WO2020076322A1

WO2020076322A1 - Systems and methods for deployable mechanical load isolation in transportable storage container

Info

Publication number: WO2020076322A1
Application number: PCT/US2018/055391
Authority: WO
Inventors: Charles Erklin Seeley; Naveenan Thiagarajan; Philip Michael Cioffi; John Erik Hershey
Original assignee: General Electric Company
Priority date: 2018-10-11
Filing date: 2018-10-11
Publication date: 2020-04-16

Abstract

A transportable storage container includes a housing mountable to a transportation device and including a floor plate. The transportable storage container also including an energy storage system including at least one deployable isolator assembly coupled to the floor plate and positioned within the housing. The at least one deployable isolator assembly deployable between at least a first position and a second position. The energy storage container also including a battery rack coupled to the at least one deployable isolator assembly and a plurality of battery modules coupled to the battery rack.

Description

SYSTEMS AND METHODS FOR DEPLOYABLE

MECHANICAL LOAD ISOLATION IN TRANSPORTABLE STORAGE CONTAINER

BACKGROUND

[0001] The subject matter described herein relates generally to transportable storage containers and, more particularly, to mechanical load isolation in transportable storage containers.

[0002] Transportable storage containers are used to transport a variety of goods between multiple locations. Storage containers are transported from a starting location to a destination by transportation devices such as trucks, railcars, forklifts, and ships. Often, storage containers transport goods that are fragile and/or may be damaged if the storage container experiences mechanical load events such as shocks or vibrations. Shocks to the storage container may occur as the storage container is loaded onto a transportation device. Such shocks result in movement of the goods relative to the storage container. The relative movement of the goods may cause the goods to contact an interior surface of the storage container and/or other goods within the storage container, resulting in damage to or destruction of the goods.

[0003] Some transportable storage containers are used to transport and house energy storage systems. Such systems are used to store and provide energy in a variety of settings including industrial applications. Some known energy storage systems utilize a plurality of battery modules housed within a storage container to store and provide energy. In the energy storage market, it is advantageous to fill the storage container with as many battery modules as possible to achieve a greater energy capacity of an energy storage system. However, clearances are required around the battery modules to allow for movement of the battery modules and to prevent battery damage resulting from contact with other objects inside the transportable storage container. Such energy storage systems additionally require passages of cooling air in the container to allow a heating, ventilation, and air conditioning (“HVAC”) system to keep the battery modules within a required temperature range. These clearances and passages require space within the storage container that cannot be occupied by battery modules. [0004] Accordingly, battery modules contained within a transportable storage container may be subjected to multiple shock and vibrational loads during transport. These mechanical loads can damage the battery modules, resulting in significant operational issues. Alternatively, some known energy storage systems are assembled into a storage container on site after transporting the unassembled system components to an installation site. Such techniques complicate logistics as each component may be shipped separately and from separate suppliers. Additionally, installing each component of the energy storage system at the installation site is highly time consuming and costly.

BRIEF DESCRIPTION

[0005] In one aspect, a transportable storage container is provided. The transportable storage container includes a housing mountable to a transportation device and an energy storage system. The housing includes a floor plate. The energy storage system includes at least one deployable isolator assembly coupled to the floor plate and positioned within the housing. The at least one deployable isolator assembly deployable between at least a first position and a second position. The energy storage system also including a battery rack coupled to the at least one deployable isolator assembly and a plurality of battery modules coupled to the battery rack.

[0006] In another aspect, a method of transporting a transportable storage container is provided. The transportable storage container includes a housing mountable to a transportation device and an energy storage system including at least one deployable isolator assembly positioned within the housing, a battery rack coupled to the at least one deployable isolator assembly, and a plurality of battery modules coupled to the battery rack. The method includes deploying the at least one deployable isolator assembly to a first position and mounting the transportable storage container to the transportation device at a first location. The method further includes transporting the transportable storage container from the first location to a second location while the at least one deployable isolator assembly is deployed and dismounting the transportable storage container from the transportation device at the second location. The method further includes retracting the at least one deployable isolator assembly to a second position. [0007] In yet another aspect, a method of assembling an energy storage system within a transportable storage container is provided. The method includes providing a housing mountable to a transportation device and positioning at least one deployable isolator assembly within the housing. The at least one deployable isolator is deployable between a deployed position and a retracted position. The method also includes coupling at least one battery rack to the at least one deployable isolator assembly and coupling a plurality of battery modules to the at least one battery rack.

DRAWINGS

[0008] These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0009] FIG. 1 is a perspective view of an exemplary transportable storage container;

[0010] FIG. 2 is a perspective view of the transportable storage container of FIG. 1 with its ceiling plate removed that includes an energy storage system;

[0011] FIG. 3 is a perspective view of an exemplary housing structure of the transportable storage container of FIG. 1;

[0012] FIG. 4 is a perspective view of an exemplary transportable storage container that includes an energy storage system;

[0013] FIG. 5 is a perspective view of an exemplary energy storage system transportable by the transportable storage container of FIG. 1;

[0014] FIG. 6 is a perspective view of an exemplary configuration of battery racks coupled to an exemplary floor structure of the transportable storage container of FIG. 1;

[0015] FIG. 7 is a perspective view of a wire rope isolator; [0016] FIG. 8 is a perspective view of an exemplary deployable isolator assembly that includes the wire rope isolator of FIG. 7;

[0017] FIG. 9 is a side schematic view of an energy storage system coupled to the transportable storage container of FIG. 1 with a deployable isolator assembly;

[0018] FIG. 10 is a side schematic view of the energy storage system of FIG. 9 coupled to the transportable storage container of FIG. 1 with an alternative deployable isolator assembly;

[0019] FIG. 11 is a schematic view of the deployable isolator assembly of FIG. 8 in combination with the energy storage system of FIG. 9 in a transportation position; and

[0020] FIG. 12 is a schematic view of the deployable isolator assembly of FIG. 8 in an operational position.

[0021] Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of the disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of the disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.

DETAILED DESCRIPTION

[0022] In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.

[0023] The singular forms“a”,“an”, and“the” include plural references unless the context clearly dictates otherwise.

[0024] “Optional” or“optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. [0025] Approximating language, as used herein throughout the specification and claims, may be applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “substantially,” and“approximately,” are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations may be combined and/or interchanged, such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.

[0026] The systems and methods described herein include a transportable storage container that includes a deployable isolator assembly configured to reduce mechanical loads or disturbances that are experienced by an energy storage system housed within the container. The deployable isolator assembly described herein is deployable between a first position, such as a transportation position, and a second position, such as an operational position, to efficiently allocate space within the transportable storage container during transportation of the transportable storage container and during operation of the energy storage system. To maintain the temperature within the transportable storage container, the systems and methods described herein also include an HVAC system that includes one or more ducts configured for air flow management to maintain the temperature of the energy storage system within a predetermined temperature range. During transportation, the deployable isolator assembly is deployed by an actuator to the transportation position to prevent damage to the energy storage system during transportation While deployed to the transportation position, the energy storage system is separated from the transportable storage container floor plate by a clearance and the deployable isolator assembly allows movement of the energy storage system while preventing contact between the energy storage system and the container. To create the clearance, the energy storage system at least partially extends into a volume of air used by the HVAC system. Although the extension of the energy storage system into the space utilized by the ducts decreases the air flow rate which decreases the temperature control capabilities of the HVAC system, the battery modules are in a non-operational state during transportation and are not generating a significant heat load. During operation of the energy storage system, one or more battery modules of the energy storage system undergo a charging or discharging operation which may generate a substantial heat load and increase the temperature within the transportable storage container. Prior to operation of the energy storage system, the deployable isolator assemblies are retracted to the operational position such that the energy storage system does not interfere with the volume of space utilized by the HVAC system to maintain a consistent temperature within the transportable storage container. When the deployable isolator assemblies are in the operational position, the ducts are not restricted and more air flow is available to maintain the temperature of the battery modules while they are generating a heat load.

[0027] By deploying the deployable isolator assembly prior to transportation and retracting the deployable isolator assembly prior to operation of the energy storage system, the transportable storage container includes sufficient clearances to prevent damage to the energy storage system due to shock and/or vibrational loads during transportation and provides appropriate HVAC capacity to maintain the temperature of the energy storage system within the predetermined temperature range during operation of the energy storage system. Additionally, by including one or more deployable isolator assemblies, the systems and methods described herein facilitate the installation of an energy storage system within the storage container prior to shipment of the container to the final site where the energy storage system stores and provides power. As such, the systems and methods described herein mitigate the mechanical loads or disturbances caused during transport that are experienced by energy storage systems housed within the container, maintain the temperature of the energy storage systems within a predetermined temperature range, decrease on site installation time and costs, and simplify logistics for energy storage systems.

[0028] FIG. 1 is an exemplary transportable storage container 10 including a housing 12 having a floor 14, a ceiling 16, and a plurality of side walls 18. Housing 12 may be made of steel or other suitable materials. Ceiling 16 includes a ceiling plate 20 having an interior face 22 and an exterior face 24. Each side wall 18 includes an interior face 26 and an exterior face 28. In some embodiments, side wall 18 also includes one or more doors 30 for accessing the interior of housing 12. Housing 12 includes vertical posts 32 that are coupled to floor 14, ceiling 16, and side walls 18. In the exemplary embodiment, floor 14, ceiling 16, and side walls 18 form a generally cuboid and/or box configuration. In some embodiments, vertical posts 32 include interlocking assemblies 34 positioned on upper and/or lower ends of vertical posts 32. Interlocking assemblies 34 are configured to interface with interlocking assemblies of standardized shipping containers, such as intermodal or ISO shipping containers, to interlock transportable storage container 10 with one or more various shipping containers during transport. In some embodiments, the dimensions of housing 12 comply with at least some standardized ISO shipping container dimension requirements. In the exemplary embodiment, the dimensions of housing 12 comply with at least some of the dimension requirements of a standardized twenty foot ISO shipping container. In some embodiments, floor 14 includes forklift pockets 36 that are generally rectangular in shape and configured to receive forks of a forklift. Forklift pockets 36 allow for placement and/or movement of transportable storage container 10 by the forklift.

[0029] Transportable storage container 10 is used to transport one or more goods, also referred to as transportation products 38, from a first location to a second location. Transportation products 38 include fragile goods, i.e., goods that may be damaged or destroyed by shocks and/or vibrations experienced during transportation of transportable storage container 10 by a transportation device. In the exemplary embodiment, transportation products 38 are accessible through door 30 of side wall 18. In the exemplary embodiment, transportation products 38 include an energy storage system 40, that includes a battery rack system including a plurality of battery modules 42 and one or more battery racks 44.

[0030] FIG. 2 is an exemplary transportable storage container 10, with ceiling plate 20 (shown in FIG. 1) removed, that includes energy storage system 40. Transportable storage container 10 includes a first end 50, a second end 52, a first side 54, and a second side 56. In the exemplary embodiment, transportable storage container 10 includes power electronics 58 positioned adjacent first end 50 of transportable storage container 10. Power electronics 58 are operatively coupled to energy storage system 40 and are configured to enable charging and discharging of battery modules 42 (shown in FIG. 1) of energy storage system 40. In some embodiments, door 30 is positioned adjacent power electronics 58 to facilitate access to power electronics 58. That is, door 30 is positioned on side wall 18 that is at first end 50 of transportable storage container 10. Alternatively, power electronics 58 are positioned in any orientation and manner that enables transportable storage container 10 to function as described herein. [0031] In the exemplary embodiment, transportable storage container 10 includes an HVAC system 62. HVAC system 62 includes a plurality of ducts, or air flow passages, 64 for heating and/or cooling transportable storage container 10. In one embodiment, air flow passage 64 is positioned between energy storage system 40 and ceiling 16 and functions as a return duct of HVAC system 62. In an alternative embodiment, air flow passage 64 functions as a supply duct of HVAC system 62. When battery modules 42 of energy storage system 40 are in an operational state (i.e., charging or discharging), transportable storage container 10 experiences a heat load caused by the charging or discharging of energy storage system 40. HVAC system 62 removes this heat load by distributing air through the ducts to maintain the temperature of energy storage system 40 within a predetermined temperature range. The predetermined temperature range is any range of temperatures that allows battery modules 42 of energy storage system 40 to function as described herein without overheating. When transportable storage container 10 is in a non-operational state (i.e., during transportation of transportable storage container 10), transportable storage container 10 experiences minimal heat loads for HVAC system 62 to remove. For HVAC system 62 to maintain the temperature of energy storage system 40 within the predetermined temperature range within transportable storage container 10, a larger air flow rate through air flow passage 64 is needed during the operational state than during the non-operational state.

[0032] In the exemplary embodiment, ceiling 16 of transportable storage container 10 includes a plurality of ceiling beams 60 that are laterally spaced and extend between first side 54 and second side 56 of transportable storage container 10. Ceiling beams 60 are coupled to interior face 22 of ceiling plate 20 (shown in FIG. 1) and are configured to provide structural support for transportable storage container 10. Ceiling beams 60 are also configured to increase rigidity of transportable storage container 10.

[0033] FIG. 3 is an exemplary configuration of housing 12 of transportable storage container 10, with ceiling plate 20 and side walls 18 (both shown in FIG. 1) omitted for clarity. Ceiling 16 includes ceiling end rails 70 and ceiling longitudinal beams 72. Ceiling beams 60 extend between and are coupled to ceiling longitudinal beams 72 and are positioned substantially parallel to ceiling end rails 70. Ceiling 16 also includes a central ceiling beam 74 that extends between ceiling end rails 70. In one embodiment, central ceiling beam 74 is positioned substantially parallel to and midway between ceiling longitudinal beams 72. In one embodiment, ceiling beams 60 are coupled to interior face of ceiling plate 20 (shown in FIG. 1) and to central ceiling beam 74. In an alternative embodiment, central ceiling beam 74 is coupled to interior face 22 of ceiling plate 20 and to ceiling beams 60.

[0034] Floor 14 includes a floor plate 76 having an interior face 78 and an exterior face 80. Floor 14 also includes end rails 82 and longitudinal beams 84. Floor 14 further includes a plurality of cross beams 86 which are laterally spaced and positioned substantially parallel to end rails 82. In the exemplary embodiment, cross beams 86 are coupled to interior face 78 of floor plate 76. In one embodiment, floor 14 includes a central beam 88 that extends the longitudinal length of housing 12, i.e., from first end 50 to second end 52 of housing 12. Central beam 88 is coupled to interior face 22 of floor plate 76 and extends between end rails 82. Cross beams 86 extend between and are coupled to longitudinal beams 84 and central beam 88. In some embodiments, floor 14 does not include central beam 88. In those embodiments, each cross beam 86 extends laterally between and is connected to floor longitudinal beams 84 such that each floor cross beam 86 extends between first side 54 and second side 56 of housing 12. Alternatively, cross beams 86 and central beam 88 are positioned in any orientation and manner that enables transportable storage container 10 to function as described herein.

[0035] In the exemplary embodiment, ceiling end rails 70, floor end rails 82, ceiling longitudinal beams 72, and floor longitudinal beams 84 are coupled to vertical posts 32 to form a generally cuboid configuration. Ceiling end rails 70 and floor end rails 82 are positioned at a first end 50 and a second end 52 of housing 12. Ceiling longitudinal beams 72 and floor longitudinal beams 84 are positioned at a first side 54 and a second side 56 of housing 12.

[0036] In some embodiments, housing 12 includes a plurality of columns 90 coupled to interior face 26 of side wall 18 (shown in FIG. 1) Columns 90 extend between ceiling longitudinal beams 72 and floor longitudinal beams 84. In some embodiments, columns 90 also extend between ceiling end rails 70 and floor end rails 82. Columns 90 are configured to provide support for housing 12. Columns 90 are also configured to increase rigidity of housing 12. In alternative embodiments, housing 12 does not include a plurality of columns 90 and side walls 18 include a corrugated profile to provide support for and increase rigidity of housing 12.

[0037] FIG. 4 illustrates transportable storage container 10 including energy storage system 40. In the exemplary embodiment, transportable storage container 10 is used to transport energy storage system 40 from a first location to a second location. In the exemplary embodiment, the first location is an assembly location and the second location is a use location. At the use location, energy storage system 40 is set up in the operational state. In alternative embodiments, the first location is a prior use location. Energy storage system 40 utilizes an isolator system to cushion battery modules 42 and prevent damage to battery modules 42 caused by mechanical load events during transport of transportable storage container 10. During transportation, transportable storage container 10 may experience mechanical load events such as shocks or vibrations. Shocks to transportable storage container 10 may occur as transportable storage container 10 is loaded onto a transportation device such as a truck, a railcar, a ship, and/or a forklift. For example, transportable storage container 10 may experience a shock if transportable storage container 10 is improperly loaded or unloaded by a forklift operator, dropped onto the transportation device, and/or dropped during unloading of the transportable storage container at its second location. Transportable storage container 10 may also experience vibrations as the transportation device transports transportable storage container 10 from the first location to the second location. Such shocks and/or vibrations may result in vertical, lateral, longitudinal, and/or rotational movement of transportable storage container 10. The movement of transportable storage container 10 causes movement of energy storage system 40 relative to transportable storage container 10 which may cause energy storage system 40 to contact an interior surface of transportable storage container 10, resulting in potential damage to the energy storage system 40.

[0038] To allow movement of energy storage system 40 relative to transportable storage container 10 while preventing damaging contact between energy storage system 40 and housing 12, transportable storage container 10 includes one or more deployable isolator assemblies 100 to provide a cushion for battery modules 42. In the exemplary embodiment, battery rack 44 is coupled to floor plate 76 by one or more deployable isolator assemblies 100. In the exemplary embodiment, deployable isolator assembly 100 is coupled to interior face 78 and is positioned between a pair of cross beams 86. By positioning deployable isolator assemblies 100 between cross beams 86 and positioning floor plate 76 below cross beams 86, deployable isolator assemblies 100 provide a cushion for energy storage system 40 without decreasing the space available within transportable storage container 10 for battery modules 42. Alternatively, deployable isolator assembly 100 is positioned in any orientation and manner that enables transportable storage container 10 to function as described herein.

[0039] Transportable storage container 10 also includes a plurality of clearances 102 to prevent damage to energy storage system 40 during a shock and/or vibrational disturbance caused by a mechanical load event. Deployable isolator assemblies 100 facilitate movement of energy storage system 40 within clearance 102, e.g., movement of energy storage system 40 towards and away from cross beams 86 and floor plate 76 without energy storage system 40 contacting cross beams 86. Cross beams 86 are separated from battery modules 42 of energy storage system 40 by one or more clearances 102 to prevent battery modules 42 and battery rack 44 from contacting cross beams 86. Dimensions of clearance 102 are based on at least the magnitude of expected mechanical disturbances, dimensions of housing 12, and/or deployable isolator assembly 100 parameters such as geometry, material, mass, and stiffness.

[0040] In some embodiments, housing 12 additionally includes insulation to help maintain a desired temperature within transportable storage container 10. Insulation is applied to the interior of housing 12 (e.g., interior face 78 of floor plate 76, interior face 22 of ceiling plate 20 (shown in FIG. 1), and/or interior face 26 of side wall 18 (shown in FIG. 1)) and/or the exterior of housing 12 (e.g., exterior face 80 of floor plate 76, exterior face 24 of ceiling plate 20 (shown in FIG. 1), and/or exterior face 28 of side wall 18 (shown in FIG. l)). In some embodiments, housing 12 includes insulation positioned between each pair of cross beams 86 and on interior face 78 of floor plate 76. In some embodiments, insulation at least partially fills a void 104 that is at least partially defined by deployable isolator assembly 100, energy storage system 40, central beam 88 (shown in FIG. 3), cross beams 86, and/or floor plate 76. Various types of insulation may be used to fill void 104 such as spray foam insulation, fiber glass insulation, and/or other types of insulation that allow transportable storage container 10 to function as described herein. In some embodiments, insulation provides additional damping for energy storage system 40 during a mechanical disturbance caused by a shock or vibration event. Deployable isolator assembly 100 also serves as additional insulation as the contained air within the isolator volume is a good insulation material.

[0041] FIG. 5 is an exemplary energy storage system 40 that may be transported by transportable storage container 10 as shown in FIG. 1. Energy storage system 40 includes at least one battery module 42 coupled to and received in one or more battery racks 44. Battery module 42 may be a lithium ion battery or any other suitable battery that enables transportable storage container 10 to function as described herein. In the exemplary embodiment, each battery rack 44 includes one or more upright panels 110 and a plurality of supports 112, also referred to as battery shelves, extending perpendicularly from upright panels 110. In the exemplary embodiment, supports 112 are generally L-shaped. Upright panels 110 may be substantially planar, substantially corrugated, and/or any other configuration that enables energy storage system 40 to function as described herein.

[0042] Battery rack 44 includes a plurality of compartments 114 for receiving battery modules 42. In the exemplary embodiment, each compartment 114 receives one or more battery modules 42. Upright panels 110 and supports 112 at least partially define compartments 114. In some embodiments, battery modules 42 rest on supports 112 and are coupled to supports 112 through contact, friction fit, snap fit, and/or fasteners. In some embodiments, battery modules 42 include a notch, and each compartment 114 of battery rack 44 includes a latch so that the latch may snap into and/or engage with the notch of battery modules 42 to secure battery modules 42 within compartment 114. In alternative embodiments, battery modules 42 are suspended from supports 112. Alternatively, battery modules 42 and battery rack 44 are positioned in any orientation and manner that enables energy storage system 40 to function as described herein.

[0043] Energy storage system 40 includes at least one bracket 120 configured to couple battery rack 44 to deployable isolator assembly 100 (shown in FIG. 4). In the exemplary embodiment, a cross section of bracket 120 is substantially T-shaped. Bracket 120 includes a slot 122 for receiving upright panel 110 of battery rack 44. In the exemplary embodiment, upright panel 110 of battery rack 44 is coupled to slot 122 through friction. In some embodiments, bracket 120 also includes a plurality of holes for receiving fasteners to couple bracket 120 to deployable isolator assembly 100. [0044] When loaded with battery modules 42, each battery rack 44 creates a column of battery modules 42. In the exemplary embodiment, two columns of battery modules 42 are positioned on battery rack 44. In other embodiments, each battery rack 44 is loaded with any amount of columns of battery modules 42 that enables transportable storage container 10 to function as described herein. Battery modules 42 of energy storage system 40 are operatively connected to power electronics 58 (shown in FIG. 2). In one embodiment, power electronics 58 are connected to battery modules 42 by one or more cables that pass through a plurality of openings 116 in battery rack 44. In the exemplary embodiment, openings 116 are positioned on a rear upright panel 118. Alternatively, openings 116 are positioned in any orientation and manner that enables transportable storage container 10 to function as described herein.

[0045] FIG. 6 is an exemplary configuration of a plurality of battery racks 44 coupled to floor 14. In the exemplary embodiment, battery racks 44 are positioned to facilitate access of compartments 114 from first side 54 and/or second side 56. In some embodiments, as shown in FIG. 2, transportable storage container 10 includes doors 30 positioned on first side 54 and second side 56 to allow access to compartments 114 of battery racks 44. In the exemplary embodiment, battery racks 44 are positioned such that upright panel 110 of one battery rack 44 is adjacent upright panel 110 of a second battery rack 44 to form a row. Additionally, rear upright panel 118 of one battery rack 44 is adjacent rear upright panel 118 of a second battery rack 44 to form two rows. The two rows of battery racks 44 are positioned substantially parallel to longitudinal beams 84 and central beam 88. Alternatively, battery racks 44 are positioned in any orientation and manner that enables transportable storage container 10 to function as described herein. Battery racks 44 are coupled to deployable isolator assemblies 100 that are configured to allow movement of battery racks 44 towards and away from cross beams 86 during a mechanical load event. In the exemplary embodiment, each battery rack 44 is able to move independently of other battery racks 44, e.g., battery racks 44 are not directly coupled together. In some embodiments, battery racks 44 are coupled together such that all battery racks 44 move in unison.

[0046] FIG. 7 illustrates a wire rope isolator 130 included in one embodiment of deployable isolator assembly 100. Wire rope isolator 130 functions as a shock and/or vibration isolator for use with deployable isolator assembly 100. Other embodiments of a shock and/or vibration isolator include a pad or sheet of flexible material such as elastomers, rubber, cork, dense foam, and laminate materials, a pneumatic isolator, an air spring, and/or a mechanical spring. Wire rope isolator 130 includes a coil 132 of wire rope and at least two of pairs of retaining bars 134. In one embodiment, coil 132 is steel cable and retaining bars 134 are aluminum, however other suitable materials may be used. In the exemplary embodiment, wire rope isolator 130 includes a first pair 136 of retaining bars 134 and a second pair 138 of retaining bars 134 that are equally spaced about coil 132. First pair 136 and second pair 138 of retaining bars 134 each include a clamp block 140 and a mount plate 142. In the exemplary embodiment, clamp block 140 and mount plate 142 include a plurality of holes 144 for receiving a plurality of fasteners such as bolts 146. Clamp block 140 is coupled to mount plate 142 using a plurality of bolts 146 such that when bolts 146 are tightened, coil 132 is secured between clamp block 140 and mount plate 142. In some embodiments, a subset of the plurality of holes 144 of clamp block 140 and mount plate 142 are configured to mount wire rope isolator 130 in a desired location using fasteners such as bolts 146.

[0047] FIG. 8 illustrates an exemplary deployable isolator assembly 100 that includes one or more wire rope isolators 130 and an air spring 150 which functions as an actuator coupled to a section of floor plate 76. Other embodiments of an actuator include a linear actuator operated electrically, manually, and/or by various fluids such as air and hydraulic. In the exemplary embodiment, air spring 150 is positioned between two wire rope isolators 130 and includes a tubular elastomeric sleeve 152 and a pair of end plates 154 coupled to opposing ends of sleeve 152. Sleeve 152 may be made of one or more layers of rubber such as layers of calendered rubber, layers of fabric reinforced with rubber cords, and/or layers of other suitable rubber. One end plate (not shown in FIG. 8) of the pair of end plates 154 is coupled to floor plate 76.

[0048] Sleeve 152 and end plates 154 at least partially define a fluid pressure chamber 156. In the exemplary embodiment, fluid pressure chamber 156 is filled with air by a compressor, a pump, and/or another suitable inflation device. When fluid pressure chamber 156 is filled with air, fluid pressure chamber 156 expands such that air spring 150 is inflated and pressurized. When air spring 150 is pressurized, deployable isolator assembly 100 exerts an actuator force on battery rack 44 (shown in FIG. 4) as deployable isolator assembly 100 moves to a first position, causing battery rack 44 to at least partially extend into an unoccupied volume of air, such as air flow passage 64 (shown in FIG. 2) adjacent ceiling 16. In some embodiments, air springs 150 of one or more deployable isolator assemblies 100 are supplied with air pressure from a single inflation device. By supplying air pressure to multiple air springs 150 from a single inflation device, the load experienced by the one or more deployable isolator assemblies 100 is automatically balanced among all of the air springs 150. After air spring 150 is pressurized, no additional energy and/or input is needed to maintain the actuator force of air spring 150.

[0049] FIG. 9 is a side schematic view of energy storage system 40 including deployable isolator assembly 100 within transportable storage container 10. In the exemplary embodiment, wire rope isolators 130 and air spring 150 of deployable isolator assembly 100 are coupled to one or more shims 160. Shims 160 are coupled to floor plate 76 and are configured to allow isolators of different geometries to be used in deployable isolator assembly 100 while maintaining a substantially uniform height of deployable isolator assembly 100 with respect to floor plate 76. Dimensions of shims 160 are based on at least the magnitude of expected mechanical disturbances, dimensions of transportable storage container 10, and/or deployable isolator assembly 100 parameters such as geometry, material, mass, and stiffness of the one or more shock and/or vibration isolators and actuators included in deployable isolator assembly 100. In the exemplary embodiment, a taller shim 160 is coupled to wire rope isolator 130 than is coupled to air spring 150. Alternatively, shims 160 are configured in any orientation and manner that enables deployable isolator assembly 100 to function as described herein. In the exemplary embodiment, one shim 160 is coupled to mount plate 142 (shown in FIG 7) of wire rope isolator 130 and another shim 160 is coupled to a first end plate 162 of air spring 150. In the exemplary embodiment, bracket 120 of energy storage system 40 is coupled to mount plate 142 of wire rope isolators 130 and a second end plate 164 of air spring 150.

[0050] In some embodiments, transportable storage container 10 further includes a shock and/or vibration isolator, such as wire rope isolator 130, coupled to side wall 18 and/or ceiling 16 (shown in FIG. 1). In the exemplary embodiment, wire rope isolator 130, which functions as a shock and/or vibration isolator, is coupled to side wall 18 and battery rack 44. Other embodiments of a shock and/or vibration isolator include a pad or sheet of flexible material such as elastomers, rubber, cork, dense foam, and laminate materials, a pneumatic isolator, an air spring, and/or a mechanical spring. Wire rope isolator 130 is coupled to side wall 18 and/or ceiling 16 to prevent damage to energy storage system 40 by preventing battery rack 44 from contacting side wall 18 and/or ceiling 16 during vertical, lateral, longitudinal, and/or rotational movement of transportable storage container 10.

[0051] FIG. 10 is a side schematic view of energy storage system 40 including an alternative deployable isolator assembly 200 within transportable storage container 10. In the alternative embodiment, a magnetic isolator system 202 is coupled to floor plate 76 and battery rack 44. Magnetic isolator system 202 includes a first member 204 having a first end 206 coupled to floor plate 76 and a second member 208 having a first end 210 coupled to battery rack 44. In the alternative embodiment, first member 204 and second member 208 are cylindrical structures and first member 204 is hollow and sized to receive second member 208 therein. In further alternative embodiments, first member 204 and second member 208 can have any shape.

[0052] When storage container 10 is in the operation state, second member 208 rests within first member 204 on one or more stops (not shown). During transportation, magnetic isolation system 202 is set at the first position, i.e., the deployed position, prior to transportation of transportable storage container 10 and maintained in the first position during transport. In the first position, a second end 212 of second member 208 is proximate a second end 214 of first member 204 and is not within second member 208. At least one of first member 204 and second member 208 are energized to provide a resistance against the insertion of second member 208 within first member 204. During a mechanical load event, such as a shock or vibration, a sufficient opposing magnetic force is initiated between first member 204 and second member 208 to cushion battery rack 44 and prevent battery rack 44 from contacting cross beams 86 (shown in FIG. 6). For example, during a mechanical load event, transportable storage container 10 contacts an object, such as the ground or a loading platform, at speed S length units per second. Second member 208 has a length of D length units. Second member 208 slides into first member 204 for a distance of D length units during which the speed of battery rack 44 is magnetically braked to zero. In this example, if battery rack 44 has a mass of M mass units, the kinetic energy of battery rack 44 is MS^z/2 energy units at the start of deceleration and this energy is to be dissipated over D length units. The magnetic braking force is controlled such that the magnetic braking force is constant over the kinetic energy dissipation distance D length units. Accordingly, the magnetic braking force is controlled to be constant over the kinetic energy dissipation distance D length units.

[0053] FIG. 11 is a schematic view of energy storage system 40, within storage container 10, including deployable isolator assembly 100 in the deployed position, i.e., the first position. Deployable isolator assembly 100 may be deployed to the first position prior to transportation of the transportable storage container 10 and maintained in the first position during transportation. Transportation may include at least one of mounting transportable storage container 10 to a transportation device, transporting transportable storage container 10 by the transportation device from a first location to a second location, dismounting transportable storage container 10 from the transportation device, positioning transportable storage container 10 at its final location, and/or repositioning transportable storage container 10 with a forklift or other transportation device. During transportation, transportable storage container 10 may experience shocks and/or vibrations which may result in vertical, lateral, longitudinal, and/or rotational movement of transportable storage container 10. Transportable storage container 10 experiences a greater magnitude of mechanical disturbances during transportation than when transportable storage container 10 is not being transported, e.g., when energy storage system 40 is in an operational state.

[0054] In one embodiment, a deployable isolator assembly 100 is positioned between each pair of cross beams 86. Deployable isolator assemblies 100 are deployed to the first position to distance energy storage system 40 from cross beams 86 by clearance 102. When deployed to the first position, deployable isolator assemblies 100 facilitate movement of energy storage system 40 within clearance 102, e.g., movement of energy storage system 40 towards and away from cross beams 86 without energy storage system 40 contacting cross beams 86. Dimensions of clearance 102 are based on at least the magnitude of expected mechanical disturbances, dimensions of housing 12, and/or parameters of deployable isolator assembly 100 such as geometry, actuation capability, material, mass, and stiffness. [0055] In the exemplary embodiment, in the first position, fluid pressure chamber 156 of air spring 150 (both shown in FIG. 8) of deployable isolator 100 contains a first predetermined volume of air. The first predetermined volume of air within air spring 150 is constant while deployable isolator assembly 100 is in the deployed position. In the exemplary embodiment, the first predetermined volume of air within fluid pressure chamber 156 is pressurized such that air spring 150 exerts an actuator force on battery rack 44 when deployable isolator assembly 100 is deployed. After one or more air springs 150 within transportable storage container 10 are pressurized, no additional energy and/or input is needed to maintain the actuator force of air spring 150. In the deployed position, actuator force of deployable isolator assembly 100 causes battery rack 44 to at least partially extend into air flow passage 64, which partially decreases the size of air flow passage 64. In some embodiments, air springs 150 of one or more deployable isolator assemblies 100 may be supplied with the first predetermined volume of air from a single inflation device, e.g., a single compressor.

[0056] In the exemplary embodiment, while deployable isolator assembly 100 is deployed to the first position, air spring 150 exerts at least an actuator force on battery rack 44 and wire rope isolators 130 (shown in FIG. 8) exert at least a spring force on battery rack 44. In some embodiments, air spring 150 exerts sufficient actuator and spring forces such that deployable isolator assembly 100 does not include additional types of shock and/or vibration isolators. During a mechanical load event, the actuator and spring forces of deployable isolator assemblies 100 that are deployed to the first position prevent battery modules 42 of energy storage system 40 from contacting floor cross beams 86, i.e., maintaining at least some portion of clearance 102.

[0057] When transportable storage container 10 is in a non-operational state (i.e., during transportation of transportable storage container 10), transportable storage container 10 experiences minimal heat loads for HVAC system 62 (shown in FIG. 2) to remove. As such, in the first position, energy storage system 40 at least partially extends into air flow passage 64 during transportation without interfering with the functionality of HVAC system 62 (shown in FIG. 2). [0058] FIG. 12 is a schematic view of energy storage system 40 including deployable isolator assembly 100 in a second position. Deployable isolator assembly 100 is retracted to the second position when transportable storage container 10 is stationary, e.g., after installation of transportable storage container 10 at the second location. When transportable storage container 10 is stationary and/or secured at the second location, transportable storage container 10 is expected to experience a minimal magnitude of mechanical disturbances. For example, transportable storage container 10 should not experience shock and/or vibrational loads caused by transportation devices. However, transportable storage container 10 may experience some mechanical disturbances caused by seismic activity after transportable storage container 10 is positioned at the installation site. In some embodiments, transportable storage container 10 includes seismic isolators (not shown) coupled to exterior face 80 of floor plate 76. Embodiments of seismic isolators include a mechanical spring, a pad or sheet of flexible material such as elastomers, rubber, cork, dense foam, and laminate materials, a pneumatic isolator, an air spring, and/or a wire rope isolator. Seismic isolators prevent damage to energy storage system 40 by reducing the mechanical load experienced by the transportable storage container 10 caused by seismic activity such as earthquakes.

[0059] In the first position of deployable isolator assembly 100, as described above in connection with FIG. 11, battery rack 44 at least partially extends into a previously unoccupied volume of air, such as air flow passage 64. Clearance 102 between battery modules 42 and cross beams 86 is larger in the first position compared to the second position to account for the greater magnitude of expected mechanical disturbances caused during transportation of the transportable storage container 10. Given the greater magnitude of expected mechanical disturbances and the potential relative movement of energy storage system 40, a larger clearance 102 is beneficial to prevent damage to battery modules 42.

[0060] In the second position, also referred to as an operational or retracted position, deployable isolator assembly 100 is retracted such that battery rack 44 of energy storage system 40 does not extend into air flow passage 64, as shown in FIG. 12. In the exemplary embodiment, battery modules 42 and cross beams 86 are separated by a compressed clearance 102. When deployable isolator assembly 100 is in the second position, a smaller clearance 102 exists between battery modules 42 and cross beams 86. Clearance 102 is smaller since the mechanical disturbances are expected to be of smaller magnitude while transportable storage container 10 is stationary and therefore the expected relative movement of energy storage system 40 is proportionally reduced.

[0061] In the exemplary embodiment, in the second position, fluid pressure chamber 156 of air spring 150 contains a second predetermined volume of air. In some embodiments, in the second position, air spring 150 is depressurized such that the second predetermined volume of air includes air at atmospheric pressure. As deployable isolator assembly 100 is retracted, fluid pressure chamber 156 is depressurized, allowing energy storage system 40 to compress deployable isolator assembly 100. In the exemplary embodiment, as deployable isolator assembly 100 is retracted, battery rack 44 compresses deployable isolator assembly 100 to its geometric stop. The geometric stop of deployable isolator assembly 100 is the point at which deployable isolator assembly 100 will not compress any further based on geometry, e.g., the geometry of wire rope isolator 130 and/or air spring 150 prevents further compression. For example, wire rope isolator 130 is compressed to its geometric stop when clamp block 140 of first pair 136 of retaining bars 134 contacts clamp blocks 140 of second pair 138 of retaining bars 134 (all shown in FIG.

7)·

[0062] When battery modules 42 are in an operational state (i.e., charging or discharging), transportable storage container 10 experiences a heat load caused by the charging and discharging of battery modules 42. HVAC system 62 (shown in FIG. 2) removes this heat load by circulating air through air flow passage 64 to maintain the temperature of the battery modules 42 within a predetermined temperature range. When battery modules 42 are in the operational state, deployable isolator assembly 100 is retracted such that battery rack 44 does not extend into air flow passage 64 which preserves the functionality of HVAC system 62. When energy storage system 40 is in the second position, HVAC system 62 uses all of air flow passage 64 to maintain the temperature of battery modules 42 within the predetermined temperature range.

[0063] The embodiments described herein include a transportable storage container that includes a deployable isolator assembly configured to mitigate mechanical loads experienced by an energy storage system housed within the container and to efficiently allocate space within the transportable storage container during transportation and operation of the energy storage system. The transportable storage containers described herein include a housing that can be mounted on a transportation device such as a truck, a railcar, a forklift, and/or a ship. To prevent damage to the energy storage system during transportation and to maintain the temperature within the transportable storage container during operation of the energy storage system, the systems and methods described herein include one or more deployable isolator assemblies deployable between a transportation position and an operational position. The systems and methods described herein also include an HVAC system that utilizes one or more air flow passages configured to maintain the temperature of the energy storage system within the predetermined temperature range. The transportable storage containers described herein are used to transport energy storage systems to a use location and the energy storage systems are configured to be installed prior to shipment of the transportable storage container to the use location. As such, the transportable storage containers described herein may reduce damage to goods housed within the container during transport of the container and maximize storage space for goods within the container. The transportable storage containers described herein maximize the energy capacity of an energy storage system stored within the container while complying with clearance and HVAC requirements and maximize temperature control capacity of an HVAC system during operation of the energy storage system housed within the transportable storage container. The transportable storage containers described herein also reduce installation time and costs for energy storage systems housed within the container and simplify logistics for energy storage systems housed within the container.

[0064] An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: a) reducing damage to goods housed within a transportable storage container caused by mechanical load events during transport of the transportable storage container, b) maximizing the energy capacity of an energy storage system housed within the transportable storage container while complying with clearance and HVAC requirements, c) maximizing temperature control capacity of an HVAC system during operation of the energy storage system housed within the transportable storage container, d) reducing time and costs for installing an energy storage system housed within a transportable storage container at a final installation site, and e) simplifying logistics for installing an energy storage system housed within a transportable storage container at a final installation site. [0065] Exemplary embodiments of transportable storage containers configured to provide shock or vibration isolation are described above in detail. The transportable storage containers, and methods of using and manufacturing such systems are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the methods may also be used in combination with other transportable storage containers, and are not limited to practice with only the transportable storage containers, and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other transportation systems.

[0066] Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.

[0067] This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A transportable storage container comprising: a housing mountable to a transportation device, said housing comprising a floor plate; and an energy storage system comprising: at least one deployable isolator assembly coupled to said floor plate and positioned within said housing, said at least one deployable isolator assembly deployable between at least a first position and a second position; a battery rack coupled to said at least one deployable isolator assembly; and a plurality of battery modules coupled to said battery rack.

2. The transportable storage container of Claim 1, wherein said housing further comprises a ceiling and a side wall, said transportable storage container further comprising a vibration isolator assembly coupled to said battery rack and one of said ceiling and said sidewall.

3. The transportable storage container of Claim 2, wherein, in said first position, said deployable isolator assembly is deployed such that said battery rack is separated from said floor plate by a first distance, and wherein in said second position, said deployable isolator assembly is retracted such that said battery rack is separated from said floor plate by a second distance, wherein the first distance is greater than the second distance.

4. The transportable storage container of Claim 1, wherein said deployable isolator assembly includes at least one actuator and at least one isolator.

5. The transportable storage container of Claim 1, wherein said deployable isolator assembly includes at least one of an air spring, a wire rope isolator, and a magnetic isolator system.

6. The transportable storage container of Claim 5, wherein said deployable isolator assembly is deployed to the first position such that said air spring contains a first predetermined volume of air and said battery rack at least partially extends into a previously unoccupied volume within said housing.

7. The transportable storage container of Claim 5, wherein said deployable isolator assembly is deployed to the second position such that said air spring contains a second predetermined volume of air and is retracted, and said deployable isolator assembly is compressed to a geometric stop of said deployable isolator assembly.

8. The transportable storage container of Claim 1, further comprising one or more shims coupled to said floor plate and said at least one deployable isolator assembly, wherein said one or more shims are configured to maintain a substantially uniform height of said deployable isolator assembly with respect to said floor plate.

9. The transportable storage container of Claim 1, wherein said at least one deployable isolator assembly is configured to allow movement of said plurality of battery modules during a mechanical load event without said plurality of battery modules contacting said housing.

10. The transportable storage container of Claim 1, wherein said floor plate includes an interior face and an exterior face, wherein said housing further comprises a plurality of cross beams coupled to said interior face of said floor plate, and wherein said at least one deployable isolator assembly is positioned between an adjacent pair of said plurality of cross beams.

11. A method of transporting a transportable storage container, wherein the transportable storage container includes a housing mountable to a transportation device and an energy storage system, the energy storage system including at least one deployable isolator assembly positioned within the housing, a battery rack coupled to the at least one deployable isolator assembly, and a plurality of battery modules coupled to the battery rack, said method comprising: deploying the at least one deployable isolator assembly to a first position; mounting the transportable storage container to the transportation device at a first location; transporting the transportable storage container from the first location to a second location while the at least one deployable isolator assembly is deployed; dismounting the transportable storage container from the transportation device at the second location; and retracting the at least one deployable isolator assembly to a second position.

12. The method of Claim 11, wherein, in the first position, the battery rack at least partially extends into a previously unoccupied volume of the housing.

13. The method of Claim 11, wherein retracting the at least one deployable isolator assembly to the second position further comprises compressing, by the battery rack, the at least one deployable isolator assembly to a geometric stop.

14. The method of Claim 11, wherein the first location is an assembly location and the second location is a use location.

15. A method of assembling an energy storage system within a transportable storage container comprising: providing a housing mountable to a transportation device; positioning at least one deployable isolator assembly within the housing, wherein the at least one deployable isolator assembly is deployable between a deployed position and a retracted position; coupling at least one battery rack to the at least one deployable isolator assembly; and coupling a plurality of battery modules to the at least one battery rack.

16. The method of Claim 15, wherein the at least one deployable isolator assembly is configured to allow movement of the plurality of battery modules during a mechanical load event without the plurality of battery modules contacting said housing.

17. The method of Claim 15, further comprising providing an air flow passage within the housing, wherein, in the deployed position, the at least one battery rack at least partially extends into the air flow passage.

18. The method of Claim 15, further comprising coupling one or more shims to the housing and the at least one deployable isolator assembly, wherein the one or more shims are configured to maintain a substantially uniform height of the deployable isolator assembly with respect to the housing.

19. The method of Claim 15, wherein the housing includes a floor plate having an interior face and an exterior face, said method further comprising coupling the at least one deployable isolator assembly to the interior face of the floor plate.

20. The method of Claim 19, further comprising: coupling a plurality of cross beams to the interior face of the floor plate; and positioning the at least one deployable isolator assembly between a pair of floor beams of the plurality of floor beams.