WO2022124883A1

WO2022124883A1 - Battery enclosure

Info

Publication number: WO2022124883A1
Application number: PCT/MY2021/050105
Authority: WO
Inventors: Bin Chee TAN
Original assignee: Swift Energy Sdn. Bhd.
Priority date: 2020-12-09
Filing date: 2021-11-23
Publication date: 2022-06-16

Abstract

The present invention discloses a weatherproof battery enclosure (100) for safely housing batteries within an explosive environment, comprising a bottom compartment (102) for holding said battery, a base lid (104) attached to the bottom compartment (102) having a ventilation channel (106), an air filter (108) for preventing dust ingress attached along and across the ventilation channel (106), an elevated frame (110) attached onto the base lid (104) framing the ventilation channel (106), a top lid (112) with a bigger perimeter from the base lid (104) having a vertical wall element around the top lid perimeter, a top lid barrier (114) with a smaller perimeter attached to the top lid (112) while having a bigger perimeter from the elevated frame (110) and a means for attaching the top lid (112) to the base lid (116), characterized in that, the means for attaching the top lid to the base lid (106) holds the top lid (112) and the top lid barrier (114) at an elevated height from the base lid (104) to allow air ventilation, wherein the top lid (106) and the elevated frame (110) provide a bended airflow path which prevents water from entering the battery enclosure (100) while allowing ventilation.

Description

BATTERY ENCLOSURE

FIELD OF INVENTION

The present invention generally relates to a weatherproof and explosion proof enclosure for batteries in an explosive environment. In particular, the weatherproof and explosion proof battery enclosure having a top lid designed to prevent water and dust ingress while allowing ventilation to prevent explosion.

BACKGROUND ART

The UPS or solar power system battery bank is useful to ensure uninterrupted and continuous supply of electrical power in any installation base. The battery would be charged and discharged on a daily basis for off-grid solar power system, while the battery in UPS system would be charged whenever the UPS is connected to utility power and discharged on condition when the AC source from utility power is lost.

The batteries, especially flooded lead acid batteries, release hydrogen gas while being recharged and in overcharged condition. Hydrogen gas is highly explosive when the concentration exceeds the lower explosion level (LEL) of 4% of the battery room or enclosure which houses the batteries. Explosion risk would become imminently high when the oxygen level and surrounding area surface temperature are high, or ignition source is present. Explosions could occur and risk human lives and valuable assets. When a user or operator installs the battery bank to be in service at site either indoor or outdoor, it is important for the user or operator to provide adequate ventilation to release the hydrogen gas out of the room or enclosure which housed the battery bank, while preventing water and dust ingress.

The current available battery housing in the market provides ventilation. However, said available battery housing does not prevent rain, dust and probably insect ingress into the battery compartment, while providing adequate ventilation. The present invention suggests a solution to the above problems by encountering the rain, dust and insect ingress problem while also maintaining adequate ventilation to prevent explosion by having a top lid structured to prevent rain, dust and insect ingress into the enclosure while having a bended airflow path to allow adequate air ventilation.

SUMMARY OF INVENTION

One embodiment of the present invention provides a weatherproof battery enclosure for safely housing batteries within an explosive environment, comprising a bottom compartment for holding said battery, a base lid attached to the bottom compartment having a ventilation channel, an air filter for preventing dust ingress attached along and across the ventilation channel, an elevated frame attached onto the base lid framing the ventilation channel, a top lid with a bigger perimeter from the base lid having a vertical wall element around the top lid perimeter, a top lid barrier with a smaller perimeter from the top lid attached to the top lid while having a bigger perimeter from the elevated frame, and a means for attaching the top lid to the base lid, characterized in that, the means for attaching the top lid to the base lid holds the top lid and the top lid barrier at an elevated height from the base lid to allow air ventilation, wherein the top lid and the elevated frame provide a bended airflow path which prevents water from entering the battery enclosure while allowing ventilation.

Preferably, the elevated frame is shaped like a funnel to provide an inverted awning effect to prevent water ingress.

Preferably, there are three layers of barriers to prevent water and dust ingress comprising the top lid, top lid barrier, and the elevated frame.

Preferably, the ambient operating temperature ranges from -40°C to 60°C.

Preferably, a means for attaching the top lid onto the base lid act as a support to hold the top lid in position.

Preferably, the battery enclosure is made of stainless steel, galvanised or painted steel, wood or high-performance plastics or any other type of nonconductor materials. The present invention may be embodied in other specific forms without departing from its essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore indicated by the appended claims rather than by the foregoing description. All changes, which come within the meaning and range of equivalency of the claims, are to be embraced within their scope.

BRIEF DESCRIPTION OF DRAWINGS

To further clarify various aspects of some embodiments of the present invention, a more particular description of the invention will be rendered by references to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the accompanying drawings in which:

FIGURE 1.0 illustrates an exploded perspective view of the battery enclosure of the present invention.

FIGURE 2.0 illustrates a cross-sectional side view of the battery enclosure of the present invention.

FIGURE 3.0 illustrates a cross-sectional top view of the battery enclosure of the present invention.

FIGURE 4.0 illustrates a close-up arrangement of the lid of the battery enclosure of the present invention.

DETAILED DESCRIPTION OF INVENTION

Hereinafter, the a weatherproof and explosion proof enclosure for batteries in an explosive environment according to the present invention will be described in detail with reference to FIGURE 1.0 through FIGURE 4.0 according to the preferred embodiments. It is to be understood that limiting the description to the preferred embodiments of the invention is merely to facilitate discussion of the present invention and it is envisioned without departing from the scope of the appended claims.

The present invention discloses a preferred embodiment of a weatherproof and explosion proof battery housing or enclosure for safely housing batteries in an explosive environment. FIGURE 1.0 illustrates an exploded perspective view of the battery enclosure of the present invention. According to FIGURE 1.0, the weatherproof and explosion proof battery housing or enclosure comprises of a bottom compartment (102) for safely holding or housing batteries, a removable front lid cover (103), a base lid (104) attached to the top of the bottom compartment (102) having a ventilation channel (106), an air filter (108) for preventing dust or possibly insect ingress attached along and across the ventilation channel (106), an elevated frame or elevated funnel-shaped frame (110) attached onto the base lid (104) framing the ventilation channel (106), a top lid (112) having a bigger perimeter from the base lid (104) and covers the ventilation channel (106), a top lid barrier (114) with a smaller perimeter from the top lid (112) attached to the top lid (112) for providing a second layer of barrier, and a means for attaching and supporting (116) the top lid (112) on the base lid (104). The front lid cover (103) is attached to the front part of the bottom compartment. The top lid (112) has a vertical wall element (112a) providing protective shield around the top lid perimeter and hangs above the base lid (104). The top lid barrier (114) is a second vertical wall element within the top lid (112) which provides the second protective shield above the base lid (104). The elevated frame or elevated funnel-shaped frame (110) is shaped like a wide but short funnel to provide an inverted awning effect to prevent water ingress into the ventilation channel from under the top lid barrier (1 14).

The means for attaching (116) the top lid (112) on the base lid (114) supports the top lid (112) and the top lid barrier (114) in position at an elevated height from the base lid (104) to allow air ventilation, wherein the top lid (112), the top lid barrier (114) and the elevated funnel-shaped frame (110) keeps water from entering the battery enclosure. The means for attaching (116) the top lid (112) and the base lid (114) is arranged at 4 corners of the top lid (112), in between the top lid and the top lid barrier (114).

In the preferred embodiment, the base lid (104) is hinged to the bottom compartment (102) to allow top opening of the lid. This top opening is secured by padlock locking on the front section of the battery enclosure.

The batteries, especially flooded lead acid batteries, release hydrogen gas while charging and in overcharged condition. At standard temperature and pressure, hydrogen is colourless, odourless, tasteless, non-toxic and highly combustible diatomic gas. Hydrogen gas is highly explosive when the concentration exceeds the lower explosion level (LEL) of 4% of the battery room or enclosure which houses the batteries. Explosion risk would become imminently high when there are oxygen, fuel and ignition source. Therefore, the top lid (112) is designed to prevent water and dust ingress while allowing ventilation. Ventilation of hydrogen gas is even more so important when the installation site of uninterrupted power supply (UPS) or solar power systems is in an Oil and Gas or Petrochemical plant. Hydrogen gas is lighter or less dense than air. When released by the battery while charging and in overcharged condition, the hydrogen gas will rise upwards and pass through the ventilation channel (106) through the air filter (108) and further escape the top lid (112) via a bended airflow path.

Internationally, there is an established BS/IEC standard providing guidance on safe use of battery in any installation site where the risk of explosion is highly probable. The general IEC standard which is applicable to this subject is reference to IEC 60079. The design consideration of the product is based on relevant standard listed below: a) IEC60079-0 b) IEC60079-7 c) IEC60079-18 d) IEC 60529

The preferred embodiment of the present invention has design criteria covering ventilation capability to maintain the hydrogen gas concentration not exceeding 2% (as dictated by the IEC60079-0) on a prudent basis although the lower explosion level (LEL) is 4% (explosive limits are 4.1 to 72 percent hydrogen in air). In addition, the design of the preferred embodiment of the present invention is required to provide mechanical protection against dust, and water ingress.

For the filter, non-metallic or metallic filter with small filtration size that can prevent dust ingress is used. The filtration size needs to be smaller than the dust particle. Further, the top lid was designed using special metal structure or profile to prevent water or rain ingress. The present invention has been tested with water jet prescribed in IEC529 testing for IP56.

The present invention can be made of stainless steel, galvanised or painted steel, wood or high-performance plastics or any other type of non-conductor materials. The battery enclosure is coated with two (2) parts acid resistant epoxy paint for insulation and to provide protection coating against spilling of battery electrolytes, especially vented type battery. According to the preferred embodiment, the two (2) parts acid resistant epoxy paint is comprised of PLASTI DIP PMR Flex Primer and PLASTI DIP UV Black.

The top lid and the elevated funnel-shaped frame provide a bended airflow path which prevents water ingress effectively. Use of metallic filter in the preferred embodiment allows for use in environment with ambient operating temperature range of -40°C to 60°C, although technically it can be used for -60°C depending on the limit of top lid gasket limit of -60°C to 150°C.

FIGURE 2.0 illustrates a cross-sectional side view of the battery enclosure of the present invention. According to the preferred embodiment, the battery enclosure comprises of bottom compartment (202) for safely housing batteries (205), a removable front lid cover (203), a base lid (204) attached on top of the bottom compartment (202) having a ventilation channel (206), an air filter (208) for preventing dust or possibly insect ingress attached fully along and across the ventilation channel (206), an elevated frame or elevated funnel-shaped frame (210) attached onto the base lid (204) framing the ventilation channel (206), a top lid (212) having a bigger perimeter from the base lid (204) and covers the ventilation channel (206), a top lid barrier (214) attached to the top lid (212) for providing a second layer of barrier, and a means for attaching and supporting (216) the top lid (212) on the base lid (204). There is a temperature probe sensor (207) to measure the amount of heat energy or even coldness that is generated by the system to allow detection of any physical change in that system to produce either an analogue or digital output.

The top lid (212) has a vertical wall element (212a) providing protective shield around the top lid perimeter and hangs above the base lid (204). The top lid barrier (214) is a second vertical wall element within the top lid (212) which provides the second protective shield above the base lid (204). The elevated frame or elevated funnel-shaped frame (210) is shaped like a wide but short funnel to provide an inverted awning effect to prevent water ingress into the ventilation channel from under the top lid barrier (214). FIGURE 3.0 illustrates a cross-sectional top view of the battery enclosure (300) of the present invention. In the preferred embodiment, the base lid is hinged to the bottom compartment by a hinge (317) to allow top opening of the lid. This top opening is secured by padlock locking component (318) on the front section of the battery enclosure. As shown in FIGURE 3.0, the temperature probe sensor (307) probes deep into the battery enclosure to measure the internal temperature of the battery enclosure (300).

FIGURE 4.0 illustrates a close-up arrangement of the lid of the battery enclosure of the present invention. As shown in FIGURE 4.0, there are three layers of barriers to prevent strong water jet from penetrating the barrier to enter the ventilation channel. The three barriers include the top lid (412), top lid barrier (414), and the elevated funnel-shaped frame (410).

When hydrogen gas is released by the battery while charging and in overcharged condition, the hydrogen gas will rise upwards and pass through the ventilation channel (406) through the air filter (408) and further escape the top lid (412) via the bended airflow path.

Unless the context requires otherwise or specifically states to the contrary, integers, steps or elements of the invention recited herein as singular integers, steps, or elements clearly encompass both singular and plural forms of the recited integers, steps or elements.

Throughout this specification, unless the context requires otherwise, the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated step or element or integer or group of steps or elements or elements or integers, but not the exclusion of any other step or element or integer or group of steps, elements or integers. Thus, in the context of this specification, the term “comprising” is used in an inclusive sense and thus should be understood as meaning “including principally, but not necessarily solely”.

Claims

1 . A weatherproof battery enclosure (100) for safely housing batteries within an explosive environment, comprising: a bottom compartment (102) for holding said battery; a base lid (104) attached to the bottom compartment (102) having a ventilation channel (106); an air filter (108) for preventing dust ingress attached along and across the ventilation channel (106); an elevated frame (110) attached onto the base lid (104) framing the ventilation channel (106); a top lid (112) with a bigger perimeter from the base lid (104) having a vertical wall element around the top lid perimeter; a top lid barrier (114) with a smaller perimeter from the top lid (112) attached to the top lid while having a bigger perimeter from the elevated frame (110); and a means for attaching the top lid (112) to the base lid (116), characterized in that, the means for attaching the top lid to the base lid (106) holds the top lid (112) and the top lid barrier (114) at an elevated height from the base lid (104) to allow air ventilation, wherein the top lid (106) and the elevated frame (110) provide a bended airflow path which prevents water from entering the battery enclosure (100) while allowing ventilation.

2. The weatherproof battery enclosure (100) as claimed in claim 1 , wherein the elevated frame (110) is shaped like a funnel to provide an inverted awning effect to prevent water ingress.

3. The weatherproof battery enclosure (100) as claimed in claim 1 , wherein there are three layers of barriers to prevent water and dust ingress comprising the top lid (112), top lid barrier (114), and the elevated frame (110).

4. The weatherproof battery enclosure (100) as claimed in claim 1 , wherein the ambient operating temperature ranges from -40°C to 60°C.

5. The weatherproof battery enclosure (100) as claimed in claim 1 , wherein a means for attaching (116) the top lid (112) on the base lid (104) act as a support to hold the top lid in position.

6. The weatherproof battery enclosure (100) as claimed in claim 1 , wherein the battery enclosure is made of stainless steel, galvanised or painted steel, wood or high-performance plastics or any other type of non-conductor materials.