Prefabricated road pavement energy storage system

Abstract

This invention belongs to the field of energy storage technology and provides a prefabricated road surface energy storage system, including several battery modules, a thermal management system, and an electrical connection system. The battery modules are disposed at the lower end of the road base layer and include two battery layers and a liquid-cooled plate layer located in the middle of the battery layers. The liquid-cooled plate layer includes a liquid-cooled plate with cooling liquid channels inside. The thermal management system includes thermally conductive adhesive connecting layers between the upper battery layer and the upper surface of the liquid-cooled plate, and between the lower battery layer and the lower surface of the liquid-cooled plate. The electrical connection system includes intra-layer busbars, inter-layer busbars, and outgoing busbars, connecting the individual battery cells of the two battery layers in series into a continuous link. Each end face of the entire battery module is equipped with an end plate, and the upper end plate is provided with an elastic element. An energy storage shell is provided on the outside of the end plate. This invention improves the feasibility and promotional value of prefabricated road surface energy storage systems in practical engineering.

Description

Technical Field

[0001] This invention belongs to the field of energy storage technology, specifically relating to a prefabricated road surface energy storage system. Background Technology

[0002] The statements in this section are merely background information related to the present invention and do not necessarily constitute prior art.

[0003] Clean transportation tools, represented by new energy vehicles, are showing a rapid growth trend, and the demand for supporting infrastructure such as charging and swapping facilities and distributed energy storage systems is increasing significantly in tandem.

[0004] However, with the continuous improvement of urbanization, urban land resources are becoming increasingly scarce, especially in core urban areas and transportation hubs, where space available for the construction of new charging stations, energy storage power stations, and other energy facilities is extremely limited. Traditional ground-mounted energy storage systems often occupy a large land area and are difficult to coordinate with existing roads and municipal facilities, thus restricting the large-scale deployment of new energy transportation infrastructure.

[0005] Prefabricated pavement energy storage technology is gradually gaining attention. It typically embeds the energy storage system in the form of modular components inside the road structure, making the energy storage device an integral part of the overall road structure. This allows for the combined use of road traffic function and electrical energy storage function without occupying additional ground space.

[0006] However, existing prefabricated ground-based energy storage technologies still face many technical challenges that urgently need to be overcome in engineering applications. Firstly, because the space beneath roads is typically a relatively enclosed underground environment with limited ventilation and significantly affected by factors such as construction depth and structural dimensions, the arrangement and installation structure of battery modules in traditional energy storage systems are difficult to directly adapt to such application scenarios. Furthermore, roads continuously endure periodic dynamic loads and instantaneous impacts from vehicle traffic during long-term service, leading to significant mechanical vibration and fatigue effects. This highlights the shortcomings of existing technologies: traditional battery modules often use thick, rigid metal busbars for electrical connections and generally lack vibration damping design. Under long-term vibration, this rigid connection cannot effectively absorb displacement and deformation, easily leading to stress concentration. This not only causes relative displacement, structural loosening, or mechanical damage to battery cells, electrical connectors, and supporting components, but also induces metal fatigue cracks at welds or joints.

[0007] The aforementioned defects greatly increase the risk of electrical failure in the system, severely restricting the overall safety and service life of prefabricated road energy storage systems. Summary of the Invention

[0008] To address the aforementioned problems, this invention proposes a prefabricated road surface energy storage system. This invention enables the integration of energy storage systems with urban roads and other public infrastructure without increasing land occupation. Furthermore, it balances structural load-bearing capacity and vibration damping performance within limited space, thereby enhancing the feasibility and promotional value of prefabricated road surface energy storage systems in practical engineering projects.

[0009] According to some embodiments, the present invention adopts the following technical solution: A prefabricated road surface energy storage system includes several battery modules, a thermal management system, and an electrical connection system, wherein: The battery module is disposed at the lower end of the road base layer. The battery module includes two battery layers and a liquid cooling plate layer located in the middle of the battery layers. Each battery layer is formed by several battery cells arranged side by side along the length of the sandwich structure. The liquid cooling plate layer includes a liquid cooling plate, and the liquid cooling plate has a cooling liquid flow channel inside. The thermal management system includes a thermally conductive adhesive bonding layer disposed between the upper battery layer and the upper surface of the liquid cooling plate, and between the lower battery layer and the lower surface of the liquid cooling plate. This allows the heat generated by the batteries in the two battery layers to be conducted to the liquid cooling plate through the thermally conductive adhesive bonding layer and carried out of the battery module through the cooling liquid flow channel, thereby achieving synchronous cooling of the upper and lower battery cells. The electrical connection system includes an intra-layer bus, an inter-layer bus, and a lead-out bus. The intra-layer bus is disposed between adjacent cells in each battery layer. The inter-layer bus is used to connect two battery layers. The inter-layer bus is connected to the intra-layer bus and the lead-out bus, so that each battery cell in the two battery layers is connected in series to form a continuous link. Each end face of the entire battery module is equipped with an end plate, and the end plates are fixedly connected to each other. The side end plates are reserved with liquid cooling pipe inlets and outlets, electrical interfaces and signal interfaces, and the upper end plate is equipped with an elastic element. An energy storage shell is set on the outside of the end plate. One end of the elastic element abuts against the corresponding end plate, and the other end abuts against the inner wall of the energy storage shell. The elastic element provides elastic support and isolates vibration and impact loads.

[0010] As an alternative implementation, each battery layer is composed of multiple battery cells arranged sequentially along the length of the battery module, and each battery cell is arranged horizontally.

[0011] As an alternative implementation, the inlet and outlet of the coolant flow channel are arranged on the same side of the liquid cooling plate; the coolant interface side of the liquid cooling plate is located on the same side as the electrical input / output port and the signal output port.

[0012] As an alternative implementation, the intralayer busbar is welded to the positive and negative electrodes of adjacent battery cells in the same layer, the interlayer busbar is welded to the positive and negative electrodes of the battery cells at the ends of the upper and lower layers of batteries, and the lead-out busbar is welded to the positive and negative electrodes of the battery cells at the beginning of the upper and lower layers of batteries for connection to the outside.

[0013] As an alternative implementation, the middle of both the intralayer busbar and the interlayer busbar is provided with a transition protrusion, an arched transition section, or a bent elastic buffer section that runs through the width direction.

[0014] As an alternative implementation, the battery cell is provided with a limiting guard plate and a signal acquisition device on the tab side. The limiting guard plate is made of flame-retardant insulating material, extends along the length of the module, and covers and isolates the busbar area, the sampling device area, and the non-functional conductive area. The limiting guard plate has functional openings corresponding to the pressure relief valve, the busbar connection point, and the sampling point.

[0015] As a further defined implementation, the intralayer busbar, interlayer busbar and lead-out busbar form a cooperative constraint relationship with the limiting guard plate through adhesive bonding, embedding or partial limiting methods, so that the vibration load is preferentially borne by the guard plate and its mounting base, rather than entirely borne by the busbar weld joints; The signal acquisition device is set along the length of the battery module and is connected to the voltage sampling point and / or temperature sampling point of each battery cell through a multi-point sampling line.

[0016] As an alternative implementation, a heat insulation sheet is provided between two adjacent battery cells on the same layer. The heat insulation sheet is connected to the outer wall of the adjacent battery cell through adhesive layers on both sides to form a stable connection structure, which is used to delay the rapid conduction of heat directly to the adjacent cell in the early stage of abnormal heating or thermal runaway of the cell.

[0017] As an alternative implementation, each battery module has composite rubber vibration isolation springs installed at the four corners of its upper surface end plate. The composite rubber vibration isolation springs include upper and lower metal mounting end plates and a drum-shaped rubber elastic body vulcanized in the middle. The upper metal end plate is bonded to the surface of the energy storage shell, and the lower metal end plate is fixed to the upper surface end plate of the battery module by bolts.

[0018] As an alternative implementation, the battery module is provided with two separate circumferential straps on its outer periphery, which are respectively arranged on both sides of the module; the straps are closed along the circumference of the module and form an overall enclosure around the module. The battery module is also covered with a sealed shell, and a waterproof and breathable valve is provided on the non-stress side of the sealed shell to balance the internal and external pressure difference and discharge internal condensation.

[0019] As an alternative implementation, the individual battery cells within the battery module are connected in series, different battery modules are connected in parallel, and multiple battery cells in the same layer are connected in series end to end in a predetermined order to form a single series circuit. The positive terminal of the previous battery cell is electrically connected to the negative terminal of the next battery cell. The two ends of the series link serve as the positive and negative output terminals of the battery module, respectively. The battery cells in the upper and lower layers are also connected in series. The same-name terminals of each battery module are connected in parallel to the system DC bus, that is, the positive terminals of each module are connected in parallel to form the system positive bus, and the negative terminals of each module are connected in parallel to form the system negative bus.

[0020] Compared with the prior art, the beneficial effects of the present invention are as follows: In terms of heat dissipation and space utilization, this invention adopts a centrally located liquid-cooled plate sandwich structure and an interface integrated design on the same side, which meets the underground height constraints, achieves good heat conduction, and can improve assembly efficiency and temperature consistency.

[0021] In terms of structural load-bearing capacity, the horizontal arrangement of the battery terminals avoids the direct pressure of longitudinal loads on the terminals. Combined with the stable enclosure of the outer left and right circumferential straps, this invention helps to improve the overall load-bearing capacity and structural stability of the system.

[0022] In terms of vibration reduction and buffering to cope with complex loads, this invention uses multiple designs, such as the bus transition protrusion absorbing deformation, the insulating protective plate bearing mechanical stress, and the addition of rubber vibration isolation springs between the module upper surface end plate and the system shell, to reduce the impact of lateral and longitudinal mechanical vibrations on the battery cell.

[0023] This invention arranges the batteries with horizontally placed terminals. By changing the spatial orientation of the battery terminals, the longitudinal load generated during battery module loading is less likely to be directly transmitted to the terminals and their connection areas. Instead, it is preferentially transmitted through the battery casing, end plates, and supporting structures. This helps reduce the stress concentration at the terminals, lowers the risk of terminal damage and structural failure, and improves the structural reliability of the battery module. Since stress concentration easily occurs at locations with abrupt changes in cross-sectional shape, and the surface corresponding to the terminals has a composite structure of metal and plastic seals, it is a natural stress concentration point. By changing the spatial orientation of the battery terminals, the longitudinal load is less likely to be directly transmitted to the terminals during module loading, thereby reducing the risk of terminal stress and structural damage. Using this technical solution, the overall load-bearing capacity and structural stability of the battery module can be improved, thus enhancing the module's applicability and reliability under complex working conditions.

[0024] The heat generated by the battery cell during charging and discharging is first conducted from the inside of the battery cell to its heat dissipation contact surface, then transferred to the surface of the liquid cooling plate through the thermally conductive adhesive layer, and then conducted through the liquid cooling plate body to the inner flow channel wall of the liquid cooling plate. Finally, the heat is carried away by the convective heat transfer of the coolant in the flow channel.

[0025] The intralayer busbar and interlayer busbar structures of the present invention both have a transition protrusion in the middle that runs through the width direction. These are used to reduce the influence of lateral load and longitudinal load on the busbar connection, respectively. That is, when facing vibration or impact from the external environment, the structure can play a mechanical damping and buffering role, effectively isolate the transmission of high-frequency vibration between adjacent cells, reduce the force amplitude of the pole, and fundamentally avoid fatigue fracture caused by stress concentration.

[0026] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0027] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0028] Figure 1 This is a diagram of the battery module layout architecture proposed in this invention; Figure 2 This is the electrical connection diagram of the battery module proposed in this invention; Figure 3 This is a schematic diagram of the limiting guard plate and accessories proposed in this invention; Figure 4 This is an internal electrical connection diagram of the energy storage system proposed in this invention; Among them, 1 is the outer shell of the energy storage system, 2 is the waterproof and breathable valve, 3 is the road surface, 4 is the road base layer, 5 is the upper surface end plate, 6 is the rubber vibration isolation spring, 7 is the battery cell, 8 is the liquid cooling plate and side end plate, 9 is the limiting guard plate, 10 is the in-layer busbar, 11 is the lead-out busbar, 12 is the signal acquisition device, 13 is the inter-layer busbar, 14 is the left binding strap, 15 is the right binding strap, 16 is the lower surface end plate; 17 is the liquid cooling plate, 18 is the connection / sampling part of the signal acquisition device, 19 is the sampling base of the signal acquisition device, 20 is the pressure relief valve, and 21 is the signal interface of the signal acquisition device. Detailed Implementation

[0029] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0030] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0031] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0032] Where there is no conflict, the embodiments and features described in this application may be combined with each other.

[0033] Example 1 A prefabricated road surface energy storage system includes several battery modules. In this embodiment, the battery modules are suitable for underground energy storage scenarios such as urban roads, logistics park roads, bus stops, and highways, where structural height is limited, load-bearing requirements are high, and vibration conditions are complex. The battery modules can serve as the core energy storage components of the prefabricated road surface energy storage unit, installed inside the box or load-bearing cavity of the prefabricated road surface 3 or on the road base layer 4. They have an energy storage system shell 1 and are connected to an external battery management system, liquid cooling circulation system, and power distribution system, forming a prefabricated road surface energy storage system with energy storage, power supply, and road coordination functions.

[0034] like Figure 1 As shown, the battery module in this embodiment adopts a flattened box-like structure. Its length direction is consistent with the cross-sectional direction of the road, its width direction is consistent with the road paving direction, and its height direction is the road surface thickness direction. Preferably, the module has a cuboid shape. To accommodate the space constraints of road installation, the battery module can be designed as a low-profile structure, and its total height is preferably no greater than the allowable installation height of a conventional shallow-buried road surface energy storage cavity.

[0035] In this embodiment, the battery module adopts a sandwich arrangement of "upper battery pack - middle liquid cooling plate - lower battery pack". The upper battery pack and the lower battery pack are arranged opposite each other, with a liquid cooling plate 17 sandwiched between them, forming a layered structure that is symmetrical or approximately symmetrical along the thickness direction of the module. Each battery pack consists of multiple battery cells 7 arranged sequentially along the length of the module, and each battery cell 7 is arranged horizontally. That is, the axial direction of the terminal post or tab of the battery cell 7 is not along the height direction of the module, but extends basically along the width direction of the module, which is different from the traditional vertical arrangement of the terminal post. Through this horizontal arrangement, the probability of vertical pressure and road vibration loads on the road surface being directly transmitted to the terminal post through the battery casing can be effectively reduced, thereby reducing the risk of fatigue damage to the terminal post welding area, sealing area and electrical connection area under long-term mechanical load.

[0036] In this embodiment, the battery cell 7 is preferably a rectangular aluminum-cased battery, but steel-cased batteries or other rechargeable battery cells 7 suitable for modular integration can also be selected according to system design requirements. The battery system is preferably a lithium iron phosphate battery to balance thermal stability, safety, cycle life, and cost. In this embodiment, the rated voltage of the cell is preferably 3.6V, and the cell capacity can be selected according to the target capacity of the module. For example, aluminum-cased lithium iron phosphate battery cells 7 in the range of 50Ah to 120Ah can be selected.

[0037] like Figure 2 As shown, in this embodiment, nine battery cells are arranged in each of the upper and lower layers, for a total of 18 battery cells. The nine battery cells in the upper layer and the nine battery cells in the lower layer together form a series module, which enables the module to form a high output voltage platform. Furthermore, all 18 battery cells within each module are connected in series to form a 1P18S series structure; multiple such modules are connected in parallel on the system side to form an energy storage array that meets the power and capacity requirements of the road energy storage system. Of course, without departing from the concept of this invention, the number of cells in a single module can also be set to 12, 16, 20, or other suitable numbers, and the number of cells in the upper and lower layers can also be equal or adaptively adjusted according to space utilization requirements. In this embodiment, the module's external dimensions are 1620mm × 210mm × 155mm (with an error of ±1.0mm), and its weight is 120kg to 140kg.

[0038] To further clarify the structural form of this embodiment, preferably, the wide side of the single battery cell is arranged along the length direction of the module, the thickness direction corresponds to the height direction of the module, and the two battery layers and the central liquid cooling plate 17 are stacked sequentially along the thickness direction.

[0039] The centrally located liquid cooling plate 17 is preferably a flat plate structure. In this embodiment, it is 20mm thick and has a U-shaped flow channel inside. The flow channel opening is circular, with a diameter of 10mm in this embodiment. The center of both the upper and lower flow channel openings is 50mm from the edge of the liquid cooling plate 17. To facilitate centralized arrangement of interfaces in a confined installation space, the liquid inlet and outlet of the liquid cooling plate 17 are located on the same side. This side also serves as the thermal management interface side of the module. Preferably, the electrical output terminal, signal acquisition interface, and liquid inlet and outlet interfaces of the liquid cooling plate 17 are integrated and arranged at the same end or side of the module to reduce the crossing of pipelines and wiring harnesses during on-site installation, thereby improving the convenience of batch installation of the module.

[0040] By arranging the wiring on the same side, the risk of interference between external wiring and pipelines is reduced, and the system assembly efficiency and space utilization are improved.

[0041] In terms of thermal management, thermally conductive adhesive bonding layers (with a thickness of less than 1 mm) are respectively provided between the upper battery pack and the upper surface of the liquid cooling plate 17, and between the lower battery pack and the lower surface of the liquid cooling plate 17. This serves both to fill the assembly gap between the battery casing and the liquid cooling plate 17 and to establish a stable heat conduction path. The heat generated during battery operation is conducted through the battery casing to the thermally conductive adhesive bonding layer, and then from the thermally conductive adhesive bonding layer to the central liquid cooling plate 17. The heat is then carried out of the module through the coolant circulation, thereby achieving synchronous cooling of the upper and lower battery cells 7.

[0042] Since the liquid cooling plate 17 is located between the two battery layers, it can shorten the heat transfer path from most of the battery cells 7 to the cooling components, and improve the uniformity of temperature distribution inside the module, compared to a scheme that places the cooling components separately on one side of the module. For high-temperature environments, solar irradiation heat storage environments, and high-rate charge and discharge conditions commonly encountered in road burial projects, the centrally located liquid cooling plate 17 structure adopted in this embodiment can more effectively suppress the formation of local hot spots, reduce the temperature difference between cells, and thus improve the overall module lifespan consistency and operational safety.

[0043] In terms of electrical connection, in this embodiment, each battery cell 7 is connected in series via an in-layer busbar 10, an inter-layer busbar 13, and a lead-out busbar 11. Adjacent cells in the upper battery pack are connected sequentially via the in-layer busbar 10, and adjacent cells in the lower battery pack are also connected sequentially via the in-layer busbar 10. The upper end cell is connected to the corresponding lower end cell via the inter-layer busbar 13, thus connecting the upper and lower layers into a continuous series link. The beginning and end of the module are connected via the lead-out busbar 11 to form the module's positive and negative output terminals, respectively. The busbars are preferably made of copper, aluminum, or a copper-aluminum composite conductive material, and have a nickel plating layer, a tin plating layer, or other anti-corrosion conductive coating on their surface. Both the intralayer busbar 10 and the interlayer busbar 13 are provided with a transition protrusion, an arched transition section or a bent elastic buffer section that runs through the width direction in the middle, so that when the battery module is subjected to road load, vibration impact or thermal expansion and contraction, the busbar itself can absorb part of the displacement and reduce the possibility of rigid tension acting directly on the welding point or the terminal connection position.

[0044] In this embodiment, a limiting guard plate 9 and a signal acquisition device 12 are provided on the battery tab side inside the module. The limiting guard plate 9 is preferably made of flame-retardant insulating material, extends along the length of the module, and is a long strip-type insulating component. It is preferably integrally formed or segmented spliced ​​from flame-retardant insulating material, and covers and isolates the busbar area, sampling device area, and non-functional conductive area. Functional openings corresponding to the pressure relief valve 20, busbar electrical connection point, and sampling point are provided on the guard plate to maximize the insulation shielding area while ensuring the necessary functions are exposed.

[0045] In this embodiment, the functional openings are elongated holes, rectangular holes, or irregularly shaped windows distributed in an array, and their opening sizes meet the principle of "exposing only the necessary functional parts and covering and shielding the non-functional conductive areas other than the functional openings".

[0046] All busbars are bonded to the limiting guard plate to ensure that mechanical loads such as vibration are borne by the insulating guard plate rather than by the busbars. In this embodiment, each busbar forms a cooperative constraint relationship with the limiting guard plate 9 through bonding, embedding, or partial limiting, so that the vibration load is preferentially borne by the guard plate and its mounting base, rather than entirely by the busbar welds, thereby reducing the fatigue impact of high-frequency micro-vibrations on the electrical connection structure during road use.

[0047] When multiple components bear external loads together, the load is distributed according to the stiffness ratio of the components. The stiffer the component, the more force it bears. Busbars are usually thin copper or aluminum busbars with extremely low stiffness, while insulating liner plates are usually much thicker, with an overall structural stiffness far exceeding that of the busbar. After the two are bonded together to form a composite whole, the mechanical loads transmitted from the outside are naturally borne by the extremely stiff liner plate, thus preventing the busbar from deforming due to excessive load.

[0048] like Figure 3 As shown, the signal acquisition device 12 includes an acquisition base 19 and multiple connection / sampling parts 18 spaced apart on the edge of the acquisition base. The multiple connection / sampling parts 18 are arranged in an array along the length of the device and are used to connect to the corresponding cell signal points (such as voltage sampling points or temperature sampling points) of each battery cell 7 point by point to realize multi-channel synchronous acquisition.

[0049] In this embodiment, a mica sheet is disposed between adjacent battery cells 7. This mica sheet, with a thickness of 0.4mm to 0.6mm, is located between two adjacent battery cells 7 in the same row. It is connected to the outer wall of the adjacent battery cells 7 via adhesive layers on both sides, forming a stable connection structure. The preferred material is mica, which possesses insulation, flame retardancy, and heat resistance. This structure can, to a certain extent, delay the rapid direct transfer of heat to adjacent cells during the early stages of abnormal heating or thermal runaway in a single cell, providing time for system monitoring, early warning, and disconnection protection.

[0050] Of course, in other embodiments, the mica sheet can be replaced with a heat insulation sheet made of other heat insulation materials. The heat insulation sheet is thin and is set in the corresponding gap area of ​​adjacent battery cells. It is bonded and fixed to the outer surface of the battery cells on both sides by the first adhesive layer and the second adhesive layer respectively to form a flexible connection. The heat insulation sheet material is preferably mica, but aerogel felt or other fireproof and heat insulation materials can also be used. The first adhesive layer and the second adhesive layer are structural adhesives or elastic adhesives with a certain shear deformation capability.

[0051] Each battery module is equipped with end plates on its upper surface, lower surface, and both sides, all of which are integrally die-cast from aluminum alloy. The side end plates are welded to the liquid cooling plate, and rectangular windows are provided on the end plates for liquid cooling pipe inlets / outlets, electrical interfaces, and signal interfaces to facilitate subsequent layout.

[0052] In this embodiment, steel plate bonded composite rubber vibration isolation springs 6 (4 in total) are also provided at the four corners of the upper surface end plate 5 of the battery module. The vibration isolation spring is composed of upper and lower square metal mounting end plates and a drum-shaped high-damping rubber elastic body vulcanized in the middle: the upper metal end plate is bonded to the inner wall of the energy storage shell (or the bearing bracket) by structural adhesive (adhesive layer thickness 1.5~2.5 mm), and the lower surface end plate 16 is connected to the module end plate by 4 M10 bolts. The typical size of the vibration isolation spring is 350mm×100mm×(4~5)mm for the end plate, 30mm for the height of the rubber body, Φ80mm for the maximum diameter, and about 40mm for the total height. Through the high elasticity and high damping of the rubber, the elastic support and vibration energy dissipation of the system shell are achieved, which can effectively isolate the lateral vibration / impact load generated by road traffic and reduce the peak value of longitudinal alternating load, reduce the risk of fatigue damage at the cell, busbar welding point and sampling connection, thereby improving the structural reliability and service life of the battery module under the prefabricated road energy storage condition.

[0053] Finally, two separate circumferential straps are provided around the battery module, located on the left and right sides of the module respectively; both straps are closed around the circumference of the module and form an overall enclosure around the module. Regarding the external constraint of the module, this embodiment also provides two circumferential straps around the battery module, namely a left strap 14 and a right strap 15. The left strap 14 is located on the left side of the module, and the right strap 15 is located on the right side of the module. Both are closed around the circumference of the module to form an overall binding constraint. In this embodiment, the distance between the left strap 14 and the right strap 15 and the adjacent side of the module is 10mm. The straps are preferably made of high-strength fiber-reinforced strips, metal strips, or composite strips. The separate arrangement of the left and right straps provides stable out-of-plane constraint and circumferential positioning for the upper and lower battery layers and the central liquid cooling plate 17, suppressing problems such as interlayer loosening, local bulging, or increased assembly gaps in the module under long-term alternating load conditions.

[0054] The battery module is also covered by a sealed shell, and a waterproof and breathable valve 2 is provided on the non-stressed side of the sealed shell to balance the internal and external pressure difference and discharge internal condensation.

[0055] In terms of load-bearing and stress response, this embodiment is specifically designed to address the lateral load, longitudinal load, and overall structural load-bearing issues faced by prefabricated road energy storage systems.

[0056] First, for lateral loads, i.e. impacts, compressions, or displacements mainly generated along the length of the road or the width of the module, this embodiment addresses them in the following ways: First, it adopts a double-layer symmetrical arrangement and a central liquid cooling plate 17 sandwich arrangement, so that the overall center of gravity of the module is located near the middle of the cross section, improving the stress balance of the module cross section; Second, the inner busbar 10 is provided with a transition protrusion, which can provide deformation compensation when lateral micro-displacement occurs, avoiding the rigid connecting parts from breaking under tension.

[0057] Secondly, regarding longitudinal loads, especially those caused by road traffic, impact vibrations, and the resulting fatigue, this embodiment employs a horizontal arrangement of the battery cells 7. This prevents the terminals or tabs, which are prone to direct axial compression in traditional vertical arrangements, from becoming the primary stress path. In other words, external vertical loads are preferentially distributed through limiting components, binding structures, the wide surface of the battery casing, and the centrally located liquid cooling plate 17, rather than being concentrated on the terminal weld points or sealing sensitive areas. This significantly reduces the risk of fatigue cracks, incomplete welds, loosening, or sealing failures at electrical connection points under long-term vehicle rolling conditions. Simultaneously, the thermally conductive adhesive layer between the upper and lower layers and the liquid cooling plate 17, as well as the elastic transition structure of the busbar, can collectively absorb micro-vibrations and cyclic displacements, further mitigating the adverse effects of high-frequency vibrations on the welded and sampling connection points. Finally, the steel-plate bonded composite rubber vibration isolation spring 6 installed on the upper surface end plate 5 of the module serves as a transition device between the battery module and the system casing, greatly isolating the direct propagation of longitudinal vibrations between cells.

[0058] Furthermore, regarding the overall structural load-bearing capacity, the battery module in this embodiment does not rely solely on the casing of the individual battery cells 7 for load-bearing. Instead, it achieves its load-bearing function through a multi-component collaborative force-bearing system consisting of "binding straps—liquid cooling plate—battery layer—insulating protective plate." The centrally located liquid cooling plate, in addition to its thermal management function, also serves as a plate-like reinforcement in the interlayer, improving the overall bending stiffness and compressive stability of the module's cross-section. The left and right binding straps provide pre-tightening constraints to the module, reducing the loosening and shifting of internal components under alternating loads. The lateral limiting protective plates are used to suppress local component warping and excessive deformation of electrical connection areas. Thus, static and dynamic loads from the road surface can be more evenly distributed and transmitted within the module, avoiding early structural failure caused by localized stress concentration.

[0059] When the system is used, such as Figure 4As shown, multiple battery modules are installed in parallel within a prefabricated road surface energy storage chamber. The positive and negative output terminals of each module are connected in parallel to a combiner unit, thus forming a module-level parallel energy storage system. After processing by the combiner unit, a DC positive bus and a DC negative bus are led out. These two buses finally reach the power conversion unit, from which two AC buses are led out. The liquid cooling interface of each module is connected to an external liquid cooling circulation manifold, and the signal acquisition interface leads out a signal acquisition line to the battery management system. This system can operate in conjunction with distributed photovoltaic systems, road lighting, traffic monitoring equipment, charging facilities, or emergency power supply systems to achieve peak shaving and valley filling, energy allocation, and coordinated energy supply for road infrastructure.

[0060] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made by those skilled in the art without creative effort within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A prefabricated road surface energy storage system, characterized in that, It includes several battery modules, a thermal management system, and an electrical connection system, among which: The battery module is disposed at the lower end of the road base layer. The battery module includes two battery layers and a liquid cooling plate layer located in the middle of the battery layers. Each battery layer is formed by several battery cells arranged side by side along the length of the sandwich structure. The liquid cooling plate layer includes a liquid cooling plate, and the liquid cooling plate has a cooling liquid flow channel inside. The thermal management system includes a thermally conductive adhesive connecting layer between the upper battery layer and the upper surface of the liquid cooling plate, and between the lower battery layer and the lower surface of the liquid cooling plate. This allows the heat generated by the batteries in the two battery layers to be conducted to the liquid cooling plate through the thermally conductive adhesive connecting layer and carried out of the battery module through the cooling liquid flow channel, thereby achieving synchronous cooling of the upper and lower battery cells. The electrical connection system includes an intra-layer bus, an inter-layer bus, and a lead-out bus. The intra-layer bus is disposed between adjacent cells in each battery layer. The inter-layer bus is used to connect two battery layers. The inter-layer bus is connected to the intra-layer bus and the lead-out bus, so that each battery cell in the two battery layers is connected in series to form a continuous link. Each end face of the entire battery module is equipped with an end plate, and the end plates are fixedly connected to each other. The side end plates are reserved with liquid cooling pipe inlets and outlets, electrical interfaces and signal interfaces, and the upper end plate is equipped with an elastic element. An energy storage shell is set on the outside of the end plate. One end of the elastic element abuts against the corresponding end plate, and the other end abuts against the inner wall of the energy storage shell. The elastic element provides elastic support and isolates vibration and impact loads.

2. The prefabricated road surface energy storage system as described in claim 1, characterized in that, Each battery layer consists of multiple battery cells arranged sequentially along the length of the battery module, and each battery cell is arranged horizontally.

3. The prefabricated road surface energy storage system as described in claim 1, characterized in that, The inlet and outlet of the coolant flow channel are arranged on the same side of the liquid cooling plate; the coolant interface side of the liquid cooling plate is located on the same side as the electrical input / output port and the signal output port.

4. The prefabricated road surface energy storage system as described in claim 1, characterized in that, The intralayer busbar is welded to the positive and negative terminals of adjacent battery cells in the same layer. The interlayer busbar is welded to the positive and negative terminals of the battery cells at the ends of the upper and lower layers of batteries. The lead-out busbar is welded to the positive and negative terminals of the battery cells at the beginning of the upper and lower layers of batteries, for connection to the outside. Both the intralayer busbars and interlayer busbars are provided with a transition protrusion, an arched transition section, or a bent elastic buffer section that runs through the width direction in the middle.

5. The prefabricated road surface energy storage system as described in claim 1, characterized in that, The battery cell is provided with a limiting plate and a signal acquisition device on the tab side. The limiting plate is made of flame-retardant insulating material, extends along the length of the module, and covers and isolates the bus area, the sampling device area and the non-functional conductive area. The limiting guard plate has functional openings corresponding to the pressure relief valve, the busbar connection point, and the sampling point.

6. The prefabricated road surface energy storage system as described in claim 5, characterized in that, The intralayer busbars, interlayer busbars, and lead-out busbars form a cooperative constraint relationship with the limiting guard plate through adhesive bonding, embedding, or partial limiting methods, so that the vibration load is preferentially borne by the guard plate and its mounting base, rather than entirely by the busbar weld points; The signal acquisition device is set along the length of the battery module and is connected to the voltage sampling point and / or temperature sampling point of each battery cell through a multi-point sampling line.

7. The prefabricated road surface energy storage system as described in claim 1, characterized in that, A heat insulation sheet is installed between two adjacent battery cells on the same layer. The heat insulation sheet is connected to the outer wall of the adjacent battery cell through adhesive layers on both sides to form a stable connection structure. This structure is used to delay the rapid transfer of heat directly to the adjacent cell in the early stage of abnormal heating or thermal runaway of the cell.

8. The prefabricated road surface energy storage system as described in claim 1, characterized in that, Each battery module has a composite rubber vibration isolation spring installed at each of its four corners on the upper surface end plate. The composite rubber vibration isolation spring includes upper and lower metal mounting end plates and a drum-shaped rubber elastic body vulcanized in the middle. The upper metal end plate is bonded to the surface of the energy storage shell, and the lower metal end plate is fixed to the upper surface end plate of the battery module by bolts.

9. A prefabricated road surface energy storage system as described in claim 1, characterized in that, The battery module is provided with two separate circumferential straps on its outer periphery, which are respectively arranged on both sides of the module. The straps are closed along the circumference of the module and form an overall enclosure around the module. The battery module is also covered with a sealed shell, and a waterproof and breathable valve is provided on the non-stress side of the sealed shell to balance the internal and external pressure difference and discharge internal condensation.

10. A prefabricated road surface energy storage system as described in claim 1, characterized in that, The individual battery cells within the battery module are connected in series, and different battery modules are connected in parallel. Multiple battery cells in the same layer are connected in series end to end in a predetermined order to form a single series circuit. The positive terminal of the previous battery cell is electrically connected to the negative terminal of the next battery cell. The two ends of the series link serve as the positive and negative output terminals of the battery module, respectively. The battery cells in the upper and lower layers are also connected in series. The same-name terminals of each battery module are connected in parallel to the system DC bus, that is, the positive terminals of each module are connected in parallel to form the system positive bus, and the negative terminals of each module are connected in parallel to form the system negative bus.

Images