Battery Energy Storage System (BESS) with three phaseGrid Integrated Inverter using 3D printed Magnetics componentswith Nanocrystalline soft magnetic material.

Nano crystalline soft magnetic alloys provide unique combination of High Flux density, High permeability and low coercivity. Presently these alloys are produced using Rapid solidification or spin casting process. The current production methods- with ribbons- it is difficult to take advantage of all unique product attribute due extraneous losses and limitations of core manufacturing methods. Additive manufacturing (AM) process presents us the cooling rates like Rapid solidification Process (106-107 °C/sec). Due to this unique attribute one can expect Nanocrystalline structure without the limitation of the spin casting methods. AM process will be explored for printing magnetic cores for Dual-active-bridge Converter (DABC) magnetic components on fiber glass reinforced FR4 PCB’s. In this new proposed method one can use wider operating temperature range, higher flux density and lower losses of the Nanocrystalline soft magnetic material to the fullest extent. This proposal involves two small businesses MAM Inc., NJ, USA specializing in high frequency custom magnetic cores and components; C4V, NY, USA specializing in novel Li-ion battery manufacturing; and power electronics and additive manufacturing experts from Binghamton University (BU). The Power system envisioned will help streamline large scale deployment of Battery Energy Storage (BESS). Such systems can be used as energy storage during off peak-load time; the stored energy can be used during peak local duration avoiding the demand charges, address the intermittency concerns to an extent while integrating Renewable energy source and assisting in grid support functions. DABC provide high frequency light weight galvanic isolation ,reducing concerns with logistics and real estate for deploying bulk line frequency transformers, and provide level shifting between high voltage of the grid and the low voltage of the battery and soft switching to minimize the power conversion losses. To address this market need, two small businesses MAM Inc., NJ, USA specializing in high frequency custom magnetic cores and components; C4V, NY, USA specializing in novel Li-ion battery manufacturing has teamed up with Binghamton University, a major power electronics and electronic manufacturing and packaging research center to research on additive manufacturing (AM) process for printing magnetic cores for Dual-active-bridge Converter (DABC) on metal core PCBs. The DoE Funding will de-risk the initial exploration of the suitable printing processes for nano-crystalline cores, prototyping and testing of an integrated DABC converter with printed nano-crystalline magnetic components. If successful, this project will enable mass scale deployment of a high-performance Li-ion Battery from C4V integrated to the power grid by an new DABC converter with printed nano-crystalline magnetic components. This will lead to significant high quality renewable energy based job creation of about 120 jobs in NY and NJ by the two small businesses MAM Inc., NJ, USA and C4V, NY, USA.