Granted Patent B2

US 12,556,017 · App. 17/615,400 · Granted Feb 17, 2026

Inventors: Rainer Fasching (Mill Valley, CA); Roozbeh Naderi (Foothill Ranch, CA); Mikhail Slepchenkov (Lake Forest, CA); Ghyrn Loveness (Mountain View, CA)

Assignee: TAE Technologies, Inc.

H02J7/00711H02J7/0019H02J7/0049H02J7/06H02M1/007H02M3/158H02M7/49

Abstract

Claims (48)

1 . A modular energy storage system, comprising:

a plurality of converter modules coupled together in at least one array, each converter module comprising a battery cell and switch circuitry, wherein in a discharge state the at least one array is configured to generate at least one AC voltage waveform comprising a superposition of output voltages from the plurality of converter modules; and

control circuitry associated with the plurality of converter modules, wherein in a charge state the control circuitry is configured to control application of pulses in a manner sufficient to initiate an electrochemical reaction in a battery cell of the plurality of converter modules without substantially driving a side reaction in the battery cell, wherein, to control the application of the pulses, the control circuitry is configured to:

cause measurement of a parameter of the battery cell;

cause generation of a first pulse from a power connection with switch circuitry associated with the battery cell;

cause application of a first controlled pulse to the battery cell, wherein the first controlled pulse is generated from the first pulse;

cause measurement of a response of the battery cell; and

determine if a pulse cutoff condition is satisfied based on the response and cause termination of application of the first controlled pulse after satisfaction of the pulse cutoff condition, wherein the pulse cutoff condition is based on a first derivation and a second derivation of the response.

2 . The modular energy storage system of claim 1 , wherein at least one pulse is applied at a first voltage greater than an expected voltage of the battery cell at full charge.

3 . The modular energy storage system of claim 1 , wherein at least one pulse is applied at a first voltage greater than an expected voltage of the battery cell at 100% state of charge.

4 . The modular energy storage system of claim 3 , wherein the first voltage is a voltage that is between 101 and 200% of the expected voltage of the battery cell at 100% state of charge.

5 . The modular energy storage system of claim 3 , wherein the control circuitry is configured to control application of pulses such that the at least one pulse is applied when a state of charge of the battery cell is less than 100%.

6 . The modular energy storage system of claim 3 , wherein the control circuitry is configured to control application of pulses such that the at least one pulse is applied when a state of charge of the battery cell is less than 80%.

7 . The modular energy storage system of claim 5 , wherein the at least one pulse is at least one first pulse, and wherein the control circuitry is configured to control the application of pulses such that at least one second pulse is applied at a second voltage less than the first voltage when a state of charge of the battery cell is greater than the state of the charge of the battery cell at application of the at least one first pulse, wherein the second voltage is greater than an expected voltage of the battery cell at 100% state of charge.

8 . The modular energy storage system of claim 7 , wherein the control circuitry is configured to control application of pulses such that the at least one first pulse and the at least one second pulse is applied when a state of charge of the battery cell is less than 80%.

9 . The modular energy storage system of claim 1 , wherein the control circuitry is configured to control the application of pulses in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving the side reaction in the battery cell while a state of charge of the battery cell does not exceed 80%.

10 . The modular energy storage system of claim 3 , wherein the control circuitry is configured to control the application of pulses in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving the side reaction in the battery cell, wherein each pulse has a duration of between 0.1 milliseconds and 5 seconds.

11 . The modular energy storage system of claim 3 , wherein the control circuitry is configured to control the application of pulses in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving the side reaction in the battery cell, wherein each pulse has a duration of between 1 millisecond and 100 milliseconds.

12 . The modular energy storage system of claim 3 , wherein the control circuitry is configured to control the application of pulses in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving the side reaction in the battery cell, wherein each pulse has a duration of between 5 milliseconds and 25 milliseconds.

13 . The modular energy storage system of claim 2 , wherein each module comprises a plurality of battery cells, and the control circuitry is configured to control the application of pulses in a manner sufficient to initiate an electrochemical reaction in the plurality of battery cells without substantially driving a side reaction in the plurality of battery cells.

14 . A method of charging a modular energy storage system comprising: a plurality of converter modules coupled together in at least one array, each converter module comprising a battery cell and switch circuitry, the method comprising:

applying pulses in a manner sufficient to initiate an electrochemical reaction in a battery cell of the plurality of converter modules by:

measuring a parameter of the battery cell;

generating a first pulse from a power connection with switch circuitry associated with the battery cell;

applying a first controlled pulse to the battery cell, wherein the first controlled pulse is generated from the first pulse;

measuring a response of the battery cell; and

determining if a pulse cutoff condition is satisfied based on the response and cause termination of application of the first controlled pulse after satisfaction of the pulse cutoff condition, wherein the pulse cutoff condition is based on a first derivation and a second derivation of the response.

15 . The method of claim 14 , further comprising applying at least one pulse at a first voltage greater than an expected voltage of the battery cell at full charge.

16 . The method of claim 14 , further comprising applying at least one pulse at a first voltage greater than an expected voltage of the battery cell at 100% state of charge.

17 . The method of claim 16 , wherein the first voltage is a voltage that is between 101 and 200% of the expected voltage of the battery cell at 100% state of charge.

18 . The method of claim 16 , further comprising applying the at least one pulse when a state of charge of the battery cell is less than 100%.

19 . The method of claim 16 , further comprising applying the at least one pulse when a state of charge of the battery cell is less than 80%.

20 . The method of claim 19 , wherein the at least one pulse is at least one first pulse, the method further comprising applying at least one second pulse at a second voltage less than the first voltage when a state of charge of the battery cell is greater than the state of the charge of the battery cell at application of the at least one first pulse, wherein the second voltage is greater than an expected voltage of the battery cell at 100% state of charge.

21 . The method of claim 20 , wherein the at least one first pulse and the at least one second pulse are applied when a state of charge of the battery cell is less than 80%.

22 . The method of claim 16 , wherein the pulses are applied in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving a side reaction in the battery cell.

23 . The method of claim 16 , wherein the pulses are applied in a manner sufficient to initiate the electrochemical reaction in the battery cell without substantially driving a side reaction in the battery cell while a state of charge of the battery cell does not exceed 80%.

24 . A modular energy storage system, comprising:

a plurality of converter modules coupled together in at least one array, each converter module comprising an energy source and switch circuitry coupled with a power connection, wherein in a discharge state the at least one array is configured to generate at least one AC voltage waveform comprising a superposition of output voltages from the plurality of converter modules; and

control circuitry associated with the plurality of converter modules, wherein the control circuitry is configured to:

cause measurement of a parameter of an energy source of the plurality of converter modules;

cause generation of a first pulse from the power connection with switch circuitry associated with the energy source;

cause application of a first controlled pulse to the energy source, wherein the first controlled pulse is generated from the first pulse; and

cause measurement of a response of the energy source;

determine if a pulse cutoff condition is satisfied based on the response and cause termination of application of the first controlled pulse after satisfaction of the pulse cutoff condition, wherein the pulse cutoff condition is based on a first derivation and a second derivation of the response.

25 . The modular energy storage system of claim 24 , wherein the control circuitry is configured to determine if the energy source is at a sub maximum charge threshold.

26 . The modular energy storage system of claim 25 , wherein the control circuitry is configured to transition to a different charge method if the sub maximum charge threshold is reached.

27 . The modular energy storage system of claim 24 , wherein the control circuitry is configured to determine whether to adjust a voltage or current of a second controlled pulse.

28 . The modular energy storage system of claim 27 , wherein the control circuitry is configured to cause adjustment of a voltage or current of the second controlled pulse such that the voltage or current is less than that of the first controlled pulse.

Assignments (7)

Continuity (2)

References Cited (352)