A cooling and life prolonging device for electrically powered transportation equipment and its accessories

Abstract

The battery module of the existing electric transportation equipment and its auxiliary facilities relies on heating or heat preservation device to cope with low temperature environment, which not only has high energy consumption, but also has high cost. Based on the experimental finding, the application discloses a cooling and life prolonging device suitable for electric transportation equipment and its auxiliary facilities, which comprises but is not limited to the following functional units: battery module 405, cooling system 101, air duct 102, which is used to actively maintain the battery module in a low temperature interval to prolong the battery life and improve the economy in the whole life cycle, and a comprehensive strategy of multi-stage cooling, intelligent temperature control and capacity redundancy is designed, so that the battery can still operate stably at low temperature. The cooling and life prolonging device converts the scientific discovery of "low temperature life prolonging" into an engineering implementable technical solution, significantly improves the service life of the battery and the system efficiency, and can effectively reduce the energy consumption and operation cost of heat dissipation, and has significant creativity and industrialization value.

Description

Technical Field

[0001] This invention relates to the field of battery technology for electric vehicles and electric transportation equipment, and more particularly to a cooling and life-extending device capable of actively reducing the temperature of battery modules to extend battery life. This invention is applicable to various electric vehicles and specialized equipment, including passenger cars, electric trucks, flying cars, electric mining vehicles, electric construction machinery, electric ships, electric port equipment, military equipment, and unmanned vehicles. Furthermore, this invention can be extended to ancillary facilities such as battery swapping stations, charging and discharging stations, mobile energy storage devices, rail charging facilities, and maintenance and testing platforms, and is applicable to power infrastructure fields such as energy storage power stations, emergency power supplies, and microgrids. Background Technology

[0002] With the rapid development of battery technology, electric transportation equipment and its ancillary facilities are being used more and more widely. As the core power source, the performance and lifespan of battery modules directly determine the range, power output, and economy of electric transportation equipment and its ancillary facilities. However, compared to traditional gasoline vehicles, existing electric vehicles generally suffer from shorter battery lifespans. This not only limits the vehicle's lifespan but also significantly impacts consumer purchasing decisions and the overall lifespan economy of the vehicle. Therefore, how to significantly enhance battery module lifespan has become a key technical challenge for promoting the widespread application of electric vehicles.

[0003] Furthermore, in low-temperature environments, especially in winter, the usable capacity of batteries decreases, leading to a significant reduction in the driving range of electric vehicles. Existing technologies typically employ heating or insulation devices to maintain battery temperature and prevent damage or performance degradation at low temperatures. However, these methods are passive solutions, consuming significant energy and incurring high costs. Traditional thermal management technologies are primarily safety-oriented, aiming to maintain the battery within its normal temperature range, lacking effective solutions for actively extending battery life at low temperatures. Therefore, this provides a clear area for technological improvement for this invention, highlighting its innovative value and industrial application potential in battery life extension and energy saving. Summary of the Invention

[0004] This invention innovatively addresses the bottleneck problems existing in battery usage scenarios. Existing battery heating or insulation devices are mainly based on the principle of heating compensation, which has high energy consumption and limited effectiveness. Therefore, this invention proposes a disruptive concept centered on "actively embracing low temperatures and extending battery life," and achieves a technological breakthrough through systematic innovation. It not only significantly extends battery life but also effectively controls system energy consumption, achieving a balance between economy and safety throughout the entire life cycle. While the technical solution of this invention may seem similar to traditional battery thermal management technologies at first glance, they are fundamentally different. Existing battery thermal management technologies only focus on maintaining the battery at normal temperature conditions to prevent overheating or overcooling; their design philosophy is "avoiding high temperatures, avoiding low temperatures, and maintaining normal temperature." Under this philosophy, the energy consumption of the heat dissipation system is usually low, and ordinary heat dissipation methods can meet the needs of practical applications.

[0005] The inventors of this invention discovered through long-term systematic experiments that various types of batteries can achieve unexpectedly extended lifespans under low-temperature conditions, even significantly extending them by three to four times, which is of revolutionary significance. This discovery completely overturns the existing battery thermal management concept: evolving from "avoiding high temperatures, avoiding low temperatures, and embracing room temperature" to "embracing low temperatures and embracing longevity." The core of this invention lies in effectively utilizing experimental findings to make battery life extension the primary design goal, breaking through traditional concepts. Based on scientific discoveries and objective laws, this invention achieves a transformation and upgrade based on existing battery thermal management device solutions.

[0006] To achieve this goal, the battery temperature must be lowered to a low-temperature operating range, which obviously increases the energy consumption of the cooling system significantly. However, this is something that professionals in the field would not choose and would even try to avoid, because low-temperature environments can cause capacity loss in the battery, and maintaining low-temperature scenarios requires a more complex heat exchange design than "normal temperature scenarios," while also consuming additional energy during operation—a triple loss. This solution, through new discoveries and designs, overcomes these problems: it not only extends battery life, reduces energy consumption and operating costs, but also achieves a higher return on investment from a life-cycle perspective.

[0007] This invention designs a comprehensive cooling and lifespan extension system that minimizes energy consumption while ensuring extended battery life. Through multi-stage cooling, intelligent temperature control, and capacity redundancy strategies, it achieves long-term stable battery operation at low temperatures, yielding unexpected results. Compared to existing technologies, this invention not only breaks free from the constraints of traditional thermal management concepts but also proposes entirely new solutions in system design, functional implementation, and control strategies, achieving a leapfrog development and simultaneously improving battery life and system efficiency. This design philosophy, which focuses on extending lifespan to enhance economics throughout the entire battery lifecycle, rather than merely preventing overheating, forms the core inventiveness of this invention.

[0008] Compared with existing technologies, this invention has significant inventiveness. Firstly, in terms of technical design philosophy, this invention takes battery life extension as its core objective, rather than merely preventing overheating or maintaining normal temperature, successfully upgrading the concept from traditional "safety temperature management" to "low-temperature life extension management." This concept breaks through the basic understanding of existing battery thermal management, enabling system design to not only focus on safety but also proactively pursue the goal of significantly extending battery life. This is because the inventors discovered through long-term experiments that batteries can significantly slow down the aging rate of electrode materials and electrolytes in low-temperature environments, thereby extending cycle life and overall life-cycle economics. This discovery completely overturns traditional understanding and represents an unexpected effect that existing technologies could not foresee.

[0009] Furthermore, lower temperatures also mean higher heat dissipation energy consumption. How to control system energy consumption under low-temperature operating conditions and maintain high energy efficiency of the cooling system while achieving the lifespan extension target is another challenge. To address this, this invention proposes a comprehensive solution including a multi-stage cooling system, optimized airflow ducts, a refrigerant auxiliary circuit, capacity redundancy design, and an intelligent temperature control module. By dynamically adjusting coolant flow, fan speed, or the start / stop of the cooling system, the system can accurately control battery temperature under different loads and environmental conditions, while avoiding unnecessary energy consumption at low temperatures. This system design, centered on low-temperature lifespan extension and also considering energy efficiency optimization, represents a fundamental innovation in existing battery thermal management technologies and is the core technological breakthrough of this invention.

[0010] Furthermore, this invention addresses extreme operating conditions that traditional technologies struggle to handle. In high-load, high-temperature, or high-dust mining vehicle environments, conventional cooling systems are prone to insufficient heat dissipation, localized overheating, or blockages. This invention, however, achieves long-term stable, efficient, and reliable system operation through modular design, redundant functions, thermal coupling and insulation strategies, as well as dustproofing, anti-blocking, and airflow optimization. Simultaneously, the combination of capacity redundancy and intelligent temperature control compensates for capacity loss caused by decreased chemical reaction rates under low-temperature extended lifespan conditions, ensuring stable range and power output. This not only demonstrates technological innovation but also showcases the system's adaptability and reliability advantages under complex operating conditions.

[0011] This invention also proposes several innovative measures in areas such as local temperature control, zoned heat dissipation, branch circuits, thermal coupling and insulation design, and phase change material cold storage assistance to ensure uniform internal temperature of the battery module and solve the problem of local overcooling or performance degradation that may occur during low-temperature life extension. The intelligent temperature control closed-loop system monitors battery temperature, coolant temperature, and environmental parameters in real time, and dynamically adjusts the system's operating mode, operating intensity, and topology to unify life extension goals and energy efficiency optimization, achieving low-temperature life extension and energy-saving control that cannot be simultaneously met by existing technologies.

[0012] Through the above technical solutions, this invention not only proposes a novel design concept centered on extending battery life, but also achieves a unified approach to low-temperature battery life extension and energy efficiency optimization through systematic and multi-dimensional technological innovation, forming a significant and overwhelming advantage over existing technologies. This innovative solution can significantly extend battery life throughout its entire life cycle, while simultaneously ensuring low energy consumption and high reliability, providing unprecedented industrial application value for electric vehicles and electric transportation equipment. Most importantly, this invention can produce unexpected technical effects. When operating in the extended-life low-temperature range, the battery cycle life is significantly extended, and capacity decay is significantly slowed down, thereby achieving economic benefits that existing technologies cannot achieve. This not only verifies the scientific validity of the low-temperature life extension concept, but also fully demonstrates the overwhelming advantages of this invention in technological innovation, system integration, and industrial application.

[0013] The core idea of ​​this invention is to overturn the traditional temperature control concept of "avoiding low temperatures" and actively utilize the low-temperature environment as a key condition for optimizing battery life. It designs a low-temperature management scheme for battery modules based on the characteristics of electric vehicles, aiming to improve the lifespan of lithium batteries. This scheme not only extends battery life but also significantly reduces system energy consumption, improving the overall economy and safety of the system. Through the scientific layout of the cooling and life-extending device and precise temperature monitoring strategies, this invention achieves battery life extension in low-temperature environments in the electric vehicle field, providing a new technical path and economic model for large-scale intelligent electric vehicles. To achieve the above and other related objectives, this invention provides a cooling and life-extending device suitable for electric transportation equipment and its auxiliary facilities, characterized by: The cooling and life-extending device includes several functional units, sub-components and secondary components. The functional units may include, but are not limited to: battery module, cooling system, and air duct. The sub-components of the cooling system include a coolant pump, a radiator, a cooling plate, and interconnected cooling pipes. The air duct defines the airflow path, allowing air to flow through the radiator and finally be discharged to the outside after heat exchange. The cooling and life-extending device can stably control the temperature of the battery module within the life-extending low temperature range, thereby extending the life of the battery module and significantly enhancing its economic efficiency throughout its entire life cycle. The life-extending low-temperature range is a low-temperature range below room temperature but above the dew point. When the battery module is used for a long time within this life-extending low-temperature range, it can slow down the aging and degradation of electrode materials and electrolyte, thereby extending its lifespan. The cooling system contains circulating coolant. A coolant pump drives the coolant to circulate within the system. The cooling plate is in close contact with the battery module requiring cooling, enabling the coolant to efficiently absorb the heat generated by the battery module during operation. The coolant is transported to a radiator via cooling pipes, where it exchanges heat with the air through convection. The cooled coolant then flows back to the cooling plate, achieving a continuous and stable cooling effect. The cooling plate can also be in close contact with other sub-components or secondary components requiring cooling to achieve the same purpose. The battery module undertakes the core functions of energy storage and output, and is the core component of the electric transportation equipment and its auxiliary facilities. It is also the direct cooling target and life extension carrier of the cooling and life extension device. The functional unit refers to the overall module in the cooling and life extension device used to realize the main function. The sub-component refers to the subdivided structure or independently operable component under the functional unit. The secondary component refers to the specific element or hardware component after the sub-component is further subdivided.

[0014] This invention, through a systematic cooling and life-extending device, not only precisely controls the battery module temperature within the optimal life-extending range, thus significantly extending battery life, but also achieves highly efficient thermal management, reduces energy loss, and improves the economy and reliability of the entire vehicle system. Furthermore, the device has a rational structure, combining the cooling system and air ducts to facilitate rapid and efficient heat transfer and dissipation.

[0015] Optionally, the cooling and life-extending device is used to actively promote the temperature reduction of the battery module and maintain it in the life-extending low temperature range, rather than just to prevent thermal runaway; the functional unit of the cooling and life-extending device can be replaced with other structures, or combined with other structures, to achieve the above-mentioned cooling and life-extending purpose; the functional unit can also select to implement any of the following temperature control strategies according to specific needs: passive heat dissipation, air cooling, convection cooling, active cooling or thermal compensation, or select a combination of multiple strategies to construct a multi-level coupled temperature control system.

[0016] This design actively utilizes multiple heat dissipation methods to achieve temperature control, thereby extending battery life.

[0017] Optionally, each functional unit, sub-component, and secondary component in the cooling and life-extending device can be configured as an option, wherein the electrically related parts have a sealed structure to suppress condensation and improve adaptability under low-temperature conditions.

[0018] Optionally, while the battery module can extend its lifespan when operating in the extended-life low-temperature range, its electrochemical reaction rate decreases, resulting in a reduction in initial capacity; therefore, the battery module is equipped with a capacity redundancy function.

[0019] Optionally, the capacity redundancy function is implemented by pre-setting additional redundant capacity for the battery module to compensate for the capacity loss of the battery module when operating in a low-temperature environment; the capacity redundancy function is an optional configuration.

[0020] Optionally, the capacity redundancy function can be achieved by adding a battery expansion pack and cooperating with the battery module to achieve excess redundancy; or by designing the total capacity of the battery module according to a preset redundancy ratio to achieve excess redundancy design from the source of the solution.

[0021] Optionally, the capacity redundancy function can selectively enable or disable the battery expansion pack or automatically adjust the overall operating intensity of the battery module according to external load demand, so that the total capacity of the battery module can flexibly meet external load demand and respond promptly when demand suddenly increases.

[0022] Optionally, the capacity redundancy function can not only compensate for the capacity loss of the battery module in the low-temperature life extension range, but also further improve the life of the battery module on the basis of the life extension caused by low temperature.

[0023] The capacity redundancy function can dynamically compensate for capacity loss in low-temperature environments, improve the reliability and range flexibility of the battery module, and ensure stable power supply under different load conditions.

[0024] Optionally, the air duct can also facilitate airflow through any functional unit or its sub-components and secondary components and exchange heat with them, thereby enhancing the overall heat dissipation effect of the cooling and life-extending device.

[0025] This design optimizes the airflow path, enabling the air duct to guide air to any functional unit or its sub-components and secondary components for heat exchange, thereby enhancing overall heat dissipation efficiency. This not only improves the balance of heat conduction and dissipation but also enhances the temperature distribution stability of the battery module, further extending battery life and reducing the risk of localized overheating.

[0026] Optionally, the functional unit of the cooling and life-extending device may further include: a refrigeration system.

[0027] Optionally, the sub-components of the refrigeration system include a condenser, a compressor, a throttling device, an evaporator, and interconnected refrigeration pipes.

[0028] Optionally, the refrigeration system contains a refrigerant; the refrigerant circulates and undergoes a phase change within the refrigeration system, and exchanges heat with each sub-component in the refrigeration system in sequence.

[0029] Optionally, the refrigeration system is activated when the ambient temperature is too high or the cooling system's heat dissipation efficiency is insufficient to lower the coolant to the target temperature, in order to further enhance the heat dissipation effect of the cooling and life extension device and ensure that the battery module is in the life extension low temperature range.

[0030] Optionally, the compressor compresses the low-pressure gaseous refrigerant into a high-temperature, high-pressure gas, and sends it through a refrigeration pipe into the condenser to release heat and condense it into a liquid. Subsequently, the refrigerant enters the evaporator after being depressurized and cooled by a throttling device, where it absorbs heat and evaporates into a gas, and then returns to the compressor to form a cyclic refrigeration process. The condenser is coupled to the air duct, and the heat released by the refrigerant in the condenser is transferred through the air duct and finally discharged to the outside. The evaporator is coupled to the radiator (or other components) in the cooling system, and the refrigerant absorbs heat in the evaporator, thereby reducing the temperature of the radiator in the cooling system and achieving auxiliary cooling of the coolant.

[0031] Optionally, the throttling device is preferably a thermostatic expansion valve or an electronic expansion valve, but it can also be a capillary tube, a float valve, a needle valve, an electronic proportional valve, a two-stage expansion valve, or an adjustable orifice capillary tube, which can adjust the refrigerant flow according to the evaporator load or system control requirements, thereby ensuring the stable heat absorption and circulating cooling effect of the evaporator.

[0032] By introducing a refrigeration system, this invention provides an auxiliary cooling method based on traditional cooling systems. It can be activated when the ambient temperature is high or the cooling system is inefficient, achieving precise temperature control of the battery module. This multi-loop collaborative heat dissipation method not only enhances cooling capacity but also maintains the stability of the battery module in the extended-life low-temperature range.

[0033] Optionally, the functional units of the cooling and life-extending device may also include: an integrated control module.

[0034] Optionally, the integrated control module is also equipped with a decision control algorithm that can dynamically adjust the coolant flow rate, fan speed, or cooling system start / stop based on the battery module temperature, coolant temperature, ambient temperature, or the load requirements of the battery module, so that the battery temperature remains stable in the long-term life-extending low-temperature range; wherein, if the ambient temperature is too low, the coolant flow rate is reduced to prevent the battery from being overcooled.

[0035] Optionally, the functional unit of the cooling and life extension device also includes an integrated control module; the integrated control module can ensure that one or more operating characteristics of the battery module do not exceed a preset operating condition threshold during charging and discharging, so as to avoid the rapid increase of the side reaction rate of the battery module under adverse operating conditions.

[0036] Optionally, the operating condition characteristics include one or more of the following: charging current, charging voltage, discharging voltage, discharging current, charging and discharging power, temperature, and other battery operating condition parameters.

[0037] Optionally, when the integrated control module detects that one or more operating condition characteristics are close to or exceed the preset operating condition threshold, a protection mechanism will be triggered. The protection mechanism includes, but is not limited to: reducing the charging current, reducing the discharging current, reducing the charging and discharging power and / or voltage, performing a circuit breaker action, and issuing an alarm signal.

[0038] Optionally, the integrated control module can also monitor the internal and external operating parameters of the electric transportation equipment, its auxiliary facilities, and the cooling and life extension device in real time, analyze the parameters through a decision control algorithm, and adjust the operating strategy and / or operating intensity of the cooling and life extension device as needed based on the analysis results, so as to enhance the continuous temperature control capability and the precise temperature control capability.

[0039] The integrated control module enables dynamic and intelligent adjustment, keeping the battery in the optimal low-temperature range for extended lifespan, improving battery life, system stability, and overall energy efficiency, while avoiding overcooling or energy waste.

[0040] Optionally, the life-extending low-temperature range can be around 10°C, around 15°C, around 20°C, or other temperature ranges below room temperature.

[0041] Optionally, the range of the extended life low temperature range and the setting of the preset operating condition threshold may vary depending on the type and model of the battery module, and will be affected by the battery module's chemical system, capacity, rated voltage and operating environment conditions.

[0042] Optionally, the life-extending low-temperature range and / or preset operating condition threshold can be determined by experiments, tests, or a combination of methods. Specific determination methods include, but are not limited to: determining by accelerated aging tests, charge-discharge cycle tests, or thermal characteristic analysis; selecting based on experience or manufacturer recommendations; predicting by combining battery thermal management models, aging models, or chemical kinetic simulations; performing statistical analysis based on historical operating data; and determining by a multi-factor combination optimization method.

[0043] Defining the low-temperature range for extending battery life allows for precise control of the battery's operating environment, which helps slow down battery aging, extend battery life, and provides quantifiable optimization criteria for different battery types.

[0044] Optionally, an electric fan may be additionally installed in the air duct. The electric fan can actively promote airflow when there is a lack of natural wind or relative airflow, so as to maintain the heat dissipation capacity of the air duct.

[0045] Optionally, the cooling and life-extending device can be configured with a multi-stage cooling strategy: primary cooling is achieved by a cooling system and air duct in conjunction with natural wind or relative airflow, without the need for additional energy consumption; secondary cooling is assisted by an electric fan; tertiary cooling is initiated by a refrigeration system to achieve cooling and temperature control under extreme high-temperature conditions; the multi-stage cooling strategy can be arbitrarily combined and switched by the control module to ensure that the cooling and life-extending device can adjust the temperature of the battery module as needed under any operating condition.

[0046] A multi-stage cooling strategy enables on-demand temperature control, ensuring that the battery remains in the low-temperature range for extended lifespan under different operating conditions, thereby improving system reliability and thermal management efficiency.

[0047] Optionally, the specific control measures that the integrated control module can take include, but are not limited to, dynamically adjusting the execution sequence, operating mode, operating parameters, and operating intensity of any functional unit or its sub-components or secondary components, or reconstructing or switching the topological connection structure of any functional unit or its sub-components, secondary components, or secondary components; enabling the battery module to achieve temperature balance and maintain it in the low-temperature range for life extension under different operating conditions, thereby stabilizing the life extension effect; and also configuring a series of controllable components in the cooling life extension device to achieve flexible adjustment as needed.

[0048] Optionally, any functional unit or its sub-components and secondary components can be quickly connected through multi-way valves, quick-connect pipes, bypass loops, or quick-switch interfaces, thereby enabling the integrated control module to dynamically adjust the execution sequence, operating mode, operating parameters, and operating intensity of any functional unit or its sub-components, secondary components, and secondary components, or to reconstruct or switch the topological connection structure of any functional unit or its sub-components, secondary components, and secondary components.

[0049] The dynamic adjustment of the temperature control module and the rapid reconfiguration of functional units enable the battery to achieve temperature balance under various operating conditions.

[0050] Optionally, any functional unit or its sub-components and secondary components can be arranged in a zoned and coordinated manner for different parts of the battery module, and work in a zoned and coordinated manner to achieve differentiated heat dissipation and local temperature control, thereby improving the overall thermal management performance.

[0051] Optionally, any of the functional units or their sub-components and secondary components can be integrated with the battery module to make the heat dissipation structure closely integrated with the battery module, thereby achieving centralized heat dissipation and overall temperature control, and further improving the compactness and heat dissipation efficiency of the device.

[0052] Optionally, the cooling and life-extending device is internally equipped with partitions to divide the battery module into multiple independent module compartments to form a modular thermal management structure, and to isolate faults when a single module malfunctions, thus preventing the risk from spreading to other modules.

[0053] Optionally, any of the functional units or their sub-components and secondary components can be designed in a branched manner to distribute heat dissipation for different parts of the battery module and improve temperature uniformity.

[0054] Optionally, any functional unit or its sub-components and secondary components can be repeatedly configured as needed to achieve fault redundancy, so that when some units fail, other units can take over the operation to ensure system stability; at the same time, heat dissipation can be enhanced by adding parallel heat dissipation units to improve the overall heat dissipation capacity; and hierarchical control can be achieved by hierarchical start-stop and adjustment of multiple units, thereby taking into account both energy efficiency and precise regulation.

[0055] Through partitioning and branching design, this invention enables precise temperature control and temperature equalization for different parts of the battery module, significantly improving overall battery performance and lifespan. Simultaneously, redundant configurations and units ensure stable system operation even when some functions fail, and energy efficiency optimization and precise heat dissipation control are achieved through tiered start-stop systems.

[0056] Optionally, the functional unit of the cooling and life extension device also includes an anti-condensation module; the anti-condensation module can be automatically activated when the battery module temperature is close to the dew point to reduce the humidity of the air around the battery module, so that the dew point is lower than the battery surface temperature, thereby preventing condensation on the battery surface and ensuring the safe operation of the battery.

[0057] The anti-condensation module effectively prevents condensation on the battery surface, reducing safety risks caused by humidity and ensuring stable battery operation in low-temperature or high-humidity environments. This feature also improves the reliability of the battery system.

[0058] Optionally, any functional unit or its sub-components and secondary components can be thermally coupled as needed, thereby improving the heat exchange efficiency between functional units and optimizing the heat dissipation performance of the entire system. The thermal coupling can achieve rapid heat exchange directly by connecting any functional unit or its sub-components and secondary components, or it can achieve indirect heat conduction by arranging heat exchange plates, heat dissipation fins, heat pipes, heat bridges, heat conduction pipelines, or using heat exchange media (such as liquid cooling media or phase change materials) between any functional unit or its sub-components and secondary components. Alternatively, any functional unit or its sub-components and secondary components can also be equipped with thermal insulation structures as needed to block unwanted thermal coupling. Various methods, including thermal insulation boards, thermal insulation sleeves, air layers, low thermal conductivity materials, or thermal insulation layers, can be used to slow down heat transfer, thereby preventing local overheating while maintaining the necessary heat exchange efficiency and improving system safety and temperature uniformity. The two design methods (thermal coupling / thermal insulation) can be selected independently without conflict.

[0059] Through flexible design of thermal coupling and insulation, this invention improves the heat exchange efficiency between functional units while preventing local overheating.

[0060] Optionally, any functional unit or its sub-components and secondary components can adopt a modular design concept as needed to form independent modules. Flexible piping, quick connectors, and standardized interfaces facilitate coupling and disassembly, allowing each unit to be disassembled for cleaning or replacement, thereby reducing maintenance costs and downtime, improving system maintainability and adaptability, and facilitating flexible configuration and upgrades. Alternatively, any functional unit or its sub-components and secondary components can also adopt an integrated design as needed, coupling any functional unit or its sub-components and secondary components into a unified structure, improving heat exchange efficiency, reducing heat loss, improving thermal management efficiency, shortening piping, and enhancing structural compactness. These two design methods (modular design / integrated design) can be selected independently without conflict.

[0061] Modular design improves the system's maintainability, flexible configuration, and upgrade adaptability, making it easier to disassemble, clean, or replace, thus reducing maintenance costs and downtime; while integrated design enhances the heat exchange efficiency between functional units and improves structural compactness.

[0062] Optionally, the air duct can be configured as a multi-stage flow distribution structure or a parallel channel structure to realize air diversion and convergence and path selection, so that the air flows sequentially or separately through any of the functional units or their sub-components and secondary components and exchanges heat with them, thereby optimizing air distribution, improving heat dissipation uniformity and reducing wind resistance.

[0063] Optionally, the air duct can adopt an automatic switching structure or an adjustable opening structure, which can dynamically adjust the airflow path or opening size according to needs to optimize wind resistance and heat dissipation efficiency.

[0064] Optionally, the air duct may be equipped with an adjustable baffle, a servo-driven baffle, a vortex generator, a damper (variable opening), a louver, or adjustable blades to improve the airflow path, reduce dead zones or local hot spots, and adjust the airflow direction and flow rate as needed.

[0065] Optionally, the electric fan includes a variable speed control or stepless wind speed control fan, and may further include variable pitch blades or a bidirectional impeller structure to automatically adjust the air volume and blade angle according to demand, thereby improving energy efficiency and heat dissipation efficiency.

[0066] The multi-stage diversion and adjustable air duct design optimizes the airflow path, improves heat dissipation uniformity and reduces wind resistance. At the same time, through the active adjustment of the adjustable guide plate, damper and electric fan, efficient heat dissipation and energy efficiency optimization are achieved under different operating conditions, ensuring stable operation of the battery module.

[0067] Optionally, the electric fan includes a low-resistance operating structure, which is used to allow the fan to rotate freely with the airflow direction in high-speed airflow scenarios, so as to reduce air resistance and enhance the convective ventilation effect of the radiator.

[0068] Optionally, the low-resistance operating structure includes at least one of the following: a non-reverse drag control circuit, a one-way clutch mechanism, a low-resistance bearing structure, a magnetic levitation bearing structure, or an automatic stop / retract blade structure.

[0069] Optionally, the non-reverse drag control circuit is used to suppress the reverse electric resistance generated by the motor when the fan blades are driven to rotate by high-speed airflow; the one-way clutch mechanism is used to achieve free rotation under the action of high-speed airflow, while being driven by the motor in low-wind-speed scenarios; the low-resistance bearing structure is used to reduce the rotational friction of the fan in the follow-up state; the magnetic levitation bearing is used to further reduce mechanical friction loss; the automatic stop or blade retraction structure is used to separate the fan from the airflow when the high-speed airflow is sufficient to meet the heat dissipation requirements, thereby further reducing air resistance and improving the overall heat dissipation efficiency.

[0070] The low-resistance fan can rotate freely with the airflow when running at high speed, reducing air resistance and enhancing natural ventilation. At the same time, multiple low-friction and automatic adjustment structures improve heat dissipation efficiency and system energy efficiency.

[0071] Optionally, any functional unit or its sub-components or secondary components may be equipped with a temperature equalization device to improve the overall temperature uniformity and thermal response efficiency of the functional unit.

[0072] Optionally, any functional unit or its sub-components or secondary components may be covered with phase change material to freeze and store cold energy when the battery module load is low or the ambient temperature is low at night, and melt and release cold energy when the temperature rises during the day or the battery module load suddenly increases, thereby reducing the start-up frequency of the refrigeration system and achieving cross-day and cross-seasonal temperature control optimization; the phase change material can be precisely controlled by alloy formulation optimization or microencapsulation technology to meet the precise temperature control requirements under different application scenarios.

[0073] Optionally, the phase change material can be arranged in a hierarchical array or deployed in different locations to achieve a hierarchical phase change process through a combination of multiple melting points, storing and releasing cold energy at different temperature points or locations, thereby enhancing the ability to maintain and regulate low temperatures.

[0074] The combination of temperature equalization device and phase change material improves temperature uniformity and thermal response efficiency. At the same time, by storing and releasing cold energy, it achieves temperature control optimization across day and night and across seasons, reducing the frequency of refrigeration system start-up.

[0075] Optionally, the cooling and life-extending device is also equipped with a heat preservation system. When the ambient temperature is too low, the heat preservation system can quickly reduce the heat exchange efficiency of any functional unit or its sub-components and secondary components to prevent the battery module temperature from being too low. If necessary, the heat preservation system can activate an electric heating unit, a small reversible heat pump or other compensating heating device to perform compensating heating, thereby ensuring that the battery module temperature is stable in the life-extending low temperature range rather than in an overcooled state.

[0076] Optionally, the cooling system further includes a bypass circuit. When the heat load of the battery module is low, the coolant can bypass the radiator and return directly to the cooling plate through the bypass circuit, thereby keeping the coolant temperature from getting too low and preventing the battery module from being in an overcooled state.

[0077] Optionally, the anti-condensation module can also monitor the surface temperature of the battery module, the temperature of the coolant, and the ambient humidity in real time, and judge the risk of condensation based on the condensation model or threshold. In this way, it can control the heating device to heat the surface of the battery module or the surrounding air, or reduce the air humidity or increase the air circulation through the air conditioning device, thereby inhibiting water vapor condensation and ensuring that the system operates safely in a low temperature and high humidity environment without affecting the low temperature life extension effect.

[0078] The insulation system, bypass circuit, and anti-condensation module work together to prevent the battery from becoming too cold and condensation from forming on its surface, keeping the battery temperature stable within the extended lifespan range.

[0079] Optionally, the cooling and life-extending device further includes a thermosiphon circuit or heat pipe array, connecting the battery cold plate and the radiator, to achieve partial or complete pump-free natural circulation cooling driven by temperature difference, so that the coolant can complete circulation without relying on a water pump, thereby still having basic low-temperature maintenance capability when the pump fails.

[0080] Optionally, the device is equipped with redundant control logic: when the cooling and life extension device cannot effectively reduce the battery temperature to the low-temperature operating range (e.g., radiator failure, coolant pump failure, insufficient fan speed, or excessively high ambient temperature), the redundant control logic will automatically switch to the overheat protection mode to prioritize ensuring that the battery module does not overheat, thereby improving system reliability and preventing thermal runaway.

[0081] The insulation system, bypass circuit, and anti-condensation module work together to prevent the battery from becoming too cold and condensation from forming on its surface, keeping the battery temperature stable within the extended lifespan range.

[0082] Optionally, any of the aforementioned functional units or their sub-components and secondary components can be linked with the vehicle's powertrain system, BMS, or on-board air conditioning system to switch heat dissipation strategies according to operating conditions, thereby achieving optimized temperature control for the entire vehicle.

[0083] Optionally, the condenser shares part of the refrigeration system with the vehicle's original air conditioning system to reduce system redundancy, lower costs, and improve refrigerant circulation efficiency. However, the cooling and life-extending device can also have an evaporator and control valve set up independently, so that it can operate independently when the battery module needs low-temperature control, thus not affecting the comfort of the passenger compartment.

[0084] Optionally, the cooling and life-extending device can also integrate a heat recovery function to use the heat generated by the battery module for vehicle cabin or auxiliary heating.

[0085] Optionally, the cooling and life-extending device may also be equipped with a damping or noise reduction device to reduce noise.

[0086] The cooling and life-extending device works in conjunction with the vehicle's powertrain, BMS, and air conditioning systems to optimize temperature control throughout the vehicle. It also balances cost and comfort by sharing a cooling system and independently controlling the evaporator. Integrated heat recovery and noise reduction designs further enhance energy efficiency, system reliability, and the passenger experience.

[0087] Optionally, the radiator adopts a variable fin spacing structure. Under normal circumstances, the fin spacing is small to improve heat exchange efficiency, while in dusty or polluted environments, the fin spacing can be increased to reduce the risk of blockage, thereby maintaining a long-term stable low-temperature heat dissipation effect.

[0088] Optionally, a spray cooling device may also be provided on any of the functional units or their sub-components or secondary components, which can further enhance heat dissipation efficiency through spray evaporation and heat absorption in ultra-high temperature or continuous high load scenarios.

[0089] Optionally, the cooling and life-extending device may also be equipped with an elevated heat dissipation tower, and any functional unit or its sub-components and secondary components may be preferentially installed in the elevated heat dissipation tower.

[0090] Optionally, the elevated heat dissipation tower may be equipped with a shield, air guide plate, dust filter chamber and sealing protection structure, and can form an air film or air curtain through a fan, nozzle or air guide plate to reduce the direct entry of ground dust and reduce the impact of windward dust on the heat dissipation tower.

[0091] Optionally, the elevated heat dissipation tower can also ensure smooth airflow by reasonably arranging the airflow guiding structure and optimizing the airflow guiding in combination with the vehicle's movement direction, thereby maintaining the long-term stable and efficient heat dissipation performance of the cooling and life extension device.

[0092] Variable-pitch heat sinks and spray cooling devices improve the system's heat dissipation efficiency and reliability under different environments and high loads. Elevated heat towers and protective designs effectively reduce dust impact, optimize airflow, and achieve long-term, stable, and efficient battery temperature control.

[0093] Optionally, the elevated heat dissipation tower can be equipped with multiple axial flow fans, which can be controlled by frequency conversion or constant speed, and have a back-blowing dust removal function. The fans can remove dust from the fins and pipe surfaces through periodic or real-time reverse airflow. At the same time, they can be used with airflow guide plates to optimize the airflow path and reduce the risk of dust accumulation in dead corners.

[0094] Optionally, the elevated heat dissipation tower can be supplemented with sound waves or ultrasonic vibrations to actively shake off the attached dust, and in special cases, it can be combined with slight spray atomization pretreatment to allow some dust to settle in the pretreatment area, ensuring long-term stable heat dissipation performance.

[0095] Optionally, the elevated heat dissipation tower can flexibly adjust the fan frequency and airflow direction according to the concentration of mineral dust, operating environment and seasonal changes, so as to achieve environmentally adaptive dust control.

[0096] Optionally, the fin spacing of the radiator can be appropriately increased, and the structural design can include trapezoidal, corrugated or spiral. It can also be coated with anti-stick powder or hydrophobic coating to reduce dust adhesion and clogging.

[0097] Optionally, a dust removal device may be installed at the air inlet or air channel of the cooling and life-extending device, including but not limited to a filter screen, a washable filter element, a composite filter element, a microporous filter layer, a cyclone separator, or an electrostatic dust collection device, to classify and intercept dust according to its size or electrical properties.

[0098] The vibration-dissipation, spray pretreatment, and environmentally adaptive wind control of the elevated heat dissipation tower effectively prevent dust and ensure long-term stable heat dissipation. Combined with optimized fin design and a multi-stage dust removal system, dust adhesion and clogging are further reduced, improving the reliability and lifespan of the battery temperature control system in complex environments.

[0099] Optionally, the cooling and life-extending device can be equipped with a dust sensor to monitor the dust concentration in the air in real time, and automatically trigger backflushing, vibration cleaning or spray washing functions according to the actual situation.

[0100] Optionally, the cooling and life-extending device can also achieve intelligent dust management by using fan adjustment strategies, flow guide structure optimization, fin spacing selection, material composites, and the synergistic effect of various dust prevention measures, thereby ensuring heat dissipation efficiency and extending the device's lifespan.

[0101] Optionally, the cooling and life-extending device can also flexibly adjust its operating strategy according to the concentration of mine dust, operating environment and seasonal changes, while recording cleaning logs to optimize maintenance cycles and reduce maintenance costs.

[0102] The combination of dust sensing and intelligent dust management enables the radiator to adaptively clean and maintain dust according to the environment, ensuring long-term efficient heat dissipation.

[0103] Optionally, the integrated control module can monitor internal and external operating parameters including, but not limited to, temperature and temperature difference, flow rate and flow rate difference, pressure and pressure difference, liquid level, air velocity, wind pressure, airflow direction and wind speed difference at any measuring point or location of any functional unit, its sub-components or secondary components, and any difference between these measuring points or locations, such as the difference between different measuring points within the same functional unit, sub-component or secondary component, or the difference between different measuring points in different functional units, sub-components or secondary components, and derived quantities calculated from the above parameters; it also includes, but is not limited to, the operating status of the battery module (such as battery heat generation, cell and module temperature, state of charge (SOC / DOI), charge and discharge power, cycle count, health status), vehicle operating status (such as vehicle speed, acceleration, braking status, steering status, load, driving mode), and environmental conditions (such as ambient temperature, humidity, air pressure, wind direction and wind speed, solar radiation intensity).

[0104] Optionally, the controllable components include, but are not limited to, adjustable speed electric pumps, adaptive pumps, micro circulating pumps, bidirectional pumps, electronic control valves, three-way valves, four-way valves, eight-way valves, multi-way valves, flow dividers, switching valves, multi-way switching valves, throttling devices, solenoid valves, adjustable throttling valves, differential pressure regulating valves, compressors (variable frequency compressors, twin-rotor compressors, or scroll compressors), turbo expanders, adjustable condenser brackets, heat exchanger bypass valves, cooling plate adjustment components, heat pipe control switches, phase change material start / stop control devices, intelligent control modules, power drive units, non-reverse drag control circuits, and automatic stop or folding blade mechanisms.

[0105] The temperature control module comprehensively monitors internal operating parameters and external performance parameters, and combines multiple controllable components to achieve closed-loop intelligent regulation of local and overall thermal balance, thereby improving battery temperature control accuracy, system response speed and operational reliability, while optimizing energy efficiency and lifespan.

[0106] Optionally, the decision control algorithm includes, but is not limited to, predetermined strategies, adaptive methods, predictive methods, fuzzy control, PID control, model predictive control (MPC), reinforcement learning, neural networks, generative large models and other data-driven or physical model-based optimization control methods, or a combination of these algorithms.

[0107] Optionally, any functional unit or its sub-components and secondary parts may be made of a variety of materials, including but not limited to metals (aluminum alloys, copper, stainless steel, carbon steel with anti-corrosion treatment, titanium alloys, magnesium alloys), plastics or polymers (polyethylene PE, cross-linked polyethylene PEX, polyurethane PU foam pipes, polypropylene PP, polyvinylidene fluoride PVDF, polytetrafluoroethylene PTFE, chlorinated polyvinyl chloride CPVC), high thermal conductivity plastics (graphite-filled polypropylene, thermally conductive nylon, carbon fiber reinforced PEEK), composite materials (glass fiber reinforced plastic FRP, carbon fiber reinforced materials, aramid fiber composite materials), metal-ceramic composite pipes, high thermal conductivity concrete-coated pipes, ceramic pipes, ceramic coating materials (alumina ceramics, silicon nitride ceramics, metal-ceramic composite coatings), graphene composite materials, carbon nanotube composite polymers, and nano-aerogel thermal insulation composite layers.

[0108] The aforementioned functional unit or its sub-components and secondary components may be equipped with a heat exchange medium. The heat exchange medium may be a gaseous medium, a liquid medium, a phase change medium, or a refrigeration medium. Specific types include, but are not limited to, water, deionized water, ethylene glycol aqueous solution, propylene glycol aqueous solution, liquid nitrogen, liquid helium, organic solvents, inorganic solvents, environmentally friendly Freon refrigerants, compressed air, nitrogen, carbon dioxide, and ammonia. The medium may be used alone or its thermal management performance may be optimized through mixing or circulation.

[0109] Diverse control algorithms provide comprehensive support for temperature regulation, ranging from rule-driven to intelligent learning, enabling the system to have higher adaptability and optimization capabilities, and allowing for flexible selection of various high-performance materials and heat exchange media.

[0110] Optionally, the battery module may take the form of, but is not limited to, a single cell, a battery cell unit formed by combining several single cells, a battery pack, a battery cluster, or other modular units. Its structural forms may include, but are not limited to, stacking, layering, honeycomb, grid, ring, matrix, three-dimensional arrangement, flexible battery array, foldable structure, and modular splicing structure, to meet the capacity, power, and volume requirements of different application scenarios, or to adapt to the requirements of space-constrained or scalable devices. The shape of the battery module may include, but is not limited to, cylindrical, square, rectangular, flat sheet, sheet stack, ring, elliptical, polygonal, prism, triangular, rollable flexible sheet, or a modular geometric structure formed by combining battery cells, to achieve flexible arrangement and assembly. The packaging form of the battery module may include, but is not limited to, metal shell, plastic shell, composite material shell, soft pack, modular shell, waterproof and dustproof seal, heat dissipation enhancement, embedded packaging, surface coating packaging, or other packaging solutions that can provide environmental protection, thermal management, and mechanical strength.

[0111] The diverse battery module forms, structures, and packaging methods enhance the system's flexibility in terms of capacity, power, space adaptability, and environmental protection. This design not only meets the needs of different application scenarios but also enhances the battery's overall performance in thermal management and mechanical strength.

[0112] Optionally, the battery module can be any electrochemical device suitable for energy storage and release, including but not limited to lithium-based batteries (such as lithium-ion, lithium iron phosphate, ternary materials, lithium-sulfur and polymer lithium batteries), sodium-based batteries (sodium batteries, sodium-ion batteries), aluminum-based batteries (aluminum batteries, aluminum-ion batteries), magnesium-based batteries and their ion batteries, graphene-based batteries, sulfur batteries, nickel-metal hydride batteries, lead-acid batteries, all-solid-state batteries, solid-liquid hybrid batteries, metal and metal-ion batteries, air batteries, fuel cells, halide batteries, silicon-based batteries, supercapacitors, or other similar energy storage devices, thereby enabling the battery module to achieve efficient, safe and reliable energy supply in energy systems and other applications.

[0113] Optionally, the upper limit of the life-extending low-temperature range (including but not limited to) can be directly selected from the temperature values ​​listed below, or arbitrarily selected within ±2.5℃ of the following temperatures: -30℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 30℃ The lower limit of the life-extending low-temperature range (including but not limited to) can be directly selected from the temperature values ​​listed below, or arbitrarily selected within ±2.5℃ of the following temperatures: -27.5℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 30℃.

[0114] Optionally, the specific melting point values ​​of the phase change material include, but are not limited to, 25℃, 22.5℃, 20℃, 17.5℃, 15℃, 12.5℃, 10℃, 7.5℃, 5℃, 2.5℃, 0℃, -2.5℃, -5℃, -7.5℃, -10℃, -12.5℃, -15℃, -17.5℃, -20℃, -22.5℃, and -25℃, and can be finely adjusted within ±2.5℃ of the listed values.

[0115] This solution is compatible with various types of electrochemical energy storage devices, and combines a flexible and adjustable low-temperature range for extended lifespan with the melting point setting of phase change materials, enabling the system to adapt to different battery chemistry systems and application scenarios.

[0116] Optionally, the form of the temperature equalization device includes, but is not limited to, microchannel liquid cooling plate, liquid cooling temperature equalization plate, serpentine tube liquid cooling, immersion liquid cooling structure, air-cooled heat dissipation duct, forced convection air cooling, hot air circulation channel, heat pipe, flat plate heat pipe, steam chamber, graphite sheet thermal conductive layer, graphene film, carbon nanotube thermal conductive film, metal foam thermal conductive structure, thermal conductive gel, thermal conductive silicone grease, thermal conductive pad, spray cooling, boiling heat exchange, and aerogel insulation-thermal conductive composite structure.

[0117] The diverse types of temperature equalization devices offer flexible options for different operating conditions, effectively improving the temperature uniformity and thermal response speed of the battery module. The combination of multi-layered heat conduction and heat exchange methods also enhances heat dissipation efficiency and system reliability while ensuring safety.

[0118] This invention aims to solve the economic and safety issues of batteries throughout their entire life cycle through a disruptive technological concept. Traditional thermal management technologies only focus on maintaining the battery temperature at room temperature to avoid overheating or overcooling. However, through long-term experiments, the inventors have discovered that various types of batteries can significantly extend their lifespan by three to four times in low-temperature environments. This discovery completely changes the existing concept, upgrading the core design goal from "safe temperature management" to "low-temperature lifespan extension management," proactively utilizing the low-temperature environment to extend battery life.

[0119] To achieve this goal, this invention overcomes the challenges of increased energy consumption, capacity loss, and design complexity that may arise from low-temperature operation. Through a comprehensive strategy encompassing multi-stage cooling, intelligent temperature control, and capacity redundancy, this invention designs a highly efficient cooling and lifespan extension system. This system can dynamically adjust the cooling intensity, minimizing energy consumption while ensuring lifespan extension. Furthermore, the system boasts high reliability, effectively coping with extreme operating conditions. Modular design and dust / clogging prevention measures ensure long-term stable operation even under high load, high temperature, or high dust environments. Simultaneously, the combination of capacity redundancy and intelligent temperature control compensates for capacity loss caused by decreased chemical reaction rates at low temperatures, guaranteeing battery range and power output stability.

[0120] Compared with existing technologies, this invention possesses significant inventiveness and overwhelming advantages. It not only represents a leap from passive management to proactive optimization in its technological concept, but also proposes entirely new solutions in system design and functional implementation. By unifying low-temperature lifespan extension with energy efficiency optimization, this invention significantly extends battery life throughout its entire lifespan, reduces operating costs, and delivers economic benefits and industrial application value that existing technologies cannot achieve. This innovation, which fundamentally improves battery performance and economics, provides an unprecedented technological breakthrough for fields such as electric vehicles and electric transportation equipment. Attached Figure Description

[0121] Figure 1This is a schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0122] Figure 2 This is another schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0123] Figure 3 This is another schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0124] Figure 4 This is another schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0125] Figure 5 This is another schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0126] Figure 6 The original experimental data are used to demonstrate the low-temperature life extension effect of this case.

[0127] Cooling system 101, air duct 102, coolant pump 401, radiator 402, cooling plate 403, cooling pipe 404, battery module 405, refrigeration system 103, condenser 501, compressor 502, throttling device 503, evaporator 504, refrigeration pipe 505. Detailed Implementation

[0128] The embodiments of the present invention are described below with reference to the accompanying drawings. These descriptions are merely illustrative and not limiting, intended to help those skilled in the art understand the scope and effects of the invention. The present invention can be implemented in various forms; the embodiments provided herein are for illustration only and not limitation. Unless otherwise specified, component arrangements, materials, parameters, and values ​​are exemplary, and terminology should be interpreted according to the ordinary understanding of those skilled in the art, rather than idealized or overly formalized. Known technologies, methods, and devices are not described in detail, but their application can be understood in conjunction with this specification. The embodiments are merely illustrative; details can be modified, substituted, or adjusted without departing from the core concept, and those skilled in the art can understand other advantages and applications of the present invention accordingly. The technical features of the present invention can be used individually or in combination, all of which fall within the scope of protection. The accompanying drawings are for illustrative purposes only; the number, size, shape, and proportion of components can be adjusted or replaced as needed without affecting the purpose and effects of the present invention. The present invention is applicable to the illustrated and other similar scenarios, and improvements to functional modules and control methods are also included within the scope of protection. In summary, the embodiments are only used to illustrate the technical solutions and effects, and are not intended to limit the scope of protection. Any equivalent substitutions or improvements made without departing from the core concept should be considered to fall within the scope of protection of this invention, which is defined by the claims. The specification and drawings are only used to explain the principles and effects.

[0129] The technical solutions of this invention can be implemented independently or in combination with other cooling methods, temperature control strategies, or components. Although the specification describes low-temperature life-extending strategies, cooling systems, air ducts, and intelligent temperature control solutions with specific embodiments, the core is "extending battery life and optimizing system performance through low-temperature control." As long as the implementation achieves this core objective, even if the specific structure, parameters, or components are adjusted, it should still be considered within the scope of protection of this invention. This invention not only covers specific implementation methods but also includes equivalent technical solutions without departing from the core concept of life-extending, providing a technical basis for improving the performance and optimizing the economy of electric vehicles and electric transportation equipment throughout their entire life cycle. The scope of application includes electric vehicles, transportation tools, and special equipment that use batteries as their primary power source.

[0130] like Figures 1 to 3 This is a schematic diagram of a cooling and life-extending device suitable for electric transportation equipment and its accessories, according to some embodiments of this disclosure. In some embodiments, such as Figure 1 As shown, the cooling and life extension device includes several functional units, sub-components and secondary components. The functional units may include, but are not limited to: battery module 405, cooling system 101, and air duct 102. The sub-components in the cooling system 101 include a coolant pump 401, a radiator 402, a cooling plate 403, and interconnected cooling pipes 404. The air duct 102 defines the airflow path, allowing air to flow through the radiator 402, and the air is finally discharged to the outside after heat exchange. The cooling and life-extending device can stably control the temperature of the battery module 405 within the life-extending low temperature range, thereby extending the life of the battery module 405 and significantly enhancing its economic efficiency throughout its entire life cycle. The life-extending low-temperature range is a low-temperature range below room temperature but above the dew point. When the battery module 405 is used for a long time within this life-extending low-temperature range, it can slow down the aging and degradation of the electrode materials and electrolyte, thereby extending its lifespan. The cooling system 101 contains circulating coolant; such as Figure 2 As shown, the coolant pump 401 drives the coolant to circulate within the cooling system 101. The cooling plate 403 is in close contact with the battery module 405 that needs to be cooled, enabling the coolant to efficiently absorb the heat generated by the battery module 405 during operation. The coolant is transported to the radiator 402 via the cooling pipe 404, where it exchanges heat with the air through convection. After the temperature is reduced, the coolant flows back to the cooling plate 403, thus achieving a continuous and stable cooling effect. The cooling plate can also be in close contact with other sub-components or secondary components that need to be cooled to achieve the purpose of cooling. The battery module 405 undertakes the core functions of energy storage and output, and is the core component of the electric transportation equipment and its auxiliary facilities. It is also the direct cooling target and life extension carrier of the cooling and life extension device. The functional unit refers to the overall module in the cooling and life extension device used to realize the main function. The sub-component refers to the subdivided structure or independently operable component under the functional unit. The secondary component refers to the specific element or hardware component after the sub-component is further subdivided.

[0131] like Figure 2 As shown, the air duct 102 can define the airflow path and allow air to flow through the radiator 402.

[0132] In this invention, the life-extending low-temperature range refers to the temperature range below the ambient reference temperature but still above the critical temperature at which water vapor in the air begins to condense. The ambient reference temperature can be set according to different application requirements; for example, 20°C, 25°C, or 30°C can be selected as a reference value. The critical temperature can be obtained using known dew point calculation methods. For example, when the ambient reference temperature is set to 25°C and the relative humidity is 60%, the corresponding critical temperature is approximately 16°C, and the life-extending low-temperature range can be determined to be 16°C to 25°C. Through this definition, those skilled in the art can flexibly determine suitable temperature ranges under different environmental conditions, thereby ensuring the operability and universality of this invention.

[0133] In some embodiments, the cooling and life-extending device is used to actively promote the temperature reduction of the battery module and maintain it in the life-extending low temperature range, rather than just to prevent thermal runaway; the functional unit of the cooling and life-extending device can be replaced with other structures, or combined with other structures, to achieve the above-mentioned cooling and life-extending purpose; the functional unit can also select to implement any of the following temperature control strategies according to specific needs: passive heat dissipation, air cooling, convection cooling, active cooling or thermal compensation, or select a combination of multiple strategies to construct a multi-level coupled temperature control system.

[0134] In some embodiments, the air duct can also facilitate airflow through any functional unit or its sub-components and secondary components and exchange heat with them, thereby enhancing the overall heat dissipation effect of the cooling and life-extending device.

[0135] like Figure 3 As shown, the air duct 102 can define the airflow path and direct airflow through the cooling plate 403. Figure 4 and Figure 5 This is a schematic diagram of a cooling and life-extending device applicable to electric transportation equipment and its accessories, according to some embodiments of the present disclosure.

[0136] In some embodiments, the functional unit of the cooling and life-extending device further includes: a refrigeration system 103.

[0137] In some embodiments, such as Figure 5 As shown, the sub-components of the refrigeration system 103 include a condenser 501, a compressor 502, a throttling device 503, an evaporator 504, and interconnected refrigeration pipes 505.

[0138] In some embodiments, the refrigeration system 103 contains a refrigerant; the refrigerant circulates and undergoes a phase change within the refrigeration system 103, and exchanges heat with each sub-component in the refrigeration system 103 in sequence.

[0139] In some embodiments, the refrigeration system 103 is activated when the ambient temperature is too high or the heat dissipation efficiency of the cooling system 101 is insufficient to reduce the coolant to the target temperature, so as to further enhance the heat dissipation effect of the cooling and life extension device and ensure that the battery module 405 is in the life extension low temperature range.

[0140] like Figure 4As shown, in some embodiments, the compressor 502 compresses the low-pressure gaseous refrigerant into a high-temperature, high-pressure gas, and sends it through the refrigeration pipe 505 into the condenser 501 to release heat and condense it into a liquid. Subsequently, the refrigerant enters the evaporator 504 after being depressurized and cooled by the throttling device 503, where it absorbs heat and evaporates into a gas, and then returns to the compressor 502 to form a cyclic refrigeration process. The condenser 501 is coupled to the air duct 102, and the heat released by the refrigerant in the condenser 501 is transferred through the air duct 102 and finally discharged to the outside. The evaporator 504 is coupled to the radiator 402 (or other components) in the cooling system 101, and the refrigerant absorbs heat in the evaporator 504, thereby reducing the temperature of the radiator 402 in the cooling system 101 and achieving auxiliary cooling of the coolant.

[0141] In some embodiments, the throttling device 503 is preferably a thermostatic expansion valve or an electronic expansion valve, but it can also be a capillary tube, a float valve, a needle valve, an electronic proportional valve, a two-stage expansion valve, or an adjustable orifice capillary tube, etc., which can adjust the refrigerant flow according to the load of the evaporator 504 or the system control requirements, thereby ensuring the stable heat absorption and circulating cooling effect of the evaporator 504.

[0142] In some embodiments, each functional unit, sub-component, and secondary component in the cooling and life-extending device is optional, wherein the electrically related parts have a sealed structure to suppress condensation and improve adaptability under low-temperature conditions.

[0143] In some embodiments, when the battery module operates in the extended-life low-temperature range, although its lifespan can be extended, its electrochemical reaction rate decreases, resulting in a reduction in initial capacity; therefore, the battery module is configured with a capacity redundancy function.

[0144] In some embodiments, the capacity redundancy function is implemented by pre-setting additional redundant capacity for the battery module to compensate for the capacity loss of the battery module when operating in a low-temperature environment; the capacity redundancy function is an optional configuration.

[0145] In some embodiments, the capacity redundancy function achieves excess redundancy by adding a battery expansion pack and cooperating with the battery module; or by designing the total capacity of the battery module according to a preset redundancy ratio, thus achieving excess redundancy design from the source of the solution.

[0146] In some embodiments, the capacity redundancy function can selectively enable or disable the battery expansion pack or automatically adjust the overall operating intensity of the battery module according to external load demand, so that the total capacity of the battery module can flexibly meet external load demand and respond promptly when demand suddenly increases.

[0147] In some embodiments, the capacity redundancy function can not only compensate for the capacity loss of the battery module in the low-temperature life extension range, but also further improve the life of the battery module on the basis of the life extension caused by low temperature.

[0148] Scenario 1 illustrates the effect of low-temperature lifespan extension: At room temperature (30℃), a battery module with a nominal capacity of 1Ah and a cumulative charge-discharge lifespan of 1000Ah has an equivalent cycle life of 1000 cycles (1000Ah ÷ 1Ah). When operating in a low-temperature lifespan extension range of around 10℃, the cumulative charge-discharge lifespan of the battery module can be extended to three times, reaching 3000Ah, due to the low-temperature lifespan extension effect. However, at the same time, its capacity will decrease by 15%, becoming 0.85Ah (1Ah × 0.85), at which point the equivalent cycle lifespan is approximately 3529 cycles (3000Ah ÷ 0.85Ah).

[0149] This demonstrates that although operating in the low-temperature range leads to a 15% decrease in capacity, the lifespan is increased to more than three times the original, achieving a significant gain. This technical feature of "trading a partial sacrifice of capacity for a substantial increase in lifespan" unexpectedly achieves a "leveraging effect with minimal effort." Furthermore, considering the application trend of autonomous vehicles, the relative loss of capacity can be compensated for by automatic recharging, while the significantly extended lifespan is the key to ensuring its long-term operational economics.

[0150] Scenario 2 illustrates the synergistic effect of low-temperature life extension and capacity redundancy: If the battery module is further configured with capacity redundancy, the initial capacity can be increased by 1.1765 times, i.e., 1.1765 Ah, by increasing the number of cells. Under normal temperature conditions, its cumulative charge-discharge lifespan is also correspondingly increased to 1176.5 Ah (1.1765 Ah × 1000 cycles). When operating in the low-temperature life extension range of around 10℃, although there is a 15% capacity decrease, the redundant capacity can offset this adverse effect, and its actual capacity remains at 1 Ah (1.1765 Ah × 0.85). At the same time, due to the low-temperature life extension effect, its cumulative charge-discharge lifespan is still increased threefold to 3529 Ah (1176.5 Ah × 3), with an equivalent cycle count of 3529 (3529 Ah ÷ 1 Ah).

[0151] It is evident that by simply adding 0.1765Ah of redundant capacity, capacity degradation can be avoided in low-temperature operating scenarios, and the lifespan can be extended by 3.529 times, unexpectedly achieving a technological advancement that is "all benefits and no harms".

[0152] In addition, the capacity redundancy function not only replenishes the capacity, but also further extends the lifespan on the basis of the low-temperature life-extending effect: due to the low-temperature life-extending effect, the cumulative charge-discharge lifespan of the battery module in scenario 1 can be extended to 3 times to 3000Ah; however, due to the synergistic effect of the low-temperature life-extending and capacity redundancy functions, the cumulative charge-discharge lifespan of the battery module in scenario 2 can be extended to 3 times to 3529Ah; that is, the capacity redundancy function extends the cumulative charge-discharge lifespan of the battery module by an additional 0.529 times.

[0153] In the low-temperature life extension effect described herein, the life indicators are not limited to the cumulative charge and discharge amount, but may also include, but are not limited to: cumulative cycle number, cumulative charge amount, cumulative discharge amount, cumulative charge and discharge duration, cumulative driving mileage, and other parameters that can characterize battery life.

[0154] It should be noted that the numerical values ​​and calculation results mentioned above are for illustrative purposes only and do not constitute a limitation on the scope of protection of this invention.

[0155] In some embodiments, the functional unit of the cooling and life-extending device further includes: an integrated control module.

[0156] In some embodiments, the integrated control module is further configured with a decision control algorithm, which can dynamically adjust the coolant flow rate, fan speed, or cooling system start / stop according to the battery module temperature, coolant temperature, and ambient temperature, or the load requirements of the battery module, so that the battery temperature remains stable in the long-term life-extending low-temperature range; wherein, if the ambient temperature is too low, the coolant flow rate is reduced to prevent the battery from being overcooled.

[0157] In some embodiments, the integrated control module can ensure that one or more operating characteristics of the battery module do not exceed a preset operating condition threshold during charging and discharging, so as to avoid a rapid increase in the side reaction rate of the battery module under adverse operating conditions.

[0158] In some embodiments, the operating condition characteristics include one or more of the following: charging current, charging voltage, discharging voltage, discharging current, charging and discharging power, temperature, and other battery operating condition parameters.

[0159] In some embodiments, when the integrated control module detects that one or more operating condition characteristics are close to or exceed the preset operating condition threshold, a protection mechanism is triggered. The protection mechanism includes, but is not limited to: reducing the charging current, reducing the discharging current, reducing the charging and discharging power and / or voltage, performing a circuit breaker action, and issuing an alarm signal.

[0160] In some embodiments, the integrated control module can also monitor the internal and external operating parameters of the electric transportation equipment, its auxiliary facilities, and the cooling and life extension device in real time, analyze the parameters through a decision control algorithm, and adjust the operating strategy and / or operating intensity of the cooling and life extension device as needed based on the analysis results, so as to enhance the continuous temperature control capability and the precise temperature control capability.

[0161] In some embodiments, the life-extending low-temperature range can be around 10°C, around 15°C, around 20°C, or other temperature ranges below room temperature.

[0162] In some embodiments, the range of the extended life low temperature range and the setting of the preset operating condition threshold may vary depending on the type and model of the battery module, and may be affected by the battery module's chemical system, capacity, rated voltage and operating environment conditions.

[0163] In addition, the operating condition threshold can be an upper limit protection (such as the temperature cannot be too high or the current cannot be too high), or a lower limit protection (such as the voltage cannot be too low). It can be a single-sided constraint (only an upper limit or a lower limit), or a double-sided constraint (both an upper limit and a lower limit).

[0164] In some embodiments, the life-extending low-temperature range and / or preset operating condition threshold can be determined by experiments, tests, or a combination of methods. Specific determination methods include, but are not limited to: determining by accelerated aging tests, charge-discharge cycle tests, or thermal characteristic analysis; selecting based on experience or manufacturer recommendations; predicting by combining battery thermal management models, aging models, or chemical kinetic simulations; performing statistical analysis based on historical operating data; and determining through multi-factor combination optimization methods.

[0165] According to the experimental results, when setting conditions for ternary lithium batteries, their life-extending low-temperature range can be set to 5℃~15℃, their operating characteristics can be set to instantaneous charging current, and their preset operating threshold can be set to 1C charging rate. This means that when a ternary lithium battery is running at 5℃~15℃ and its instantaneous charging current does not exceed 1C charging rate, its cycle life (or charge-discharge throughput life) will be extended by 3 times.

[0166] Based on experimental results, when setting conditions for lithium iron phosphate batteries, their life-extending low-temperature range can be set to 0℃~10℃, their operating characteristics can be set as instantaneous charging current and instantaneous discharging current, and their preset operating thresholds can be set as 3C charging rate and 6C discharging rate. This means that when lithium iron phosphate batteries operate at 0℃~10℃, and their instantaneous charging current does not exceed 3C charging rate and instantaneous discharging current does not exceed 6C charging rate, their cycle life (or charge / discharge throughput life) can be significantly extended, for example, by more than 10 times the original life. This data is only the test results in a specific embodiment and is used to illustrate the effect; it does not constitute a limitation of this disclosure.

[0167] In some embodiments, the overall control strategy for low-temperature operation scenarios is to ensure the battery module operates in low-temperature conditions and reduce the charging and discharging current to slow down the side reaction rate and extend battery life. The limitation on charging current is typically stricter than that on discharging current. Furthermore, this strategy is not only applicable to ternary lithium batteries and lithium iron phosphate batteries, but can also be adjusted according to the characteristics of different battery chemistry systems, thus possessing broad applicability and scalability.

[0168] In some embodiments, the cooling and life-extending device can be configured with a multi-stage cooling strategy: primary cooling is achieved by a cooling system, air ducts, and natural or relative airflow, without additional energy consumption; secondary cooling is assisted by an electric fan; tertiary cooling is initiated by a refrigeration system to achieve cooling and temperature control under extreme high-temperature conditions; the multi-stage cooling strategy can be arbitrarily combined and switched by the control module to ensure that the cooling and life-extending device can adjust the temperature of the battery module as needed under any operating condition.

[0169] In some embodiments, the specific control measures that the integrated control module can take include, but are not limited to, dynamically adjusting the execution sequence, operating mode, operating parameters, and operating intensity of any functional unit or its sub-components or secondary components, or reconstructing or switching the topological connection structure of any functional unit or its sub-components, secondary components, or secondary components; enabling the battery module to achieve temperature balance and maintain it in the low-temperature range for life extension under different operating conditions, thereby stabilizing the life extension effect; and also configuring a series of controllable components in the cooling life extension device to achieve flexible adjustment as needed.

[0170] In some embodiments, any functional unit or its sub-components and secondary components can be quickly connected through multi-way valves, quick-connect pipes, bypass loops or quick-switching interfaces, thereby enabling the integrated control module to dynamically adjust the execution order, operating mode, operating parameters and operating intensity of any functional unit or its sub-components, secondary components and secondary components, or to reconstruct or switch the topological connection structure of any functional unit or its sub-components, secondary components and secondary components.

[0171] In some embodiments, any functional unit or its sub-components and secondary components can be arranged in a zoned and coordinated manner for different parts of the battery module, and work in a zoned and coordinated manner to achieve differentiated heat dissipation and local temperature control, so as to improve the overall thermal management performance; in particular, priority heat dissipation is given to high-heat areas in the battery module.

[0172] Optionally, any of the functional units or their sub-components and secondary components can be integrated with the battery module to make the heat dissipation structure closely integrated with the battery module, thereby achieving centralized heat dissipation and overall temperature control, and further improving the compactness and heat dissipation efficiency of the device.

[0173] Optionally, the cooling and life-extending device is internally equipped with partitions to divide the battery module into multiple independent module compartments to form a modular thermal management structure, and to isolate faults when a single module malfunctions, thus preventing the risk from spreading to other modules.

[0174] In some embodiments, any functional unit or its sub-components or secondary components may be designed in a branched manner to distribute heat dissipation for different parts of the battery module and improve temperature uniformity.

[0175] In some embodiments, any functional unit or its sub-components and secondary components can be repeatedly configured as needed to achieve fault redundancy, so that when some units fail, other units can take over the operation to ensure system stability; at the same time, heat dissipation can be enhanced by adding parallel heat dissipation units to improve the overall heat dissipation capacity; and hierarchical control can be achieved by hierarchical start-stop and adjustment of multiple units, thereby taking into account both energy efficiency and precise regulation.

[0176] In some embodiments, the functional unit of the cooling and life extension device further includes an anti-condensation module; the anti-condensation module can be automatically activated when the battery module temperature is close to the dew point to reduce the humidity of the air around the battery module, so that the dew point is lower than the battery surface temperature, thereby preventing condensation on the battery surface and ensuring the safe operation of the battery.

[0177] In some embodiments, any functional unit or its sub-components and secondary components can be thermally coupled as needed, thereby improving the heat exchange efficiency between functional units and optimizing the heat dissipation performance of the entire system. The thermal coupling can achieve rapid heat exchange directly by connecting any functional unit or its sub-components and secondary components, or it can achieve indirect heat conduction by arranging heat exchange plates, heat dissipation fins, heat pipes, heat bridges, heat conduction pipelines, or using heat exchange media (such as liquid cooling media, phase change materials) between any functional unit or its sub-components and secondary components. Alternatively, any functional unit or its sub-components and secondary components can also be equipped with thermal insulation structures as needed to block unwanted thermal coupling. Various methods, including thermal insulation boards, thermal insulation sleeves, air layers, low thermal conductivity materials, or thermal insulation layers, can be used to slow down heat transfer, thereby preventing local overheating while maintaining the necessary heat exchange efficiency, and improving system safety and temperature uniformity. The two design methods (thermal coupling / thermal insulation) can be selected independently without conflict.

[0178] In some embodiments, any functional unit or its sub-components and secondary components can adopt a modular design concept as needed to form independent modules. Flexible piping, quick connectors, and standardized interfaces facilitate coupling and disassembly, allowing each unit to be disassembled for cleaning or replacement, thereby reducing maintenance costs and downtime, improving system maintainability and adaptability, and facilitating flexible configuration and upgrades. Alternatively, any functional unit or its sub-components and secondary components can also adopt an integrated design as needed, coupling any functional unit or its sub-components and secondary components into a unified structure, improving heat exchange efficiency, reducing heat loss, improving thermal management efficiency, shortening piping, and enhancing structural compactness. These two design methods (modular design / integrated design) can be selected independently without conflict.

[0179] In some embodiments, the air duct can be configured as a multi-stage flow distribution structure or a parallel channel structure to realize air diversion and convergence and path selection, so that air flows sequentially or separately through any of the functional units or their sub-components and secondary components and exchanges heat with them, thereby optimizing air distribution, improving heat dissipation uniformity and reducing wind resistance.

[0180] In some embodiments, the air duct may adopt an automatic switching structure or an adjustable opening structure, which can dynamically adjust the airflow path or opening size as needed to optimize wind resistance and heat dissipation efficiency.

[0181] In some embodiments, the air duct may be equipped with an adjustable baffle, a servo-driven baffle, a vortex generator, a damper (variable opening), a louver, or adjustable blades to improve the airflow path, reduce dead zones or local hot spots, and adjust the airflow direction and flow rate as needed.

[0182] Figure 6The original experimental data is presented to illustrate the low-temperature life-extending effect of this case. The "△" symbol in the figure represents battery degradation data in a normal temperature (25℃) scenario. It can be observed that the initial capacity is relatively high (approximately 6.5Ah), but it decays to approximately 2.5Ah after about 1700 cycles. The "○" symbol in the figure represents battery degradation data in a low-temperature (15℃) scenario. It can be seen that although the initial capacity is lower (approximately 5.5Ah), it still maintains approximately 5.2Ah after 3000 cycles, with negligible degradation. It is evident that although low temperatures lead to a decrease in the initial battery capacity, the long-term benefit in terms of lifespan is significantly greater. Conversely, the normal temperature scenario only shows a capacity advantage in the early stages of degradation, and its lifespan is significantly inferior to that of the low-temperature scenario. In the current scenario of passenger vehicles, users mainly focus on the performance of the first approximately 100,000 kilometers (equivalent to approximately 150 cycles, i.e., ...). Figure 6 The advantage of batteries in ambient temperature scenarios lies in their extended cycle life, leading manufacturers to prioritize short-term performance and disregard lifespan. However, as autonomous vehicles become more widespread, capacity loss can be compensated for through automatic recharging (such as automatic charging or battery swapping), and the significant extension of battery life is the key factor determining their long-term operational economics. Figure 6 (It shows no significant degradation even after approximately 1 million kilometers).

[0183] In some embodiments, an electric fan may be additionally installed in the air duct. The electric fan can actively drive airflow when there is a lack of natural wind or relative airflow, so as to maintain the heat dissipation capacity of the air duct.

[0184] In some embodiments, aerodynamic air duct designs can be adopted. Option 1: Low-profile entry air duct, characterized by air entering from below the vehicle or side skirts at a low profile and being guided along the floor to the radiator. Advantages include high-speed airflow, low pressure loss, and the ability to utilize the floor effect to increase airflow velocity, suitable for scenarios with limited space and a need for high-speed heat dissipation. Option 2: Side-wing airflow air duct, characterized by air entering through side air inlets on the vehicle body and being blown directly to the radiator along a streamlined air duct. Advantages include aesthetics, reduced intrusion into the vehicle's shape, and efficient cooling of localized heat sources, suitable for localized heat dissipation optimization. Option 3: Dual-branch / guide vane air duct, characterized by the main air duct being divided into two or more branches and incorporating micro-guide vanes to guide airflow evenly across the cooling plate. Advantages include improved heat dissipation. Uniform and precisely controllable local flow rate, suitable for large battery modules or scenarios with uneven heat load distribution; Solution 4: Intake + Exhaust Integrated Airflow Duct, characterized by air being drawn in from the front grille or bumper, passing through the radiator along a streamlined channel, and then being exhausted from the rear or side wings. Advantages include smooth airflow, low overall resistance, and the ability to utilize the vehicle's natural airflow to reduce fan energy consumption, suitable for high-speed driving or long-range electric vehicles; Solution 5: Chassis / Hood Airflow Combination Airflow Duct, characterized by air entering from multiple points under the front of the vehicle, the side wings, and the gaps in the battery cover, converging to the radiator through multiple streamlined channels. Advantages include significant forced cooling effect and flexible space utilization, suitable for large battery modules or high-performance electric vehicles. It should be noted that while the air duct is an important component of the cooling system in this invention, and its design can affect airflow and heat dissipation efficiency, the core innovation of this invention does not lie in the specific streamline or shape of the air duct, but rather in the low-temperature lifespan extension and energy efficiency optimization of the battery achieved through experimental discovery and system design, effectively controlling system energy consumption, thereby achieving a balance between economy and safety throughout the entire lifespan of electric vehicles or electric transportation equipment. The scope of protection of this invention is not limited by the specific form or layout of the air duct, nor can the core technical solution of this invention be circumvented by different implementations of the air duct design. In reality, the battery capacity of most electric vehicles decreases in low-temperature environments, limiting their range. Existing electric vehicle thermal management systems mainly focus on preventing overheating or maintaining normal temperature, without specifically designed for low-temperature lifespan extension. Public information shows that the air duct design of existing mass-produced models is mostly focused on external styling, and their internal structure does not form an effective airflow guiding channel to assist in heat dissipation of the battery or key components. For example, tests and disassembly results of a Xiaomi SU7 Ultra showed that its air duct cover's internal structure was similar to a regular aluminum hood, lacking a clear airflow channel and connection to the heat dissipation components. A tissue was not noticeably moved during a blower test. This indicates that current models do not yet feature dedicated air duct designs for low-temperature lifespan extension or efficient heat dissipation.

[0185] In some embodiments, the electric fan includes a variable speed control or stepless speed control fan, and may further include variable pitch blades or a bidirectional impeller structure to automatically adjust the air volume and blade angle as needed, thereby improving energy efficiency and heat dissipation efficiency.

[0186] In some embodiments, the electric fan includes a low-resistance operating structure, which is used to allow the fan to rotate freely with the airflow direction in high-speed airflow scenarios, thereby reducing air resistance and enhancing the convective ventilation effect of the radiator.

[0187] In some embodiments, the low-resistance operating structure includes at least one of the following: a non-reverse drag control circuit, a one-way clutch mechanism, a low-resistance bearing structure, a magnetic levitation bearing structure, or an automatic stop / retract blade structure.

[0188] In some embodiments, the non-reverse drag control circuit is used to suppress the reverse electric resistance generated by the motor when the fan blades are driven to rotate by high-speed airflow; the one-way clutch mechanism is used to achieve free rotation under the action of high-speed airflow, while being driven by the motor in low-wind-speed scenarios; the low-resistance bearing structure is used to reduce the rotational friction of the fan in the follow-up state; the magnetic levitation bearing is used to further reduce mechanical friction loss; the automatic stop or blade retraction structure is used to separate the fan from the airflow when the high-speed airflow is sufficient to meet the heat dissipation requirements, thereby further reducing air resistance and improving overall heat dissipation efficiency.

[0189] In some embodiments, any functional unit or its sub-components or secondary components may be equipped with a temperature equalization device to improve the overall temperature uniformity and thermal response efficiency of the functional unit.

[0190] In some embodiments, any functional unit or its sub-components or secondary components may be covered with phase change material to freeze and store cold energy when the battery module load is low or the ambient temperature is low at night, and melt and release cold energy when the temperature rises during the day or the battery module load suddenly increases, thereby reducing the start-up frequency of the refrigeration system and achieving cross-day and cross-seasonal temperature control optimization; the phase change material can be precisely controlled by alloy formulation optimization or microencapsulation technology to meet the precise temperature control requirements under different application scenarios.

[0191] In some embodiments, the phase change material may be arranged in a hierarchical array or deployed in different locations to achieve a hierarchical phase change process through a combination of multiple melting points, storing and releasing cold energy at different temperature points or locations, thereby enhancing the ability to maintain and regulate low temperatures.

[0192] In some embodiments, the cooling and life-extending device is further provided with a heat preservation system. When the ambient temperature is too low, the heat preservation system can quickly reduce the heat exchange efficiency of any functional unit or its sub-components or secondary components to prevent the battery module temperature from being too low. If necessary, the heat preservation system can activate an electric heating unit, a small reversible heat pump or other compensating heating device to perform compensating heating, thereby ensuring that the battery module temperature is stable in the life-extending low temperature range rather than in an overcooled state.

[0193] In some embodiments, the cooling system further includes a bypass circuit, which allows the coolant to bypass the radiator and return directly to the cooling plate when the heat load on the battery module is low, thereby keeping the coolant temperature from getting too low and preventing the battery module from being in an overcooled state.

[0194] In some embodiments, the anti-condensation module can also monitor the surface temperature of the battery module, the temperature of the coolant, and the ambient humidity in real time, and judge the risk of condensation based on the condensation model or threshold, thereby controlling the heating device to heat the surface of the battery module or the surrounding air, or reducing the air humidity or increasing the air circulation through the air conditioning device, thereby inhibiting water vapor condensation, ensuring the safe operation of the system in a low temperature and high humidity environment, and without affecting the low temperature life extension effect.

[0195] In some embodiments, the cooling and life-extending device further includes a thermosiphon circuit or a heat pipe array, connecting the battery cold plate and the radiator, to achieve partial or complete pump-free natural circulation cooling driven by temperature difference, so that the coolant can complete circulation without relying on a water pump, thereby still having basic low-temperature maintenance capability when the pump fails.

[0196] In some embodiments, the device is equipped with redundant control logic: when the cooling and life extension device cannot effectively reduce the battery temperature to the low-temperature operating range (e.g., radiator failure, coolant pump failure, insufficient fan speed, or excessively high ambient temperature), the redundant control logic will automatically switch to the overheat protection mode to prioritize ensuring that the battery module does not overheat, thereby improving system reliability and preventing thermal runaway.

[0197] In some embodiments, any of the functional units or their sub-components or secondary components can be linked with the vehicle powertrain, BMS or vehicle air conditioning system to switch heat dissipation strategies according to operating conditions, thereby achieving whole-vehicle temperature control optimization.

[0198] In some embodiments, the condenser shares part of the refrigeration system with the vehicle's original air conditioning system to reduce system redundancy, lower costs, and improve refrigerant circulation efficiency. However, the cooling life extension device can also have an evaporator and control valve set independently, so that it can operate independently when the battery module requires low-temperature control, thus not affecting the comfort of the passenger compartment.

[0199] In some embodiments, the cooling and life-extending device may also integrate a heat recovery function to use the heat generated by the battery module for vehicle cabin or auxiliary heating.

[0200] In some embodiments, the cooling and life-extending device may also be equipped with a damping or noise reduction device to reduce noise.

[0201] In some embodiments, the radiator adopts a variable fin spacing structure. Under normal circumstances, the fin spacing is small to improve heat exchange efficiency, while in dusty or polluted environments, the fin spacing can be increased to reduce the risk of blockage, thereby maintaining a long-term stable low-temperature heat dissipation effect.

[0202] In some embodiments, any functional unit or its sub-components or secondary components may also be provided with a spray cooling device, which can further enhance heat dissipation efficiency through spray evaporation and heat absorption in ultra-high temperature or continuous high load scenarios.

[0203] In some embodiments, the cooling and life-extending device may also be configured with a high-level heat dissipation tower, and any functional unit or its sub-components or secondary components may be preferentially installed in the high-level heat dissipation tower.

[0204] In some embodiments, the elevated heat dissipation tower may be equipped with a shield, air guide plate, dust filter chamber and sealing protection structure, and can form an air film or air curtain through a fan, nozzle or air guide plate to reduce the direct entry of ground dust and reduce the impact of windward dust on the heat dissipation tower.

[0205] In some embodiments, the elevated heat dissipation tower can also ensure smooth airflow by reasonably arranging the airflow guiding structure and optimizing the airflow guiding in combination with the vehicle movement direction, thereby maintaining the long-term stable and efficient heat dissipation performance of the cooling and life extension device.

[0206] In some embodiments, the elevated heat dissipation tower may be equipped with multiple axial flow fans, which may be controlled by frequency conversion or constant speed, and have a back-blowing dust removal function. The fans remove dust from the fins and pipe surfaces through periodic or real-time reverse airflow. At the same time, they can be used with airflow guide plates to optimize the airflow path and reduce the risk of dust accumulation in dead corners.

[0207] In some embodiments, the elevated heat dissipation tower may be supplemented with sound waves or ultrasonic vibrations to actively shake off the attached dust, and in special cases, it may be combined with slight spray atomization pretreatment to allow some dust to settle in the pretreatment area, ensuring long-term stable heat dissipation performance.

[0208] In some embodiments, the elevated heat dissipation tower can flexibly adjust the fan frequency and airflow direction according to the concentration of mineral dust, operating environment and seasonal changes, so as to achieve environmentally adaptive dust control.

[0209] In some embodiments, the fin spacing of the radiator can be appropriately increased, and the structural design can include trapezoidal, corrugated or spiral. It can also be coated with anti-stick powder or hydrophobic coating to reduce dust adhesion and clogging.

[0210] In some embodiments, a dust removal device may be installed at the air inlet or air channel of the cooling and life-extending device, including but not limited to a filter screen, a washable filter element, a composite filter element, a microporous filter layer, a cyclone separator, or an electrostatic dust collection device, to classify and intercept dust according to its size or electrical properties.

[0211] In some embodiments, the cooling and life-extending device may be equipped with a dust sensor to monitor the dust concentration in the air in real time, and automatically trigger backflushing, vibration cleaning or spray rinsing functions according to the actual situation.

[0212] In some embodiments, the cooling and life-extending device can also achieve intelligent dust management by using fan adjustment strategies, flow guiding structure optimization, fin spacing selection, material composites, and the synergistic effect of various dust prevention measures, thereby ensuring heat dissipation efficiency and extending the device's lifespan.

[0213] In some embodiments, the cooling and life-extending device can also flexibly adjust its operating strategy according to the concentration of mineral dust, operating environment and seasonal changes, while recording cleaning logs to optimize maintenance cycles and reduce maintenance costs.

[0214] In some embodiments, the integrated control module can monitor internal and external operating parameters including, but not limited to, temperature and temperature difference, flow rate and flow rate difference, pressure and pressure difference, liquid level, air velocity, wind pressure, airflow direction and wind speed difference at any measuring point or location of any functional unit, its sub-component or secondary component, and any difference between these measuring points or locations, such as the difference between different measuring points within the same functional unit, sub-component or secondary component, or the difference between different measuring points in different functional units, sub-components or secondary components, and derived quantities calculated from the above parameters; and including, but not limited to, the operating status of the battery module (such as battery heat generation, cell and module temperature, state of charge (SOC / DOI), charge and discharge power, cycle count, health status), vehicle operating status (such as vehicle speed, acceleration, braking status, steering status, load, driving mode), and environmental conditions (such as ambient temperature, humidity, air pressure, wind direction and wind speed, solar radiation intensity).

[0215] In some embodiments, the controllable components include, but are not limited to, adjustable speed electric pumps, adaptive pumps, micro circulating pumps, bidirectional pumps, electronic control valves, three-way valves, four-way valves, eight-way valves, multi-way valves, flow dividers, switching valves, multi-way switching valves, throttling devices, solenoid valves, adjustable throttling valves, differential pressure regulating valves, compressors (inverter compressors, twin-rotor compressors, or scroll compressors), turbo expanders, adjustable condenser supports, heat exchanger bypass valves, cooling plate adjustment components, heat pipe control switches, phase change material start / stop control devices, intelligent control modules, power drive units, non-reverse drag control circuits, and automatic stop or folding blade mechanisms.

[0216] In some embodiments, the decision control algorithm includes, but is not limited to, predetermined strategies, adaptive methods, predictive methods, fuzzy control, PID control, model predictive control (MPC), reinforcement learning, neural networks, generative large models and other data-driven or physical model-based optimization control methods, or a combination of these algorithms.

[0217] In some embodiments, the upper limit of the life-extending low-temperature range (including but not limited to) can be directly selected from the temperature values ​​listed below, or arbitrarily selected within ±2.5℃ of the following temperatures: -30℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 3 0℃; the lower limit of the life-extending low-temperature range (including but not limited to) can be directly selected from the temperature values ​​listed below, or arbitrarily selected within ±2.5℃ of the following temperatures: -27.5℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 30℃.

[0218] In some embodiments, the specific melting point values ​​of the phase change material include, but are not limited to, 25°C, 22.5°C, 20°C, 17.5°C, 15°C, 12.5°C, 10°C, 7.5°C, 5°C, 2.5°C, 0°C, -2.5°C, -5°C, -7.5°C, -10°C, -12.5°C, -15°C, -17.5°C, -20°C, -22.5°C, and -25°C, and can be finely adjusted within ±2.5°C of the listed values.

[0219] In some embodiments, the form of the temperature distribution device includes, but is not limited to, microchannel liquid cooling plates, liquid cooling temperature distribution plates, serpentine tube liquid cooling, immersion liquid cooling structures, air-cooled heat dissipation ducts, forced convection air cooling, hot air circulation channels, heat pipes, flat plate heat pipes, steam chambers, graphite sheet thermal conductive layers, graphene films, carbon nanotube thermal conductive films, metal foam thermal conductive structures, thermal conductive gels, thermal conductive silicone greases, thermal conductive pads, spray cooling, boiling heat exchange, and aerogel insulation-thermal conductive composite structures.

[0220] The following are some extended embodiments. 1) AI-based predictive thermal management control: The core of this embodiment lies in the predictive control algorithm. The system utilizes reinforcement learning or generative large models to analyze massive amounts of historical data and predict future battery thermal load. For example, when the navigation system indicates that the vehicle is about to enter a long uphill section, the AI ​​model will predict in advance that the battery will generate a large amount of heat and lower the battery temperature to the lower limit of the life-extending low temperature range before the start of the uphill climb, reserving temperature rise space for the upcoming thermal load. This proactive strategy avoids temperature fluctuations caused by delayed response, achieving smoother and more efficient temperature control while reducing unnecessary energy consumption. 2) Ultra-precise temperature control system based on thermoelectric cooling: This embodiment introduces a thermoelectric cooling (TEC) module on the basis of the original cooling system. This module is directly integrated into the cooling plate and generates a temperature difference through DC power to fine-tune and precisely control the battery temperature. The cooling system first lowers the battery temperature to a lower range, and then the TEC module performs precise fine-tuning to stabilize the temperature within, for example, the life-extending low temperature range of 10℃±0.5℃. The TEC module can also be heated by reverse power, thus achieving true bidirectional precise temperature control. This design is particularly suitable for temperature-sensitive next-generation batteries, ensuring their long lifespan and high safety. 3) Micro reversible heat pump integrated with coolant heating: This embodiment deeply integrates heat pump technology into the cooling system to achieve bidirectional temperature control. Traditional electric heaters are inefficient, while this system uses a small reversible heat pump that can absorb heat from the battery in cooling mode and absorb heat from the environment in heating mode and "pump" it into the coolant for efficient battery heating. This design significantly reduces energy consumption in winter, especially for electric vehicles that need to operate in cold regions, where its economic and range advantages will be more prominent. 4) Dynamic phase change material cold energy storage and release system: This embodiment proposes a dynamically controllable phase change material (PCM) system. Traditional PCM systems operate passively, while this system, through microencapsulation and electric field, magnetic field, or ultrasonic field control technology, can actively adjust its phase change temperature and rate. This makes cold energy storage and release no longer dependent on simple temperature differences, but can be intelligently scheduled according to real-time load and peak-valley electricity prices. For example, storing cold energy using cheap electricity during off-peak hours at night and actively releasing it during high-load days significantly reduces operating energy consumption and costs. 5) Reconfigurable heat recovery and multi-source heat utilization system: This embodiment proposes a reconfigurable heat recovery system. Through multi-way valves and bypass circuits, the heat generated by the battery can be directed to different heat utilization units as needed, such as for heating the passenger compartment, preheating the battery during low-temperature charging, or heating vehicle auxiliary systems. The system can also recover waste heat from the motor controller or the motor itself, realizing cross-system heat recovery and utilization, greatly improving energy efficiency. 6) Hybrid cooling of integrated heat pipe array and liquid cooling plate: This embodiment deeply integrates efficient heat pipe technology with traditional liquid cooling plates to form a heat pipe-liquid cooling hybrid plate.Embedded heat pipes can rapidly transfer heat from local hot spots to the coolant channels with ultra-high equivalent thermal conductivity, thereby achieving rapid heat homogenization and significantly improving the temperature uniformity inside the battery module. This design combines the advantages of efficient heat pipe homogenization and large-capacity heat dissipation of liquid cooling, providing dual protection and better temperature field management for the system. 7) Intelligent airflow guiding structure based on fluid dynamics: This embodiment uses computational fluid dynamics (CFD) simulation to design an intelligent variable airflow guiding structure. This structure integrates multiple variable geometry guide plates and vortex generators, which can be adjusted according to real-time data to optimize the airflow distribution on the heat sink. This design ensures uniform and efficient airflow on the heat exchange surface, eliminates local hot spots, maximizes heat dissipation efficiency, and reduces wind resistance and noise. 8) Temperature homogenization structure based on high thermal conductivity graphene: This embodiment introduces a high thermal conductivity graphene composite material between the cooling plate and the battery module. Graphene has ultra-high in-plane thermal conductivity. Encapsulating its film or aerogel between the battery cell and the cooling plate can form a "thermal conduction layer". This layer can uniformly diffuse heat in a two-dimensional plane at an ultra-fast speed, eliminating local hot spots before the heat reaches the cooling plate, significantly improving temperature uniformity. It is particularly suitable for fast charging or high-rate discharging scenarios where thermal uniformity is extremely important. 9) Pump-free thermosiphon-based backup cooling system: This embodiment utilizes the thermosiphon principle to realize a pump-free natural circulation cooling system. When the battery generates heat during operation, the coolant evaporates at the cooling plate, rises into the radiator, condenses into liquid, and flows back under gravity. This system serves as a backup or low-load cooling method without consuming electricity to drive a coolant pump, making it particularly suitable for scenarios requiring long-term shutdown or low-power monitoring. 10) Multi-material composite cooling plate and optimized heat conduction path: This embodiment proposes a multi-material composite cooling plate design, combining materials with different thermal conductivity to optimize heat transfer. For example, the part in contact with the battery uses a high thermal conductivity copper or graphene composite material, while the pipeline flow channel uses a lightweight aluminum alloy. This "material selection on demand" design achieves an optimal balance between weight, cost, and heat dissipation performance, making it a multifunctional, composite heat-conducting structure. 11) Layered Dust Removal and Self-Cleaning Heat Dissipation Tower: This embodiment addresses the specific needs of electric transportation equipment in dusty environments by proposing a multi-stage, self-cleaning layered heat dissipation tower. The tower integrates a cyclone separator, a self-cleaning microporous filter, and radiator fins with a backflushing function. This "layered protection, active cleaning" design reduces dust entry at the source and continuously removes internal dust, ensuring the radiator maintains high efficiency even in extremely harsh environments. 12) Variable Fin Spacing and Coated Radiator: This embodiment proposes a variable fin spacing (VCS) radiator. This radiator can dynamically adjust the fin spacing based on dust sensors or operating conditions.In clean environments, the fin spacing can be reduced to maximize heat exchange efficiency; in high-dust areas, it automatically increases to prevent clogging. Furthermore, combined with a self-cleaning coating or ultrasonic vibration module, this design perfectly balances heat exchange efficiency and anti-clogging capability, solving the pain point of traditional radiators' performance degradation in extreme environments. 13) Dynamic adjustment of the life-extending low-temperature range based on multi-factor optimization: This embodiment extends the life-extending low-temperature range from a fixed range to a dynamically adjustable range. The system utilizes neural networks or reinforcement learning algorithms to comprehensively consider multiple factors such as battery health status, ambient temperature, state of charge, and driving mode, calculating and predicting the "optimal" temperature range in real time. For example, when high power output is required, the system may raise the life-extending low-temperature range to 15°C to ensure performance; and lower it to 5°C under low load to maximize lifespan. 14) Intelligent scheduling system based on IoT and cloud: This embodiment connects the thermal management system to the Internet of Things (IoT) and cloud platform to achieve intelligent remote scheduling and predictive maintenance. Vehicle thermal management data is uploaded to the cloud in real time and fused with meteorological data, map data, and historical operating data for analysis. The cloud platform can predict future heat loads or component failure risks in advance and send control commands to the vehicle or warning information to management personnel, thereby realizing a "prevention-oriented" maintenance strategy. 15) Integrated packaging of battery module and thermal management system: This embodiment integrates the battery module, cooling plate, and thermal management pipelines into a deep package. This solution embeds the cooling pipes directly into the packaging structure of the battery cell or module, greatly shortening the heat conduction path. The entire system is packaged to a high standard, forming a completely sealed "self-contained" thermal management module. This design improves the system's integration and compactness, reduces leakage risks, simplifies the vehicle assembly process, and provides great design flexibility.

[0221] It should be understood that the embodiments disclosed in this specification are merely illustrative examples, and their designs, structures, and combinations are used to explain the principles and effects of the invention, not to limit the invention. Those skilled in the art, after reading this, can make equivalent substitutions, modifications, improvements, or combinations to the embodiments without departing from the spirit and substance of the invention, and all such substitutions should be included within the scope of protection. The embodiments are described in a progressive and complementary manner, with each embodiment highlighting its main differences, and similar or identical parts referring to other embodiments. The technical features described can be arbitrarily combined, cross-referenced, or used in combination without creating contradictions, and such combinations should also be considered to fall within the scope of protection. The technical solutions of this invention are not only applicable to the illustrated embodiments but can also be extended to other related fields or systems. Those skilled in the art can make improvements or optimizations according to actual needs, including structural adjustments, component replacements, functional expansions, or parameter modifications, and all of these should be considered part of the scope of protection. The scope of protection of this invention is not limited to specific embodiments but covers all technical features, feature combinations, and their equivalent solutions. All modifications, extensions, improvements, or substitutions made within the scope of the principles and spirit of this invention, whether implemented alone or in combination, are within the scope of protection. In summary, the technical solution proposed in this invention can achieve the expected results and is applicable to different application scenarios. Its protection scope is determined by the claims. Any modifications, equivalent substitutions, or application extensions within the scope of the claims shall be protected by law.

[0222] This invention has significant practical value in industrial applications. First, by maintaining the battery module in the extended-life low-temperature range for an extended period, it can significantly delay the aging of electrode materials and electrolytes, extending battery cycle life and overall life-cycle economics, providing an efficient and reliable energy storage solution for electric vehicles and electric transportation equipment. Second, the cooling and life-extending device of this invention has overwhelming advantages in system design: the combination of multi-stage cooling, optimized air ducts, thermal coupling / insulation strategies, and capacity redundancy design achieves efficient, balanced, and dynamic control under the low-temperature life-extending target, while also considering energy saving, significantly outperforming existing single liquid cooling or air cooling technologies. Third, this invention has high adaptability and reliability: the modular and integrated design facilitates maintenance and upgrades, the redundancy design ensures stable system operation even when some units fail, and the high-dust environment protection strategy ensures long-term efficient heat dissipation for mining vehicles. Fourth, this invention achieves closed-loop optimized control under the battery life-extending target through an intelligent temperature control module combined with multiple sensors, decision algorithms, and external parameter linkage, and ensures battery performance and safety in low-temperature environments through capacity redundancy and anti-condensation strategies. In summary, this invention provides an innovative battery life extension technology that not only achieves a significant lifespan extension but also achieves energy efficiency through system optimization and intelligent control, forming an overall advantage that cannot be matched by existing technologies. It provides a completely new and unexpected solution for electric vehicle battery systems and has significant industrial application prospects and economic value.

Claims

1. A cooling and life-extending device applicable to electric transportation equipment and its auxiliary facilities, characterized in that: The cooling and life-extending device includes several functional units, sub-components and secondary components. The functional units may include, but are not limited to: battery module, cooling system, and air duct. The sub-components of the cooling system include a coolant pump, a radiator, a cooling plate, and interconnected cooling pipes. The air duct defines the airflow path, allowing air to flow through the radiator and finally be discharged to the outside after heat exchange. The battery module undertakes the core functions of energy storage and output, and is the core component of the electric transportation equipment and its auxiliary facilities. It is also the direct cooling target and life extension carrier of the cooling and life extension device. The cooling and life-extending device can stably control the temperature of the battery module within the life-extending low temperature range, thereby extending the life of the battery module and significantly enhancing its economic efficiency throughout its entire life cycle. The life-extending low-temperature range is a low-temperature range below room temperature but above the dew point. When the battery module is used for a long time within this life-extending low-temperature range, it can slow down the aging and degradation of electrode materials and electrolyte, thereby extending its lifespan. The cooling system contains circulating coolant. A coolant pump drives the coolant to circulate within the system. The cooling plate is in close contact with the battery module requiring cooling, enabling the coolant to efficiently absorb the heat generated by the battery module during operation. The coolant is transported to a radiator via cooling pipes, where it exchanges heat with the air through convection. The cooled coolant then flows back to the cooling plate, achieving a continuous and stable cooling effect. The cooling plate can also be in close contact with other sub-components or secondary components requiring cooling to achieve the same purpose. The functional unit refers to the overall module in the cooling and life extension device used to realize the main function. The sub-component refers to the subdivided structure or independently operable component under the functional unit. The secondary component refers to the specific element or hardware component after the sub-component is further subdivided.

2. The cooling and life-extending device according to claim 1, characterized in that, The cooling and life-extending device is used to actively promote the temperature reduction of the battery module and maintain it in the low-temperature range for life extension, rather than just to prevent thermal runaway. The functional unit of the cooling and life-extending device can be replaced with other structures or combined with other structures to achieve the above-mentioned purpose of cooling and life extension. The functional unit can also select to implement any of the following temperature control strategies according to specific needs: passive heat dissipation, air cooling, convection cooling, active cooling or thermal compensation, or select a combination of multiple strategies to construct a multi-level coupled temperature control system. The air duct can also facilitate airflow through any functional unit or its sub-components and secondary components and exchange heat with them, thereby enhancing the overall heat dissipation effect of the cooling and life extension device. Each functional unit, sub-component, and secondary component in the cooling and life-extending device is optional. The electrical-related parts have a sealed structure to suppress condensation and improve adaptability under low-temperature conditions. While the battery module can extend its lifespan when operating in the extended-life low-temperature range, its electrochemical reaction rate decreases, resulting in a reduction in initial capacity; therefore, the battery module is equipped with a capacity redundancy function. The capacity redundancy function is achieved by pre-setting additional redundant capacity for the battery module to compensate for the capacity loss of the battery module when it is running in a low-temperature environment. The capacity redundancy function is an optional configuration. The functional units of the cooling and life-extending device also include: a comprehensive control module; The integrated control module can also monitor the internal and external operating parameters of the electric transportation equipment, its auxiliary facilities, and the cooling and life extension device in real time. It analyzes the parameters through a decision control algorithm and adjusts the operating strategy and / or operating intensity of the cooling and life extension device as needed based on the analysis results to enhance the continuous temperature control capability and the precise temperature control capability. The integrated control module can ensure that one or more operating characteristics of the battery module do not exceed the preset operating condition threshold during charging and discharging, so as to avoid the rapid increase of the side reaction rate of the battery module under adverse operating conditions. The range of the life-extending low-temperature range and the setting of the preset operating condition threshold may vary depending on the type and model of the battery module, and will be affected by the battery module's chemical system, capacity, rated voltage and operating environment conditions.

3. The cooling and life-extending device according to claim 2, characterized in that, The functional units of the cooling and life-extending device also include: a refrigeration system; The capacity redundancy function achieves excess redundancy by adding a battery expansion pack and cooperating with the battery module; or by designing the total capacity of the battery module according to a preset redundancy ratio, thus achieving excess redundancy design from the source of the solution. The capacity redundancy function can not only compensate for the capacity loss of the battery module in the low temperature life extension range, but also further improve the life of the battery module on the basis of the life extension caused by low temperature. The cooling system is activated when the ambient temperature is too high or the cooling system's heat dissipation efficiency is insufficient to lower the coolant to the target temperature, in order to further enhance the heat dissipation effect of the cooling and life extension device and ensure that the battery module is in the life extension low temperature range. The operating condition characteristics include one or more of the following: charging current, charging voltage, discharging voltage, discharging current, charging and discharging power, temperature, and other battery operating condition parameters. An electric fan can also be installed in the air duct. The electric fan can actively promote airflow when there is a lack of natural wind or relative airflow, so as to maintain the heat dissipation capacity of the air duct. The cooling and life-extending device can be configured with a multi-stage cooling strategy: primary cooling is achieved by the cooling system and air duct in conjunction with natural wind or relative airflow, without the need for additional energy consumption; secondary cooling is assisted by an electric fan; tertiary cooling is initiated by the refrigeration system to achieve cooling and temperature control under extreme high-temperature conditions; the multi-stage cooling strategy can be arbitrarily combined and switched by the control module to ensure that the cooling and life-extending device can adjust the temperature of the battery module as needed under any operating condition. The life-extending low-temperature range can be around 10℃, around 15℃, around 20℃, or other temperature ranges below room temperature.

4. The cooling and life-extending device according to claim 3, characterized in that, When the integrated control module detects that one or more operating condition characteristics are close to or exceed the preset operating condition threshold, it will trigger a protection mechanism. The protection mechanism includes, but is not limited to: reducing the charging current, reducing the discharging current, reducing the charging and discharging power and / or voltage, performing a circuit breaker action, and issuing an alarm signal. The sub-components of the refrigeration system include a condenser, a compressor, a throttling device, an evaporator, and interconnected refrigeration pipes; The refrigeration system contains a refrigerant; the refrigerant circulates and undergoes a phase change within the refrigeration system, and exchanges heat with each sub-component of the refrigeration system in sequence; The life-extending low-temperature range and / or preset operating condition threshold can be determined through experiments, tests, or a combination of methods. Specific determination methods include, but are not limited to: using accelerated aging tests, charge-discharge cycle tests, or thermal characteristic analysis; selecting based on experience or manufacturer recommendations; and predicting by combining battery thermal management models, aging models, or chemical kinetic simulations. Statistical analysis was conducted based on historical operational data; the determination was made through a multi-factor combination optimization method. The specific control measures that the integrated control module can take include, but are not limited to, dynamically adjusting the execution sequence, operating mode, operating parameters, and operating intensity of any functional unit or its sub-components and secondary components, or reconstructing or switching the topological connection structure of any functional unit or its sub-components, secondary components, and secondary components; enabling the battery module to achieve temperature balance and maintain it in the low-temperature range for life extension under different operating conditions, thereby stabilizing the life extension effect; and also configuring a series of controllable components in the cooling life extension device to achieve flexible adjustment as needed; The aforementioned functional units or their sub-components and secondary components can be quickly connected through multi-way valves, quick-connect pipes, bypass loops, or quick-switching interfaces. This allows the integrated control module to dynamically adjust the execution sequence, operating mode, operating parameters, and operating intensity of any functional unit or its sub-components, secondary components, and secondary components, or to reconstruct or switch the topological connection structure of any functional unit or its sub-components, secondary components, and secondary components.

5. The cooling and life-extending device according to claim 4, characterized in that, The aforementioned functional unit or its sub-components and secondary components can be arranged in a coordinated manner for different parts of the battery module and work in coordination according to the zones to achieve differentiated heat dissipation and local temperature control, thereby improving the overall thermal management performance. The functional unit of the cooling and life extension device also includes an anti-condensation module; the anti-condensation module can be automatically activated when the battery module temperature is close to the dew point to reduce the humidity of the air around the battery module, so that the dew point is lower than the battery surface temperature, thereby preventing condensation on the battery surface and ensuring the safe operation of the battery. The aforementioned functional unit or its sub-components and secondary components can be designed in a branched manner to distribute heat dissipation for different parts of the battery module and improve temperature uniformity; The aforementioned functional units or their sub-components and secondary components can be repeatedly configured as needed to achieve fault redundancy, so that when some units fail, other units can take over to ensure system stability; at the same time, heat dissipation can be enhanced by adding parallel heat dissipation units to improve the overall heat dissipation capacity; and hierarchical control can be achieved by hierarchical start-stop and adjustment of multiple units, thereby taking into account both energy efficiency and precise regulation. The aforementioned functional units or their sub-components and secondary components can be thermally coupled as needed, thereby improving the heat exchange efficiency between functional units and optimizing the overall system's heat dissipation performance. This thermal coupling can achieve rapid heat exchange directly by connecting any functional unit or its sub-components and secondary components, or it can achieve indirect heat conduction by arranging heat exchange plates, heat dissipation fins, heat pipes, thermal bridges, heat conduction pipelines, or using heat exchange media (such as liquid cooling media or phase change materials) between any functional unit or its sub-components and secondary components. Alternatively, the aforementioned functional units or their sub-components and secondary components can also be equipped with thermal insulation structures as needed to block unwanted thermal coupling. Various methods, including thermal insulation boards, thermal insulation jackets, air layers, low thermal conductivity materials, or insulation layers, can be used to slow down heat transfer, thereby preventing localized overheating while maintaining necessary heat exchange efficiency, and improving system safety and temperature uniformity. The two design methods (thermal coupling / thermal insulation) can be selected independently without conflict. The aforementioned functional units or their sub-components and secondary components can adopt a modular design concept as needed to form independent modules. Through flexible piping, quick connectors, and standardized interfaces, a structure that facilitates coupling and disassembly can be achieved, allowing each unit to be disassembled for cleaning or replacement. This reduces maintenance costs and downtime, improves system maintainability and adaptability, and facilitates flexible configuration and upgrades. Alternatively, the aforementioned functional units or their sub-components and secondary components can also adopt an integrated design as needed, coupling the aforementioned functional units or their sub-components and secondary components into an integral structure. This improves heat exchange efficiency between them, reduces heat loss, improves thermal management efficiency, shortens piping, and enhances structural compactness. These two design methods (modular design / integrated design) can be selected independently without conflict.

6. The cooling and life-extending device according to claim 5, characterized in that, The compressor compresses the low-pressure gaseous refrigerant into a high-temperature, high-pressure gas, which is then sent to the condenser through a refrigeration pipe to release heat and condense into a liquid. Subsequently, the refrigerant is depressurized and cooled by a throttling device before entering the evaporator, where it absorbs heat and evaporates into a gas, before returning to the compressor to form a cyclic refrigeration process. The condenser is coupled to the air duct, and the heat released by the refrigerant in the condenser is transferred through the air duct and eventually discharged to the outside. The evaporator is coupled to the radiator (or other components) in the cooling system, and the refrigerant absorbs heat in the evaporator, thereby reducing the temperature of the radiator in the cooling system and achieving auxiliary cooling of the coolant. The air duct can be configured as a multi-stage flow distribution structure or a parallel channel structure to realize the flow distribution and convergence of air and path selection, so that the air flows sequentially or separately through any of the functional units or their sub-components and secondary components and exchanges heat with them, thereby optimizing air distribution, improving heat dissipation uniformity and reducing wind resistance. The air duct can adopt an automatic switching structure or an adjustable opening structure, and the air flow path or opening size can be dynamically adjusted according to the needs to optimize wind resistance and heat dissipation efficiency. The air duct can be equipped with a guide plate (adjustable), an adjustable baffle (servo driven), a vortex generator, a damper (variable opening), louvers or adjustable blades to improve the airflow path, reduce dead zones or local hot spots, and adjust the airflow direction and flow rate as needed. The electric fan includes a variable speed control or stepless wind speed control fan, and may further include variable pitch blades or a bidirectional impeller structure to automatically adjust the air volume and blade angle according to demand, thereby improving energy efficiency and heat dissipation efficiency. The electric fan includes a low-resistance operating structure, which is used to allow the fan to rotate freely with the airflow direction in high-speed airflow scenarios, so as to reduce air resistance and enhance the convective ventilation effect of the radiator. The low-resistance operating structure includes at least one of the following: a non-reverse drag control circuit, a one-way clutch mechanism, a low-resistance bearing structure, a magnetic levitation bearing structure, or an automatic stop / retract blade structure. The non-reverse drag control circuit is used to suppress the reverse electric resistance generated by the motor when the fan blades are driven to rotate by high-speed airflow; the one-way clutch mechanism is used to achieve free rotation under the action of high-speed airflow, while being driven by the motor in low-wind-speed scenarios; the low-resistance bearing structure is used to reduce the rotational friction of the fan in the follow-up state; the magnetic levitation bearing is used to further reduce mechanical friction loss; the automatic stop or blade retraction structure is used to separate the fan from the airflow when the high-speed airflow is sufficient to meet the heat dissipation requirements, thereby further reducing air resistance and improving the overall heat dissipation efficiency.

7. The cooling and life-extending device according to claim 6, characterized in that, The throttling device is preferably a thermostatic expansion valve or an electronic expansion valve, but can also be a capillary tube, a float valve, a needle valve, an electronic proportional valve, a dual-stage expansion valve, or an adjustable orifice capillary tube. It can adjust the refrigerant flow according to the evaporator load or system control requirements, thereby ensuring the stable heat absorption and circulating cooling effect of the evaporator. Any functional unit or its sub-components and secondary components can be equipped with a temperature equalization device to improve the overall temperature uniformity and thermal response efficiency of the functional unit; Any functional unit or its sub-components and secondary components can be covered with phase change material to freeze and store cold energy when the battery module load is low or the ambient temperature is low at night, and melt and release cold energy when the temperature rises during the day or the battery module load suddenly increases, thereby reducing the start frequency of the refrigeration system and achieving cross-day and cross-seasonal temperature control optimization; the phase change material can be precisely controlled by alloy formula optimization or microencapsulation technology to meet the precise temperature control requirements under different application scenarios. The phase change material can be used in a graded array or deployed in different locations in a graded manner. A graded phase change process can be achieved through a combination of multiple melting points. Cold energy can be stored and released at different temperature points or different locations, thereby enhancing the ability to maintain and regulate low temperature. The cooling and life extension device is also equipped with a heat preservation system. When the ambient temperature is too low, the heat preservation system can quickly reduce the heat exchange efficiency of any functional unit or its sub-components and secondary components to prevent the battery module temperature from being too low. If necessary, the heat preservation system can activate an electric heating unit, a small reversible heat pump or other compensating heating device to perform compensating heating, thereby ensuring that the battery module temperature is stable in the life extension low temperature range rather than in an overcooled state. The cooling system further includes a bypass circuit. When the heat load of the battery module is small, the coolant can bypass the radiator and return directly to the cooling plate through the bypass circuit, thereby keeping the coolant temperature from getting too low and preventing the battery module from being in an overcooled state. The anti-condensation module can also monitor the surface temperature of the battery module, the temperature of the coolant and the ambient humidity in real time, and judge the risk of condensation based on the condensation model or threshold. In this way, it can control the heating device to heat the surface of the battery module or the surrounding air, or reduce the air humidity or increase the air circulation through the air conditioning device, thereby inhibiting water vapor condensation and ensuring that the system operates safely in a low temperature and high humidity environment without affecting the low temperature life extension effect. The cooling and life extension device further includes a thermosiphon circuit or heat pipe array, connecting the battery cold plate and the heat sink, and achieving partial or complete pump-free natural circulation cooling under temperature difference drive, so that the coolant can complete circulation without relying on the water pump, thereby still having basic low temperature maintenance capability when the pump fails.

8. The cooling and life-extending device according to claim 7, characterized in that, The device is equipped with redundant control logic: when the cooling and life extension device cannot effectively reduce the battery temperature to the low temperature operating range (e.g., radiator failure, coolant pump failure, insufficient fan speed or excessively high ambient temperature), the redundant control logic will automatically switch to the overheat protection mode to prioritize ensuring that the battery module does not overheat, thereby improving system reliability and preventing thermal runaway. The cooling and life-extending device can also be equipped with a damping or noise reduction device to reduce noise. The radiator adopts a variable fin spacing structure. Under normal circumstances, the fin spacing is small to improve heat exchange efficiency. In dusty or polluted environments, the fin spacing can be increased to reduce the risk of blockage, thereby maintaining a long-term stable low-temperature heat dissipation effect. The aforementioned functional unit or its sub-components and secondary components can be integrated with the battery module, so that the heat dissipation structure is closely integrated with the battery module, thereby achieving centralized heat dissipation and overall temperature control, and further improving the compactness and heat dissipation efficiency of the device. The cooling and life extension device is equipped with partitions to divide the battery module into multiple independent module compartments to form a modular thermal management structure. It also isolates faults when a single module malfunctions, preventing the risk from spreading to other modules. Spray cooling devices can also be installed on any of the functional units or their sub-components and secondary components, which can further enhance heat dissipation efficiency through spray evaporation and heat absorption in ultra-high temperature or continuous high load scenarios. The integrated control module can monitor internal and external operating parameters including, but not limited to, temperature and temperature difference, flow rate and flow rate difference, pressure and pressure difference, liquid level, air velocity, wind pressure, airflow direction and wind speed difference at any measuring point or location of any functional unit, its sub-components or secondary components, as well as any difference between these measuring points or locations, and the derived quantities calculated from the above parameters; it also includes, but is not limited to, the operating status of the battery module (such as battery heat generation, individual cell and module temperature, state of charge (SOC / DOI), charge and discharge power, cycle count, health status) and environmental conditions (such as ambient temperature, humidity, air pressure, wind direction and wind speed, solar radiation intensity).

9. The cooling and life-extending device according to claim 8, characterized in that, The cooling and life extension device may also be equipped with a high-level heat dissipation tower, and any functional unit or its sub-components and secondary components may be preferentially installed in the high-level heat dissipation tower. The elevated heat dissipation tower may be equipped with a shield, air guide plate, dust filter chamber and sealed protection structure, and can form an air film or air curtain through a fan, nozzle or air guide plate to reduce the direct entry of ground dust and reduce the impact of windward dust on the heat dissipation tower. The high-level heat dissipation tower can be equipped with multiple axial flow fans, which can be controlled by frequency conversion or constant speed, and have a back-blowing dust removal function. The dust on the surface of the fins and pipes is removed by periodic or real-time reverse airflow. At the same time, it can be used with airflow guide plates to optimize the airflow path and reduce the risk of dust accumulation in dead corners. The elevated heat dissipation tower can be supplemented with sound waves or ultrasonic vibrations to actively shake off the attached dust, and in special cases, it can be combined with slight spray atomization pretreatment to make some dust settle in the pretreatment area, ensuring long-term stable heat dissipation performance. The fin spacing of the radiator can be appropriately increased, and the structural design can include trapezoidal, corrugated or spiral. It can also be coated with anti-stick powder or hydrophobic coating to reduce dust adhesion and clogging. Dust removal devices, including but not limited to filter screens, washable filter elements, composite filter elements, microporous filter layers, cyclone separators, or electrostatic dust collection devices, can be installed at the air inlet or air channel of the cooling and life-extending device to classify and intercept dust according to its size or electrical properties. The cooling and life extension device can be equipped with a dust sensor to monitor the dust concentration in the air in real time, and automatically trigger back-blowing, vibration cleaning or spray washing functions according to the actual situation. The cooling and life-extending device can also achieve intelligent dust management by adjusting the fan adjustment strategy, optimizing the airflow structure, selecting the fin spacing, combining materials, and working together with various dust prevention measures to ensure heat dissipation efficiency and extend the device's lifespan. The cooling and life extension device can also flexibly adjust its operating strategy according to the concentration of mine dust, operating environment and seasonal changes, and record cleaning logs to optimize the maintenance cycle and reduce maintenance costs.

10. The cooling and life-extending device according to claim 9, characterized in that, The controllable components include, but are not limited to, adjustable speed electric pumps, adaptive pumps, micro circulation pumps, bidirectional pumps, electronic control valves, three-way valves, four-way valves, eight-way valves, multi-way valves, flow dividers, switching valves, multi-way switching valves, throttling devices, solenoid valves, adjustable throttling valves, differential pressure regulating valves, compressors (variable frequency compressors, twin-rotor compressors, or scroll compressors), turbo expanders, adjustable condenser brackets, heat exchanger bypass valves, cooling plate adjustment components, heat pipe control switches, phase change material start / stop control devices, intelligent control modules, power drive units, non-reverse drag control circuits, and automatic stop or folding blade mechanisms. The upper limit of the life-extending low-temperature range can be directly selected from the temperature values ​​listed below (including but not limited to), or arbitrarily selected within ±2.5℃ of the following temperatures: -30℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 30℃; The lower limit of the life-extending low-temperature range can be directly selected from the temperature values ​​listed below (including but not limited to), or arbitrarily selected within ±2.5℃ of the following temperatures: -27.5℃, -25℃, -22.5℃, -20℃, -17.5℃, -15℃, -12.5℃, -10℃, -7.5℃, -5℃, -2.5℃, 0℃, 2.5℃, 5℃, 7.5℃, 10℃, 12.5℃, 15℃, 17.5℃, 20℃, 22.5℃, 25℃, 30℃; The specific melting point values ​​of the phase change material include, but are not limited to, 25℃, 22.5℃, 20℃, 17.5℃, 15℃, 12.5℃, 10℃, 7.5℃, 5℃, 2.5℃, 0℃, -2.5℃, -5℃, -7.5℃, -10℃, -12.5℃, -15℃, -17.5℃, -20℃, -22.5℃, and -25℃, and can be finely adjusted within ±2.5℃ of the listed values; The forms of the temperature equalization device include, but are not limited to, microchannel liquid cooling plates, liquid cooling temperature equalization plates, serpentine tube liquid cooling, immersion liquid cooling structures, air-cooled heat dissipation ducts, forced convection air cooling, hot air circulation channels, heat pipes, flat plate heat pipes, steam chambers, graphite sheet thermal conductive layers, graphene films, carbon nanotube thermal conductive films, metal foam thermal conductive structures, thermal conductive gels, thermal conductive silicone greases, thermal conductive pads, spray cooling, boiling heat exchange, and aerogel insulation-thermal conductive composite structures. The integrated control module can monitor internal and external operating parameters, including but not limited to vehicle operating status (such as vehicle speed, acceleration, braking status, steering status, load, and driving mode). Any of the aforementioned functional units or their sub-components and secondary components can be linked with the vehicle's powertrain, BMS, or onboard air conditioning system to switch heat dissipation strategies according to operating conditions, thereby achieving optimized temperature control for the entire vehicle. The condenser shares part of the refrigeration system with the vehicle's original air conditioning system to reduce system redundancy, lower costs and improve refrigerant circulation efficiency. However, the cooling life extension device can also be equipped with an evaporator and control valve independently, so that it can operate independently when the battery module needs low temperature control, thus not affecting the comfort of the passenger compartment. The cooling and life-extending device can also integrate heat recovery function to use the heat generated by the battery module for vehicle cabin or auxiliary heating. The elevated heat dissipation tower can also ensure smooth airflow by rationally arranging the airflow guide structure and optimize the airflow guide in combination with the vehicle movement direction, thereby maintaining the long-term stable and efficient heat dissipation performance of the cooling and life extension device. The elevated heat dissipation tower can flexibly adjust the fan frequency and airflow direction according to the concentration of mineral dust, operating environment and seasonal changes, so as to achieve environmentally adaptive dust control.

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