A flexible, fillable, and rapidly assembled energy storage module and its fabrication method.

Abstract

This invention relates to a flexible, fillable, and rapidly assembled energy storage module and its manufacturing method. The module includes segmented energy storage units, with adjacent units physically connected via connecting components. Each energy storage unit is equipped with a flexible encapsulation assembly, which, when inflated, forms a casting cavity for filling functional materials. A flexible diaphragm bag assembly is located inside the encapsulation assembly. This flexible diaphragm bag assembly is ion-permeable and consists of multiple liquid-permeable flexible diaphragm bags with embedded flexible electrode sheets. Adjacent units are connected via a reconfigurable plug-in electrical connection device to achieve series-parallel logic switching. The functional material filling the energy storage unit is a fluidized solidified soil slurry incorporating ion-conducting electrolytes, possessing both ion conduction and mechanical load-bearing capabilities. This invention integrates flexible forming, filling construction, electrical reconfigurability, and long-term protection, solving the problems of complex installation, fixed electrical logic, and poor protection in irregularly shaped spaces for energy storage systems. It can effectively promote the deep integration of energy storage systems with civil engineering.

Description

Technical Field

[0001] This invention belongs to the field of energy storage system technology, and particularly relates to a flexible, fillable, and rapidly assembled energy storage module and its preparation method. Background Technology

[0002] In civil engineering infrastructure, integrated energy storage systems have enabled on-site energy storage and utilization, representing an important direction for the development of distributed energy storage. Such applications require energy storage units to adapt to irregular structural spaces, function as functional fillers, and support rapid deployment and flexible expansion.

[0003] Currently, energy storage modules suitable for this scenario have significant limitations: First, their fixed shape, mostly rigid encapsulation, makes it difficult to fit into irregularly shaped spaces such as trenches and holes, resulting in low space utilization and difficulty in forming a tight mechanical bond with the backfill. Second, on-site assembly is complex, with mechanical and electrical connections between modules often separated, requiring extensive manual alignment, wiring, and insulation, leading to low efficiency and reliability dependent on construction skill. Third, the fixed electrical topology, with series and parallel connections between multiple modules typically pre-set, cannot be flexibly reconfigured according to actual voltage and capacity requirements on-site, resulting in poor engineering adaptability. Fourth, in harsh engineering environments such as humidity, compression, and corrosion, exposed electrical interfaces and leads lack long-term reliable integrated protection, affecting the safety and stability of the system throughout its entire lifecycle. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a flexible, infillable, and rapidly assembled energy storage module and its preparation method, which integrates flexible forming, filling construction, rapid assembly, electrical reconfigurability, and long-term reliable protection to promote the efficient and deep integration of energy storage systems with civil engineering.

[0005] A flexible, fillable, and rapidly assembled energy storage module includes one or more segmented energy storage units, with adjacent units physically connected via end-integrated connectors. Each energy storage unit is equipped with a flexible encapsulation assembly, which, when inflated, forms a casting cavity. The casting cavity is filled with functional materials. A flexible diaphragm bag assembly is located inside the flexible encapsulation assembly. This assembly consists of multiple liquid-permeable flexible diaphragm bags fixed to the inner wall of the flexible encapsulation assembly. Each flexible diaphragm bag is made of a porous insulating diaphragm material, used to house electrode sheets and allow ion permeation. The electrode sheets are housed within the flexible diaphragm bags, and the leads connecting the electrode sheets converge to form an electrical interface. Adjacent energy storage units are connected via a reconfigurable plug-in electrical connection device to switch between series and parallel connection logic.

[0006] The flexible packaging component is an inflatable membrane bag made of fiber-reinforced flexible composite material, which can be designed as a ring, a long strip, or other shapes that adapt to the target filling space as needed; the axial ends of the inflatable membrane bag are closed.

[0007] The flexible wrapping component is provided with a grouting component for grouting, including at least one grouting hole at the bottom of the inflatable membrane bag and at least one venting hole at the top of the inflatable membrane bag, and both the grouting hole and the venting hole are connected to the interior of the casting cavity to pump grout from the bottom to the top.

[0008] An automatic float valve is integrated at the vent.

[0009] The functional material is a fluidized solidified soil slurry mixed with an ion-conducting electrolyte. The electrolyte is an aqueous solution that provides an ion-conducting pathway, and its type and concentration are selected according to electrochemical performance and engineering requirements. The slurry has a spread of 180 mm ± 10 mm and has ion conduction and mechanical load-bearing functions after solidification.

[0010] The flexible diaphragm bag assembly is fixed to the inner wall of the flexible packaging assembly by adhesive, sewing or heat sealing. The flexible diaphragm bag assembly includes multiple sets of liquid-permeable flexible diaphragm bags arranged at intervals along the axial direction of the energy storage unit. Each set of flexible diaphragm bags includes multiple sets arranged circumferentially along the inner side of the energy storage unit. The total volume of all flexible diaphragm bags does not exceed 15% of the total volume of the internal cavity after the flexible packaging assembly is inflated and shaped.

[0011] The axial length, width, and thickness of each flexible diaphragm bag are jointly determined by the characteristic dimension D of the target filling space and the overall radial thickness W of the cast cavity formed after inflation. For a cylindrical shape, the characteristic dimension D of the target filling space is the outer diameter; for a rectangular shape, the characteristic dimension D of the target filling space is the length of the long side of the cross-section; for other shapes, the representative dimension of the volume equivalent or the direction of the tightest spatial constraint is taken.

[0012] The electrode sheet has a minimum The high specific surface area flexible electrode sheet has a waterproof seal at the exit hole of the flexible diaphragm bag where the electrode lead wires pass through.

[0013] It also includes a flexible protective jacket that wraps around one or more segmented energy storage units to provide protection, and has an operating window with a sealed cover.

[0014] The above-mentioned method for preparing a flexible, fillable, and rapidly assembled energy storage module specifically includes the following steps:

[0015] Factory prefabrication: The electrode sheet and lead wire are put into a liquid-permeable flexible diaphragm bag to form an electrode module. The electrode module is fixed to the inner wall of the flexible wrapping component. A reconfigurable plug-in electrical connection device is installed. The reconfigurable plug-in electrical connection device is preset to the target series or parallel position.

[0016] On-site assembly: The prefabricated energy storage unit is placed in the target filling space and inflated to shape. The reconfigurable plug-in electrical connection device is adjusted to achieve series-parallel switching, and physical fixation is completed through mechanical connection components.

[0017] System testing: Conduct continuity, insulation, and functional tests on each energy storage unit and the overall circuit.

[0018] Protection and Casting: Install and seal a flexible protective jacket, and fill the casting cavity with functional material through the grouting assembly;

[0019] Integrated maintenance: After the functional materials have cured and maintained, the main circuit leads are led out and connected to the external energy management system.

[0020] By employing the above technical solution, the present invention has at least the following beneficial effects:

[0021] (1) This invention integrates traditionally separate structural backfilling with electrochemical energy storage function, effectively improving the utilization efficiency of irregular space;

[0022] (2) The present invention provides a flexible protective jacket on the outermost side, which provides uniform and good mechanical and environmental protection for all external electrical components, and significantly improves the long-term reliability and durability of the device in harsh engineering environments;

[0023] (3) The present invention integrates a mature, reliable, and intuitive rotary changeover switch as a reconfigurable plug-in electrical connection device, which is installed inside a flexible protective jacket. While providing effective protection, it also gives the device configurability of electrical connection, which can flexibly adapt to the voltage and capacity requirements of different projects. It is also simple to operate and highly reliable.

[0024] (4) The flexible filling type energy storage module provided by the present invention is highly prefabricated in the factory, with a clear on-site installation logic. It is electrically connected first and then protected as a whole. It is simple to operate, compatible with conventional backfilling process, and greatly reduces the dependence on professional skills.

[0025] (5) The present invention uses a flexible diaphragm bag with ion permeability to physically isolate the electrodes, thereby preventing short circuits while ensuring ion conduction. Combined with an optimized electrode layout and a functional material system adapted to the target engineering environment, the present invention ensures the capacitance performance, structural strength and long-term durability of the energy storage module.

[0026] (6) The segmented structure design and standardized reconfigurable plug-in connection of the energy storage module of the present invention make the whole device highly flexible in terms of transportation, storage, deployment and maintenance.

[0027] (7) This invention uses fluidized solidified soil, a bulk engineering material, as the main body, which reduces the cost of raw materials; at the same time, integrated construction reduces the number of procedures and labor, and has significant comprehensive economic benefits.

[0028] (8) The segmented structure and external reconfigurable plug-in electrical connection device of the present invention enable any energy storage unit to be quickly electrically isolated or bypassed through the connection devices at both ends when a fault occurs, thereby realizing the fault-tolerant operation and easy maintenance of the system and improving the reliability of the entire life cycle. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the energy storage unit in the flexible, fillable, and rapidly assembled energy storage module provided by the present invention.

[0030] Figure 2 This is a schematic diagram of the internal structure of the energy storage unit in this invention;

[0031] Figure 3 This is a schematic cross-sectional view of the interior of the energy storage unit after inflation and shaping in this invention.

[0032] Figure 4 This is a disassembled perspective view of the energy storage unit in this invention;

[0033] Figure 5 This is a schematic diagram showing the dimensions of a single flexible diaphragm bag in this invention;

[0034] Figure 6 A schematic diagram of the connection between energy storage units in the flexible, fillable, and rapidly assembled energy storage module provided by this invention;

[0035] Figure 7 This is a schematic diagram of the rotary changeover switch in Example 1. Figure 1 ;

[0036] Figure 8 This is a schematic diagram of the rotary changeover switch in Example 1. Figure 2 ;

[0037] Figure 9 A schematic diagram showing the overall connection of multiple energy storage units;

[0038] in:

[0039] 1. Flexible wrapping assembly; 2. Flexible diaphragm bag assembly; 3. Electrode module; 4. Protruding terminal; 5. Grouting hole; 6. Inflation / depression hole; 7. Vent hole; 8. Mechanical connection component; 9. Electrode lead; 10. Line connector; 11. Circuit lead; 12. Flexible protective jacket; 13. Protective jacket butt joint; 14. Reconfigurable plug-in electrical connection device; 15. Handle; 16. Terminal block; 17. Gear position indicator; 18. Operation window. Detailed Implementation

[0040] The principles and features of the present invention are described below with reference to the accompanying drawings. The examples given are only for explaining the present invention and are not intended to limit the scope of the present invention.

[0041] like Figures 1-9 As shown, a flexible, infillable, and rapidly assembled energy storage module includes multiple energy storage units forming a modular structure, with each segment being an independent energy storage unit. Adjacent energy storage units are physically connected and fixed together via mechanical connection components 8 integrated into the ends of the energy storage units. These mechanical connection components 8 include, but are not limited to, reusable and rapidly openable waterproof zippers, male-female buckle assemblies, or waterproof straps with locking buckles, and are fixedly connected to the ends of the energy storage units through stitching, heat sealing, or embedding to achieve reliable connection and tight joint between adjacent segments.

[0042] The energy storage unit includes a flexible packaging component 1, which is an inflatable membrane bag. Its shape can be designed as annular, cylindrical, or elongated depending on the target filling space. The inner wall of the inflatable membrane bag forms a sealed casting cavity boundary. The axial ends of the inflatable membrane bag are closed and equipped with interfaces for grouting, venting, and inflation. After inflation, a shaped sealed casting cavity is formed inside the membrane bag.

[0043] Specifically, the inflatable membrane bag is made of fiber-reinforced flexible composite material, namely, an airtight polymer-coated fabric. This material uses high-strength polyester, nylon, or aramid fabric as the reinforcing base, and forms a composite structure by coating, laminating, or calendering a waterproof and airtight layer of polyvinyl chloride (PVC), thermoplastic polyurethane (TPU), or neoprene rubber onto the surface of the base fabric. The technical specifications of this material, including but not limited to tensile strength, peel strength, airtightness, and weather resistance, all meet the requirements of the national standard GB / T12753 "Coated Fabrics and Painted Fabrics" and related membrane structure technical specifications, and can meet the tensile strength, tear strength, and long-term waterproof and corrosion-resistant performance required in civil engineering environments.

[0044] The flexible wrapping component 1 is equipped with a grouting assembly for grouting. The grouting assembly includes at least one grouting hole 5 at the bottom of the inflatable membrane bag and at least one venting hole 7 at the top of the inflatable membrane bag, both of which are connected to the interior of the casting cavity. The grouting hole 5 is located at the bottom of the inflatable membrane bag to facilitate pumping grout from bottom to top, ensuring dense filling and reducing air pockets. The venting hole 7 is located at the top of the inflatable membrane bag and integrates an automatic float valve. When the grout level rises to the top, the float automatically closes the valve under buoyancy to prevent grout overflow. Furthermore, the flexible wrapping component 1 is equipped with a deflation assembly for inflation and deflation. Specifically, the deflation assembly includes a deflation hole 6 located at the top of the inflatable membrane bag. A one-way valve is installed at the deflation hole 6 to inject gas into the inflatable membrane bag, causing it to expand and solidify.

[0045] Furthermore, the cavity is filled with a functional material, which is a fluidized solidified soil slurry incorporating an ion-conducting electrolyte. The electrolyte is an aqueous solution that provides an ion-conducting pathway, and its type and concentration can be selected based on the required conductivity and compatibility with the material. This includes, but is not limited to, alkaline electrolytes such as KOH and NaOH, acidic electrolytes such as H₂SO₄, or neutral electrolytes such as Na₂SO₄ and KCl. Specifically, for example, a 4M to 8M KOH alkaline electrolyte solution with a spread of 180±10 mm can be used. When an alkaline electrolyte is selected, the pH value after solidification should be maintained within a stable range of 12 to 12.5 to achieve a synergy between the rheological properties and strength required for engineering and the ion conductivity required for energy storage. The solid material formed after the functional material solidifies possesses both ion conduction and mechanical load-bearing capacity.

[0046] A flexible diaphragm bag assembly 2 is disposed on the inner side of the flexible packaging assembly 1. The flexible diaphragm bag assembly 2 is fixed to the inner wall of the flexible packaging assembly 1 by adhesive bonding, sewing, or heat sealing. The flexible diaphragm bag assembly 2 consists of multiple independent flexible diaphragm bags. Each flexible diaphragm bag is made of an electronically insulating material with a controllable microporous structure. Its core characteristic is that it allows electrolyte ions and water molecules to pass through, i.e., it has liquid permeability; at the same time, it can block direct electron conduction, i.e., it has electronic insulation. The materials used to make the flexible diaphragm bags include, but are not limited to: industrial-grade non-woven fabric, electrolyte-resistant fiberglass mesh, or porous polymer membrane. The selected materials must maintain structural integrity and ion permeability in the target electrolyte environment. The flexible diaphragm bag electrically isolates adjacent electrodes to prevent short circuits, while possessing excellent ion permeability, ensuring that water molecules and electrolyte ions in the externally filled functional material, i.e., the fluidized solidified soil slurry, can smoothly pass through the bag wall and fully wet the internally contained electrode plates, thereby forming a connected ion transport pathway. When the electrode is connected to an external circuit, ions are rapidly adsorbed / desorbed at the electrode-electrolyte interface through this pathway, achieving efficient charge storage and release based on the double-layer principle.

[0047] Each flexible diaphragm bag is rectangular. In any cross-section perpendicular to the axis of the flexible packaging assembly 1, every two flexible diaphragm bags are arranged radially side-by-side to form an electrode pair receiving unit, used to accommodate one positive electrode sheet and one negative electrode sheet respectively. This arrangement ensures that the space between the positive and negative electrode sheets is minimized, thereby forming an effective and efficient electrochemical coupling interface after the functional material is filled, constructing an electric double-layer capacitor; multiple electrode pair receiving units are evenly distributed along the inner circumferential direction of the flexible packaging assembly 1. The total volume of all flexible diaphragm bags does not exceed 15% of the total volume of the internal cavity after the flexible packaging assembly is inflated and shaped, to ensure that the functional material is fully filled and forms a continuous ion pathway, while ensuring the structural integrity.

[0048] The geometric dimensions of each flexible diaphragm bag are jointly determined by the characteristic dimension D of the target filling space and the overall radial thickness W of the cast cavity formed after inflation. The characteristic dimension D of the target filling space is defined as follows: for cylindrical modules, it is the outer diameter; for rectangular cross-section modules, it is the length of the long side of the cross-section; for other shapes, it is a representative dimension taken from the direction that is equivalent to or most spatially constrained by the target filling space volume.

[0049] The axial length L of a single flexible diaphragm bag satisfies: ;in, This is the length scaling factor, with a value ranging from 0.15 to 0.25;

[0050] The width B of a single flexible diaphragm bag satisfies: ;in, This is the width scaling factor, with a value ranging from 0.075 to 0.125;

[0051] The thickness T of a single flexible diaphragm bag satisfies: ;in, This is the thickness scaling factor, with a value ranging from 0.0125 to 0.01875.

[0052] Multiple sets of flexible diaphragm bags extend along the axial direction of the energy storage unit at fixed intervals, forming a regularly arranged three-dimensional spatial array within the casting cavity. Each flexible diaphragm bag has an outlet hole on its outer ring side for threading electrode leads 9. Furthermore, the minimum interval S between the multiple sets of flexible diaphragm bags arranged along the axial direction of the energy storage unit satisfies:

[0053] ;in, This is the axial spacing proportionality coefficient, with a value ranging from 0.02 to 0.035. This is the length influence coefficient, with a value ranging from 0.15 to 0.25. , where is the length of a single energy storage unit, in meters (m).

[0054] This relationship shows that the value of S is determined by the characteristic size D and the length of a single energy storage unit. The ratio of the two elements and the overall radial thickness W of the cast cavity formed after inflation determine the spacing of the electrodes, which can be adjusted according to the length parameters of the energy storage unit in the actual project. This optimizes the axial integrity of the structure while meeting the minimum electrolyte thickness electrochemical requirements.

[0055] Each flexible diaphragm bag in the flexible diaphragm bag assembly 2 is provided with a flexible electrode sheet, forming an electrode module 3. The flexible electrode sheet has a minimum... High-surface-area flexible electrode sheets are housed within flexible diaphragm bags. One end of the flexible electrode sheet has a bare conductive area without active material coating, serving as a protruding terminal 4, which is connected to corrosion-resistant electrode leads 9 via a low-resistance soldering process. The electrode leads 9 are connected to external wiring connectors 10, which are led out via circuit leads 11, forming a circuit connection system for the electrical connection of the entire device. Specifically, the positive and negative flexible electrode sheets within each electrode pair housing unit are connected to electrode leads 9, which then pass through the lead-out holes in the flexible diaphragm bags. After waterproof sealing of the portion of the electrode leads 9 passing through the lead-out holes, all positive leads within the same energy storage unit are connected to the positive bus, and all negative leads are connected to the negative bus, leading out via circuit leads 11 to achieve parallel connection and external connection of all electrode modules 3 within the energy storage unit. Furthermore, adjacent energy storage units are electrically connected via a reconfigurable plug-in electrical connection device 14. The reconfigurable plug-in electrical connection device 14 is a key component of the circuit connection system, used to achieve rapid and reliable switching of the electrical connection logic between adjacent energy storage units in series or parallel. Preferably, this device employs a multi-position manual rotary switch, with multiple main terminals 16 connected to the interface terminals of the total positive and negative buses of two adjacent energy storage units. By rotating the switch handle 15 to different positions, the switching of the electrical connection logic between adjacent energy storage units in series or parallel is achieved. The reconfigurable plug-in electrical connection device 14 is equipped with an independent maintenance window with a waterproof sealing cover. This maintenance window corresponds to the operation window 18 on the flexible protective cover 12, allowing independent operation, isolation, or bypassing of the electrical connection logic of any energy storage unit without compromising the overall protection.

[0056] In another preferred embodiment, one or more of the series-connected energy storage units are provided with a flexible protective jacket 12 to enclose all electrode leads 9, line connectors 10, circuit leads 11, and some grouting holes 5 and inflation / deflation holes 6 extending from the inflatable membrane bag, providing uniform mechanical protection and environmental isolation. The flexible protective jacket 12 is made of a high-strength, wear-resistant, and corrosion-resistant flexible composite material. In this embodiment, the material is specifically an aramid fiber reinforced polyurethane (TPU) composite material.

[0057] The flexible protective jacket 12 is an independent tubular or segmented structure. For segmented structures, a protective jacket butt joint 13 is provided at the joint to achieve opening, closing, and sealing. Preferably, the flexible protective jacket 12 is made of high-strength polyester fabric coated with polyvinyl chloride (PVC) or thermoplastic polyurethane elastomer (TPU). The protective jacket butt joint 13 is opened and closed by a longitudinal waterproof zipper or Velcro, and the ends are sealed and tied to achieve a sealed connection with adjacent flexible protective jackets 12. Furthermore, the flexible protective jacket 12 has an operating window 18 with a sealing cap at its end corresponding to the grouting hole 5 and the air filling / deflating hole 6 of the flexible wrapping component 1.

[0058] The above-mentioned method for preparing a flexible, fillable, and rapidly assembled energy storage module specifically includes the following steps:

[0059] Step 1: Factory Prefabrication: Assemble the flexible electrode sheet and electrode lead 9, place them into a liquid-permeable flexible diaphragm bag, and seal the bag opening to prevent the electrode from falling out, forming an electrode module 3 with ion permeation capability; fix multiple electrode modules 3 evenly along the circumference of the inner wall of the inflatable membrane bag, and integrate grouting holes 5, venting holes 7, inflation / deflation holes 6, and connecting components for connecting energy storage units; connect the electrode leads 9 in the same energy storage unit to the line connector 10, and install a rotary changeover switch at the end of each energy storage unit or in the protective space formed by the flexible protective jacket 12, as a reconfigurable plug-in electrical connection device 14. In the factory prefabrication stage, preset the switch handle 15 to the required position (e.g., parallel position), and connect its multiple main terminals 16 to the positive and negative bus lines of two adjacent energy storage units respectively.

[0060] Step 2: On-site installation and assembly: Place the prefabricated energy storage unit at the target installation location, such as a trench or pit, and use the inflation / deflation system to expand and shape it; for multi-segment projects, according to the target electrical parameters of total voltage or total capacity, select the parallel or series connection position by rotating the operating handle 15 of the changeover switch to the corresponding position; select the required connection mode to realize the electrical connection between adjacent energy storage units, and use the mechanical connection component 8 to complete the physical fixation.

[0061] Step 3: System Testing: After completing the splicing and electrical connection, conduct continuity, insulation and functional tests on each energy storage unit and the overall circuit. Only after confirming that there are no problems can subsequent work be carried out.

[0062] Step 4: Overall protection installation: Put the flexible protective jacket 12 over the outside of one or more connected energy storage units, close and seal it through the butt joint 13 of the protective jacket, so that all external leads and connection interfaces are under the protection of the flexible protective jacket 12. The operating handle 15 of the rotary changeover switch is located inside the operating window 18 of the flexible protective jacket 12.

[0063] Step 5: Material pouring: Through the operation window 18 reserved on the flexible protective jacket 12, pump the fluid solidified soil slurry mixed with ion-conductive electrolyte into the inflatable membrane bag through the grouting hole 5 and the vent hole 7 of the grouting component until the filling is completed.

[0064] Step Six: Curing and Integration: After the fluidized solidified soil slurry has been completely cured, the main circuit leads 11 at both ends of the entire energy storage module are led out and connected to the external energy management system through the sealed outlet at the end of the flexible protective jacket 12.

[0065] This invention combines high energy storage density, excellent structural reliability, long-term environmental durability, overall external protection, convenient construction and reconfigurable electrical connections. It integrates structure and function, enabling high prefabrication in the factory, plug-and-play on-site, and seamless integration with conventional backfilling processes.

[0066] Example 1

[0067] This embodiment provides a flexible, infillable, and rapidly assembled energy storage module for backfilling in municipal engineering projects, such as providing energy storage for street lighting systems. Specifically, depending on the target installation location, the energy storage module in this embodiment is designed to fill a cylindrical space, with the characteristic dimension D of the target filling space being the outer diameter, designed to be 500mm. The length of each energy storage unit... The length is 2 meters, and the overall radial thickness W of the cast cavity formed after inflation is 150 mm.

[0068] The specific production method and process are as follows:

[0069] Step 1: Factory Prefabrication

[0070] Electrode module 3 is fixed to the inner wall of the inflatable membrane bag by adhesive. The microporous structure of the flexible diaphragm bag itself ensures that electrolyte ions in the slurry can permeate through the bag wall during subsequent casting processes, thereby making full contact with the electrode surface inside the bag and forming a continuous ion transport pathway. Electrode leads 9 pass through the pre-set outlet holes of the flexible diaphragm bag, and then the periphery of the outlet holes is sealed with waterproof sealant. This sealing operation aims to prevent slurry leakage from the threading holes, while ensuring that the other parts of the flexible diaphragm bag, except for the outlet holes, maintain their inherent liquid permeability. All positive and negative leads are connected to the line connector 10, and a rotary changeover switch with a rated current of 32A and a protection rating of IP65 is installed at the end of each energy storage unit as a reconfigurable plug-in electrical connection device 14. In this embodiment, an LW26 series changeover switch conforming to industrial standards is specifically used. The four main terminals 16 of the switch are respectively connected to the total positive and negative terminals of the corresponding energy storage units, as well as the reserved positive and negative terminals of the interfaces of adjacent energy storage units. The rotary handle 15 of the rotary changeover switch has clear position markings 17, including parallel position (position I) and series position (position II). During factory prefabrication, the handle 15 is preset to the parallel position (position I). Grouting holes 5, air inflation / deflation holes 6, and air vents 7 are installed on the inflatable membrane bag. At the same time, a mechanical connection component 8 is provided at the end of each energy storage unit. In this embodiment, an industrial-grade waterproof zipper sewn and fixed to the edge of the membrane bag is used to achieve physical docking between adjacent units. In addition, a tubular flexible protective jacket 12 is independently prepared, and its material is black weather-resistant PVC-coated polyester fabric. The end of the flexible protective jacket 12 is provided with a protective jacket butt joint 13 for docking and sealing. The specific structure of the protective jacket butt joint 13 can be a waterproof clamp or a high-strength binding strap. An operating window with a flip cover is heat-sealed on the flexible protective jacket 12. At the installation position corresponding to the rotary changeover switch, the operation window 18 is set as a dedicated window with a sealed cover, so that the operation handle 15 can be exposed.

[0071] Step Two: On-site Installation and Assembly

[0072] The prefabricated energy storage units are placed sequentially at the target installation locations, such as trenches or pits. First, the inflatable membrane bag of the first energy storage unit is placed in the predetermined position, and gas is injected through the inflation / deflation port 6 to inflate and shape it. Subsequently, the inflatable membrane bag of the second energy storage unit is placed in the adjacent predetermined position, and is similarly inflated and shaped through the inflation / deflation port 6.

[0073] After the two adjacent energy storage units are finalized, the mechanical connection component 8 of the second energy storage unit is aligned and fastened to the corresponding connection component of the first energy storage unit to complete the physical docking of the two.

[0074] At this point, since the rotary changeover switch at the ends of the two energy storage units has been pre-set to the parallel position (position I) at the factory, the electrical connection between the two units is automatically completed simultaneously with the physical connection: in the parallel position, the internal contacts of the switch have connected the positive terminal P1 of the first energy storage unit to the positive terminal P2 of the second energy storage unit, and the negative terminal N1 of the first energy storage unit to the negative terminal N2 of the second energy storage unit, thereby realizing the parallel connection of the two energy storage units in electrical logic. If it is necessary to check or change to the series mode, the rotary handle 15 can be operated to the series position (position II) through the operation window 18 on the flexible protective cover 12.

[0075] For projects containing more energy storage units, repeat the above process: place them sequentially, inflate and shape them, and then physically connect them. The series or parallel electrical connection mode of all units can be independently set at each connection point by operating the corresponding rotary switch.

[0076] Step 3: System Detection

[0077] Using multimeters and other testing equipment, the voltage and internal resistance of the two connected energy storage units were tested respectively, and the insulation resistance of the overall circuit was checked to confirm that the electrical connection was correct, the insulation was good, and the function was normal.

[0078] Step 4: Size Design

[0079] Given D=500mm, W=150mm, Select the median coefficient: , , , , .

[0080] Calculation yielded:

[0081] Axial length of flexible diaphragm bag ;

[0082] Flexible diaphragm bag width ;

[0083] Flexible diaphragm bag thickness ;

[0084] Minimum spacing S of multiple sets of flexible diaphragm bags arranged axially: Basic item ; Length Influence Item Taking the maximum value, we get... This design optimizes space utilization while ensuring an effective electrolyte thickness between electrodes.

[0085] Step 5: Overall Protection Installation:

[0086] The prefabricated flexible protective jacket 12 is fitted over the two connected energy storage units, and the waterproof zipper is closed to completely enclose the device. The flexible protective jacket 12 is tightened at both ends with stainless steel clamps to create a sealed environment, protecting all exposed electrical components. The operating handle 15 of the changeover switch is located inside the operating window 18 of the flexible protective jacket 12.

[0087] Step Six: Material Pouring and Curing

[0088] Open the corresponding bottom operating window 18 on the flexible protective jacket 12, connect the pumping pipeline to the grouting hole 5, and pour the fluidized solidified soil slurry. In this embodiment, the functional material used is a fluidized solidified soil slurry with a spread of 185mm, and a 6M KOH aqueous solution is used as the ion-conducting electrolyte. Observe the status of the vent 7 through the top window. After pouring, close all operating windows 18. The slurry is cured for 7 days under the additional protection of the protective jacket to form a stable backfill.

[0089] Step 7: Circuit Integration

[0090] At the end of the backfill section, loosen the clamps at the end of the flexible protective jacket 12, carefully lead out the main positive and main negative circuit leads 11, connect them to the pre-buried street light energy storage system junction box, and then reseal the end of the flexible protective jacket 12.

[0091] Example 2

[0092] This embodiment provides a flexible, infillable, and rapidly assembled energy storage module for slope reinforcement energy storage projects. In slope anchoring energy storage projects requiring higher voltage, the target is an anchoring hole or a similar elongated structure, and the length of each energy storage unit is... It is 5 meters long. The specific manufacturing method and process of this embodiment differ from that of Embodiment 1 only in the following aspects:

[0093] Electrical Connection: After assembling and physically fixing multiple energy storage units on site, rotate the rotary changeover switch handle 15 on each energy storage unit from the parallel position (position I) to the series position (position II) through the operating window on the flexible protective cover 12. In this position, the internal contacts of the rotary changeover switch connect the total positive terminal P1 of the previous energy storage unit to the negative terminal N2 of the next energy storage unit, and simultaneously connect the total negative terminal N1 of the previous energy storage unit to the positive terminal (P2) of the next energy storage unit, thereby achieving electrical series connection between adjacent segments and increasing the total output voltage.

[0094] Functional material: The functional material used in this embodiment is the same as that in embodiment 1, which is a fluidized solidified soil slurry with a spread of 185 mm and mixed with 6 MKOH electrolyte solution.

[0095] Size design: When calculating the minimum spacing S of multiple sets of flexible diaphragm bags arranged axially, the length influence term becomes The value is still much larger than the basic value of 3.75 mm, so S is still taken as 200 mm. This reflects the stability of the formula and its adaptability to long pipe sections.

[0096] The remaining steps are exactly the same as in Example 1.

[0097] The final device provides structural reinforcement while outputting a high DC voltage.

Claims

1. A flexible, fillable, and rapidly assembled energy storage module, characterized in that, The system includes one or more segmented energy storage units, with adjacent units physically connected via end-integrated connectors. Each energy storage unit is equipped with a flexible encapsulation assembly, which, when inflated, forms a casting cavity. The casting cavity is filled with functional materials. A flexible diaphragm bag assembly is located inside the flexible encapsulation assembly. This assembly consists of multiple liquid-permeable flexible diaphragm bags fixed to the inner wall of the flexible encapsulation assembly. Each flexible diaphragm bag is made of porous insulating diaphragm material, used to house electrode plates and allow ion permeation. The electrode plates are housed within the flexible diaphragm bags, and the leads connecting the electrode plates converge to form an electrical interface. Adjacent energy storage units are connected via a reconfigurable plug-in electrical connection device to switch between series and parallel connection logic. The functional material is a fluidized solidified soil slurry mixed with an ion-conducting electrolyte. The electrolyte is an aqueous solution that provides an ion-conducting pathway, and its type and concentration are selected according to electrochemical performance and engineering requirements. The slurry has a spread of 180 mm ± 10 mm and has ion conduction and mechanical load-bearing functions after solidification.

2. The flexible, fillable, and rapidly assembled energy storage module according to claim 1, characterized in that: The flexible packaging component is an inflatable membrane bag made of fiber-reinforced flexible composite material, which can be designed as a ring, a long strip, or other shapes that adapt to the target filling space as needed; the axial ends of the inflatable membrane bag are closed.

3. The flexible, fillable, and rapidly assembled energy storage module according to claim 2, characterized in that: The flexible wrapping component is provided with a grouting component for grouting, including at least one grouting hole at the bottom of the inflatable membrane bag and at least one venting hole at the top of the inflatable membrane bag, and both the grouting hole and the venting hole are connected to the interior of the casting cavity to pump grout from the bottom to the top.

4. A flexible, fillable, and rapidly assembled energy storage module according to claim 3, characterized in that: An automatic float valve is integrated at the vent.

5. A flexible, fillable, and rapidly assembled energy storage module according to claim 1, characterized in that: The flexible diaphragm bag assembly is fixed to the inner wall of the flexible packaging assembly by adhesive, sewing or heat sealing. The flexible diaphragm bag assembly includes multiple sets of liquid-permeable flexible diaphragm bags arranged at intervals along the axial direction of the energy storage unit. Each set of flexible diaphragm bags includes multiple sets arranged circumferentially along the inner side of the energy storage unit. The total volume of all flexible diaphragm bags does not exceed 15% of the total volume of the internal cavity after the flexible packaging assembly is inflated and shaped.

6. A flexible, fillable, and rapidly assembled energy storage module according to claim 5, characterized in that: The axial length, width, and thickness of each flexible diaphragm bag are jointly determined by the characteristic dimension D of the target filling space and the overall radial thickness W of the cast cavity formed after inflation. For a cylindrical shape, the characteristic dimension D of the target filling space is the outer diameter; for a rectangular shape, the characteristic dimension D of the target filling space is the length of the long side of the cross-section; for other shapes, the representative dimension of the volume equivalent or the direction of the tightest spatial constraint is taken.

7. A flexible, fillable, and rapidly assembled energy storage module according to claim 5, characterized in that: The electrode sheet is a flexible electrode sheet with a high specific surface area of ​​not less than 1000 m² / g, and the lead wires are waterproofed and sealed at the exit holes of the flexible diaphragm bag.

8. A flexible, fillable, and rapidly assembled energy storage module according to claim 1, characterized in that: It also includes a flexible protective jacket that wraps around one or more segmented energy storage units to provide protection, and has an operating window with a sealed cover.

9. A method for preparing a flexible, fillable, and rapidly assembled energy storage module according to any one of claims 1 to 8, characterized in that, Specifically, the following steps are included: Factory prefabrication: The electrode sheet and lead wire are put into a liquid-permeable flexible diaphragm bag to form an electrode module. The electrode module is fixed to the inner wall of the flexible wrapping component. A reconfigurable plug-in electrical connection device is installed. The reconfigurable plug-in electrical connection device is preset to the target series or parallel position. On-site assembly: The prefabricated energy storage unit is placed in the target filling space and inflated to shape. The reconfigurable plug-in electrical connection device is adjusted to achieve series-parallel switching, and physical fixation is completed through mechanical connection components. System testing: Conduct continuity, insulation, and functional tests on each energy storage unit and the overall circuit. Protection and Casting: Install and seal a flexible protective jacket, and fill the casting cavity with functional material through the grouting assembly; Integrated maintenance: After the functional materials have cured and maintained, the main circuit leads are led out and connected to the external energy management system.

Images