THERMAL ENERGY STORAGE FOR A FIREPLACE
A fireplace system includes a fireplace, a thermal energy storage system (TESS) implemented with the fireplace and including one or more heat storing materials in which thermal energy is stored, and a control system comprising one or more controllers operatively coupled with the fireplace and the TESS. The control system is operable to control operation of the fireplace and the TESS to release the stored thermal energy from the one or more heat storing materials into a surrounding environment based on one or more inputs.
This application claims the benefit of U.S. App. No. 63/673,298, filed Jul. 19, 2024, the disclosure of which is incorporated herein by reference in its entirety for all purposes.
FIELDThe present disclosure relates generally to fireplaces, and more specifically to fireplaces with additional heating components.
BACKGROUNDElectric fireplaces cannot operate without electricity. During power outages, electric fireplaces are unable to generate heat. Existing technology options for addressing power outages incorporate battery electric storage systems (BESS), e.g., rechargeable lithium-ion battery packs such as Tesla Powerwall® (Tesla, Inc.) that store energy generated by locally or from the grid. However, the power density required to operate an electric fireplace at either normal operating conditions or even reduced thermal output precludes the use of anything less than a large, dedicated BESS system, because the power from smaller BESS units do not meet the electrical requirements for providing heat from an electric fireplace for an extended period. Additionally, current costs for battery electric storage systems are substantial and limit most consumers from adopting the technology. Current BESS options available for residential installation typically provide about 10 kWh of electricity that can be metered out to support critical home systems operating during an outage (e.g., refrigerator, cooking, well pumps). This level of BESS is expensive to purchase and to install, and an electric fireplace running at full power for 4 hours would require 60% of the stored capacity. As such, there is a need for fireplaces to have additional heating components that can be relied upon for operation.
SUMMARYAccording to one example (“Example 1”), a fireplace system includes a fireplace, a thermal energy storage system (TESS) implemented with the fireplace and including one or more heat storing materials in which thermal energy is stored, and a control system comprising one or more controllers operatively coupled with the fireplace and the TESS. The control system is operable to control operation of the fireplace and the TESS to release the stored thermal energy from the one or more heat storing materials into a surrounding environment based on one or more inputs.
According to another example (“Example 2”) further to Example 1, one or more of the fireplace or the TESS are fluidly coupled with one or more vents for intake or outflow of air, and the TESS is configured to release the stored thermal energy through the one or more vents.
According to another example (“Example 3”) further to Example 1 or 2, the one or more inputs include user inputs, instructions from a programmable or smart thermostat operatively coupled with the fireplace, sensor data associated with the fireplace or the TESS, or data from an external input device.
According to another example (“Example 4”) further to Example 3, the external input device includes one or more of: an electric utility grid from which the fireplace and the TESS receive electrical power, or a weather monitoring system.
According to another example (“Example 5”) further to Example 3 or 4, the control system selects an operating mode from a plurality of operating modes based on the one or more inputs. The plurality of operating modes includes different heat outputs and durations.
According to another example (“Example 6”) further to any preceding Example, the one or more heat storing materials include one or more air cavities through which the air passes during the operation of the fireplace and the TESS.
According to another example (“Example 7”) further to Example 6, the system includes one or more fans or one or more blowers configured to generate convection to facilitate intake or outflow of air or the passing of air through the one or more air cavities.
According to another example (“Example 8”) further to Example 6 or 7, the one or more heat storing materials include a plurality of heat storing materials arranged in an assembly having a repeating pattern, and the assembly defines the one or more air cavities.
According to another example (“Example 9”) further to Example 6 or 7, the one or more heat storing materials include a monolithic structure of heat storing material, and the one or more air cavities extend through the monolithic structure.
According to another example (“Example 10”) further to Example 9, the one or more air cavities extend parallel to each other through the monolithic structure.
According to another example (“Example 11”) further to Example 6 or 7, the one or more heat storing materials include a monolithic structure of heat storing material having a plurality of continuous pores that are interconnected to form a network of airflow pathways, and the one or more air cavities extend through the continuous pores of the monolithic structure.
According to another example (“Example 12”) further to any one of Examples 9-11, the one or more heat storing materials include a plurality of the monolithic structures in a stacked configuration to add or reduce a heating capacity of the TESS.
According to another example (“Example 13”) further to any one of Examples 9-11, the one or more heat storing materials include a plurality of the monolithic structures arranged in a repeating pattern or matrix.
According to another example (“Example 14”) further to Example 6 or 7, the one or more heat storing materials includes a first sensible or latent heat material portion having a first cavity and a second sensible or latent heat material portion having a second cavity, the second sensible or latent heat material portion is disposed within the first cavity, and the second cavity is one of the one or more air cavities.
According to another example (“Example 15”) further to Example 14, the first sensible or latent heat material portion and the second sensible or latent heat material portion are made of different materials.
According to another example (“Example 16”) further to any one of Examples 6-15, the TESS comprises one or more separators at least partially defining the one or more air cavities.
According to another example (“Example 17”) further to any one of Examples 6-15, the TESS comprises a pipe at least partially defining the one or more air cavities.
According to another example (“Example 18”) further to any preceding Example, the TESS comprises a housing storing therein the one or more heat storing materials.
According to another example (“Example 19”) further to Example 18, the housing comprises at least a first housing component and a second housing component configured to be disposed within the first housing component.
According to another example (“Example 20”) further to Example 19, the first housing component and the second housing component at least partially defines the one or more air cavities.
According to another example (“Example 21”) further to any one of
Examples 18-20, the TESS comprises one or more heating elements disposed within the housing and configured to increase temperature of the one or more heat storing materials.
According to another example (“Example 22”) further to any preceding Example further to Example 2, the one or more vents of the fireplace are disposed on a front portion of the fireplace.
According to another example (“Example 23”) further to Example 22, the TESS is coupled with the fireplace at a rear portion of the fireplace.
According to another example (“Example 24”) further to Example 22 or 23, the fireplace comprises a display, and the one or more vents of the fireplace are disposed adjacent to the display.
According to another example (“Example 25”) further to Example 22 or 23, a side portion of the TESS includes an intake vent facilitating intake of air.
According to another example (“Example 26”) further to any preceding Example, the control system is operable to: select between a first mode in which a first heater associated with the TESS is activated and a second mode in which a second heater associated with the fireplace is activated; and manage power use to direct power to the first heater or the second heater.
According to another example (“Example 27”) further to Example 26, the control system is operable to select one of at least three operation states comprising: (a) a first operation state in which the first heater is powered; (b) a second operation state in which the second heater is powered; and (c) a third operation state in which both the first heater and the second heater are powered.
According to another example (“Example 28”) further to Example 27, the one of the at least three operation states is selected based on one or more of: an increased power source or an additional power source.
According to another example (“Example 29”) further to Example 26, the control system is operable to manage the power use for the first heater based on predicted weather data.
According to another example (“Example 30”) further to Example 26, the control system is operable to manage the power use by enabling or disabling heat delivery from the TESS based on an indication from a smart hub control device.
According to another example (“Example 31”) further to Example 26, the control system is operable to manage the power use by enabling heat delivery from the TESS based on a detected loss of electricity from one or more power sources.
According to another example (“Example 32”) further to Example 26, the control system is operable to: manage the power use by activating the first heater and enabling charging of the TESS during an off-peak time; and manage the power use by activating the first heater and enabling charging of the TESS during a non-off-peak time in response to user approval.
According to another example (“Example 33”) further to any one of Examples 26-32, the control system is operable to: manage the power use during a first period of time by activating the first heater and enabling charging of the TESS; and manage the power use during a second period of time subsequent to the first period of time by activating the second heater and releasing the stored thermal energy from the one or more heat storing materials of the charged TESS into the surrounding environment. A heat output from a combination of the second heater and the charged TESS is greater than a heat output from the second heater alone.
According to another example (“Example 34”) further to any preceding Example, the control system is operable to: perform a system fault check procedure in response to the system being powered on; perform a heat delivery evaluating procedure in response to the system fault check procedure confirming there is no system fault; perform a charge evaluating procedure in response to the heat delivery evaluating procedure confirming there is no heat delivery from the TESS; and perform charging of the TESS in response to the charge evaluating procedure confirming that the TESS is to be charged.
According to another example (“Example 35”) further to any preceding Example, the control system includes a first controller operable to control operation of the TESS and a second controller operable to control operation of the fireplace and one or more fans associated with the TESS to control outlet temperature.
According to one example (“Example 36”), a method of controlling a fireplace system includes: selecting between a first mode in which a first heater associated with a thermal energy storage system (TESS) is activated and a second mode in which a second heater associated with a fireplace is activated, the TESS comprising one or more heat storing materials in which thermal energy is stored and releasable into a surrounding environment; and managing power use to direct power to the first heater or the second heater.
According to another example (“Example 37”) further to Example 36, the method includes selecting one of at least three operation states comprising: (a) a first operation state in which the first heater is powered; (b) a second operation state in which the second heater is powered; and (c) a third operation state in which both the first heater and the second heater are powered.
According to another example (“Example 38”) further to Example 37, the method includes: managing the power use during a first period of time by activating the first heater and enabling charging of the TESS; and managing the power use during a second period of time subsequent to the first period of time by activating the second heater and releasing the stored thermal energy from the one or more heat storing materials of the charged TESS into the surrounding environment. A heat output from a combination of the second heater and the charged TESS is greater than a heat output from the second heater alone.
While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description serve to explain the principles of the disclosure.
The present disclosure is generally directed to a fireplace or fireplace system which includes a fireplace (e.g., an electric fireplace), a thermal energy storage system (TESS) that is operable independently from the fireplace, and a control system that controls the operation of the fireplace, the TESS, or both. The fireplace is fluidly coupled with one or more vents for intake or outflow of air. The TESS is implemented with the fireplace and includes one or more heat storing materials in which thermal energy is stored. The control system is operatively coupled with the fireplace and the TESS. The control system controls operation of the fireplace and the TESS to release the stored thermal energy from the one or more heat storing materials into a surrounding environment through the one or more vents of the fireplace based on one or more inputs.
In some examples, the one or more inputs include user inputs, instructions from a programmable or smart thermostat operatively coupled with the fireplace, or data from an electric utility grid from which the fireplace and the TESS receive electrical power. In some examples, the control system selects an operating mode from a plurality of operating modes based on the one or more inputs, and the plurality of operating modes include different heat outputs and durations. For reference, the control system may automatically select operating modes or may receive a user input or other input that results in selection of an operating mode by the controller.
In some examples, the one or more heat storing materials include one or more air cavities through which the air passes during the operation of the fireplace and the TESS. In some examples, the system also includes a fan to generate convection to facilitate the intake or outflow of air or the passing of air through the one or more air cavities.
In some examples, the one or more heat storing materials include a plurality of heat storing materials arranged in an assembly having a repeating pattern, and the assembly defines the one or more air cavities. In some examples, the one or more heat storing materials include a monolithic structure of heat storing material, and the one or more air cavities extend through the monolithic structure. In some examples, the one or more air cavities extend parallel to each other through the monolithic structure.
In some examples, the one or more heat storing materials include a monolithic structure of heat storing material having a plurality of continuous pores that are interconnected to form a network of airflow pathways, and the one or more air cavities extend through the continuous pores of the monolithic structure. In some examples, the one or more heat storing materials include a plurality of the monolithic structures in a stacked configuration to add or reduce a heating capacity of the TESS. In some examples, the one or more heat storing materials include a plurality of the monolithic structures arranged in a repeating pattern or matrix.
In some examples, the one or more heat storing materials includes a first sensible or latent heat material portion having a first cavity and a second sensible or latent heat material portion having a second cavity, the second sensible or latent heat material portion is disposed within the first cavity, and the second cavity is one of the one or more air cavities. In some examples, the first sensible or latent heat material portion and the second sensible or latent heat material portion are made of different materials.
In some examples, the one or more vents of the fireplace are disposed on a front portion of the fireplace. In some examples, the TESS is coupled with the fireplace at a rear portion of the fireplace. In some examples, the fireplace comprises a display, and the one or more vents of the fireplace are disposed adjacent to the display. In some examples, a side portion of the TESS includes an intake vent facilitating intake of air.
In some examples, the power source 106 may include one or more batteries or battery electric storage systems (BESS), such as rechargeable lithium-ion battery packs, providing voltage to operate one or more components of the fireplace 102 or of the TESS 104 that is coupled therewith. In some examples, the power source 106 may include renewable (or natural) energy sources, and the TESS 104 may take advantage of peak electricity generation when natural energy sources are abundant (e.g., sun, wind, water, and/or geothermal energy), and the heat may be stored for use later when such sources are scarce.
The fireplace 102 and the TESS 104 may both be operatively coupled with a control system 108, which may include one or more controllers 109 such as a computer and/or a smart device, which is capable of sending instruction signals to the fireplace 102 and the TESS 104 to control operation of the fireplace and the TESS (or components associated with the fireplace and the TESS, such as vents, fans, heaters, etc.) in response to certain inputs such as user input or detection of certain conditions. In some examples, the control system 108 includes a single controller 109 controlling operation of the fireplace 102 and the TESS 104. In some examples, the control system 108 includes two or more controllers, such as controllers 109A and 109B for separately controlling operation of the fireplace 102 and the TESS 104, respectively. In some examples, the controller 109A that controls the fireplace 102 (as well as operation of the fan/blower 110A and/or the heater 112A associated therewith) may also control operation of the fan/blower 110B and/or the heater 112B of the TESS 104 so as to control the outlet temperature, for example. Conditions that may affect the operation of the fireplace system 100 includes but are not limited to: detection of a power outage, detection of the fireplace being disconnected from a power source, or update/calculation of electric utility rates. In some examples, the TESS 104 may be incorporated as a part of a home's smart environmental controls (e.g., thermostat and/or sensors) to better balance comfort and cost of delivery heating/cooling to the home, also opening opportunities for the home to be connected to a smart grid (e.g., via the controller) to allow utility (power grid) to better balance electricity demand. In some examples, the control system 108 may be connected to the Internet or other types of communications network to send and receive data regarding the electric utility.
The TESS 104 represents a heat battery. In some examples, the heat stored in a TESS may also be released from the system in a manner to better simulate an authentic fire experience. Some fireplaces using smaller power sources are incapable of heating a large space or providing an intensity of heat reminiscent of either a biomass or gas fireplace. The fireplace 102 that incorporates a TESS 104 would allow the TESS to provide more heat than an electric fireplace with a common power supply, such as a 120V power supply, can provide on its own. The TESS 104 may be operated to dissipate heat at a rate similar to that of an electric fireplace using a larger electric power source (such as a 240V power supply) for a certain period of time. The TESS 104 is sized through the main electric power source that the TESS is coupled therewith, and the amount of storage material (or heat storing material) included with the TESS. In a typical electric fireplace, choosing the rating of the power supply circuit sets the maximum amount of heat that the fireplace can deliver to a space. For a TESS-incorporated fireplace system, choosing a higher power-rated source allows the users to charge the TESS at a faster rate. Including a larger mass of storage material (or heat storing material) increases the total amount of thermal energy stored therein. The users may also purchase a TESS capable of providing heat to a room larger than what a similarly-sized electric fireplace could provide. Heat output may be provided at a slower rate to maximize the usage of the stored heat, or provided quickly to maximize the comfort of the users in the space. Users may select the system with a standard power source for ease of installation, such as 120 VAC, or select the system with a higher-rated power source to maximize charging speed for the TESS, such as 240 VAC. Referring to
In some examples, the TESS 104 may be scaled to meet the heating requirements of the users. A larger TESS may provide more heat for a longer time during a power outage or to provide consistent heat to a large room. A smaller TESS may be more economical, providing heat for the electric fireplace experience but not offering an extended heat supply during power outages. The sizing of TESS 104 is typically delineated by energy requirements to generate heat and total amount of heat stored. For example, a small TESS could provide less than 1 kW/hr of heat generating power and store 2 kW of heat over time. For example, a larger TESS may provide 2-3 kW/hr of heat generating power and store more than 10-20 kW of heat. In some examples, it may be advantageous to provide the TESS 104 with thermal battery units that are stacked or stackable to add or reduce the heating capacity of the TESS, for example as shown in
In some examples, the heat for the fireplace is not a “point source” consisting of an electric heater such as a positive temperature coefficient (PTC) heater or a resistive heater and an integrated blower/fan, thus providing more options for designing the heat extraction from the TESS. In some examples, a single duct/vent or multiple ducts, vents, and/or outlets may be provided to direct the heat in different ways to exit the fireplace system, as shown in
The fireplace 102 includes a fireplace housing 204, and the TESS 104 includes a TESS housing 214 that is attachable to the fireplace housing 204. The fireplace housing 204 includes the display 206 and defines the locations of the intake vent 210 and the outlet vent 212. The TESS housing 214 includes insulating material (not depicted) for retaining heat, and a thermal storage medium 216 (or alternatively referred to as a heat storing material) with high heat capacity that allows thermal energy to be stored in high density, and the thermal storage medium 216 may be configured in any form such as in layers or in blocks, or be formed in a monolithic structure, for example as shown in
In some examples, the thermal storage medium 216 may include a ceramic material paired with electric resistance elements capable of holding a large amount of heat and maintained therein for a prolonged period of time, for example from 2 to 4 hours, from 4 to 6 hours, from 6 to 8 hours, from 8 to 10 hours, from 10 to 12 hours, from 12 hours to 1 day, from 1 to 2 days, from 2 to 3 days, from 3 to 4 days, from 4 to 5 days, or any other suitable length of time. The TESS housing 214 also includes at least one fan 222 and/or at least one blower (not shown) that is electrically operated, which may be used to draw air (air inflow 224) into the TESS housing 214 and into the thermal storage medium 216 from the external environment (such as an indoor space) via the intake vent 210, and/or to discharge heated air (air outflow 226) via the outflow vent 212 using the convection generated by the fan 222 or using natural convection. A fan may be designed to facilitate general air circulation with a certain space or to push air out of the system, and a blower may be designed to move air to a specific (predetermined) location or to create a focused stream of fluid flow at a higher pressure. In some examples, heated air may be either delivered directly into the room or mixed with the air from the room in a way that increases the temperature of the air from the room before releasing the heated air back into the room, which may be assisted by incorporating the fan 222 or blower.
In some examples, heat from the TESS 104 may be released so as to provide a consistent temperature to the room in which the fireplace system 100 is installed, or the heat may be released at a higher rate so as to simulate a more intense or authentic fire experience for the users. This may be achieved while maintaining the power source at a low voltage level, such as 120V or lower, without increasing the power requirements (e.g., requiring the power source to increase in voltage level, such as from 120V to 240V) in order to generate the additional heat. In some examples, when paired with a control system or controller(s) as shown in
In some embodiments, the TESS 104 is a stand-alone unit that may be separately and independently operable from the fireplace. The TESS 104 contains sensible and/or latent heat storing materials (thermal storage medium 216) combined with at least one electric heating element (e.g., heating elements 700 shown in
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The first heat material portion 400 surrounds the air cavity such that the air cavity, which receives the air inflow, is defined by the first heat material portion. The second heat material portion 402 surrounds the first heat material portion such that the first heat material portion is disposed between the air cavity and the second heat material portion. In some examples, the second heat material portion 402 has a preformed cavity (second cavity) in which a core, or the first heat material portion 400 (which defines therein the air cavity 218), is disposed or contained, such that the preformed cavity of the second heat material portion 402 is concentric with the air cavity 218 (first cavity) defined by the first heat material portion 400. The first heat material portion 400 and the second heat material portion 402 may be formed using the same material or using different materials with different properties such as heat capacity. Because the air cavity 218 carries heated air, the first heat material portion 400 may have a greater heat capacity than the second heat material portion 402 to accommodate the increased heat of the air that passes through the first heat material portion 400.
In some examples, the inputs 510 may include user inputs from user interface 512, e.g., a touchscreen of a mobile device or monitor/display coupled with the fireplace system, instructions from the programmable or smart thermostat 514 that is implemented in the fireplace system, and/or notification from the electric utility grid 516 such as the power grid or the power supply company. Based on the input(s) 510, the process 500 determines or selects the next modes/settings 520 for the system, where each mode/setting operates the system differently, as explained above.
Based on the determined or selected mode/setting 520, the process 500 causes the system to output heat in a certain way based on the mode/setting. For example, the outputs 530 may include high heat output 532 for a short duration of energy storage (that is, of the TESS), a low-to-medium heat output 534 with a long duration of energy storage, and a low heat output 536 with a long duration of energy storage. Therefore, the outputs 530 determine both the intensity of heat output as well as an intended duration time for which the energy storage is expected to operate and provide the additional heat for the system. With greater heat output demand, the duration decreases because the TESS is expected to release the stored heat at a greater rate than in other lower-intensity outputs.
As shown, the TESS housing 214 can include one or more sub-sections, each having all the elements of the TESS housing 214 but smaller in size than the completed TESS housing 214. The exterior of the first TESS housing component 214A has components that are attached in a way to create a channel that air can travel across the surface in a set path (e.g., the separators 600 forming the flow path 602). Doing so creates a heat exchanger system. Heat from the sensible heat material (thermal storage medium 216) is transferred to the airflow. This construction is housed in the second TESS housing component 214B that is insulated from outside air in a way that, when the heating elements (e.g., the heating elements 700 of
In some examples, the heating elements 700 may be disposed between two parallel portions of a pipe 704 to efficiently heat the pipe 704 as well as the air cavity 218 formed therein. The pipe 704 may be in the form of a sinusoidal or undulating configuration to maximize the path length of the air cavity 218 within a given volume. The pipe 704 may be made of any suitable material that is capable of conducting and tolerating heat, such as steel. The fan 222 may be positioned at any suitable location to assist in drawing out and circulating warmed air from the system to the room.
It is to be understood that the figures are provided for illustrative purposes only, and that there are three variables regarding how the airflow through the system may be changed or altered. The first variable is path orientation; the orientation of the flow path 602 can be altered by changing the positions, orientations, shapes, and/or number of the separators 600. The second variable is surface area of the path; the surface area of the flow path 602 can be increased or decreased by changing the positions, orientations, shapes, materials, and/or numbers of separators 600. The third variable is path length; the length of the flow path 602 can also be increased or decreased based on the configuration of the separators 600. The separators 600 may be configured in any other suitable form, including but not limited to smooth, rough, straight, and curved. Different materials may also be used for the separators 600 such that the separators 600 may use materials different from the material used in the walls of the TESS housing 214.
By providing a nested enclosure for a heat storage system, heat storage in the heat storing material can be retained for longer periods of time and delivered at a desired time (time shifted) when the heat is called for from a control system. By designing the airflow path as shown, the heated air can be delivered at a more flexible volume, rate, and/or temperature than is possible with existing common, residential electric heat storage technology.
The use of more than one blower in the blower system allows for air mixing from two states that can be combined to moderate air output temperature. Air could be blown from, for example, the highest-heat internal heat storage system volume, from the surrounding room, and/or from an intermediate cavity within the heat storage system, among others. Additionally, the air mixing from more than one blower could be combined with metering from each contributing blower, such that the air temperature output from the system could be tuned to a target temperature or temperature range. Through this use of combined blowers and air of different temperatures, air output temperature to a room or space could be moderated more or less according to consumer preference. The design also provides for improved air quality in the space where the heated air is delivered as the room air does not come in direct contact with the sensible heat storing material. Time shifting of the heating and delivering of the heated air can provide for customized delivery of heat that is controlled by manual user operation or through a programmable controller or through “smart home” technology.
The use of one enclosure allows for generating, storing, and delivering heat to a room. The use of more than one enclosure or sub-sections separated within the enclosure allows for more than one action at the same time from one system. For example, one enclosure sub-section may deliver heat to a room while another enclosure sub-section may instead be generating or storing heat. Generating heat in one sub-section has the advantage to take less time to heat than generating heat in the full enclosure, thus shortening cycle time from a first state with no stored heat to a second state with full heat storage, or reducing the energy use of the system if the heat stored in a sub-section is sufficient to heat a room. Additionally, the use of more than one enclosure or sub-section separated within the enclosure with separate airflow paths could be reversibly and mechanically connected to add length to the airflow path and extend the time of heat delivery to a room or modulate temperature of heat delivered to a room.
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The fireplace 102 includes a fireplace controller (“FP Controls”) and one or more heaters (“Heater”) associated with the fireplace 102. When the “TESS Disable” switch is operated in the open position, the TESS 104 is disconnected from the power source, and the fireplace 102 is allowed to use the electric power to activate the associated heater in order to generate heat, thus disabling the TESS 104 entirely. Alternatively, when the “TESS Disable” switch is in the closed position, the “TESS Disconnect” switch may be in an open position (in which the TESS 104 would still not receive any electric power) or a closed position (in which the TESS 104 would be able to receive electric power). The difference between “disabling” and “disconnecting” is that the “disconnecting” of the TESS 104 is temporary or for a short periods of time when the TESS 104 itself is still active and capable of providing heat, whereas “disabling” the TESS 104 causes the TESS 104 to be shut down and/or no longer active, such as when TESS 104 is discharged, thus no longer capable of providing heat even when the TESS 104 is activated.
In some examples, the power source may provide electric power to both the fireplace 102 and the TESS 104 simultaneously, such as when the “TESS Disable” and “TESS Disconnect” switches are both closed, and the heater associated with the fireplace 102 is activated by the controller. In such situations, the power source may simultaneously power the fireplace 102 and charge the TESS 104, and the power distribution between the fireplace and the TESS may be controlled using the controller (which may be any suitable ratio, e.g., 20% to the fireplace and 80% to the TESS, or 50% to both, or 80% to the fireplace and 20% to the TESS, etc.). In some examples, the TESS 104 includes a TESS distribution module 900 which operates to distribute the amount of power received to different purposes, such as to a TESS charging module 902 and a TESS heat supply module 904. The TESS charging module 902 operates to charge the TESS 104 to increase the internal temperature of the TESS 104 to a predetermined temperature. The TESS heat supply module 904 operates to deliver heat from the TESS 104 to increase the temperature of the external environment by releasing the stored heat within the TESS 104. In some examples, the TESS charging module 902 and the TESS heat supply module 904 may operate different heaters associated with the TESS 104. In some examples, the TESS heat supply module 904 may operate one or more dampers associated with the TESS 104 to release the heat stored therein or to release the heat provided by the heater associated with the TESS 104.
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Using any one or more of the examples shown in
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If step 1204 returns “false” indicating there is no system fault, the process proceeds to step 1208 in which charge level of the TESS is acquired, and user indicators are updated. The charge level may be defined as the amount of heat stored in the TESS, for example as indicated by whether the internal temperature of TESS has reached a threshold temperature which may be set by the user or by the manufacturer of the system. In step 1210, the control system enters an “evaluate heat delivery request” subroutine in which the control system analyzes the charge level as well as user indicators regarding whether charge mode was instructed. If step 1210 returns “true”, the process proceeds to step 1212 in which the control system disables the heaters, opens the damper(s), and enters a “Heat Delivery” subroutine, for example a “PID” or Proportional-Integral-Derivative control loop feedback mechanism. If step 1210 returns “false”, the process proceeds to step 1214 in which the control system enters an “evaluate charge request” subroutine. If step 1214 returns “true”, the process proceeds to step 1216 in which the control system enables the heaters, closes the damper(s), and disables the fans. If step 1214 returns “false”, the process proceeds to step 1218 in which the control system closes the damper(s) and disables the heaters and fans. After each of steps 1216 and 1218, the process returns to step 1204 to again check for any system faults. The subroutines will be explained in detail herein.
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While example combinations of features have been described above in association with the various figures, those features may be combined, substituted, and/or modified with one another across the various examples.
Implementing the TESS with the fireplace beneficially allows for the system to build up heat that can be accessed at a future time or at an intensity level that is not possible with only the fireplace. Because thermal energy is stored for use later, heat can be provided when electrical power is not available to the home, such as when an adverse event happens (e.g. brown-out, wild-fire, or storms), or is otherwise in use, such as to power other components. Using a TESS also provides advantages over using a BESS to provide backup electricity to the fireplace during an outage. A typical electric fireplace heater has power requirements (e.g., 1.5 kWh) that would require a physically large BESS capacity to operate the fireplace heater for an extended period (e.g., longer than 1 or 2 hours) at maximum output. Storing the necessary energy for the electric fireplace to provide heat during a power outage as heat using the TESS allows the fireplace system to store more energy and access the stored energy with no (or minimal) electrical requirements. Any electrical requirements (e.g., to operate a fan or electronic controls) may be provided by a more typically sized BESS (e.g., smaller battery packs) that can be found in many portable electronic devices. It is also understood that storing energy as heat, when the final use-case is heat, is more efficient than storing energy as electricity and then converting the stored electricity to heat at a later time.
When paired with a control system, the TESS can be charged and deliver heat to take advantage of more affordable electric utility rates that are offered in some locales (e.g., off-peak rates or tariffs). The TESS is also amenable to be paired with renewable energy sources to take advantage of peak electricity generation when natural energy sources are abundant (e.g., sun, wind, water, and/or geothermal energy), and the heat can be stored for use later when such sources are scarce. When utilities (power grid) cannot use the electricity generated from wind, the turbines are forced to shut down, even though wind conditions may be amenable to continue generating power. The use of TESS may beneficially enable the use of this “extra” energy, further allowing the utilities to balance electricity generation. When a residential photovoltaic (PV) system is generating more electricity than required by a home, the excess electricity is fed back into the grid, and the utilities do not pay back for this excess electricity at a competitive price. If a better use of generated power is found, the users may continue to reap the benefits of their PV system. Storing the excess electricity in the TESS, therefore, would allow the users to access such excess power as heat.
Converting electricity into heat and storing this heat for future use in the TESS is both more energy-efficient and economical when the intended use is to provide the level of heat that a fireplace is scaled to for an extended period of time (e.g., from 12 to 48 hours). Beneficially, heat stored in the TESS may also be released from the system in a manner to better simulate an authentic fire experience for the users. Using the TESS may beneficially simulate a more realistic ember/fuel bed and recreate the heat radiating from a gas, or wood, fireplace, thus providing a different heating experience from that of using only the fireplace.
An experience that is pleasing to the users for relaxation or social gathering that is not typically offered by space-heating products (e.g., storage heater or home space heaters) can be created by combining together the elements of thermal storage and adjusted heat output/delivery in an aesthetic fire feature that incorporates the simulation of a fire experience.
The TESS may also provide users with a more economical manner to generate heat, thus saving on energy costs. Many utilities offer, are in the process of offering, or will be requiring residential utility customers to implement, on-peak/off-peak rate plans in order to better balance the supply and demand of electricity generated on the utility grid. With efforts to drive electrification, decarbonize energy generation, and reduce greenhouse gas emissions, manufacturers may more readily design products that better align to such trends by implementing the fireplace with the TESS. An electric fireplace utilizing TESS technology allows users to purchase electricity during off-peak rates that can be used to charge the TESS (e.g., overnight), and the stored energy can be released as heat during times of the day when electricity rates are higher, thus beneficially allowing users to reduce the demand for electricity, for example by reducing the amount of electricity that is used on the HVAC system for the home in real time and relying more on the stored energy that was purchased more cheaply.
Freeing the electric fireplace from a dedicated electrical requirement also beneficially allows the fireplace to not be attached to a wall and thus not requiring a dedicated electrical connection, for example to a power outlet. A thermal battery or TESS allows the fireplace to be installed in different spaces throughout the home or outdoors, as well as enabling portability of the product, or the fireplace system. For example, the fireplace system may be charged electrically for a time and thereafter unplugged to be used independently. Weight of the TESS (such as weight of the heat storing material) would impact portability; therefore, scaling the heating experience and selection of the heat storing material would be important to enable easier transport of the product.
Numerous characteristics and advantages have been set forth in the preceding description, including various alternatives together with details of the structure and function of the devices and/or methods. Moreover, the scope of the various concepts addressed in this disclosure has been described both generically and with regard to specific examples. The disclosure is intended as illustrative only and as such is not intended to be exhaustive. It will be evident to those skilled in the art that various modifications may be made, especially in matters of structure, materials, elements, components, shape, size, and arrangement of parts including combinations within the principles of the disclosure, to the full extent indicated by the broad, general meaning of the terms in which the appended claims are expressed. To the extent that these various modifications do not depart from the spirit and scope of the appended claims, they are intended to be encompassed therein.
Claims
1. A fireplace system comprising:
- a fireplace;
- a thermal energy storage system (TESS) implemented with the fireplace and including one or more heat storing materials in which thermal energy is stored; and
- a control system comprising one or more controllers operatively coupled with the fireplace and the TESS, wherein the control system is operable to control operation of the fireplace and the TESS to release the stored thermal energy from the one or more heat storing materials into a surrounding environment based on one or more inputs.
2. The system of claim 1, wherein one or more of the fireplace or the TESS are fluidly coupled with one or more vents for intake or outflow of air, and the TESS is configured to release the stored thermal energy through the one or more vents.
3. The system of claim 1, wherein the one or more inputs include user inputs, instructions from a programmable or smart thermostat operatively coupled with the fireplace, sensor data associated with the fireplace or the TESS, or data from an external input device.
4. The system of claim 3, wherein the external input device includes one or more of: an electric utility grid from which the fireplace and the TESS receive electrical power, or a weather monitoring system.
5. The system of claim 3, wherein the control system selects an operating mode from a plurality of operating modes based on the one or more inputs, and wherein the plurality of operating modes includes different heat outputs and durations.
6. The system of claim 1, wherein the one or more heat storing materials include one or more air cavities through which the air passes during the operation of the fireplace and the TESS.
7. The system of claim 6, further comprising one or more fans or one or more blowers configured to generate convection to facilitate intake or outflow of air or the passing of air through the one or more air cavities.
8. The system of claim 6, wherein the one or more heat storing materials include a plurality of heat storing materials arranged in an assembly having a repeating pattern, and the assembly defines the one or more air cavities.
9. The system of claim 6, wherein the one or more heat storing materials include a monolithic structure of heat storing material, and the one or more air cavities extend through the monolithic structure.
10. The system of claim 9, wherein the one or more air cavities extend parallel to each other through the monolithic structure.
11. The system of claim 6, wherein the one or more heat storing materials include a monolithic structure of heat storing material having a plurality of continuous pores that are interconnected to form a network of airflow pathways, and the one or more air cavities extend through the continuous pores of the monolithic structure.
12. The system of claim 9, wherein the one or more heat storing materials include a plurality of the monolithic structures in a stacked configuration to add or reduce a heating capacity of the TESS.
13. The system of claim 9, wherein the one or more heat storing materials include a plurality of the monolithic structures arranged in a repeating pattern or matrix.
14. The system of claim 6, wherein the one or more heat storing materials includes a first sensible or latent heat material portion having a first cavity and a second sensible or latent heat material portion having a second cavity, the second sensible or latent heat material portion is disposed within the first cavity, and the second cavity is one of the one or more air cavities.
15. The system of claim 14, wherein the first sensible or latent heat material portion and the second sensible or latent heat material portion are made of different materials.
16. The system of claim 6, wherein the TESS comprises one or more separators at least partially defining the one or more air cavities.
17. The system of claim 6, wherein the TESS comprises a pipe at least partially defining the one or more air cavities.
18. The system of claim 1, wherein the TESS comprises a housing storing therein the one or more heat storing materials.
19. The system of claim 18, wherein the housing comprises at least a first housing component and a second housing component configured to be disposed within the first housing component.
20. The system of claim 19, wherein the first housing component and the second housing component at least partially defines the one or more air cavities.
21. The system of claim 18, wherein the TESS comprises one or more heating elements disposed within the housing and configured to increase temperature of the one or more heat storing materials.
22. The system of claim 2, wherein the one or more vents of the fireplace are disposed on a front portion of the fireplace.
23. The system of claim 22, wherein the TESS is coupled with the fireplace at a rear portion of the fireplace.
24. The system of claim 22, wherein the fireplace comprises a display, and the one or more vents of the fireplace are disposed adjacent to the display.
25. The system of claim 22, wherein a side portion of the TESS includes an intake vent facilitating intake of air.
26. The system of claim 1, wherein the control system is operable to:
- select between a first mode in which a first heater associated with the TESS is activated and a second mode in which a second heater associated with the fireplace is activated; and
- manage power use to direct power to the first heater or the second heater.
27. The system of claim 26, wherein the control system is operable to:
- select one of at least three operation states comprising: a) a first operation state in which the first heater is powered; b) a second operation state in which the second heater is powered; and c) a third operation state in which both the first heater and the second heater are powered.
28. The system of claim 27, wherein the one of the at least three operation states is selected based on one or more of: an increased power source or an additional power source.
29. The system of claim 26, wherein the control system is operable to:
- manage the power use for the first heater based on predicted weather data.
30. The system of claim 26, wherein the control system is operable to:
- manage the power use by enabling or disabling heat delivery from the TESS based on an indication from a smart hub control device.
31. The system of claim 26, wherein the control system is operable to:
- manage the power use by enabling heat delivery from the TESS based on a detected loss of electricity from one or more power sources.
32. The system of claim 26, wherein the control system is operable to:
- manage the power use by activating the first heater and enabling charging of the TESS during an off-peak time; and
- manage the power use by activating the first heater and enabling charging of the TESS during a non-off-peak time in response to user approval.
33. The system of claim 26, wherein the control system is operable to:
- manage the power use during a first period of time by activating the first heater and enabling charging of the TESS; and
- manage the power use during a second period of time subsequent to the first period of time by activating the second heater and releasing the stored thermal energy from the one or more heat storing materials of the charged TESS into the surrounding environment, wherein a heat output from a combination of the second heater and the charged TESS is greater than a heat output from the second heater alone.
34. The system of claim 1, wherein the control system is operable to:
- perform a system fault check procedure in response to the system being powered on;
- perform a heat delivery evaluating procedure in response to the system fault check procedure confirming there is no system fault;
- perform a charge evaluating procedure in response to the heat delivery evaluating procedure confirming there is no heat delivery from the TESS; and
- perform charging of the TESS in response to the charge evaluating procedure confirming that the TESS is to be charged.
35. The system of claim 1, wherein the control system includes a first controller operable to control operation of the TESS and a second controller operable to control operation of the fireplace and one or more fans associated with the TESS to control outlet temperature.
36. A method of controlling a fireplace system, the method comprising:
- selecting between a first mode in which a first heater associated with a thermal energy storage system (TESS) is activated and a second mode in which a second heater associated with a fireplace is activated, the TESS comprising one or more heat storing materials in which thermal energy is stored and releasable into a surrounding environment; and
- managing power use to direct power to the first heater or the second heater.
37. The method of claim 36, further comprising:
- selecting one of at least three operation states comprising: a) a first operation state in which the first heater is powered; b) a second operation state in which the second heater is powered; and c) a third operation state in which both the first heater and the second heater are powered.
38. The method of claim 37, further comprising:
- managing the power use during a first period of time by activating the first heater and enabling charging of the TESS; and
- managing the power use during a second period of time subsequent to the first period of time by activating the second heater and releasing the stored thermal energy from the one or more heat storing materials of the charged TESS into the surrounding environment, wherein a heat output from a combination of the second heater and the charged TESS is greater than a heat output from the second heater alone.
Type: Application
Filed: Jul 18, 2025
Publication Date: Jan 22, 2026
Inventors: Corey Radloff (Muscatine, IA), Jamie Wheeler (Muscatine, IA), Tommie Kelley (Muscatine, IA), Erika Saffer (Muscatine, IA), Julie Milum (Muscatine, IA), Joseph Kuefler (Muscatine, IA), Timothy Johnson (Muscatine, IA), Jacob Clifton (Muscatine, IA), Destin Peters (Muscatine, IA), Moffat Omuya (Muscatine, IA), Hunter Miller (Muscatine, IA)
Application Number: 19/274,181