Patent Application
20180006280
This invention relates to containment trays and containment systems for aligning, storing, and transporting battery modules that are formed from one or more electrochemical cells.
Electrolyte batteries, such as zinc-halide batteries (e.g., zinc-bromine batteries, zinc-chlorine batteries, and the like), offer a potential to overcome limitations associated with commonly used lead-acid batteries. In particular, the useful lifetime of zinc-halide batteries is not affected by deep discharge applications, and the energy to weight ratio of zinc-halide batteries is up to six times higher than that of lead-acid batteries.
Batteries may be stored on battery racks where the batteries serve to power electrical devices. Alternatively, batteries may be stored on battery racks where the batteries serve to discharge energy into the grid or recharge from energy sources such as the grid, wind turbine, or solar cell. These batteries typically contain a liquid electrolyte that may leak or spill onto other batteries, cables, equipment and other devices as well as personnel, thereby posing a hazard to people and property. Moreover, during transportation, batteries can be jostled or jarred to collide with one another or the walls of a container, which may damage the batteries and result in leakage or spillage of electrolyte. Additionally, large batteries and battery racks can be too heavy for people to transport without the assistance of a machine such as a forklift.
The present invention provides containment trays and containment systems that are useful for aligning, storing, and transporting one or more battery modules that comprise one or more electrochemical cells.
In one aspect, the present invention provides an apparatus for storing one or more battery modules comprising a containment tray defined by opposing front and back faces, opposing side faces, and opposing top and bottom surfaces oriented perpendicular to the front, back, and side faces, wherein the containment tray has a receiving area formed in the top surface for receiving one or more battery modules, the receiving area comprising a receiving surface oriented parallel to and located between the opposing top and bottom surfaces for supporting the one or more battery modules.
In some embodiments, the front and back faces are oriented in parallel and separated by a distance that defines a width of the containment tray, the side faces are oriented perpendicular to the front and back faces and separated by a distance that defines a length of the containment tray, and the top and bottom surfaces are separated by a distance that defines a height of the containment tray.
In some embodiments, the receiving area is defined by a receiving front wall oriented parallel to and inward from the front face; a receiving back wall oriented parallel to and inward from the back face, the receiving front wall and back wall separated by a distance to define a length of the receiving area; a pair of receiving side walls oriented parallel to and inward from associated ones of the side faces, the pair of receiving side walls separated by a distance to define a width of the receiving area; and the receiving surface oriented perpendicular to the receiving front wall, the receiving back wall, and the pair of receiving side walls, the receiving surface separated from the top surface by a distance to define a depth of the receiving area.
In some embodiments, the depth of the receiving area is greater than a height of the one or more battery modules.
In some embodiments, the depth of the receiving area is substantially equal to a height of the one or more battery modules.
In some embodiments, the depth of the receiving area is less than a height of the one or more battery modules.
In some embodiments, a plurality of side wall spacers that protrude inward from each of the pair of receiving side walls, each side wall spacer comprising a side contact surface for contacting at least a first surface of the one or more battery modules adjacent to the receiving side walls; and a plurality of front-back wall spacers protruding inward from the receiving front wall or the receiving back wall, each front-back wall spacer comprising a contact surface for contacting at least a second surface of the one or more battery modules adjacent to the receiving front wall or the receiving back wall.
In some embodiments, one or more divider walls are disposed within the receiving area and extending between the receiving front wall and the receiving back wall, the one or more divider walls oriented in parallel with respect to the receiving side walls and configured to divide the receiving area into substantially equally spaced rows each having a substantially uniform width.
In some embodiments, one or more sets of dividers are disposed within the receiving area and extend between the receiving side walls, each set of dividers oriented in parallel with respect to the receiving front wall and the receiving back wall and configured to divide the receiving area into equally spaced columns each having a uniform width, wherein the sets of the dividers and the one or more divider walls are configured to segment the receiving area into a plurality of receiving compartments each separated from one another and configured to accommodate the one or more battery modules.
In some embodiments, a plurality of divider wall spacers protrude outward from one or more surfaces of the one or more divider walls toward the opposing receiving side walls, each divider wall spacer comprising a surface for contacting one or more surfaces of the one or more battery modules adjacent to the one or more divider walls.
In some embodiments, one or more of the divider walls extend between the receiving sidewalls, the divider walls oriented in parallel with respect to the front wall and the back wall and configured to divide the receiving area into substantially equally spaced columns each having a uniform length, wherein the one or more divider walls extending between the receiving sidewalls and the one or more divider walls extending between the front wall and the back wall are configured to segment the receiving area into a plurality of receiving compartments each separated from one another and configured to accommodate the one or more battery modules.
In some embodiments, a plurality of ribs protruding from the receiving surface to provide a spacer between the one or more battery modules and the receiving surface.
In some embodiments, the bottom surface of the containment tray rests upon a ground surface.
In some embodiments, the containment tray is stacked upon a top surface of another containment tray and provides a cover for one or more battery modules within the receiving area of the other containment tray underneath.
In some embodiments, the top surface of the containment tray is configured to support at least a portion of a lid for covering the one or more battery modules within the receiving area.
In some embodiments, the containment tray further comprises one or more openings extending through the front and back faces or one or more openings extending through opposing side faces. In some embodiments, the openings are fork openings configured to receive forks from a forklift.
In some embodiments, the containment tray further comprises one or more conduit terminals for connecting the one or more battery modules to one another. In some embodiments, the containment tray further comprises one or more conduit terminals for connecting the one or more battery modules to an electronic device.
In some embodiments, the containment tray further comprises a flame retardant material. In some embodiments, the flame retardant material comprises at least one of high-density polyethylene or polypropylene.
In another aspect, a containment system of the present invention comprises two or more containment trays stacked in a parallel orientation to form a stack, each containment tray comprising: opposing front and back faces, opposing side faces, and opposing top and bottom surfaces, wherein the opposing top and bottom surfaces are oriented perpendicular to the opposing front and back faces and the opposing side faces; and a receiving area on the top surface for receiving one or more battery modules, the receiving area comprising a receiving surface oriented parallel to and located between the opposing top and bottom surfaces for supporting the one or more battery modules.
In some embodiments, one or more containment lids are each oriented parallel to the two or more containment trays and configured to cover the one or more battery modules within the receiving areas of the containment trays, the containment lids and the two or more containment trays stacked in an alternating repeating pattern.
In some embodiments, at least one of the two or more containment trays includes one or more openings. In some embodiments, the one or more openings are slots for receiving forks from a forklift.
In some embodiments, a base rests upon a ground surface and is configured to support the bottom surface of the containment tray at the bottom of the stack.
In some embodiments, one or more conduit terminals are disposed at one or more of the containment trays for connecting the one or more battery modules to one another. In some embodiments, one or more conduit terminals are disposed at one or more of the containment trays for connecting the one or more battery modules to an electronic device.
The following figures are provided by way of example and are not intended to limit the scope of the invention.
Like reference symbols in the various drawings indicate like elements.
The present invention provides containment trays and containment systems that are useful for aligning, storing, and transporting one or more battery modules that comprise one or more electrochemical cells.
As used herein, the terms “battery module” and “battery” are used interchangeably to refer to an energy storage device comprising one or more electrochemical cells. A “secondary battery” is rechargeable, whereas a “primary battery” is not rechargeable. For secondary batteries of the present invention, a battery anode is designated as the positive electrode during discharge, and the negative electrode during charge.
As used herein, the term “electrochemical cell” and “cell” are used interchangeably to refer to a galvanic cell. Examples of electrochemical cells include, without limitation, zinc halide cells.
As used herein, an “electrolyte” refers to a substance that behaves as an electrically conductive medium. For example, the electrolyte facilitates the mobilization of electrons and cations in the cell. Electrolytes include mixtures of materials such as aqueous solutions of zinc halide or other zinc and halide containing materials. Some electrolytes also comprise additives such as buffers. For example, an electrolyte comprises a buffer comprising a borate or a phosphate.
As used herein, the term “polyethylene” and its abbreviation “PE” are used interchangeably to refer to a polymer material that comprises polyethylene. Use of the term polyethylene or initials in no way implies the absence of other constituents. This term also encompasses substituted polyethylene and co-polymers thereof (e.g., block and alternating co-polymers). In some instances, high-density polyethylene is any polyethylene having a density of greater than or equal to 0.94 g/cm2. In other instances, low-density polyethylene is any polyethylene having a density of less than 0.94 g/cm2.
As used herein, the term “Flame Retardant High-Density Polyethylene” and its corresponding initials “FR HDPE” are used interchangeably to refer to any high-density polyethylene that is treated to resist fire or combustion, including, without limitation, fire rated high-density polyethylene and fire retardant high-density polyethylene. Other examples of ‘FR HDPE’ include high-density polyethylene that is coated or otherwise combined with a flame-retarding agent (e.g., a fire resistant epoxy resin binder, a phosphorous compound, a bromine compound, antimony trioxide, or any combination thereof).
As used herein, the term “polypropylene” and its abbreviation “PP” are used interchangeably to refer to a polymer material comprising polypropylene. Use of the term polypropylene or initials in no way implies the absence of other constituents. This term also encompass substituted polymers, and co-polymers (e.g., block and alternating co-polymers).
As used herein, an “anode” is a negative electrode from which electrons flow during the discharging phase of the cell. The anode is also the electrode or material that undergoes chemical oxidation during the discharging phase. However, in secondary, or rechargeable, cells, the anode is the electrode or material that undergoes chemical reduction during the cell's charging phase. Anodes are formed from electrically conductive or semiconductive materials, e.g., metals, metal oxides, metal alloys, metal composites, semiconductors, or the like. Anode materials such as zinc may even be sintered. In zinc halide cells, zinc is the anode material that undergoes oxidation upon discharge of the cell.
As used herein, a “cathode” is a positive electrode from which electrons flow during the discharging phase of the battery. The cathode is also the electrode or material that undergoes chemical reduction during the discharging phase. However, in secondary, or rechargeable, cells, the cathode is the electrode or material that undergoes chemical oxidation during the cell's charging phase. Cathodes are formed from electrically conductive or semiconductive materials, e.g., metals, metal oxides, metal alloys, metal composites, semiconductors, or the like. Common cathode materials include, without limitation, halide ions. For example, in zinc halide cells, halide (X−), wherein X is a halogen atom, is the cathode material that undergoes oxidation upon discharge of the cell.
As used herein, the term “electronic device” is any device that is powered by electricity.
As used herein, the terms “containment tray”, “tray”, and “container” are used interchangeably to refer to a structure that is configured to align and store one or more battery modules. In some examples, the tray comprises a receiving area for aligning and storing one or more battery modules. In other examples, the receiving area may be divided into one or more receiving compartments, each receiving compartment storing an associated battery module. The receiving area may include front, back, and sidewalls enclosing at least a portion of the sides of the battery modules.
As used herein, the terms “cover”, “lid”, and “containment lid” are used interchangeably to refer to a structure that at least partially encloses a top surface of one or more battery modules stored within a receiving area of a containment tray. The cover or lid may include a hollowed portion having a depth for enclosing a portion of battery module sides.
As used herein, the term “containment system” refers to a plurality of containment trays and at least one cover. In some embodiments, the containment system comprises containment trays that are stacked on top of each other and the topmost tray is at least partially covered by a lid. In other embodiments, the system comprises containment trays and containment lids stacked in an alternating repeating pattern. For example, a bottom first containment tray may rest on a ground surface, a containment cover may stack on top of the bottom containment tray, and a second containment tray may stack on top of the containment cover. Faces of the containment trays or containment covers may include conduit terminals configured to connect the one or more battery modules in series or in parallel and for connecting the one or more battery modules to an electronic device or power grid.
Referring to
Exemplary containment systems 200, 400, 600, 900 are depicted in
The containment trays of the present invention comprise a receiving area for enclosing at least a portion of sides of a battery module received therein. In some embodiments, the containment trays 300, 500 (
In some embodiments, the containment trays 300, 500, 700, 1000 and containment lids 800, 1000′ comprise non-conductive materials such as FR HDPE and polypropylene materials. FR HDPE and PP materials are commonly recyclable and each provide an improved strength to density ratio (e.g., from 0.80 to 0.99 g/cm3) and can withstand high temperatures (e.g., from about 110° C. to about 180° C.) before melting or undergoing structural failure.
In some embodiments, the containment system comprises one or more conduit terminals such as holes 90, snap-in-connectors 92, or gaps 1099 (e.g., as shown in
Referring to
Referring to
The receiving area 302 is formed in the top surface 312 of the tray 300 and is defined by a receiving front wall 324, a receiving back wall 326 and receiving sidewalls 328. The receiving front and back walls are oriented in parallel with respect to the y-z plane and separated by a distance L2 while the receiving sidewalls 328 are oriented in parallel with respect to the x-z plane and separated by a distance W2. In the example shown, L2 is greater than W2. However, in other examples, W2 is greater than L2, W2 is equal to L2, or W2 is less than L2. The receiving area includes a receiving surface 320 parallel to the x-y plane. A distance between the receiving surface and the top surface defines a height of the walls 324, 326, 328 and denotes a depth of the receiving area 302. In some examples, the receiving area depth is selected based on the height of the battery modules being received therein. For example, the receiving area depth may be greater than the height of the battery modules being received therein. In other examples, the receiving area depth may be less than or equal to the height of the battery modules being received therein. The receiving surface is configured to support the battery modules received by the receiving area.
In some embodiments, the receiving area optionally comprises a plurality of ribs 322 that protrude from the receiving surface to provide space between resting surfaces of the received battery module and the receiving surface. Ribs can be configured to have any shape. In some embodiments, the receiving area comprises a plurality of ribs, wherein the distance from the receiving surface and the top of the rib extending therefrom is substantially the same (e.g., ±1 mm, ±0.75 mm, ±0.5 mm, or ±0.25 mm). In one example, the ribs are configured such that if one of the battery modules leaks, the leaked electrolyte may be contained along the receiving surface without contacting the resting surfaces of the battery modules within the receiving area. The ribs may be arranged in any suitable configuration (e.g., uniformly spaced rows across the receiving surface). In the example shown, the ribs are arranged in uniformly spaced rows each oriented in parallel with respect to the x-axis. In some examples, the ribs may be arranged in two sets of uniformly spaced rows. For example, a first set may include rows oriented in parallel with respect to the x-axis while a second set may include rows oriented in parallel with respect to the y-axis.
In some examples, the receiving area comprises one or more divider walls 330 disposed therein. The divider walls 330 may be oriented in parallel with respect to the x-axis and extend between the front and back walls 324, 326, respectively. The divider walls 330 include a height associated with the receiving area 302 depth (i.e., distance between the receiving surface 320 and the top surface 302). The divider walls are configured to divide the receiving area into equally spaced rows each having a substantially uniform width with respect to the y-axis. In the example shown, one divider wall is disposed within the receiving area 302 to divide the receiving area into two equally spaced rows. As shown in
Additionally, the receiving area includes dividers 332 disposed therein. The dividers may be oriented parallel to or along the y-axis and extend between the sidewalls. The dividers 332 include a height associated with the divider walls and the receiving area depth. The dividers are configured to divide the receiving area into equally spaced columns having a substantially uniform length with respect to the x-axis. In the example shown, one set of four dividers 332 oriented along the y-axis divide the receiving area into two substantially equally spaced columns. As shown in
In the example shown, a pair of dividers is disposed within the first row on one side of the divider wall while another pair of dividers is disposed within the second row on the other side of the divider wall. Each divider comprises a first contact surface parallel to and facing the front wall and a second contact surface parallel to and facing the back wall. The first contact surfaces are associated with a first column of the receiving area while the second contact surfaces are associated with a second column of the receiving area. The first contact surfaces of the pair of dividers disposed within the first row are configured to contact a surface of a first battery module received within the first column of the first row between the divider wall, the back wall, and the sidewall adjacent to the first row of the receiving area. The second contact surfaces of the pair of dividers disposed within the first row are configured to contact a surface of a second battery module received within the second column of the first row between the divider wall, the front wall, and the sidewall adjacent to the first row of the receiving area 302.
Similarly, the first contact surfaces of the pair of dividers disposed within the second row are configured to contact a surface of a third battery module received within the first column of the second row between the divider wall, the back wall, and the side wall adjacent to the second row of the receiving area. The second contact surfaces of the pair of dividers disposed within the second row are configured to contact a surface of a fourth battery module 100 received within the second column of the second row between the divider wall 330, the front wall 325, and the side wall 328 adjacent to the second row of the receiving area 302.
Accordingly, the dividers and the one or more divider walls are configured to segment each of the receiving compartments of the receiving area. In some embodiments, spacers 334, 336, 338 are provided to prevent surfaces of the battery modules within each of the receiving compartments from contacting the front, back, side or divider walls 324, 326, 328, 330, respectively. For example, the divider wall 330 includes a plurality of divider wall spacers 334 that protrude outward from the divider wall 330 toward the sidewalls 328 with respect to the x-y plane. Each divider wall spacer includes a contact surface for contacting surfaces of the battery modules adjacent to the divider wall. Similarly, the sidewalls include a plurality of sidewall spacers 338 that protrude inward from the sidewalls toward the divider wall with respect to the x-y plane. Each sidewall spacer 338 includes a contact surface for contacting surfaces of the battery modules adjacent to the sidewalls. The front and back walls comprise a plurality of front-back wall spacers 336 protruding inward from the walls 324 or 326 toward the dividers 332 with respect to the x-y plane. Each front-back wall spacer includes a contact surface for contacting surfaces of the battery modules adjacent to the front wall 324 or the back wall 326. In the example shown, each receiving compartment is defined by a width W4 and a length L4. The width W4 denotes the distance between the contact surface of the sidewall spacers and the contact surface of the divider wall spacers associated with each receiving compartment. The length L4 denotes the distance between the contract surface of the front-back wall spacers and the first or second contact surfaces of the dividers associated with each receiving compartment.
Referring to
A top surface of the base is oriented in parallel with respect to the x-y plane and is configured to support the base portion of the bottom tray 500a when stacked thereon. In some examples, a lip 408 extends upward from the perimeter of the top portion of the base. The lip may enclose the outer perimeter of the base portion of the bottommost tray 500a to assist in aligning and securing the bottommost tray on top of the base. However, the base portions of trays 500b-500d stacked on top of the bottommost tray are each configured to cover the battery modules stored at the receiving portion 510 of the associated tray underneath. The top lid of the containment system is configured to cover the battery modules stored at the receiving portion of the topmost tray 500d. A bottom perimeter surface 412 of the top lid 410 rests along a top perimeter surface 522 of the receiving portion 510 of the topmost tray. The top and bottom perimeter surfaces are oriented in parallel with respect to the x-y plane. The top lid 410 further includes a hollowed portion inward from the bottom perimeter surface for accepting the height of the battery modules that is exposed above the receiving portion 510 of the topmost tray. For example, the top lid may be hollowed by a depth extending perpendicularly from the bottom perimeter surface. Thus, the hollowed portion of the top lid encloses portions the battery modules stored at the receiving portion of the topmost tray.
Referring to
The receiving portion for each tray includes a receiving area 518 for receiving one or more battery modules. The receiving area is formed inward from the top perimeter surface and is defined by a receiving front wall 524, a receiving back wall 526 and receiving sidewalls 528. The receiving front and back walls are oriented in parallel with respect to the y-z plane while the receiving sidewalls 528 are oriented in parallel with respect to x-z plane. The receiving area includes a receiving surface 520 oriented in parallel with respect to the x-y plane. A distance between the receiving surface and the top perimeter surface defines a height of the walls 524, 526, 528 and denotes a depth of the receiving area. In some examples, the receiving area depth is selected based on the height of the battery modules being received therein and/or a depth of hollowed portions of the lid or base portion of a tray stacked on top. The receiving surface is configured to support the battery modules received by the receiving area 518.
In some examples, the receiving surface may include plurality of ribs protruding therefrom to provide a spacer between resting surfaces of the battery modules and the receiving surface. For example, if one of the battery modules leaks electrolyte, the leaked electrolyte may be contained along the receiving surface 520 without contacting the resting surface of other battery modules within the receiving area 518. Ribs may be arranged in any configuration along the receiving surface 520.
In some examples, one or more divider walls 530 are disposed within the receiving area. The divider walls may be oriented in parallel with respect to the x-axis and extend between the front and back walls. The divider walls may include a height associated with the receiving area depth (i.e., distance between the receiving surface 520 and the top perimeter surface 522). The divider walls are configured to divide the receiving area into equally spaced rows each having a uniform width with respect to the y-axis. In the example shown, one divider wall is disposed within the receiving area to divide the receiving area into two equally spaced rows. However, other examples can include two divider walls that divide the receiving area into three equally spaced rows, three divider walls to separate the receiving area into four equally spaced rows, and so on. In the example shown, the receiving area for each tray is configured to accommodate four battery modules.
As aforementioned, the base portion for each tray (except the bottom tray 500a) is configured to at least partially cover the battery modules stored within the receiving area of the associated tray underneath. The bottom perimeter surface 532 rests along the top perimeter surface 522 of the receiving portion 510 of the tray 500 underneath. The base portion further includes a hollowed portion inward from the bottom perimeter surface for accepting the height of the battery modules stored within the receiving area of the tray underneath. For example, the base portion may be defined by a depth extending perpendicularly from the bottom perimeter surface 532. Thus, the hollowed portions of the base portions for each of the trays 500b-500d encloses portions of the battery modules stored within the receiving area of the tray underneath.
Front and back faces 714, 716 of trays 700 are oriented in parallel with respect to the y-z plane to define widths W1 and W2, while inner and outer side faces 718, 719, are oriented in parallel with respect to the x-z plane to define a length L1. Each tray includes a top surface 712 and a bottom surface 710 oriented in parallel with respect to the x-y plane and separated by a height H1 corresponding to the height of the front and back faces. The top surface 712 may be grated to provide structural support when transporting the trays 700 and to reduce weight. The bottom surface 710 is defined by the width W1 extending between the inner side faces 718. The top surface 712 is defined by the width W2 extending between the outer side faces 719. Fork support surfaces 713 oriented perpendicular to and extending away from the inner side faces 718 to the outer side faces 719 are configured to receive forks from a forklift for lifting the trays. In the example shown in
Bottom surfaces 710 of the trays 700 are each configured to mate with an associated top surface 810 of the containment lids 800. For instance, in the example shown, the bottom surface 710 of tray 700b is configured to mate with the top surface 810 of the containment lid 800. Accordingly, the bottom and top surfaces comprise substantially equal surface areas and are oriented in parallel with respect to the x-y plane. In some embodiments, the bottom surface may comprise grooves 711 oriented in parallel with respect to the x-axis for receiving corresponding slots 811 disposed upon the top surface 810 of the compartment lid 800. In other embodiments, the bottom surface 710 includes slots for receiving corresponding grooves disposed upon the top surface 810. The groove and slot pairs may assist in aligning the trays over top the compartment lids 800 and in securing engagement between the bottom and top surfaces.
The containment lids 800 each include front and back faces 814, 816, respectively, oriented in parallel with respect to the y-z plane to define widths W1 and W2 while inner and outer side faces 818, 819, respectively, are oriented in parallel with respect to the x-z plane to define the length L1. Each lid includes the top surface 810 and a bottom perimeter surface 840 oriented in parallel with respect to the x-y plane and separated by a height H3 corresponding to the height of the front and back faces 814, 816, respectively. The bottom perimeter surface 840 is defined by the width W1 extending between the outer side faces 819. The top surface 810 is defined by the width W2 extending between the inner side faces 818. Fork guide surfaces 820 oriented perpendicular to and extending away from the inner side faces 818 to the outer side faces 819 are configured to guide the forks from the forklift when stacking or removing trays 700 from above. In the example shown in
As mentioned above, each lid 800 is configured to cover the battery modules stored within the receiving area 702 (e.g., receiving compartment 804) of the associated tray underneath. Each lid covers the top surface of the battery modules. In some embodiments, each lid 800 encloses the battery module sides. The bottom perimeter surface 840 of the lid 800 rests upon the top surface 712 of the tray 700 underneath. The lid 800 further includes a hollowed portion inward from the bottom perimeter surface 840 for accepting the height of the battery modules 100 stored within the receiving compartments 704 of the tray 700 underneath. For example, the lid 800 may be hollowed by a depth extending perpendicularly from the bottom perimeter surface 840. Thus, the hollowed portion of the lid 800 encloses portions of the battery module 100 sides that extend beyond the depth of the receiving area 702 of the associated tray 700 underneath.
Referring to
In some embodiments, a plurality of ribs 722, 723 protrude from the receiving surface 720 to provide a spacer between resting surfaces of the battery modules and the receiving surface 720. For example, if one of the battery modules leaks electrolyte, the leaked electrolyte may be contained along the receiving surface 720 without contacting the resting surface of other battery modules within the receiving area. The ribs 722, 723 may be arranged in uniformly spaced rows across the receiving surface 720. In some implementations, the ribs 722 are arranged in uniformly spaced rows each oriented in parallel with respect to the x-axis. In some examples, the ribs 722 may be arranged in two sets of uniformly spaced rows. In the example shown, a first set of ribs 722 may include rows oriented in parallel with respect to the x-axis while a second set of ribs 723 may include rows oriented in parallel with respect to the y-axis.
In some examples, one or more divider walls 730 are disposed within the receiving area 702. The divider walls 730 may be oriented in parallel with respect to the x-axis and extend between the front and back walls 724, 726, respectively. The divider walls 730 include a height associated with the receiving area 702 depth, i.e., the distance between the receiving surface 720 and the top surface 712. The divider walls 730 are configured to divide the receiving area 702 into substantially equally spaced rows each having a uniform width with respect to the y-axis. In the example shown, one divider wall 730 is disposed within the receiving area 702 to divide the receiving area into two substantially equally spaced rows. For example, the divider wall 730 is parallel to and spaced halfway between the sidewalls 328. However, other examples can include two divider walls that divide the receiving area into three equally spaced rows, three divider walls that divide the receiving area into four equally spaced rows and so on.
Additionally, the receiving area 702 includes dividers 732 disposed therein. The dividers 732 may be oriented in parallel with respect to the y-axis and extend between the sidewalls 728. The dividers 732 include a height associated with the divider walls 730 and the receiving area 702 depth. The dividers 732 are configured to divide the receiving area 702 into substantially equally spaced columns having a uniform length with respect to the x-axis. In the example shown, one set of four dividers 732 oriented longitudinally with respect to the y-axis divide the receiving area 702 into two substantially equally spaced columns. In the example shown, the dividers 732 are parallel to and spaced halfway between the front and back walls 724, 726, respectively. However, other examples can include two sets of dividers 732 each oriented parallel to each other that divide the receiving area 702 into three equally spaced columns, three sets of four dividers 732 each oriented parallel to one another that divide the receiving area 702 into four equally spaced columns and so on.
In the example shown, a pair of dividers 732 is disposed within the first row on one side of the divider wall 730 while another pair of dividers 732 is disposed within the second row on the other side of the divider wall 730. Each divider 732 includes a first contact surface parallel to and facing the front wall 724 and a second contact surface parallel to and facing the back wall 726. The first contact surfaces are associated with a first column of the receiving area 702 while the second contact surfaces are associated with a second column of the receiving area 702. The first contact surfaces of the pair of dividers 732 disposed within the first row are configured to contact a surface of a first battery module received within the first column of the first row between the divider wall 730, the back wall 726, and the side wall 728 adjacent to the first row of the receiving area 702. The second contact surfaces of the pair of dividers 732 disposed within the first row are configured to contact a surface of a second battery module received within the second column of the first row between the divider wall 730, the front wall 724, and the side wall 728 adjacent to the first row of the receiving area 702.
Similarly, the first contact surfaces of the pair of dividers 732 disposed within the second row are configured to contact a surface of a third battery module received within the first column of the second row between the divider wall 730, the back wall 726, and the side wall 728 adjacent to the second row of the receiving area 702. The second contact surfaces of the pair of dividers 732 disposed within the second row are configured to contact a surface of a fourth battery module received within the second column of the second row between the divider wall 730, the front wall 724, and the side wall 728 adjacent to the second row of the receiving area 702.
Accordingly, the dividers 732 and the one or more divider walls 730 are configured to segment each of the receiving compartments 704 of the receiving area 702. In some implementations, spacers 734, 736, 738 are provided to prevent surfaces of the battery modules within each of the receiving compartments 704 from contacting the front, back, side, and/or divider walls 724, 726, 728, 730, respectively. For example, the divider wall 730 includes a plurality of divider wall spacers 734 protruding outward from the divider wall 730 toward the sidewalls 728 with respect to the x-y plane. Each divider wall spacer 734 includes a contact surface for contacting surfaces of the battery modules adjacent to the divider wall 730. Similarly, the sidewalls 728 include a plurality of sidewall spacers 738 that protrude inward from the sidewalls 728 toward the divider wall 726 with respect to the x-y plane. Each sidewall spacer 738 includes a contact surface for contacting surfaces of the battery modules adjacent to the sidewalls 728. The front and back walls 724, 726, respectively, include a plurality of front-back wall spacers 736 protruding inward from the walls 724 or 726 toward the dividers 732 with respect to the x-y plane. Each front-back wall spacer 736 includes a contact surface for contacting surfaces of the battery modules 100 adjacent to the front wall 724 or the back wall 726.
Front and back faces 1014, 1016 of the trays 1000 are oriented in parallel with respect to the y-z plane to define a width W of the trays while side faces 1018, 1018′ are oriented in parallel with respect to the x-z plane to define a length L of the trays. Each tray includes top inward edge surfaces 1011, 1011′, top outward edge surfaces 1012 and a bottom surface 1010 oriented in parallel with respect to the x-y plane, wherein the top inward and outward edge surfaces 1011, 1012 are substantially coplanar and separated from the bottom surface 1010 by a height H1 corresponding to the height of the front, back and side faces. The top inward and outward edge surfaces 1011, 1012 form a continuous top surface 1011, 1012 for the trays 1000 that defines an opening into the receiving areas 1002.
A recessed front portion 1015 formed in a portion of the front face 1014 along the top inward edge surface 1011 and oriented in parallel with the x-z plane converges with a first recessed side portion 1019 formed in a portion of one of the side faces 1018 along the top inward edge surface and oriented in parallel with the y-z plane to partially define one of the receiving compartments 1004. A ledge 1013 disposed between the top inward edge surface 1011 and the bottom surface 1010 of each tray 1000 and oriented in parallel with respect to the x-y plane extends outward from the recessed front portion 1015 and the first recessed side portion 1019 to interconnect with corresponding portions of the front face 1014 and the side face 1018. The ledge 1013 defines a height H2 that less than the height H1 defined by the distance between the bottom surface 1010 and the top surface 1011, 1012.
Similarly, a recessed back portion 1017 formed in a portion of the back face 1016 along the other top inward edge surface 1011 and oriented in parallel with the x-z plane converges with a second recessed side portion 1021 formed in a portion of the other side face 1018 along the top inward edge surface and oriented in parallel with the y-z plane to partially define another one of the receiving compartments 1004 not adjacent to the receiving compartment 1004 defined by the recessed front portion 1015 and the first recessed side portion 1019. Another ledge 1013 defined by the height H2 also extends outward from the recessed back portion 1017 and the second recessed side portion 1021 to interconnect with corresponding portions of the back face 1016 and the other side face 1018.
In some embodiments, one or more of the faces 1014, 1016, 1018 define one or more slots 1090, 1092 that protrude into the receiving area 1002. In some embodiments, the slots are defined by tapered slot sidewalls that partially extend into the receiving area 1002 and terminate at a slot wall 1091, 1093 perpendicular to the x-y plane to define a slot depth. The slots 1090 are defined by portions of the faces 1014, 1016, 1018 not including the corresponding recessed portions 1015, 1017, 1019, 1021 and extend between the bottom surface 1010 and the top outward edge surface 1012 such that the slot wall 1091 is defined. The slots 1092 are defined by the associated ones of the recessed portions 1015, 1017, 1019, 1021 and corresponding portions of the faces 1014, 1016, 1018 such that a uniform slot wall 1093 is defined. While the slots 1090 include a slot cover 1095 extending substantially parallel to the top outward edge surface 1012 of the trays 1000, the ledges 1013 interconnecting the recessed portions 1015, 1017, 1019, 1021 and the corresponding portions of the faces 1014, 1016, 1016 extend through the slots 1091.
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Additionally, the receiving area 1002 includes divider wall spacers 1032 disposed therein. In the example shown, divider wall spacers 1032 extend parallel and adjacent to each side of the divider walls 1030. For example, the divider walls 1030 include a divider wall spacer 1032 disposed along each side thereof, and each divider wall spacer includes a height less than the height of the divider walls 1030. A groove 1033, 1035 formed in the bottom surface 1010 of the tray 1000 that extending into the receiving area 1002 may define the divider wall spacers 1032 such that each divider wall spacer 1032 includes a contact surface parallel to and facing one of the receiving front wall 1024, the receiving back wall 1026, or one of the receiving sidewalls 1028. Accordingly, each row-column pair (e.g., receiving compartment 1004) of the receiving area 1002 includes a pair of divider wall spacers 1032 perpendicular to one another so that one divider wall spacer 1032 of the pair has a contact surface parallel to and facing one of the receiving front wall 1024 or the receiving back wall 1026 and the other divider wall spacer 1032 of the pair has a contact surface parallel to and facing one of the receiving sidewalls 1028. The contact surfaces of each perpendicular pair of divider wall spacers 1032 are each configured to contact at least a portion of an opposing surface of a battery module received within the associated row-column pair of the receiving area 1002. Accordingly, the divider wall 1030 and the divider wall spacers 1032 are configured to segment each of the receiving compartments 1004 of the receiving area 1002.
In some embodiments, spacers 1034, 1036 are provided to prevent surfaces of the battery modules within each of the receiving compartments 1004 from contacting the front, back, and/or sidewalls 1024, 1026, 1028, respectively. For example, the receiving front and back walls 1024, 1026, respectively, each include a plurality of front-back wall spacers 1034 protruding inward from the associated one of the receiving front wall 1024 or the receiving back wall 1026 toward the other one of the receiving front wall 1024 or the receiving back wall 1026 with respect to the x-y plane.
Each lid 1000′ comprises a containment tray 1000 rotated 180° about the y-axis. In view of the substantial similarity in structure and function of the components associated with the containment trays 1000 with respect to the lids 1000′, like numerals are used hereinafter and in the drawings to identify like components. The top outward edge surfaces 1012 and the ledges 1013 of each tray 1000 are configured to support the associated containment lid 1000′ stacked vertically above. For instance, in the example shown, the top outward edge surfaces 1012 of tray 1000a are configured to align and mate with the associated ledges 1013′ of the containment lid 1000′, while the ledges 1013 of tray 1000a are configured to align and mate with the associated top outward edge surfaces 1012′ of the containment lid 1000′. In some embodiments, the battery modules 100 received within the receiving compartments 1004 include a height greater than the receiving area depth, and therefore a portion of the battery modules are exposed from the top inward and outward edge surfaces 1011, 1012 of the tray 1000. When the lid 1000′ is supported by the tray 1000a, the receiving area 1002′ of the lid 1000′ may accommodate the exposed portions of the battery modules received by the receiving compartments 1004 of the tray 1000a. Accordingly, each lid covers the top surface of the battery modules stored within the receiving compartments 1004 of the tray 1000 underneath and may enclose a portion of the battery module sides that extend beyond the depth of the receiving area 1002 of the associated tray 1000 underneath. One or more of the slot covers 1095 and ledges 1013 of the tray 1000 may include apertures 1094 that align with corresponding apertures 1094′ formed through slot covers 1092′ and ledges 1013′ of the containment lid 1000′ stacked overtop such that fasteners may pass through the aligned apertures 1094, 1094′ to secure the lid to the tray.
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Likewise, each lid 1000′ includes a plurality of support members 1006′, 1008′ that extend through the bottom surface 1010′ and the receiving surface 1020′. The lids may include two non-adjacent support members 1006′ and two non-adjacent support members 1008′ each associated with a surface area that is smaller than a surface area associated with each of the two other support members 1006. In some examples, the surface area of the support members 1006′ of the lids 1000′ is the same as the surface area of the support members 1006 of the trays 1000, and the surface area of the support members 1008′ of the lids 1000′ is the same as the surface area of the support members 1008 of the trays 1000. Each support member 1006′, 1008′ extends substantially parallel to the z-axis and includes a first portion extending in the second direction away from the bottom surface 1010′ to receive and support the tray 1000 above (e.g., tray 1000b in
In some embodiments, the second portion of each support member 1006′, 1008′ of the lids 1000′ is configured to partially extend into the receiving area 1002 of the tray underneath and mate with an aligned one of the support members 1006, 1008 of the tray underneath. In some embodiments, the second portion of each support member 1006′ of the lid 1000′ mates with an aligned one of the second portion of each support member 1008 of the tray 1000 underneath. For example, when the top outward edge surfaces 1012 of tray 1000a align and mate with the associated ledges 1013′ of the lid 1000′ and the ledges 1013 of the tray 1000a align and mate with the associated top outward edge surfaces 1012′ of the lid 1000′, the second portion of the support members 1006′ of the lid 1000′ align and mate with the second portion of the support members 1008 of the tray 1000a and the second portion of the support members 1008′ of the lid 1000′ align and mate with the second portion of the support members 1006 of the tray 1000a. The first portion of each support member 1006, 1008 of the bottom tray 1000a is configured to mate with the ground surface such that the tray 1000a is supported above the ground surface.
In some embodiments, the first portion of each support member 1006′, 1008′ of the lids 1000′ is configured to mate with an aligned one of the support members 1006, 1008 of the tray stacked above. In some configurations, the first portion of each support member 1006′ of the lid 1000′ mates with an aligned one of the first portion of each support member 1008 of the tray 1000 stacked above. For instance, with reference to the example shown in
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A number of embodiments and examples have been described herein. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the following claims.
This PCT application claims the benefit of U.S. provisional application No. 62/100,662, filed on Jan. 7, 2015. This document is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2016/012274 | 1/6/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62100662 | Jan 2015 | US |
