capacity for each appliance based on time-of-use electricity prices, grid scale and distributed renewables enabled, and avoided electrical upgrade costs. Second, some embodiments can include hardware units which can sit between an existing appliance and the electrical outlet, before integrating with appliances. These hardware units can verify the value proposition in terms of achievable demand response under real-world use, as well as test robustness of the hardware, networking, and control electronics and can be used in place of appliances with integrated batteries, along with appliances with integrated batteries, with conventional appliances before replacement with a battery-integrated appliance, and the like. Third, various embodiments can include safety certifications through UL or another body, as well as green certifications through the nascent ENERGY STAR Connected Functionality program or similar.
In various embodiments (see, e.g.,
In various embodiments, control schemes of such appliances may operate in several modes including one or more of the following examples. First, such appliances may effectively share loads between a wall plug and a battery based on estimated usage requirements without impeding user experience. This scheme may be used in some examples to maximize the energy used from a solar installation or other alternative energy source, or to enable the use of high-capacity devices running from a 110V socket or enable the use of time-of-use electricity rates. Another control scheme may operate when the appliance is not in use, nor expected to be in use in the near future, where the appliance provides energy arbitrage services, which can enable a house to absorb and store cheap electricity from the grid for later use.
In various embodiments, control schemes for battery integrated appliances may function using several levels of data including one or more of the following examples. First, they may rely only on calendar and time of day to predict loads and supply. Second, they may incorporate historical use data to tailor the algorithms to the habits of the user. Third, they may report data back to a central system where it is aggregated and used to provide control laws. Fourth, it may accept user input to switch control modes. Fifth, they may use data about electricity rates (e.g., time-of-use rates) from the utility to tailor control laws to use the cheapest electricity from the grid. Sixth, they may use data from a rooftop solar array to predict and maximize the use of available solar electricity.
Additional benefits may be provided to the appliances by the batteries in accordance with further embodiments. For example, many conventional appliances have performance limited by the peak power provided by the wall outlet. The batteries can allow for much higher peak powers, which can be used to increase the performance of appliances. For instance, a water heater 140 can have extremely fast temperature ramp up, higher peak outputs, and lower noise. On-demand water heating can have higher capacity, enabling storage-free water heaters with higher outputs. Electric kettles can be made to boil faster. For devices with motors, these motors can be run with higher peak powers, and if desired, at voltages more optimal than the AC from the wall. In some cases, the battery thermal management can be synergistic with the appliance performance. For instance, the heat from the battery pack can boost the coefficient of performance of heat pump devices like electric dryers and water heaters 140.
With a home electric system, many costs can be proportional to peak power. Installing batteries at end uses can decrease peak power, and hence decrease these costs. By enabling hybrid AC/DC systems, battery-integrated appliances may also enable the use of higher efficiency solid state power conversion, including inverters and DC/DC voltage conversion.
Battery-integrated appliances of various embodiments can provide fire retardant capabilities, to protect against thermal runaway of lithium batteries, and can include a fire alarm to warn of an emergency. Device health monitoring may also be incorporated to monitor the state of health of the battery pack. This can be implemented through capacity monitoring, internal resistance measurements, or impedance spectroscopy. Such devices may also be made waterproof to protect batteries and electronics. These devices can also provide voltage regulation services for the house electrical system.
In various embodiments, a battery can allow high-power appliances to be usable with 120V receptacles as opposed to having to install a 240V power source. In some examples, batteries can have 4-24 hours of storage. Some embodiments can obtain real-time or historical use data for a room, house, building, block, city, state, and the like. In various examples, it can be beneficial to minimize inversions (e.g., inverter in battery module that sits on DC bus can prevent multiple inversions). Some embodiments can have power sharing between appliances (e.g., via extension cords, existing or new in-wall wiring, Ethernet, and the like). Some examples can have a battery module that is integral or replaceable within the appliance. Such a battery module can be configured to be a self-contained unit that is waterproof, heatproof, and the like, and can provide for shallow cycling of battery, fire suppression, battery monitoring, and the like. The whole module, including control systems, may be a replaceable unit since control systems may be inexpensive compared to the battery.
The battery module in various examples can obtain and use different types of data to control battery use. This can depend on network connectivity or complexity of the system. A simple battery module can simply include a clock and lookup table with the battery module operating based on time, day, season, or the like. Another more complex version can store use history from only the battery module itself or local battery modules and use a clock to control battery operation. Another more complex version can have network connectivity (e.g., to the Internet), which can provide access to data from an electrical grid, use data from remote modules, etc.
Various embodiments can be configured to forecast use based on data discussed above, or the like. Some embodiments can be configured to operate based on user input (e.g., user indicates he is about to or will cook a meal, take a shower, or take a bath, at a later time or date). Forecasting can be based on data such as user calendars, user defined schedules, or the like.
Some devices can have large ramp-up requirements and having a local battery 305 can reduce this, resulting in faster, better appliances (e.g., faster heating). Appliances can be configured to dial up voltages as necessary to provide for improved appliances. Other benefits can include electrostatics in washer/dryer, increased efficiency of inverters, and the like.
While specific examples are discussed herein, these examples should not be construed to be limiting on the wide variety of alternative and additional embodiments that are within the scope and spirit of the present disclosure. For example, appliances, devices or systems can be associated with one or more batteries as discussed herein. Also, while residential examples are the focus of some examples herein, further embodiments can include multi-family buildings, commercial buildings, vehicles, or the like.
As used herein, first, second, third, etc., are used to characterize and distinguish various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. Use of numerical terms may be used to distinguish one element, component, region, layer and/or section from another element, component, region, layer and/or section. Use of such numerical terms does not imply a sequence or order unless clearly indicated by the context. Such numerical references may be used interchangeable without departing from the teaching of the embodiments and variations herein.
The described embodiments are susceptible to various modifications and alternative forms, and specific examples thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the described embodiments are not to be limited to the particular forms or methods disclosed, but to the contrary, the present disclosure is to cover all modifications, equivalents, and alternatives. Additionally, elements of a given embodiment should not be construed to be applicable to only that example embodiment and therefore elements of one example embodiment can be applicable to other embodiments. Additionally, elements that are specifically shown in example embodiments should be construed to cover embodiments that comprise, consist essentially of, or consist of such elements, or such elements can be explicitly absent from further embodiments. Accordingly, the recitation of an element being present in one example should be construed to support some embodiments where such an element is explicitly absent.
This application is a non-provisional of and claims the benefit of U.S. provisional patent application No. 63/535,023, filed Aug. 28, 2023, entitled “Energy Storage Equipped Water Heater Architecture,” with attorney docket number 0122186-003PR0. This application is hereby incorporated herein by reference in its entirety and for all purposes. This application is also related to U.S. patent application Ser. No. 18/814,022, filed Aug. 23, 2024, entitled “BATTERY-INTEGRATED APPLIANCE SYSTEM AND METHOD,” with attorney docket number 0122186-002US0 which is a non-provisional of and claims the benefit of U.S. Provisional Application No. 63/534,727, filed Aug. 25, 2023, entitled “Battery Enhanced Appliances,” with attorney docket number 0122186-002PR0, which applications are hereby incorporated herein by reference in their entirety and for all purposes. This application is also related to U.S. patent application Ser. No. 17/692,714, filed Mar. 11, 2022, entitled “APPLIANCE LEVEL BATTERY-BASED ENERGY STORAGE,” which is a non-provisional of and claims the benefit of U.S. Provisional Application No. 63/159,851, filed Mar. 11, 2021, entitled “APPLIANCE LEVEL BATTERY-BASED ENERGY STORAGE,” which applications are hereby incorporated herein by reference in their entirety and for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 63535023 | Aug 2023 | US |
