Energy storage cabin integrated with phase change thermal insulation layer

Abstract

This invention relates to the field of phase change energy storage technology, specifically disclosing an energy storage chamber with an integrated phase change insulation layer, including a main body and at least one inspection door. The wall panels of the main body and the inspection door are both composite insulation wall panels. From the outside to the inside of the main body, the composite insulation wall panel includes a first insulation layer, a phase change energy storage layer, a second insulation layer, and an inner thermal conductive support plate arranged sequentially. A thermoelectric power generation module is arranged between the phase change energy storage layer and the inner thermal conductive support plate. The thermoelectric power generation module is electrically connected to an energy storage capacitor. The thermoelectric power generation module is used to convert the temperature difference between the phase change energy storage layer and the inner thermal conductive support plate into electrical energy. The energy storage capacitor is used to store electrical energy.

Description

Technical Field

[0001] This invention relates to the field of phase change energy storage technology, specifically an energy storage chamber with an integrated phase change insulation layer. Background Technology

[0002] With the continuous expansion of new energy power generation, electrochemical energy storage systems have been widely used as a key supporting technology for grid peak shaving, frequency regulation, and renewable energy grid connection. As the platform supporting the battery system, the size of the energy storage compartment is increasing due to factors such as cost and floor space requirements. Its thermal management performance and structural design directly affect the safety, lifespan, and energy efficiency of the battery system. Especially in cold regions, a reasonable preheating temperature before using battery modules can improve battery life.

[0003] Currently, energy storage containers face the following technical challenges in some engineering applications: 1. Limited Insulation Function and High Energy Consumption: Existing energy storage container insulation solutions mostly use single materials such as rock wool and polyurethane foam. These materials rely solely on their thermal resistance to slow down heat conduction and cannot actively absorb or release heat to mitigate temperature fluctuations within the container. To maintain the battery's suitable operating temperature range (typically 15-30℃), air conditioning or liquid cooling systems need to operate continuously, resulting in a high proportion of the power station's self-consumption energy consumption, directly impacting the economics of the energy storage system.

[0004] 2. Poor adaptability to low-temperature environments: In cold northern regions (below -20℃), energy storage systems face severe low-temperature start-up problems. At low temperatures, the internal resistance of batteries increases dramatically, charging and discharging performance decreases significantly, and some systems may even fail to function properly. Existing solutions rely on external power to preheat the batteries, which carries the risk of start-up delays or even failure, severely hindering the widespread application of energy storage in cold regions.

[0005] 4. Challenges in Integrating Phase Change Materials: Phase change materials (PCMs) have broad application prospects in the field of thermal insulation due to their high energy storage density and isothermal phase change characteristics. However, existing PCM technologies generally suffer from engineering challenges such as easy leakage, low thermal conductivity, and large volume changes during phase change. Integrating them into the wall panels of energy storage containers faces multiple challenges, including packaging reliability, structural strength, and thermal response speed.

[0006] Therefore, developing an energy storage compartment structure that combines excellent temperature regulation performance, strong environmental adaptability, and excellent energy efficiency for active thermal management of battery modules has significant engineering application value. Summary of the Invention

[0007] The purpose of this invention is to provide an energy storage compartment with an integrated phase change insulation layer to solve the problems of insufficient thermal energy utilization of the energy storage compartment and high energy consumption for battery module preheating during normal thermal management in the prior art.

[0008] The objective of this invention can be achieved through the following technical solutions: An energy storage chamber with an integrated phase change insulation layer includes a main body and at least one inspection door. The wall panels of the main body and the inspection door are both composite insulation wall panels. From the outside to the inside of the main body, the composite insulation wall panel includes a first insulation layer, a phase change energy storage layer, a second insulation layer, and an inner thermal conductive support plate arranged in sequence. A thermoelectric power generation module is arranged between the phase change energy storage layer and the inner thermal conductive support plate. The thermoelectric power generation module is electrically connected to an energy storage capacitor. The thermoelectric power generation module is used to convert the temperature difference between the phase change energy storage layer and the inner thermal conductive support plate into electrical energy. The energy storage capacitor is used to store electrical energy.

[0009] Furthermore, the phase change energy storage layer includes a honeycomb support structure with multiple independent honeycomb chambers filled with composite phase change material.

[0010] Furthermore, the composite phase change material comprises, by weight, 60-70% paraffin wax, 10-15% expanded graphite, 10-15% high-density polyethylene and 5-10% flame retardant.

[0011] Furthermore, the thermoelectric power generation module includes multiple semiconductor thermoelectric power generation chips, adjacent semiconductor thermoelectric power generation chips are connected in series, and the honeycomb support serves as a heat-conducting skeleton.

[0012] Furthermore, the hot end of the semiconductor thermoelectric generator is in contact with the heat-conducting frame, and the cold end of the semiconductor thermoelectric generator is in contact with the inner heat-conducting support plate.

[0013] Furthermore, the hot end of the thermoelectric generator is embedded in a honeycomb support, and the cold end of the thermoelectric generator is connected to the inner thermal support plate through a heat-conducting block.

[0014] Furthermore, the energy storage capacitor is electrically connected to a miniature heating unit via a micro-control switch.

[0015] Furthermore, the micro heating unit includes multiple sets of PTC heating elements electrically connected to the micro switch. The PTC heating elements are arranged at the bottom of the battery module and are used for preheating the battery module. The battery module is located inside the main body of the housing, and the micro switch is located on one side of the battery module.

[0016] Furthermore, it also includes a position sensor and a controller. The controller is located outside the main body of the enclosure and is communicatively connected to the position sensor. The position sensor is inductively connected to the maintenance door. The position sensor transmits a signal to the controller indicating whether the door is closed properly. The controller is used to control the battery management system to perform high-voltage power supply based on the signal.

[0017] Furthermore, it also includes an air conditioning system and air ducts. The air conditioning system is located on one side of the main body of the enclosure. The battery modules inside the main body of the enclosure are connected to the air conditioning system through the air ducts. When the maintenance door is closed and the battery modules do not reach the preset preheating temperature, the battery modules are preheated through the air conditioning system and air ducts.

[0018] The beneficial effects of this invention are: The first and second insulation layers of this invention facilitate the retention of latent heat in the phase change energy storage layer to generate a temperature difference with the environment. The thermoelectric power generation module generates electricity through the ambient temperature difference, and the generated electricity can preheat the battery in the absence of an external power source, thereby improving the thermal energy utilization rate of the energy storage compartment, solving the problem of starting up the energy storage system in extremely cold regions, and improving the system reliability.

[0019] The composite wall panel of this invention combines the high thermal resistance of the first and second insulation layers with the high latent heat of the phase change material, and its passive temperature fluctuation control capability is significantly better than that of traditional solutions, which can reduce air conditioning energy consumption by more than 30%.

[0020] The honeycomb-shaped support encapsulation and HDPE shaped skeleton provide double leakage prevention and reserve expansion space, solving the problems of easy leakage and volume change of phase change materials; expanded graphite improves the thermal conductivity and overcomes the defect of poor thermal conductivity of paraffin.

[0021] The position sensor design ensures reliable door closure and incorporates door status into the system's interlocking protection to prevent misoperation; the flame-retardant phase change material meets the fire safety requirements of energy storage containers. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of an energy storage compartment with an integrated phase change insulation layer in an embodiment of the present invention; Figure 2 This is a schematic diagram of the layer structure of the composite thermal insulation wall panel in an embodiment of the present invention; Figure 3 This is a front view structural diagram of the double-layer sliding door in an embodiment of the present invention; Figure 4 This is a partial schematic diagram of the honeycomb-shaped support structure in an embodiment of the present invention; In the diagram: 1. Main body of the enclosure; 2. Sliding door; 21. Inner door; 22. Outer door; 3. Composite insulation wall panel; 31. Outer heat-conducting support plate; 32. First insulation layer; 33. Phase change energy storage layer; 34. Second insulation layer; 35. Inner heat-conducting support plate; 4. Upper guide rail; 5. Lower guide rail; 6. Handle; 7. Roller; 8. Thermoelectric power generation module. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] like Figure 1 As shown, an energy storage chamber with an integrated phase change insulation layer includes a main body 1 and at least one access door. The wall panels of the main body 1 and the access door are both composite insulation wall panels 3. From the outside to the inside of the main body 1, the composite insulation wall panel 3 includes a first insulation layer 32, a phase change energy storage layer 33, a second insulation layer 34, and an inner thermally conductive support plate 35 arranged sequentially. Figure 2 As shown, a thermoelectric power generation module 8 is disposed between the phase change energy storage layer 33 and the inner thermally conductive support plate 35. The thermoelectric power generation module 8 is electrically connected to an energy storage capacitor. The thermoelectric power generation module 8 is used to convert the temperature difference between the phase change energy storage layer 33 and the inner thermally conductive support plate 35 into electrical energy, and the energy storage capacitor is used to store the electrical energy. The stored electrical energy can be used to preheat the battery module during startup or in cold areas. The heat dissipation of the battery module during operation can also be stored through the phase change energy storage layer 33 and converted into electrical energy. This can improve the energy utilization rate of the battery module during operation, thereby reducing energy consumption and increasing lifespan.

[0026] In some embodiments, such as Figure 2 As shown, to increase the rigidity of the outer layer, the composite insulation wall panel 3 consists of the following five layers from the outside to the inside, as shown in the table below:

[0027] In some embodiments, the phase change energy storage layer includes a honeycomb support having multiple independent honeycomb chambers filled with a composite phase change material.

[0028] In one specific embodiment, such as Figure 4As shown, the phase change energy storage layer 33 adopts a honeycomb aluminum box structure for its thermally conductive framework, forming multiple independent chambers. Each chamber is encapsulated with composite phase change material, with a filling rate of 85%-90%, and space is reserved for phase change expansion. This honeycomb structure also serves as a thermally conductive framework, improving the overall thermal conductivity of the phase change layer. The material of the thermally conductive framework can also be other materials that combine thermal conductivity and support.

[0029] In some embodiments, the composite phase change material comprises, by weight, 60-70% paraffin wax, 10-15% expanded graphite, 10-15% high-density polyethylene (HDPE), and 5-10% flame retardant. This composite phase change material is filled into the honeycomb cavity of a honeycomb scaffold by the following method: paraffin wax is heated to complete melting, expanded graphite is added and stirred evenly, then HDPE and flame retardant are added, and the mixture is dispersed by high-speed stirring and then cooled and solidified within the honeycomb cavity. The porous structure of the expanded graphite adsorbs the liquid paraffin wax, preventing leakage; HDPE acts as a supporting skeleton to provide shaping; and the flame retardant ensures fire safety. The phase change temperature of the composite phase change material is 25±2℃.

[0030] In some embodiments, the thermoelectric power generation module 8 includes multiple series-connected thermoelectric generators, with adjacent thermoelectric generators connected in series, and the honeycomb support serves as a thermally conductive framework. Electricity is generated by utilizing the heat stored in the phase change energy storage layer 33 and the temperature difference between the phase change energy storage layer 33 and the cabin environment.

[0031] In some embodiments, the hot end of the thermoelectric generator is in contact with the thermally conductive frame, and the cold end of the thermoelectric generator is in contact with the inner thermally conductive support plate 35, such as a metal plate. Multiple thermoelectric generators may have one end evenly distributed on the thermally conductive frame, and the other end connected to the inner thermally conductive support plate 35 via a thermally conductive block. The multiple thermoelectric generators may also be arranged at intervals, which can improve the heat conversion efficiency.

[0032] In some embodiments, the hot end of the thermoelectric generator is embedded within the honeycomb support, and the cold end of the thermoelectric generator is connected to the inner thermally conductive support plate 35 via a heat-conducting block. This facilitates heat collection from the inner thermally conductive support plate 35, such as a metal plate.

[0033] In some embodiments, the energy storage capacitor is electrically connected to a micro heating unit via a micro-control switch.

[0034] In some embodiments, the micro heating unit includes multiple sets of PTC heating elements electrically connected to a microcontroller switch. The PTC heating elements are arranged at the bottom of the battery module and used for preheating the battery module. The battery module is located inside the main body 1 of the housing, and the microcontroller switch is located on one side of the battery module. When the internal temperature is detected by the internal temperature sensor to be lower than a set value (e.g., 5°C), the energy storage capacitor and the micro heating unit are automatically connected to preheat the battery module locally. Alternatively, in a low-temperature environment, the phase change energy storage layer 33 releases stored heat, maintaining its temperature near the phase change point (approximately 25°C), creating a temperature difference with the internal environment below 0°C. The thermoelectric power generation module 8 utilizes this temperature difference to generate milliwatt-level electrical energy and stores it in the capacitor. When the internal temperature further drops below 5°C, the temperature control switch automatically closes, the capacitor discharges, and the PTC heating unit is activated, providing preheating for the battery module before startup. This preheating can last for 30-60 minutes, sufficient to raise the battery temperature to a startable state.

[0035] In some embodiments, a position sensor and a controller are also included. The controller is disposed outside the housing body 1. The controller is communicatively connected to the position sensor. The position sensor is inductively connected to the maintenance door. The position sensor transmits a signal indicating whether the door is closed in place to the controller. The controller is used to control the battery management system to perform high-voltage power-on according to the signal.

[0036] In some embodiments, an air conditioning system and an air duct are also included. The air conditioning system is located on one side of the main body 1 of the enclosure. The battery modules inside the main body 1 are connected to the air conditioning system through the air duct. When the maintenance door is closed and the battery modules do not reach the preset preheating temperature, the battery modules are preheated through the air conditioning system and the air duct. An active thermal management system can be set up to work in conjunction with the composite insulation wall panel 3: it is connected to each battery cluster through the air duct, and the air duct can also be equipped with an airflow regulating valve; the outer wall of the air duct can also be wrapped with aerogel insulation felt to reduce the loss of cold / heat during the transportation process; the controller, based on the temperature sensor data inside the enclosure, prioritizes the passive temperature regulation capability of the phase change energy storage layer 33 and only starts the air conditioning when the temperature exceeds a set threshold (such as below 10°C or above 35°C) to maintain a suitable operating temperature range for the battery, thereby reducing energy consumption.

[0037] In some embodiments, the battery module is large, and when used for chemical energy storage, such as Figure 3As shown, the maintenance door adopts a double-layer sliding door structure 2, including an inner door 21 and an outer door 22. Both the inner door 21 and the outer door 22 are installed on a composite guide rail on the side wall of the enclosure, allowing them to slide relative to each other horizontally. Specifically, the composite guide rail includes an upper guide rail 4 and a lower guide rail 5. The upper guide rail 4 has a C-shaped anti-disengagement groove structure, with guide wheels at the top of the door that slide within the anti-disengagement groove to prevent the door from tipping over. The lower guide rail 5 has a ball-bearing sliding mechanism embedded within it to reduce the pushing and pulling force on the door. Magnetic sealing strips are provided on the contact surfaces of the inner door 21 and the outer door 22, automatically engaging to form an airtight seal when the doors are closed. When both the inner door 21 and the outer door 22 are fully closed, the magnetic sealing strips engage. A handle 6 is integrated with the door; lifting the handle 6 unlocks the door and simultaneously pulls the door, achieving a continuous opening action. A locking mechanism is also included, comprising a locking rod used to lock the closed door.

[0038] The sliding door 2 has position sensors installed on its inner door 21 and outer door 22. The door automatically closes to form an airtight seal only when both doors are fully closed and the magnetic sealing strip is engaged, ensuring a gap of no more than 2mm between them. Only then will the controller allow the battery management system to perform high-voltage power-on. If either position sensor detects that the door is not closed, the system will issue an audible and visual alarm and prohibit charging and discharging operations to prevent personnel from accidentally entering a live area or energy loss due to an improperly closed door.

[0039] In some embodiments, the composite insulation wall panel can be modularly designed, and the phase change energy storage layer (33) can be replaced separately, which is convenient for later maintenance and upgrades.

[0040] In some embodiments, the first insulation layer 32 is selected as a 15mm thick aerogel felt with a thermal conductivity ≤0.020W / (m·K). The phase change energy storage layer (33) is a 25mm thick honeycomb aluminum box with a honeycomb pore size of 10mm×10mm and a wall thickness of 0.3mm. The composite phase change material is as follows by weight: paraffin wax (phase change temperature 25℃), expanded graphite (80 mesh, expansion ratio 200ml / g), HDPE, and phosphate flame retardant. During preparation, the paraffin wax is heated to 80℃ and melted, expanded graphite is added and stirred for 30 minutes, then HDPE and flame retardant are added, dispersed at high speed for 15 minutes, poured into the aluminum box and allowed to cool naturally.

[0041] The second insulation layer 34 is made of 30mm thick rigid polyurethane foam with a thermal conductivity ≤0.024W / (m·K). The outer metal plate is 2.0mm weathering steel, and the inner metal plate is 1.2mm galvanized steel plate.

[0042] With an ambient temperature of -15℃ and an initial cabin temperature of 25℃, the air conditioning system was turned off, and the test was conducted solely based on the passive insulation performance of the composite insulation wall panel 3. Test results: The time required for the internal temperature to drop to 20℃ is 6.5 hours, and the time required to drop to 15℃ is 14.2 hours. During the cooling process, the phase change energy storage layer 33 releases latent heat, and the temperature drop rate slows significantly (0.3℃ / h vs. 0.8℃ / h in the initial stage) during the 3-8 hour period. Under the same conditions, a control container using traditional rock wool insulation (100mm thick) only requires 2.1 hours to drop to 20℃ and 4.8 hours to drop to 15℃. The passive insulation time of the present invention is approximately three times that of the traditional solution.

[0043] Under ambient temperature conditions of -20°C, the initial temperature inside the chamber is 8°C. The thermoelectric power generation module 8 (TEG1-12708 type) has an open-circuit voltage of approximately 8.5V and a maximum output power of approximately 1.2W when the temperature difference between the phase change layer (approximately 23°C) and the environment (approximately -15°C) is approximately 38°C. After 8 hours of energy storage, the voltage of the energy storage capacitor (10F / 12V) rises to 9.2V. When the temperature inside the chamber drops to 5°C, the temperature control switch closes, and the PTC heating unit (6W) starts, raising the surface temperature of the battery module from 5°C to 12°C within 30 minutes, meeting the battery startup requirements. Compared with the prior art, the structure in this embodiment of the invention also has the following significant improvements: The sliding door structure does not occupy external space, making it suitable for high-density energy storage power stations; the integrated locking mechanism enables seamless unlocking and opening actions, improving operation and maintenance efficiency.

[0044] The composite wall panel combines the high thermal resistance of aerogel / VIP with the high latent heat of phase change materials, and its passive temperature fluctuation control capability is significantly better than that of traditional solutions, which can reduce air conditioning energy consumption by more than 30%.

[0045] By utilizing the temperature difference between phase change materials and the environment to generate electricity, battery preheating is achieved in the absence of external power, solving the startup problem of energy storage systems in extremely cold regions and improving system reliability.

[0046] The honeycomb aluminum box encapsulation and HDPE shaped skeleton provide double leakage prevention and reserve expansion space, solving the problems of easy leakage and volume change of phase change materials; expanded graphite improves the thermal conductivity and overcomes the defect of poor thermal conductivity of paraffin.

[0047] The dual-door interlock and position sensor design ensures reliable door closure and incorporates door status into the system's interlock protection to prevent misoperation; the flame-retardant phase change material meets the fire safety requirements of energy storage containers.

[0048] It should be noted that the terms "first," "second," etc., used in this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of this application described herein.

[0049] In the description of this specification, references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the invention. In this specification, illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0050] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. An energy storage cabin with integrated phase change thermal insulation, comprising a box body (1) and at least one access door, characterized in that, The wall panels and inspection doors of the main body (1) of the box are all composite heat-insulating wall panels (3). From the outside to the inside of the main body (1), the composite heat-insulating wall panel (3) includes a first heat-insulating layer (32), a phase change energy storage layer (33), a second heat-insulating layer (34), and an inner heat-conducting support plate (35) arranged in sequence. A thermoelectric power generation module (8) is arranged between the phase change energy storage layer (33) and the inner heat-conducting support plate (35). The thermoelectric power generation module (8) is electrically connected to an energy storage capacitor. The thermoelectric power generation module (8) is used to convert the temperature difference between the phase change energy storage layer (33) and the inner heat-conducting support plate (35) into electrical energy. The energy storage capacitor is used to store the electrical energy.

2. The energy storage cabin integrated with phase change thermal insulation layer according to claim 1, characterized in that, The phase change energy storage layer (33) includes a honeycomb support with multiple independent honeycomb chambers filled with composite phase change material.

3. The integrated phase change thermal retention layer energy storage chamber of claim 2, wherein, The composite phase change material comprises, by weight, 60-70% paraffin wax, 10-15% expanded graphite, 10-15% high-density polyethylene, and 5-10% flame retardant.

4. The energy storage compartment with an integrated phase change insulation layer according to claim 2, characterized in that, The thermoelectric power generation module (8) includes multiple semiconductor thermoelectric power generation chips, which are connected in series with adjacent semiconductor thermoelectric power generation chips, and the honeycomb support is a heat-conducting skeleton.

5. The energy storage compartment with an integrated phase change insulation layer according to claim 4, characterized in that, The hot end of the semiconductor thermoelectric generator is in contact with the heat-conducting skeleton, and the cold end of the semiconductor thermoelectric generator is in contact with the inner heat-conducting support plate (35).

6. The energy storage compartment with an integrated phase change insulation layer according to claim 4, characterized in that, The hot end of the semiconductor thermoelectric generator is embedded in the honeycomb support, and the cold end of the semiconductor thermoelectric generator is connected to the inner thermal support plate (35) through a thermally conductive block.

7. The energy storage compartment with an integrated phase change insulation layer according to claim 1, characterized in that, The energy storage capacitor is electrically connected to a miniature heating unit via a micro-control switch.

8. The energy storage compartment with an integrated phase change insulation layer according to claim 7, characterized in that, The micro heating unit includes multiple PTC heating elements electrically connected to the micro switch. The PTC heating elements are arranged at the bottom of the battery module and are used for preheating the battery module. The battery module is located inside the main body (1) of the housing. The micro switch is located on one side of the battery module.

9. The energy storage compartment with an integrated phase change insulation layer according to claim 8, characterized in that, It also includes a position sensor and a controller. The controller is located outside the main body (1) of the enclosure. The controller is communicatively connected to the position sensor. The position sensor is inductively connected to the maintenance door. The position sensor transmits a signal to the controller indicating whether the door is closed in place. The controller is used to control the battery management system to perform high-voltage power-on according to the signal.

10. An energy storage compartment with an integrated phase change insulation layer according to claim 9, characterized in that, It also includes an air conditioning system and an air duct. The air conditioning system is located on one side of the main body of the enclosure (1). The battery module inside the main body of the enclosure (1) is connected to the air conditioning system through the air duct. When the maintenance door is closed and the battery module does not reach the preset preheating temperature, the battery module is preheated through the air conditioning system and the air duct.

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