Calorimeters for testing energy storage systems and power electronics methods of making the same and methods of use

1. A large volume calorimeter, comprising:

a test chamber comprising an inner box nested inside of an outer box and a plurality of heat flux sensors in contact with the exterior sidewalls of the inner box;

at least one thermally insulative device between the floor of the inner box and the floor of the outer box;

a thermally conductive device between each exterior sidewall of the inner box and each corresponding interior sidewall of the outer box, the at least one thermally conductive device comprising a first wedge and second wedge;

at least one busbar in contact with an interior wall of the inner box; and

a test chamber lid;

wherein the test chamber is configured to be fully submerged in an isothermal bath during operation of the calorimeter.

2. The calorimeter of claim 1 , wherein the volume of the inner box is from about 4 liters to about 100 liters.

3. The calorimeter of claim 2 , wherein the volume of the inner box is 96 liters.

4. The calorimeter of claim 1 , wherein the isothermal bath comprises:

an isothermal bath container comprising a bath cavity that is larger than the test chamber, an isothermal fluid disposed in the cavity, and a lid.

5. The calorimeter of claim 4 , wherein the volume of the bath cavity is from about 100 gallons to about 200 gallons.

6. The calorimeter of claim 5 , wherein the volume of the bath cavity is about 160 gallons.

7. The calorimeter of claim 4 , wherein the isothermal bath comprises at least one heating element and at least one cooling element configured to control the temperature of the isothermal fluid in the isothermal bath.

8. The calorimeter of claim 7 , comprising at least one mixing element, comprising a motor, a long thin shaft, and at least one impeller.

9. The calorimeter of claim 1 , wherein the at least one thermally insulative device provides thermal isolation of the floor of the inner box from the floor of the outer box.

10. The calorimeter of claim 9 , wherein the at least one thermally insulative device comprises a column, comprising a sheath encircling an alternating arrangement of ceramic balls and cylinders.

11. The calorimeter of claim 1 , wherein the at least one busbar comprises a cable connected to the busbar, wherein the cable comprises a first end disposed in the interior of the inner box and a second end disposed outside of the calorimeter.

12. The calorimeter of claim 11 , wherein the cable is routed through the isothermal bath prior to connecting to the busbar.

13. The calorimeter of claim 1 , wherein the lid comprises a snorkel, a burst disk and at least one sealing mechanism.

14. The calorimeter of claim 1 , wherein the first and second wedges are triangular in cross section.

15. The calorimeter of claim 1 , wherein the first wedge has a width tapered in a first direction, the second wedge has a width tapered in a second, opposite direction, the first wedge and second wedge oriented such that the thermally conductive device has a rectangular cross section.

16. The calorimeter of claim 1 , wherein a thermally conductive element is provided at the interface between at least one of the first wedge and second wedge and the first wedge and the exterior sidewall of the inner box.

17. The calorimeter of claim 1 , wherein the thermally coupling device is configured to apply uniform pressure on the plurality of heat flux sensors.

18. The calorimeter of claim 17 , wherein the thermally coupling device is configured to apply uniform pressure on the exterior sidewall of the inner box.

19. A calorimeter, comprising:

a test chamber, comprising

an outer box comprising a plurality of heat flux sensors in contact with an interior floor of the outer box;

a first thermally conductive plate, a second thermally conductive plate and a third thermally conductive plate individually in contact with the top of some of the heat flux sensors wherein at least one thermally conductive plate is in contact with the interior floor of the outer box;

at least one busbar in contact with the interior floor of the outer box through a thermally conductive but electrically insulative pad; and

a test chamber lid;

wherein the test chamber is configured to be fully submerged in an isothermal bath during operation of the calorimeter.

20. The calorimeter of claim 19 , wherein the first thermally conductive plate is anodized and comprises a plurality of holes.

21. The calorimeter of claim 19 , wherein the isothermal bath comprises:

a container, comprising an inner bath cavity that is larger than the test chamber, an isothermal fluid disposed in the cavity, an outer box, and a lid;

wherein the container is nested inside of the outer box.

22. The calorimeter of claim 21 , comprising insulation between the container and the outer box.

23. The calorimeter of claim 19 , wherein the second thermally conductive plate and the third thermally conductive plate are individually thermally isolated from the first thermally conductive plate through at least one thermally insulative device.

24. The calorimeter of claim 23 , wherein the at least one thermally insulative device comprises a ceramic ball.

25. The calorimeter of claim 19 , wherein the at least one busbar comprises a cable connected to the busbar, wherein the cable comprises a first end disposed in the interior of the test chamber and a second end disposed outside of the calorimeter.

26. The calorimeter of claim 25 , wherein the cable is routed through the isothermal bath prior to connecting to the busbar.

27. The calorimeter of claim 19 , wherein the test chamber lid comprises a snorkel, a burst disk and at least one sealing mechanism.

28. The calorimeter of claim 27 , further comprising a cable routed through the snorkel and connected to the busbar.