Modular, stackable PCM-based thermal battery apparatus

Abstract

A thermal battery assembly includes a modules configured to be stacked vertically on top of each other. The modules includes an electronics module; a first tank module; and a second tank module. A base defines a bottom of the stack and is configured to receive thereon the lowermost module of the stack for supporting the stack on a floor. Each tank module includes a phase change material (PCM); a heat exchanger assembly with heat exchangers immersed in the phase change material, a first set thereof defining a PCM charging circuit, and a second set defining a PCM discharging circuit; a first exterior connection port configured for fluid communication with an inflow of the PCM discharging circuit and a second exterior connection port configured for fluid communication with an outflow of the PCM discharging circuit. Heating or cooling capacity can be increased by adding another tank module to the stack.

Claims

1. A method of assembling a thermal battery assembly, comprising: (a) vertically arranging a plurality of tank modules on top of one another and an electronics module on top of the tank modules to form a stack, each tank module comprising, (i) a phase change material (PCM), and (ii) a heat exchanger assembly comprising a plurality of heat exchangers immersed within the phase change material, a first set of the heat exchangers defining a PCM charging circuit for charging the phase change material, and a second set of the heat exchangers defining a PCM discharging circuit for discharging the phase change material; and (b) interconnecting in fluid communication the PCM discharging circuit of one of the plurality of tank modules with the PCM discharging circuit of another one of the plurality of tank modules, wherein one of the tank modules comprises an exterior connection port in fluid communication with an inflow of the interconnected PCM circuits and one of the tank modules comprises an exterior connection port in fluid communication with an outflow of the interconnected PCM circuits.

2. The method of assembling a thermal battery assembly of claim 1, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM discharging circuits is arranged in parallel.

3. The method of assembling a thermal battery assembly of claim 1, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM discharging circuits is arranged in series.

4. The method of assembling a thermal battery assembly of claim 1, wherein the PCM discharging circuits of the interconnected tank modules are connected to different PCM discharging appliances.

5. The method of assembling a thermal battery assembly of claim 1, wherein the PCM discharging circuits of the interconnected tank modules are connected to a common PCM discharging appliance.

6. The method of assembling a thermal battery assembly of claim 1, wherein said interconnecting step is performed by installing plumbing along recessed areas of the stacked modules.

7. The method of assembling a thermal battery assembly of claim 6, wherein the recessed areas define a chase.

8. A method of assembling a thermal battery assembly, comprising: (a) vertically arranging a plurality of tank modules on top of one another and an electronics module on top of the tank modules to form a stack, each tank module comprising, (i) a phase change material (PCM), and (ii) a heat exchanger assembly comprising a plurality of heat exchangers immersed within the phase change material, a first set of the heat exchangers defining a PCM charging circuit for charging the phase change material, and a second set of the heat exchangers defining a PCM discharging circuit for discharging the phase change material; and (b) interconnecting in fluid communication the PCM charging circuit of one of the plurality of tank modules with the PCM charging circuit of another one of the plurality of tank modules, wherein one of the tank modules comprises an exterior connection port in fluid communication with an inflow of the interconnected PCM circuits and one of the tank modules comprises an exterior connection port in fluid communication with an outflow of the interconnected PCM circuits.

9. The method of assembling a thermal battery assembly of claim 8, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM charging circuits is arranged in parallel.

10. The method of assembling a thermal battery assembly of claim 8, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM charging circuits is arranged in series.

11. The method of assembling a thermal battery assembly of claim 8, wherein said interconnecting step is performed by installing plumbing along recessed areas of the stacked modules.

12. The method of assembling a thermal battery assembly of claim 11, wherein the recessed areas define a chase.

13. The method of assembling a thermal battery assembly of claim 8, wherein the electronics module comprises an onboard charging system and wherein the interconnected PCM charging circuits are connected to the charging system of the electronics module for charging.

14. The method of assembling a thermal battery assembly of claim 13, wherein the onboard charging system comprises a heat pump.

15. The method of assembling a thermal battery assembly of claim 13, wherein the onboard charging system comprises a pump and an in-line electric heater located within fluid flow from and returning to the interconnected PCM charging circuits.

16. The method of assembling a thermal battery assembly of claim 13, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM charging circuits is arranged in parallel.

17. The method of assembling a thermal battery assembly of claim 13, wherein said interconnecting step is performed such that fluid flow through the plurality of tank modules of the interconnected PCM charging circuits is arranged in series.

18. A method of assembling a thermal battery assembly, comprising: (a) vertically arranging a plurality of tank modules on top of one another and an electronics module on top of the tank modules to form a stack, each tank module comprising, (i) a phase change material (PCM), and (ii) a heat exchanger assembly comprising a plurality of heat exchangers immersed within the phase change material, a first set of the heat exchangers defining a PCM charging circuit for charging the phase change material, and a second set of the heat exchangers defining a PCM discharging circuit for discharging the phase change material; and (b) interconnecting in fluid communication the PCM charging circuit of one of the plurality of tank modules with the PCM charging circuit of another one of the plurality of tank modules, wherein one of the tank modules comprises an exterior connection port in fluid communication with an inflow of the interconnected PCM circuits and one of the tank modules comprises an exterior connection port in fluid communication with an outflow of the interconnected PCM circuits; wherein the plurality of tank modules comprises a first tank module configured for cooling applications and a second tank module configured for heating applications; and further comprising connecting the PCM discharging circuit of the first interconnected tank module to a cooling application and connecting the PCM discharging circuit of the second interconnected tank module to a heating application.

19. The method of assembling a thermal battery assembly of claim 18, wherein the first tank module has only two external fluid connections consisting of one for external fluid flow to the PCM discharging circuit and one for external fluid flow from the PCM discharging circuit; and wherein the second tank module has only two external fluid connections consisting of one for external fluid flow to the PCM discharging circuit and one for external fluid flow from the PCM discharging circuit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) One or more preferred embodiments of the invention now will be described in detail with reference to the accompanying drawings, wherein the same elements are referred to with the same reference numerals.

(2) FIG. 1 is a perspective view of a preferred modular, PCM-based thermal battery apparatus (hereinafter Modular PCM-TB Apparatus) in accordance with one or more aspects and features of the invention; FIG. 1A is a shaded view thereof.

(3) FIG. 2 is a front elevational view of the apparatus of FIG. 1; FIG. 2A is a shaded view thereof.

(4) FIG. 3 is a first, left side elevational view of the apparatus of FIG. 1; FIG. 3A is a shaded view thereof.

(5) FIG. 4 is a second, right side elevational view of the apparatus of FIG. 1; FIG. 4A is a shaded view thereof.

(6) FIG. 5 is a back elevational view of the apparatus of FIG. 1; FIG. 5A is a shaded view thereof.

(7) FIG. 6 is a perspective view of the back of the apparatus of FIG. 1, wherein a back cover has been removed.

(8) FIG. 7 is a bottom plan view of the apparatus of FIG. 1; FIG. 7A is a shaded view thereof.

(9) FIG. 8 is a top plan view of the apparatus of FIG. 1; FIG. 8A is a shaded view thereof.

(10) FIG. 9 is a perspective view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention; FIG. 9A is a shaded view thereof.

(11) FIG. 10 is a front elevational view of the apparatus of FIG. 9; FIG. 10A is a shaded view thereof.

(12) FIG. 11 is a first, left side elevational view of the apparatus of FIG. 9; FIG. 11A is a shaded view thereof.

(13) FIG. 12 is a second, right side elevational view of the apparatus of FIG. 9; FIG. 12A is a shaded view thereof.

(14) FIG. 13 is a back elevational view of the apparatus of FIG. 9; FIG. 13A is a shaded view thereof.

(15) FIG. 14 is a bottom plan view of the apparatus of FIG. 9; FIG. 14A is a shaded view thereof.

(16) FIG. 15 is a top plan view of the apparatus of FIG. 9; FIG. 15A is a shaded view thereof.

(17) FIG. 16 is a perspective view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention; FIG. 16A is a shaded view thereof.

(18) FIG. 17 is a front elevational view of the apparatus of FIG. 16; FIG. 17A is a shaded view thereof.

(19) FIG. 18 is a first, left side elevational view of the apparatus of FIG. 16; FIG. 18A is a shaded view thereof.

(20) FIG. 19 is a second, right side elevational view of the apparatus of FIG. 16; FIG. 19A is a shaded view thereof.

(21) FIG. 20 is a back elevational view of the apparatus of FIG. 16; FIG. 20A is a shaded view thereof.

(22) FIG. 21 is a perspective view of the back of the apparatus of FIG. 16.

(23) FIG. 22 is a bottom plan view of the apparatus of FIG. 16; FIG. 22A is a shaded view thereof.

(24) FIG. 23 is a top plan view of the apparatus of FIG. 16; FIG. 23A is a shaded view thereof.

(25) FIG. 24 is an exploded, front view of the apparatus of FIG. 17.

(26) FIG. 25 is an exploded, back view of the apparatus of FIG. 17.

(27) FIG. 26 is an exploded, side view of the apparatus of FIG. 17.

(28) FIG. 27 is an isometric view of a housing of each of the tank modules of FIGS. 1 and 16; FIG. 27A is a shaded view thereof.

(29) FIG. 28 is a front elevational view of the housing of FIG. 27; FIG. 28A is a shaded view thereof.

(30) FIG. 29 is a back elevational view of the housing of FIG. 27; FIG. 29A is a shaded view thereof.

(31) FIG. 30 is a first, left side elevational view of the housing of FIG. 27; FIG. 30A is a shaded view thereof.

(32) FIG. 31 is a second, right side elevational view of the housing of FIG. 27; FIG. 31A is a shaded view thereof.

(33) FIG. 32 is a top plan view of the housing of FIG. 27; FIG. 32A is a shaded view thereof.

(34) FIG. 33 is a bottom plan view of the housing of FIG. 27; FIG. 33A is a shaded view thereof.

(35) FIG. 34 is an isometric view of a housing of the tank modules of FIGS. 9 and 16; FIG. 34A is a shaded view thereof.

(36) FIG. 35 is a cross-sectional view of the housing of FIG. 34 taken along the line 35-35 shown in FIG. 34; FIG. 35A is a shaded view thereof.

(37) FIG. 36 is a front elevational view of the housing of FIG. 34; FIG. 36A is a shaded view thereof.

(38) FIG. 37 is a back elevational view of the housing of FIG. 34; FIG. 37A is a shaded view thereof.

(39) FIG. 38 is a first, left side elevational view of the housing of FIG. 34; FIG. 38A is a shaded view thereof.

(40) FIG. 39 is a second, right side elevational view of the housing of FIG. 34; FIG. 39A is a shaded view thereof.

(41) FIG. 40 is a top plan view of the housing of FIG. 34; FIG. 40A is a shaded view thereof.

(42) FIG. 41 is a bottom plan view of the housing of FIG. 34; FIG. 41A is a shaded view thereof.

(43) FIG. 42 is an isometric view of a housing of the electronics module of each of the apparatus of FIGS. 1, 9, and 16; FIG. 42A is a shaded view thereof.

(44) FIG. 43 is a front elevational view of the housing of FIG. 42; FIG. 43A is a shaded view thereof.

(45) FIG. 44 is a back elevational view of the housing of FIG. 42; FIG. 44A is a shaded view thereof.

(46) FIG. 45 is a first, left side elevational view of the housing of FIG. 42; FIG. 45A is a shaded view thereof.

(47) FIG. 46 is a second, right side elevational view of the housing of FIG. 42; FIG. 46A is a shaded view thereof.

(48) FIG. 47 is a top plan view of the housing of FIG. 42; FIG. 47A is a shaded view thereof.

(49) FIG. 48 is a bottom plan view of the housing of FIG. 42; FIG. 48A is a shaded view thereof.

(50) FIG. 49 is an isometric view of another housing of an electronics module that is smaller in height than the housing of FIG. 42; FIG. 49A is a shaded view thereof.

(51) FIG. 50 is a front elevational view of the housing of FIG. 49; FIG. 50A is a shaded view thereof.

(52) FIG. 51 is a back elevational view of the housing of FIG. 49; FIG. 51A is a shaded view thereof.

(53) FIG. 52 is a first, left side elevational view of the housing of FIG. 49; FIG. 52A is a shaded view thereof.

(54) FIG. 53 is a second, right side elevational view of the housing of FIG. 49; FIG. 53A is a shaded view thereof.

(55) FIG. 54 is a top plan view of the housing of FIG. 49; FIG. 54A is a shaded view thereof.

(56) FIG. 55 is a bottom plan view of the housing of FIG. 49; FIG. 55A is a shaded view thereof.

(57) FIG. 56 is an isometric view of a component of each of the apparatus of FIGS. 1 and 16, the component comprising a back cover panel for the tank of FIG. 27; FIG. 56A is a shaded view thereof.

(58) FIG. 57 is an elevational view of an exterior side of the panel of FIG. 56; FIG. 57A is a shaded view thereof.

(59) FIG. 58 is a first, left side elevational view of the panel of FIG. 56; FIG. 58A is a shaded view thereof.

(60) FIG. 59 is an elevational view of an interior side of the panel of FIG. 56; FIG. 59A is a shaded view thereof.

(61) FIG. 60 is a second, right side elevational view of the panel of FIG. 56; FIG. 60A is a shaded view thereof.

(62) FIG. 61 is an isometric view of a component of each of the apparatus of FIGS. 9 and 16, the component comprising aback cover panel for the tank of FIG. 34; FIG. 61A is a shaded view thereof.

(63) FIG. 62 is an elevational view of an exterior side of the panel of FIG. 61; FIG. 62A is a shaded view thereof.

(64) FIG. 63 is a first, left side elevational view of the panel of FIG. 61; FIG. 63A is a shaded view thereof.

(65) FIG. 64 is an elevational view of an interior side of the panel of FIG. 61; FIG. 64A is a shaded view thereof.

(66) FIG. 65 is a second, right side elevational view of the panel of FIG. 61; FIG. 65A is a shaded view thereof.

(67) FIG. 66 is a top plan view of the panel of FIG. 61; FIG. 66A is a shaded view thereof.

(68) FIG. 67 is a bottom plan view of the panel of FIG. 61; FIG. 67A is a shaded view thereof.

(69) FIG. 68 is an isometric view of a component of each of the apparatus of FIGS. 1, 9 and 16, the component comprising a lid for the electronics module of each of FIGS. 42 and 49; FIG. 68A is a shaded view thereof.

(70) FIG. 69 is a front elevational view of the lid of FIG. 68; FIG. 69A is a shaded view thereof.

(71) FIG. 70 is a side elevational view of the lid of FIG. 68; FIG. 70A is a shaded view thereof.

(72) FIG. 71 is a top plan view of the lid of FIG. 68; FIG. 71A is a shaded view thereof.

(73) FIG. 72 is bottom plan view of the lid of FIG. 68; FIG. 72A is a shaded view thereof.

(74) FIG. 73 is an isometric view of a component of each of the apparatus of FIGS. 1, 9 and 16, the component comprising a base for supporting each of the stacks of the apparatus; FIG. 73A is a shaded view thereof.

(75) FIG. 74 is an elevational view of the base of FIG. 73; FIG. 74A is a shaded view thereof.

(76) FIG. 75 is a top plan view of the base of FIG. 73; FIG. 75A is a shaded view thereof.

(77) FIG. 76 is a bottom plan view of the base of FIG. 73; FIG. 76A is a shaded view thereof.

(78) FIG. 77 is a back elevational view of a preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the back cover panels are omitted.

(79) FIG. 78 is a top profile view of the upper tank module of the apparatus of FIG. 77 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(80) FIG. 79 is a top profile view of the lower tank module of the apparatus of FIG. 77 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(81) FIG. 80 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 77.

(82) FIG. 81 is a back elevational view of the preferred Modular PCM-TB Apparatus of FIG. 77, wherein the tank cover panels are shown.

(83) FIG. 82 is another schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 77.

(84) FIG. 83 is yet another schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 77.

(85) FIG. 84 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(86) FIG. 85 is a top profile view of the upper tank module of the apparatus of FIG. 84 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(87) FIG. 86 is a top profile view of the lower tank module of the apparatus of FIG. 84 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(88) FIG. 87 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 84.

(89) FIG. 88 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(90) FIG. 89 is a top profile view of the upper tank module of the apparatus of FIG. 88 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(91) FIG. 90 is a top profile view of the lower tank module of the apparatus of FIG. 88 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(92) FIG. 91 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 88.

(93) FIG. 92 is a back elevational view of the preferred Modular PCM-TB Apparatus of FIG. 84, wherein the tank cover panels are shown.

(94) FIG. 93 is a back elevational view of the preferred Modular PCM-TB Apparatus of FIG. 88, wherein the tank cover panels are shown.

(95) FIG. 94 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(96) FIG. 95 is a top profile view of the upper tank module of the apparatus of FIG. 94 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(97) FIG. 96 is a top profile view of the lower tank module of the apparatus of FIG. 94 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(98) FIG. 97 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 94.

(99) FIG. 98 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 94.

(100) FIG. 99 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 94.

(101) FIG. 100 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 102.

(102) FIG. 101 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 105.

(103) FIG. 102 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(104) FIG. 103 is a top profile view of the upper tank module of the apparatus of FIG. 102 for the purpose of, inter alia, illustrating that there are no external connection ports of the upper tank module.

(105) FIG. 104 is a top profile view of the lower tank module of the apparatus of FIG. 102 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(106) FIG. 105 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(107) FIG. 106 is a top profile view of the upper tank module of the apparatus of FIG. 105 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(108) FIG. 107 is a top profile view of the lower tank module of the apparatus of FIG. 105 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(109) FIG. 108 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(110) FIG. 109 is a back elevational view of the preferred Modular PCM-TB Apparatus of FIG. 108, wherein the tank cover panels are shown.

(111) FIG. 110 is a top profile view of the upper tank module of the apparatus of FIG. 108 for the purpose of, inter alia, illustrating external connection ports of the upper tank module.

(112) FIG. 111 is a top profile view of the lower tank module of the apparatus of FIG. 108 for the purpose of, inter alia, illustrating external connection ports of the lower tank module.

(113) FIG. 112 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 109, wherein the PCM charging circuit are arranged internally in series.

(114) FIG. 113 is a schematic diagram of heat exchange circuits of a preferred configuration utilizing the apparatus of FIG. 109, wherein the PCM charging circuit are arranged internally in parallel.

(115) FIG. 114a is a schematic diagram of heat exchange circuits of another preferred configuration utilizing a preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(116) FIG. 114b is another schematic diagram of heat exchange circuits of a preferred configuration utilizing a preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(117) FIG. 115 is a back elevational view of another preferred Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention, wherein the tank cover panels are omitted.

(118) FIG. 116 is a schematic diagram of a preferred PCM charging circuit of an upper tank module of Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(119) FIG. 117 is a schematic diagram of a preferred PCM discharging circuit of an upper tank module of Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(120) FIG. 118 is a schematic diagram of a preferred PCM charging circuit of a lower tank module of Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(121) FIG. 119 is a schematic diagram of a preferred PCM discharging circuit of a lower tank module of Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention.

(122) FIG. 120 is a table illustrating open/closed states of the valves shown in the preferred Modular PCM-TB Apparatus of FIG. 115.

(123) FIG. 121 is a table illustrating connected/capped states of the external connection ports shown in the preferred Modular PCM-TB Apparatus of FIG. 115.

DETAILED DESCRIPTION

(124) As a preliminary matter, it will readily be understood by one having ordinary skill in the relevant art (Ordinary Artisan) that the invention has broad utility and application. Furthermore, any embodiment discussed and identified as being preferred is considered to be part of a best mode contemplated for carrying out the invention. Other embodiments also may be discussed for additional illustrative purposes in providing a full and enabling disclosure of the invention. Furthermore, an embodiment of the invention may incorporate only one or a plurality of the aspects of the invention disclosed herein; only one or a plurality of the features disclosed herein; or combination thereof. As such, many embodiments are implicitly disclosed herein and fall within the scope of what is regarded as the invention.

(125) Accordingly, while the invention is described herein in detail in relation to one or more embodiments, it is to be understood that this disclosure is illustrative and exemplary of the invention and is made merely for the purposes of providing a full and enabling disclosure of the invention. The detailed disclosure herein of one or more embodiments is not intended, nor is to be construed, to limit the scope of patent protection afforded the invention in any claim of a patent issuing here from, which scope is to be defined by the claims and the equivalents thereof. It is not intended that the scope of patent protection afforded the invention be defined by reading into any claim a limitation found herein that does not explicitly appear in the claim itself.

(126) Thus, for example, any sequence(s) and/or temporal order of steps of various processes or methods that are described herein are illustrative and not restrictive. Accordingly, it should be understood that, although steps of various processes or methods may be shown and described as being in a sequence or temporal order, the steps of any such processes or methods are not limited to being carried out in any particular sequence or order, absent an indication otherwise. Indeed, the steps in such processes or methods generally may be carried out in various different sequences and orders while still falling within the scope of the invention. Accordingly, it is intended that the scope of patent protection afforded the invention be defined by the issued claim(s) rather than the description set forth herein.

(127) Additionally, it is important to note that each term used herein refers to that which the Ordinary Artisan would understand such term to mean based on the contextual use of such term herein. To the extent that the meaning of a term used hereinas understood by the Ordinary Artisan based on the contextual use of such term-differs in any way from any particular dictionary definition of such term, it is intended that the meaning of the term as understood by the Ordinary Artisan should prevail.

(128) With regard solely to construction of any claim with respect to the United States, no claim element is to be interpreted under 35 U.S.C. 112(f) unless the explicit phrase means for or step for is actually used in such claim element, whereupon this statutory provision is intended to and should apply in the interpretation of such claim element. With regard to any method claim including a condition precedent step, such method requires the condition precedent to be met and the step to be performed at least once but not necessarily every time during performance of the claimed method.

(129) Furthermore, it is important to note that, as used herein, comprising is open-ended insofar as that which follows such term is not exclusive. Additionally, a and an each generally denotes at least one but does not exclude a plurality unless the contextual use dictates otherwise. Thus, reference to a picnic basket having an apple is the same as a picnic basket comprising an apple and a picnic basket including an apple, each of which identically describes a picnic basket having at least one apple as well as a picnic basket having apples; the picnic basket further may contain one or more other items beside an apple. In contrast, reference to a picnic basket having a single apple describes a picnic basket having only one apple; the picnic basket further may contain one or more other items beside an apple. In contrast, a picnic basket consisting of an apple has only a single item contained therein, i.e., one apple; the picnic basket contains no other item.

(130) When used herein to join a list of items, or denotes at least one of the items but does not exclude a plurality of items of the list. Thus, reference to a picnic basket having cheese or crackers describes a picnic basket having cheese without crackers, a picnic basket having crackers without cheese, and a picnic basket having both cheese and crackers; the picnic basket further may contain one or more other items beside cheese and crackers.

(131) When used herein to join a list of items, and denotes all of the items of the list. Thus, reference to a picnic basket having cheese and crackers describes a picnic basket having cheese, wherein the picnic basket further has crackers, as well as describes a picnic basket having crackers, wherein the picnic basket further has cheese; the picnic basket further may contain one or more other items beside cheese and crackers.

(132) The phrase at least one followed by a list of items joined by and denotes an item of the list but does not require every item of the list. Thus, at least one of an apple and an orange encompasses the following mutually exclusive scenarios: there is an apple but no orange; there is an orange but no apple; and there is both an apple and an orange. In these scenarios if there is an apple, there may be more than one apple, and if there is an orange, there may be more than one orange. Moreover, the phrase one or more followed by a list of items joined by and is the equivalent of at least one followed by the list of items joined by and.

(133) Referring now to the drawings, one or more preferred embodiments of the invention are next described. The following description of one or more preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its implementations, or uses.

(134) FIGS. 1-8 show a first preferred modular, PCM-based thermal battery apparatus 200 or Modular PCM-TB Apparatus in accordance with one or more aspects and features of the invention. In this respect, FIG. 1 is a perspective view of the apparatus 200; FIG. 2 is a front elevational view of the apparatus 200; FIG. 3 is a first, left side elevational view of the apparatus 200; FIG. 4 is a second, right side elevational view of the apparatus 200; FIG. 5 is a back elevational view of the apparatus 200; FIG. 6 is a perspective view of the back of the apparatus 200, wherein a back cover has been removed; FIG. 7 is a bottom plan view of the apparatus 200; and FIG. 8 is a top plan view of the apparatus 200. For further clarity of illustration FIG. 1A is a shaded view of FIG. 1; FIG. 2A is a shaded view of FIG. 2; FIG. 3A is a shaded view of FIG. 3; FIG. 4A is a shaded view of FIG. 4; FIG. 5A is a shaded view of FIG. 5; and FIG. 7A is a shaded view of FIG. 7.

(135) The apparatus 200 comprises stackable modules. As shown, a stack 202 of the apparatus 200 comprises two modules: an electronics module 204, and a tank module 206. These modules are supported by a base 208 that defines a bottom of the stack 202. A detachable lid 210 covers the electronics module 204 and encloses and protects electronic that are contained within the module 204. The lid 210 defines the top of the stack 202.

(136) The tank module 206 comprises a phase change material (PCM) and a heat exchanger assembly. The PCM may comprise a paraffin, salt hydrate, fatty acids, fatty alcohols, fatty esters and the likes. The PCM preferably is a bio-based PCM. The heat exchanger assembly comprises a plurality of heat exchangers that are immersed within the phase change material and that are configured to define a PCM charging circuit for charging the phase change material, and a PCM discharging circuit for discharging the phase change material. The charging may comprise heating the PCM material to or above a phase change temperature, or cooling the PCM material to or below a phase change temperature, depending on the intended use of the PCM material for either heating or cooling during discharging. The PCM charging circuit preferably comprises a fluid flow arrangement of the heat exchangers that is in parallel. An exemplary PCM charging circuit arranged in parallel 1160 for a thermal battery TB1 is shown in FIG. 116. In contrast, the PCM discharging circuit preferably comprises a fluid flow arrangement that is in series. An exemplary PCM discharging circuit arranged in series 1170 for the thermal battery TB1 is shown in FIG. 117. Nonetheless, it is contemplated that, within the broader scope of the invention, the PCM charging circuit comprises a fluid flow arrangement that is in series like discharging circuit 1170, and that the PCM discharging circuit comprises a fluid flow arrangement that is arranged in parallel like charging circuit 1160. For further details regarding such thermal energy batteries comprising bio-based PCMs, heat exchangers, and PCM charging and discharging circuits, reference is here made to U.S. patent application 63/445,715, filed Feb. 14, 2023, and to international patent application PCT/US2023/13069, filed Feb. 14, 2023, and the publication thereof, both of which are incorporated herein by reference.

(137) With reference to FIGS. 5 and 6, the tank module 206 comprises exterior connection ports 212 preferably located on the back of the tank module 206 for fluid flow into and out of the apparatus 200. A first pair of the exterior connection ports 212 preferably handle the inflow and outflow of the PCM charging circuit, and a second pair of the exterior ports 212 preferably handle the inflow and outflow of the PCM discharging circuit.

(138) Preferably sensors are contained within the tank module 206 for determining local temperatures of the phase change material, from which a measure of charge may be determined. These sensors may be wired or configured for wireless communications. The tank module 206 further preferably includes a lighting display panel or other visual display 214 that indicates the measure of charge. For instance, a green light, a yellow light, and a red light may be displayed indicating a level of charge of the tank. Examples of this are disclosed in the appendix. Other temperatures also may be determined with sensors, including temperatures of fluid at various locations in the charging and discharging circuits and the heat exchangers of the tank module 206.

(139) The measure of charge preferably is determined by electronic components contained in the electronics module 204. These components preferably comprise a controller or processor with memory and software by which the temperature readings are received and which may process the readings for determining the measure of charge. Alternatively, the temperature data received may be communicated from the apparatus 200 for processing, in which scenario the electronics preferably comprise a transceiver. The communications may comprise Bluetooth or Wi-Fi communications. Power is supplied to the electronics within the electronics module 204 by battery or by a power cord that plugs into a conventional wall outlet (such a cord is shown in the appendix).

(140) The electronics module 204 preferably comprises a display panel or control panel 216 for communicating information to a user. For example, in implementations in which the apparatus 200 is used to heat water, a temperature of the water as output from the apparatus 200 may be indicated via the panel 216. There preferably also are interactive controls; an exemplary panel is disclosed in the appendix.

(141) By being contained within the electronics module 204, the electric components are separate from the PCM in the tank module 206 and insulated from the heat of the PCM when it is charged.

(142) The lid 210 is configured to fit onto a rim of the housing of the electronics module 204. The lid preferably snap fits onto the rim of the housing of the electronics module 204, with springy detent portions 211 of the lid 210 being received within openings located in side walls of the housing of the electronics module 204 for removably latching the lid 210 to the housing of the electronics module 204. The lid 210 further preferably comprises openings 218 for venting of the interior space of the electronics module when attached in covering relation thereto. Two groups of openings 218 comprising vents are shown, for example, in FIGS. 1 and 8. One or more electric fans also may be included for venting and cooling of electronic components housed in the electronics module 204.

(143) The base 208 is configured to receive a modular tank and support the stack of the apparatus. As shown, the base comprises a recess 220 (see FIGS. 73 and 75) for receiving a lower portion of the tank module therein. The base preferably is configured to collect and contain condensate and liquids that may run down from the stack and, preferably, is wired with a safety switch for creating an alert regarding a possible leak in the stack when a sufficient amount of condensate or liquid is detected in the containment area of the base 208. The base 208 further comprises feet 222 that inhibit slipping of the apparatus on a smooth floor. The feet 222 preferably comprise non-slip surfaces and may comprise non-slip pads. Preferably, the base 208 serves as a floor pan and captures any small amount of fluid that might escape from a tank module, whether during install, maintenance, or otherwise.

(144) It will be appreciated that the apparatus 200 utilizes a stackable, modular design. In this respect, the electronics module 204 is configured to stack on top of the tank module 206, and the tank module 206 in turn is configured to be received on and supported by the base 208.

(145) Furthermore, an additional tank module may be added to the stack or a different sized tank module may be interchanged with an existing tank module. Similarly, an additional electronics module may be added. In this regard, the electronics module 204 is configured to receive another electronics module thereon in stacked, covering relation, if another is desired, with the detachable lid 210 fitting on the housing of and covering the topmost electronics module. The tank module 206 is configured in like manner to receive another tank module thereon, with the electronics module 204 then stacking on top of the second tank module; and the tank module 206 is configured in like manner to be stacked itself on top of another tank module, with the other tank module being received on and supported by the base and with the electronics module 204 remaining stacked on top of the tank module 206. In the stacked configuration, the lid, the electronics module(s), the tank module(s), and the base collectively define a continuous exterior surface with seams defined therebetween, as shown for example in FIG. 1, illustrating seams 222 in apparatus 200.

(146) The apparatus 200 preferably comprises a detachable panel 224 that snap-fits within channels on a back of the tank module 206 in covering relation to a recessed area 226 that is defined in the back surface of the tank module 206. The panel 224 is shown in FIG. 5 and omitted in FIG. 6 to reveal the recessed area 226. The cover panel 224 and recessed area 226 preferably define a space within which plumbing may be installed for interconnecting one or more flows of stacked tanks in a Modular PCM-TB Apparatus, as discussed in detail below. The plumbing may comprise pipes, hoses, fittings, adapters, valves, and servomechanism for controlling the valves if not manually operated. A similar recessed area 326 is provided in tank module 300, discussed in detail below.

(147) The walls of the modules preferably are constructed from a material that is resistive to thermal energy transfer, i.e., a thermally insulating material. In this regard, the components defining the walls of the modules preferably are molded or printed and CNC processed. Additionally, a tank module preferable includes a double-walled/double-insulated construction for thermally insulating the heat exchangers and bio-based PCM. The double-walled construction also preferably is utilized in not only the sidewalls but also the bottom wall of a tank module. The bottom of an electronics module also preferably includes a double-wall design for thermal insulation, as the electronics module serves as a cover for the top opening of the topmost tank in a stack. The double-walled design that preferably utilized in each tank module is best shown in the cross-sectional view of the tank module of FIG. 35, described in detail below.

(148) FIGS. 9-15 show a second preferred Modular PCM-TB Apparatus 300 in accordance with one or more aspects and features of the invention. In this respect, FIG. 9 is a perspective view of the apparatus 300; FIG. 10 is a front elevational view of the apparatus 300; FIG. 11 is a first, left side elevational view of the apparatus 300; FIG. 12 is a second, right side elevational view of the apparatus 300; FIG. 13 is a back elevational view of the apparatus 300; FIG. 14 is a bottom plan view of the apparatus 300; and FIG. 15 is a top plan view of the apparatus 300. Furthermore, FIG. 9A is a shaded view of FIG. 9; FIG. 10A is a shaded view of FIG. 10; FIG. 11A is a shaded view of FIG. 11; FIG. 12A is a shaded view of FIG. 12; FIG. 13A is a shaded view of FIG. 13; FIG. 14A is a shaded view of FIG. 14; and FIG. 15A is a shaded view FIG. 15.

(149) The apparatus 300 is similar to apparatus 200 and like modules and components will not be repeated, reference instead now being made to the disclosure above with regard to apparatus 200. Accordingly, primary differences between apparatus 300 and apparatus 200 will now be described.

(150) The stack 302 of the apparatus 300 comprises tank module 306, which is similar in design but smaller in height than tank module 206. The display 314 is also smaller in height, as is the back cover panel 324. Contrasting apparatus 300 and apparatus 200 reveals the benefit of the modularity of the design; apparatus 300 is arrived at by interchanging the tank module 206 with the tank module 306.

(151) As a result of the smaller size, tank module 306 contains less PCM and therefore has a lesser energy storage capacity when used in heating implementations, such as a tankless water heater. As an example, whereas apparatus 200 having a single tank module 206 in its stack might have an energy consumption of 20 kW in its operation when using an electric heat source in its PCM charging circuit, apparatus 300 having a single tank module 306 in its stack then might have an energy consumption of 10 kW in its operation when using an electric heat source in its PCM charging circuit.

(152) FIGS. 16-23 show a third preferred Modular PCM-TB Apparatus 400 in accordance with one or more aspects and features of the invention. In this respect, FIG. 16 is a perspective view of the apparatus 400; FIG. 17 is a front elevational view of the apparatus 400; FIG. 18 is a first, left side elevational view of the apparatus 400; FIG. 19 is a second, right side elevational view of the apparatus 400; FIG. 20 is a back elevational view of the apparatus 400; FIG. 21 is a perspective view of the back of the apparatus 400; FIG. 22 is a bottom plan view of the apparatus 400; FIG. 23 is a top plan view of the apparatus 400; FIG. 24 is an exploded, front view of the apparatus 400; FIG. 25 is an exploded, back view of the apparatus 400; and FIG. 26 is an exploded, side view of the apparatus 400. Furthermore, FIG. 16A is a shaded view of FIG. 16; FIG. 17A is a shaded view of FIG. 17; FIG. 18A is a shaded view of FIG. 18; FIG. 19A is a shaded view of FIG. 19; FIG. 20A is a shaded view of FIG. 20; FIG. 22A is a shaded view of FIG. 22; and FIG. 23A is a shaded view of FIG. 23.

(153) The apparatus 400 is similar to apparatus 200,300 and like modules and components will not be repeated, reference instead now being made to the disclosure above with regard to apparatus 200,300. Accordingly, primary differences between apparatus 300 and apparatus 200 will now be described.

(154) The stack 402 of the apparatus 400 comprises both tank module 206 and tank module 306, and apparatus 300 is arrived at by adding tank module 306 to the stack 202 of apparatus 200, or by adding tank module 206 to the stack 302 of apparatus 300. In stacking, a lower portion of an upper module or component preferably is received within the lower module or component on which the upper module or component is stacked.

(155) Moreover, when stacking a module on top of a tank module, the lower portion of the upper module that is received within the lower tank module preferably includes contoured portions 812 that mate with contoured portions 814 of the lower tank module to define openings 816 from an interior of the tank for passing of the connection ports and/or plumbing, including tubes, pipes, and hoses. Access to the openings 816 is facilitated by one or more corresponding openings 818 in back cover panels of the tank modules.

(156) As a result of the modular stackability of the apparatus assembly, the tank modules of apparatus 400 collectively contain more PCM and therefore have a higher energy storage capacity than apparatus 200,300 when used in heating implementations, such as a tankless water heater. As an example, whereas apparatus 200 having a single tank module 206 in its stack might have an energy consumption of 20 kW in its operation when using an electric heat source in its PCM charging circuit, and apparatus 300 having a single tank module 306 in its stack might have an energy consumption of 10 kW in its operation when using an electric heat source in its PCM charging circuit, apparatus 400 having both tank modules 206,306 in its stack then might have an energy consumption of 30 kW in its operation when using an electric heat source in its PCM charging circuits.

(157) Housing for modules and components of preferred Modular PCM-TB Apparatus are individually shown in FIGS. 27-76.

(158) In this regard, FIGS. 27-33 illustrate housing 502 of tank module 206. Specifically, FIG. 27 is an isometric view of the housing 502; FIG. 28 is a front elevational view of the housing 502; FIG. 29 is a back elevational view of the housing 502; FIG. 30 is a first, left side elevational view of the housing 502; FIG. 31 is a second, right side elevational view of the housing 502; FIG. 32 is a top plan view of the housing 502; and FIG. 33 is a bottom plan view of the housing 502. In addition, FIG. 27A is a shaded view of FIG. 27; FIG. 28A is a shaded view of FIG. 28; FIG. 29A is a shaded view of FIG. 29; FIG. 30A is a shaded view of FIG. 30; FIG. 31A is a shaded view of FIG. 31; FIG. 32A is a shaded view of FIG. 32; and FIG. 33A is a shaded view of FIG. 33.

(159) FIGS. 34-41 illustrate housing 504 of tank module 306. Specifically, FIG. 34 is an isometric view of the housing 504; FIG. 35 is a cross-sectional view of the housing 504 taken along the line 35-35 of FIG. 34; FIG. 36 is a front elevational view of the housing 504; FIG. 37 is a back elevational view of the housing 504; FIG. 38 is a first, left side elevational view of the housing 504; FIG. 39 is a second, right side elevational view of the housing 504; FIG. 40 is a top plan view of the housing 504; and FIG. 41 is a bottom plan view of the housing 504. Additionally, FIG. 34A is a shaded view of FIG. 34; FIG. 36A is a shaded view of FIG. 36; FIG. 35A is a shaded view of FIG. 35; FIG. 37A is a shaded view of FIG. 37; FIG. 38A is a shaded view of FIG. 38; FIG. 39A is a shaded view of FIG. 39; FIG. 40A is a shaded view of FIG. 40; and FIG. 41A is a shaded view of FIG. 41.

(160) FIGS. 42-48 illustrate housing 506 of electronics module 204. Specifically, FIG. 42 is an isometric view of the housing 506; FIG. 43 is a front elevational view of the housing 506; FIG. 44 is a back elevational view of the housing 506; FIG. 45 is a first, left side elevational view of the housing 506; FIG. 46 is a second, right side elevational view of the housing 506; FIG. 47 is a top plan view of the housing 506; and FIG. 48 is a bottom plan view of the housing 506. Additionally, FIG. 42A is a shaded view of FIG. 42; FIG. 43A is a shaded view of FIG. 43; FIG. 44A is a shaded view of FIG. 44; FIG. 45A is a shaded view of FIG. 45; FIG. 46A is a shaded view of FIG. 46; FIG. 47A is a shaded view of FIG. 47; and FIG. 48A is a shaded view of FIG. 48.

(161) FIGS. 49-55 illustrate an alternative housing 508 for an electronics module. Specifically, FIG. 49 is an isometric view of housing 508; FIG. 50 is a front elevational view of the housing 508; FIG. 51 is a back elevational view of the housing 508; FIG. 52 is a first, left side elevational view of the housing 508; FIG. 53 is a second, right side elevational view of the housing 508; FIG. 54 is a top plan view of the housing 508; and FIG. 55 is a bottom plan view of the housing 508. Additionally, FIG. 49A is a shaded view of FIG. 49; FIG. 50A is a shaded view of FIG. 50; FIG. 51A is a shaded view of FIG. 51; FIG. 52A is a shaded view of FIG. 52; FIG. 53A is a shaded view of FIG. 53; FIG. 54A is a shaded view of FIG. 54; and FIG. 55A is a shaded view of FIG. 55.

(162) FIGS. 56-60 illustrate a component of the tank module 206, namely, back cover panel 224. Specifically, FIG. 56 is an isometric view of the back cover panel 224; FIG. 57 is an elevational view of an exterior side of the back cover panel 224; FIG. 58 is a first, left side elevational view of the back cover panel 224; FIG. 59 is an elevational view of an interior side of the back cover panel 224; and FIG. 60 is a second, right side elevational view of the back cover panel 224. Additionally, FIG. 56A is a shaded view of FIG. 56; FIG. 57A is a shaded view of FIG. 57; FIG. 58A is a shaded view of FIG. 58; FIG. 59A is a shaded view of FIG. 59; and FIG. 60A is a shaded view of FIG. 60.

(163) FIGS. 61-67 illustrate a component of the tank module 306, namely, back cover panel 324. Specifically, FIG. 61 is an isometric view of the back cover panel 324; FIG. 62 is an elevational view of an exterior side of the back cover panel 324; FIG. 63 is a first, left side elevational view of the back cover panel 324; FIG. 64 is an elevational view of an interior side of the back cover panel 324; FIG. 65 is a second, right side elevational view of the back cover panel 324; FIG. 66 is a top plan view of the back cover panel 324; and FIG. 67 is a bottom plan view of the back cover panel 324. Additionally, FIG. 61A is a shaded view of FIG. 61; FIG. 62A is a shaded view of FIG. 62; FIG. 63A is a shaded view of FIG. 63; FIG. 64A is a shaded view of FIG. 64; FIG. 65A is a shaded view of FIG. 65; FIG. 66A is a shaded view of FIG. 66; FIG. 67A is a shaded view of FIG. 67.

(164) FIGS. 68-72 illustrate a component of all of the apparatus 200,300,400, namely, the lid 210. Specifically, FIG. 68 is an isometric view of the lid 210; FIG. 69 is a front elevational view of the lid 210; FIG. 70 is a side elevational view of the lid 210; FIG. 71 is a top plan view of the lid 210; and FIG. 72 is bottom plan view of the lid 210. Additionally, FIG. 68A is a shaded view of FIG. 68; FIG. 69A is a shaded view of FIG. 69; FIG. 70A is a shaded view of FIG. 70; FIG. 71A is a shaded view of FIG. 71; and FIG. 72A is a shaded view of FIG. 72.

(165) FIGS. 73-76 illustrate a component of all of the apparatus 200,300,400, namely, the base 208. Specifically, FIG. 73 is an isometric view of the base 208; FIG. 74 is an elevational view of the base 208; FIG. 75 is a top plan view of the base 208; and FIG. 76 is a bottom plan view of the base 208. Additionally, FIG. 73A is a shaded view of FIG. 73; FIG. 74A is a shaded view of FIG. 74; FIG. 75A is a shaded view of FIG. 75; and FIG. 76A is a shaded view of FIG. 76.

(166) Various preferred implementations of Modular PCM-TB Apparatus will now be described with reference to FIGS. 77-121.

(167) As a result of the modular, stackability of the apparatus, a number of different combinations of tank modules in an apparatus stack are possible for meeting various implementation needs, all such apparatus having the same small footprint. Indeed, because of the different combinations of tank modules that can be included in an apparatus stack, apparatus can be deployed in a number of different ways to achieve different operational objectives.

(168) For instance, each tank module in an apparatus stack can be used in a separate application for either heating or cooling, and an additional application can be provided by adding another tank module to the stack. Alternatively, plumbing can be installed in the recessed areas that form chases in the back of the tank modules for interconnecting the tank modules, whether in parallel or in series. In this manner, all tanks in an apparatus stack can be used in for a singular application. Or one or more interconnected tank modules can be used for one application, while other tank modules in the stack can be used for one or more other applications.

(169) Moreover, the apparatus also can be used for cooling applications, and if one or more tank modules are used in cooling applications while one or more other tank modules are used in heating applications, then additional synergies can be realized by having a discharging circuit of one or more tank modules used in cooling applications serve as the charging circuit for one or more other tank modules used in heating applications.

(170) An example of an apparatus stack containing two tank modules 775,777 with each being used in a separate application is illustrated in FIGS. 77-78. FIG. 77 is a back elevational view of the preferred Modular PCM-TB Apparatus 770 with this apparatus stack. The back cover panels of the tank modules are omitted for clarity of illustration; however, FIG. 81 does illustrate the back elevational view of the apparatus 770 with back cover panels 792,794 attached.

(171) As shown in FIG. 77, tank module 775 includes thermal battery TB1 with four external connection ports. A first pair of the connection ports represent the inflow and outflow of a PCM charging circuit, and the second pair of the connection ports represent the inflow and outflow of a PCM discharging circuit. Similarly, tank module 777 includes thermal battery TB2 with four external connection ports 712,714,716,718, wherein a first pair of the connection ports represent the inflow (port 712) and outflow (port 714) of a PCM charging circuit, and the second pair of the connection ports represent the inflow (port 716) and outflow (port 718) of a PCM discharging circuit. FIG. 78 is a top profile view of the upper tank module 775 and FIG. 79 is a top profile view of the lower tank module 777. These two figures serve to illustrate the external connection ports extending from the upper and lower tank modules. These figures further illustrate the ports comprise threaded connections for connecting hoses or other plumbing in creating heat exchange circuits.

(172) Exemplary heat exchange circuits of a preferred configuration that includes apparatus 770 are schematically illustrated in FIG. 80. In this preferred configuration 800, the charging circuit of the thermal battery TB1 of the tank module 775 is connected to an external heating system via connection ports 712,714. The external heating system preferably comprises an external heating source such as solar thermal, a boiler, a heat pump, or other heat recovery source. A standard heat pump (compressor type) may be used as the charging source and, if so, may be a variable power and capacity heat pump. The input voltage may be 120V or 240V and have a range in kWs.

(173) The discharging circuit of the thermal battery TB1 of the tank module 775 is connected to a heating application such as, for example, a residential forced hot air system, via connection ports 716,718; and, separately, the charging circuit of the thermal battery TB2 of the tank module 777 is connected to another external heating system via connection ports 722,724 and the discharging circuit of the thermal battery TB2 of the tank module 775 connected to a heating application such as, for example, a residential hot water system for washing clothes, showering, and bathing, via connection ports 726,728. When connected to a residential hot water system, usable water preferably is fed by the domestic water line to the input of the discharging circuit of the thermal battery TB2. As the domestic water passes through the discharge circuit it is heated and comes out as hot water at the output of the discharge circuit of the thermal battery TB2.

(174) In contrast, another preferred configuration 820 that includes apparatus 770 is schematically illustrated in FIG. 82. In this preferred configuration, both the charging circuit of the thermal battery TB1 of the tank module 775 and the charging circuit of the thermal battery TB2 of the tank module 777 are connected to the external heating system externally in parallel; and, separately, the discharging circuit of the thermal battery TB1 of the tank module 775 is connected to a heating application such as, for example, a residential forced hot air system, the discharging circuit of the thermal battery TB2 of the tank module 777 is connected to a heating application such as, for example, a residential hot water system for washing clothes, showering, and bathing. As used herein, externally in parallel refers to a parallel arrangement of a PCM circuit (whether a charging circuit or discharging circuit) being located external to a Modular PCM-TB Apparatus, as schematically illustrated shown in FIG. 82.

(175) In further contrast, FIG. 83 is yet another schematic diagram of heat exchange circuits of a preferred configuration 830 utilizing the apparatus 770. In this preferred configuration, both the charging circuit of the thermal battery TB1 of the tank module 775 and the charging circuit of the thermal battery TB2 of the tank module 777 are connected to the external heating system externally in series; and, separately, the discharging circuit of the thermal battery TB1 of the tank module 775 is connected to a heating application such as, for example, a residential forced hot air system, the discharging circuit of the thermal battery TB2 of the tank module 777 is connected to a heating application such as, for example, a residential hot water system for washing clothes, showering, and bathing. As used herein, externally in series refers to the serial arrangement of a PCM circuit (whether a charging circuit or discharging circuit) being located external to a Modular PCM-TB Apparatus, as schematically illustrated shown in FIG. 83.

(176) Additional configurations become possible with plumbing installed in the recessed areas in the back of the tank modules for interconnecting the tank modules.

(177) Aback elevational view of a preferred apparatus 840 which includes plumbing is shown in FIG. 84, wherein the back cover panels are omitted for clarity; a representative view with back cover panels 892,894 attached is shown in FIG. 92. As shown in FIG. 84, tank module 845 includes thermal battery TB1 with four external connection ports. A first pair of the connection ports represent the inflow and outflow of a PCM charging circuit, and the second pair of the connection ports represent the inflow and outflow of a PCM discharging circuit. In contrast, tank module 847 includes thermal battery TB2 with just a pair of external connection ports representing the inflow and outflow of a PCM discharging circuit. FIG. 85 is a top profile view of the upper tank module 845 with the four connection ports extending therefrom, and FIG. 79 is a top profile view of the lower tank module 847 with the two connection ports extending therefrom.

(178) As shown in FIG. 84, plumbing is installed in the recessed areas in the back of the tank modules 845,847 for interconnecting the tank modules. Specifically, the input connection port for the charging circuit of the thermal battery TB1 of tank module 845 is connected by conduit 842 in the form of a pipe or hose to input of the charging circuit of the thermal battery TB2 of tank module 847. Similarly, the output of the charging circuit of the thermal battery TB2 of tank module 847 is connected by conduit 844 in the form of a pipe or hose to the output connection port for the charging circuit of the thermal battery TB1 of tank module 845.

(179) As a result or the plumbing, the PCM charging circuits of the thermal batteries TB1 and TB2 are arranged internally in parallel for charging by the same external heat source. This is schematically illustrated in FIG. 87, wherein heat exchange circuits of a preferred configuration 870 utilizing the apparatus 840 is shown. As used herein, internally in parallel refers to the parallel arrangement of a PCM circuit (whether a charging circuit or discharging circuit) being located internal to a Modular PCM-TB Apparatus, as schematically illustrated shown in FIG. 87.

(180) Aback elevational view of another preferred apparatus 880 which includes plumbing is shown in FIG. 88, wherein the back cover panels are omitted for clarity; a representative view with back cover panels 992,994 attached is shown in FIG. 93. As shown in FIG. 88, tank module 885 includes thermal battery TB1 with three external connection ports. A pair of the connection ports represents the inflow and outflow of a PCM discharging circuit, and the third connection port represent the inflow of a PCM charging circuit of the tank module 885. The tank module 887 includes thermal battery TB2 also with three external connection ports representing the inflow and outflow of a PCM discharging circuit. The third external discharge port of tank module 887 represents the outflow of a PCM charging circuit of the tank module 887. FIG. 89 is a top profile view of the upper tank module 885 with the three external connection ports extending therefrom, and FIG. 90 is a top profile view of the lower tank module 887 with the three connection ports extending therefrom.

(181) As shown in FIG. 88, plumbing is installed in the recessed areas in the back of the tank modules 885,887 for interconnecting the tank modules. Specifically, the output of the charging circuit of the thermal battery TB1 of tank module 885 is connected by conduit 882 in the form of a pipe or hose to input of the charging circuit of the thermal battery TB2 of tank module 887.

(182) As a result or the plumbing, the charging circuits of the thermal batteries TB1 and TB2 are arranged internally in series for charging by the same external heat source. This is schematically illustrated in FIG. 91, wherein heat exchange circuits of a preferred configuration 910 utilizing the apparatus 880 is shown. As used herein, internally in series refers to the serial arrangement of a PCM circuit (whether a charging circuit or discharging circuit) being located internal to a Modular PCM-TB Apparatus, as schematically illustrated shown in FIG. 91.

(183) While the foregoing has served to illustrate the PCM charging circuits being arranged externally in parallel, externally in series, internally in parallel, and internally in series, it will be appreciated that the PCM discharging circuits can be similarly arranged. FIGS. 98-101 are schematic diagrams representative of this. FIG. 98 shows, inter alia, the PCM discharging circuits of thermal batteries TB1 and TB2 arranged externally in parallel; FIG. 99 shows, inter alia, the PCM discharging circuits of thermal batteries TB1 and TB2 arranged externally in series; FIG. 100 shows, inter alia, the PCM discharging circuits of thermal batteries TB1 and TB2 arranged internally in parallel; and FIG. 100 shows, inter alia, the PCM discharging circuits of thermal batteries TB1 and TB2 arranged internally in series.

(184) It further should be noted that these figures illustrate a preferred apparatus in which the PCM charging circuit of an apparatus is apparatus-enclosed, which terminology refers to the fact that the circuit is entirely enclosed within the apparatus and there are no external connection ports that lead to the circuit. Preferred Modular PCM-TB Apparatus that have apparatus-enclosed charging circuits are described in greater detail next.

(185) FIG. 94 is a back elevational view of another preferred Modular PCM-TB Apparatus 940, wherein the back cover panels are omitted. FIG. 95 is a top profile view of the upper tank module 945 of the apparatus 940, and FIG. 96 is a top profile view of the lower tank module 947 of the apparatus 940.

(186) Unlike prior apparatus described above, the upper tank module 945 has an apparatus-enclosed PCM charging circuit. In this respect, the electronics module 943 comprise onboard an internal heating system that includes one or more heating sources and one or more pumps. A conduit 944 connects the outflow of the PCM charging circuit to the onboard heating system, and another conduit 942 connects the inflow of the PCM charging circuit to the onboard heating system.

(187) One or more pumps of the onboard heating system recirculates the fluid in the PCM charging circuit and a heating source heats the fluid. The system may comprise, by way of example, one heating element and one pump, or two heating elements and one pump, with an in-line heater at the inlet and another at the outlet of the pump. The heating source preferably is in the form of one or more electric heating elements each located directly within the fluid flow within the electronics module for even heating of the fluid. The circulating heating fluid can be organic fluid like mineral oil or an aqueous fluid like water, glycerin, or the like. The onboard heating system in this case does not include a compressor. Alternatively, the heating system may comprise an onboard heat pump contained within the electronics module and that is ducted or that is vented directly into the ambient space of the apparatus. Furthermore, a backup electric heater as well as a backup circulation pump may be included within the electronics module that work when the heat pump is inoperable or otherwise off. Turning the heat pump off in favor of the electric heater and circulation pump indeed may provide greater efficiency when operation of the heat pump becomes inefficient, such as in colder temperatures that are below, for instance, 25 degrees Fahrenheit.

(188) The pump and heating source preferably are powered by an external electric power source. For instance, a power supply preferably is provided in the electronics module having a power cord for plugging into a conventional electrical outlet. The heating element power preferably ranges from 100 watts to 5000 watts and is operated from a voltage source of 120 volts or 240 volts.

(189) In operation, the PCM preferably is charged a rate that is much less than the rate at which the PCM is discharged when the apparatus is in normal use. It is believed that this enables great efficiencies to be realized with Modular PCM-TB Apparatus.

(190) FIG. 97 is a schematic diagram of heat exchange circuits of a preferred configuration 970 utilizing the apparatus 940. As shown therein, the thermal battery TB1 is independently utilized from the thermal battery TB2, with the thermal battery TB1 being used with a forced hot air system and with the thermal battery TB2 being used with domestic hot water implementations, such as bathing, showering, or washing clothes. The PCM of each tank module 945,947 associated with these thermal batteries also is separately charged using an internal heating source as described above with one and using an external heating system with the other.

(191) Alternative preferred configurations utilizing apparatus 940 are disclosed in FIGS. 98 and 99. In particular, FIG. 98 shows a preferred configuration 980 in which the PCM discharging circuits of thermal batteries TB1 and TB2 are arranged externally in parallel; and FIG. 99 shows a preferred configuration 990 in which the PCM discharging circuits of thermal batteries TB1 and TB2 are arranged externally in series. In each instance, each of the PCM charging circuits are independently charged by separate heating sources, one of which is an internal heating system and the other of which is an external heating system.

(192) Additional preferred configurations utilizing apparatus similar to apparatus 940 are disclosed in FIGS. 100 and 101. FIG. 101 shows a preferred configuration 1000 in which the PCM discharging circuits of thermal batteries TB1 and TB2 are arranged internally in parallel, and FIG. 101 shows a preferred configuration 1010 in which the PCM discharging circuits of thermal batteries TB1 and TB2 are arranged internally in series.

(193) A preferred Modular PCM-TB Apparatus 1020 for use in the preferred configuration 1000 is illustrated in FIG. 102, wherein the tank cover panels are omitted. Apparatus 1020 comprises plumbing effecting the arrangement of PCM discharging circuits internally in parallel. FIG. 103 is a top profile view of the upper tank module of the apparatus 1020, which illustrates that there are no external connection ports of the upper tank module. FIG. 104 is a top profile view of the lower tank module of the apparatus 1020, which illustrates that there are four external connection ports of the lower tank module.

(194) A preferred Modular PCM-TB Apparatus 1050 for use in the preferred configuration 1010 is illustrated in FIG. 105, wherein the tank cover panels are omitted. Apparatus 1050 comprises plumbing effecting the arrangement of PCM discharging circuits internally in series. FIG. 106 is a top profile view of the upper tank module of the apparatus 1050, which illustrates that there is one external connection port of the upper tank module. FIG. 107 is a top profile view of the lower tank module of the apparatus 1050, which illustrates that there are three external connection ports of the lower tank module.

(195) A preferred embodiment having both interconnected tank modules and an internal heating system now is described.

(196) FIG. 108 is a back elevational view of a preferred Modular PCM-TB Apparatus 1080, wherein the back cover panels are omitted, and FIG. 109 is a back elevational view of the apparatus 1080, wherein attached back cover panels 1085,1087 are shown. FIG. 110 is a top profile view of the upper tank module 1085 showing two connection ports of the PCM discharging circuit extending therefrom, and FIG. 111 is a top profile view of the lower tank module 1087 showing two connection ports the PCM discharging circuit extending therefrom.

(197) Like prior apparatus 940, the upper tank module 1085 of apparatus 1080 has an apparatus-enclosed PCM charging circuit. Unlike prior apparatus 940, the lower tank module 1087 of apparatus 1080 also has an apparatus-enclosed PCM charging circuit. Moreover, the two apparatus-enclosed PCM charging circuits are arranged internally in parallel with the internal heating system located within the electronics module 1089 of apparatus 1080. In this respect, the electronics module 1089 comprises an onboard, internal heating system that includes one or more heating sources and one or more pumps.

(198) A conduit 1084 connects the outflow of the PCM charging circuit of the upper tank module 1085 to the onboard heating system, and another conduit 1082 connects the inflow of the PCM charging circuit of the upper tank module 1085 to the onboard heating system. Similarly, a conduit 1088 connects the outflow of the PCM charging circuit of the lower tank module 1087 to the onboard heating system, and another conduit 1086 connects the inflow of the PCM charging circuit of the lower tank module 1085 to the onboard heating system.

(199) Within the electronics module 1089, the arrangement of the PCM charging circuits of the tank modules 1085,1087 to the onboard, internal heating system is in parallel, as schematically shown in the heat exchange circuits of a preferred configuration 1120 of FIG. 112, or alternatively, the arrangement of the PCM charging circuits of the tank modules 1085,1087 to the onboard, internal heating system is in series, as schematically shown in the heat exchange circuits of a preferred configuration 1130 of FIG. 113. Of course, heating systems may be provided separately instead, one each being connected to a respective one of the PCM charging circuits.

(200) One or more pumps of the onboard heating system circulates the fluid in each PCM charging circuit and a heating source heats the fluid. The heating source preferably is in the form of one or more electric heating elements each located directly within the fluid flow within the electronics module 1089. The pump and heating source preferably are powered by an external electric power source. For instance, a power supply preferably is provided in the electronics module 1089 having a power cord for plugging into a conventional electrical outlet. The PCM preferably is charged a rate that is much less than the rate at which the PCM is discharged when the apparatus is in normal use. It is believed that this enables high efficiencies to be realized with Modular PCM-TB Apparatus.

(201) As noted above, apparatus in accordance with one or more aspects and features of the invention can be used not only for heating applications, but also for cooling applications. Moreover, if one or more tank modules are used in cooling applications while one or more other tank modules are used in heating applications, then additional synergies can be realized by having a discharging circuit of one or more tank modules used in cooling applications serve as the charging circuit for one or more other tank modules used in heating applications.

(202) In this regard, FIG. 114a is a schematic diagram of heat exchange circuits of a preferred configuration 1140 in which a PCM charging circuit of a first of the thermal batteries TB1 and TB2 is connected by an onboard heat pump with a PCM charging circuit of the second of the thermal batteries TB1 and TB2. Preferably, the conduits extend through the electronics module to the onboard heat pump. Optionally, an electric heater with circulating pump preferably is provided within the electronics module in connection with the PCM charging circuit for the thermal battery that is used in the heating applications, as shown in the schematic diagram of heat exchange circuits of the preferred configuration 1142 in FIG. 114b. The electronics of the electronics module preferably monitor temperatures and status of the PCM in each thermal battery for purposes of controlling the fluid circulation and heat exchanged between the PCM charging circuits via the onboard heat pump. The plumbing seen in FIG. 108 of apparatus 1080 is representative of the appearance of an apparatus in this configuration 1140, with the pump system being located in the electronics module 1089 with the other onboard electronics.

(203) FIG. 115 is a back elevational view of yet another preferred Modular PCM-TB Apparatus 1150, wherein the back cover panels are omitted. Apparatus 1150 includes plumbing installed on the back of the tank modules that interconnects the PCM circuits of the two stacked thermal batteries TB1 and TB2.

(204) The PCM circuits of apparatus 1150 are illustrated in FIGS. 116-119. FIG. 116 illustrates PCM charging circuit 1160 of thermal battery TB1; FIG. 117 illustrates PCM discharging circuit 1170 of thermal battery TB1; FIG. 118 illustrates PCM charging circuit 1180 of thermal battery TB2; and FIG. 119 illustrates PCM discharging circuit 1190 of thermal battery TB2. Each of these circuits comprises six heat exchangers immersed in a bio-based phase change material PCM1 and PCM2.

(205) Apparatus 1150 differs from prior apparatus described in connection with the drawings in that valves V1,V2,V3,V4,V5,V6,V7 are provided, and one or more external connection ports P1,P2,P3,P4,P5,P6,P7,P8 may be capped, for reconfiguring fluid flow through the plumbing. The valves and capping of the external connection ports enable great flexibility in utilizing the apparatus 1150 in a number of different heat exchange circuits. Valve open and closed states, and port connected and capped states, are set forth in tables 1 and 2 of FIGS. 120 and 121 for effecting the various configurations identified therein.

(206) It will be appreciated that while plumbing could be configured to support PCM charging in series within the scope of the invention, it is believed that PCM charging in parallel is preferred when only heating applications are intended or only cooling applications are intended. Consequently, the plumbing illustrated in FIG. 115 and tables of FIGS. 120 and 121 do not enable charging of the PCM of the thermal batteries TB1 and TB2 in series.

(207) It is additionally noted that in some preferred apparatus, plumbing is utilized with one or more thermal batteries in a stack wherein the PCM of a thermal battery is able to be charged not only with an internal heating system, but also with an external heating system upon proper adjustment of the plumbing. In this respect, the apparatus is configured to switch the PCM charging circuit between a closed loop, in which the fluid that flows through the PCM charging circuit does not flow external to the apparatus, and an open loop, in which the fluid that flows through the PCM charging circuit flows to an external heating system located on an exterior of the apparatus.

(208) The appendix to the specification, which is incorporated herein by reference, discloses additional Modular PCM-TB Apparatus including prototype assemblies, modules, and components thereof, all embodying aspects and features of the invention.

(209) From the foregoing, it will be appreciated that preferred apparatus in accordance with one or more aspects and features of the invention embody a scalable modular design in which a thermal battery assembly can be repurposed by adding additional tank modules for accommodating changed situations, such as transitioning from hot water requirements from a one bedroom apartment to those for a three bedroom apartment. Tank modules also can be taken away for a downsizing situation. Modules can also be replaced as needed without replacing other modules or components. Moreover, varying the capacity of a thermal battery assembly does not alter its footprint but, instead, only its height, allowing for options for space-heating add-ons in addition to hot water, thermal energy storage. Installations are also made easier, as the modules and components can be carried individually to the site of installation. This is especially true in multi-level or high rise buildings without elevators.

(210) Based on the foregoing description, it will be readily understood by those persons skilled in the art that the invention has broad utility and application. Many embodiments and adaptations of the invention other than those specifically described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from or reasonably suggested by the invention and the foregoing descriptions thereof, without departing from the substance or scope of the invention.

(211) For instance, as disclosed herein, an onboard pump system may comprise one or more pumps that may be located at multiple locations along a fluid pathway. Similarly, a heating system may comprise one or more heaters that may be located at one or more various locations along a fluid pathway.

(212) Accordingly, while the invention has been described herein in detail in relation to one or more preferred embodiments, it is to be understood that this disclosure is only illustrative and exemplary of the invention and is made merely for the purpose of providing a full and enabling disclosure of the invention. The foregoing disclosure is not intended to be construed to limit the invention or otherwise exclude any such other embodiments, adaptations, variations, modifications or equivalent arrangements, the invention being limited only by the claims appended hereto and the equivalents thereof.