Refrigerant direct cooling gas-liquid mixed pipeline and manufacturing method

Abstract

The application discloses a kind of refrigerant direct cooling gas-liquid mixing pipeline and manufacturing method, belong to battery energy storage technology field, the first mixing device is fixedly connected on the middle shaft by symmetrical clockwise blade and constitutes;Second mixing device is fixedly connected on the middle shaft by symmetrical counterclockwise blade and constitutes;Third mixing device is fixedly connected on the middle shaft by symmetrical clockwise blade and constitutes;Fourth mixing device is fixedly connected on the middle shaft by symmetrical counterclockwise blade and constitutes;The direction of first mixing device and second mixing device flow channel mouth is opposite to the direction of second mixing device and third mixing device flow channel mouth, and it is opposite to the direction of third mixing device and fourth mixing device flow channel mouth.The application designs the alternate change of nonlinear flow channel segmentation and rotation, fully mixes refrigerant, auxiliary distribution head carries out refrigerant dryness distribution and flow distribution, reduces the distribution difference caused by flow rate uneven, phase distribution uneven of gas phase and liquid phase.

Description

Technical Field

[0001] This invention belongs to the field of battery energy storage technology, specifically relating to a refrigerant direct cooling gas-liquid mixing pipeline and its manufacturing method. Background Technology

[0002] Current direct-cooling gas-liquid cooling technology uses liquid-cooled throttling elements to reduce pressure and introduce turbulent flow to mix the gas and liquid. Then, the liquid is evenly distributed through a distributor head to improve heat exchange performance.

[0003] In existing refrigerant direct cooling gas-liquid cooling technologies, for example, Chinese invention patent: A direct cooling heat pump air conditioning system for energy storage temperature control system, authorized announcement number: CN119713643B, discloses: including: a compressor, a four-way valve, a first branch, a second branch, and a liquid cooling device, wherein the compressor exhaust port is connected to the first valve port of the four-way valve, the compressor suction port is connected to the first valve port of the four-way valve, the second and fourth valve ports are connected to the first branch and the second branch respectively, the first branch is connected to one end of the liquid cooling device, and the second branch is connected to the other end. By switching through the four-way valve, the flow of refrigerant flowing from the compressor exhaust port to the first branch or the second branch is controlled. The liquid cooling device contains components such as a liquid cooling throttling element, a distributor, a battery, a cold plate, and pipelines, and is designed for liquid equalization. The main flow rate is controlled by the throttling element to control the refrigerant distribution and uniform cooling of the battery.

[0004] The aforementioned existing technology has the following problems: Using existing technology for refrigerant mixing, the refrigerant enters the distributor directly after throttling. At this time, the gas-liquid two-phase flow is in a state of stratification or uneven distribution, resulting in uneven flow velocity and phase distribution of the two phases when entering the distributor. This causes the refrigerant flow rate and dryness to be inconsistent to each battery pack liquid cooling plate, affecting the uniformity of heat dissipation.

[0005] For example, Chinese invention patent: an oil-gas homogenizer, application publication number: CN121016541A, discloses a device comprising: a liquid pipe divided into a ventilation zone and a mixing zone; a main ventilation pipe with its first end located outside the liquid pipe and its second end penetrating the pipe wall and extending into the interior of the liquid pipe, and equipped with a dispersion plate; multiple ventilation pipe branches evenly distributed on the dispersion plate, each with its first end penetrating the dispersion plate and communicating with the main ventilation pipe, and its second end located in the ventilation zone and extending along the axial direction of the main ventilation pipe; wherein, the multiple ventilation pipe branches have the same structure, all being frustum-shaped pipes, each with multiple small holes on its pipe wall, and each with variable pitch helical blades on its outer surface, and at least some of the ventilation pipe branches have alternating large and small ends.

[0006] The aforementioned existing technology has the following problems: 1. Its blades are variable pitch and integrally formed, which makes the processing difficult and requires high precision. The applicable scenarios are limited. It requires pitch changes of specific precision to meet the requirements of specific working conditions, and the linear design is prone to gas-liquid stratification. 2. Fluid velocity changes are prone to occur in the pitch abrupt change section, causing pressure fluctuations and noise. Furthermore, due to the large span of pitch change, the flow resistance in the abrupt change section increases rapidly, forming a flow dead zone and affecting the conveying efficiency. Summary of the Invention

[0007] The purpose of this invention is to overcome the above-mentioned existing problems and propose a refrigerant direct cooling gas-liquid mixing pipeline and manufacturing method, which solves the problem in the prior art that the refrigerant flow rate and dryness of the liquid cooling plate of the battery pack are inconsistent, and the flow resistance in the abrupt section increases rapidly, forming a flow dead zone and affecting the uniformity of heat dissipation.

[0008] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A refrigerant direct-cooling gas-liquid mixing pipeline, characterized in that: it includes a liquid distribution pipeline, a rectifier core liquid distribution head, a first vertical distribution main pipe, a gas-liquid mixer, and a second vertical distribution main pipe, which are fixedly connected in sequence; the gas-liquid mixer includes a gas-liquid mixing outer cylinder and a mixing assembly fixedly sleeved inside the mixing outer cylinder; the mixing assembly includes a fourth mixing device, a third mixing device, a second mixing device, and a first mixing device, which are fixedly connected end-to-end along the refrigerant flow direction; the first mixing device is composed of symmetrical blades and a central shaft, and the blades rotate clockwise; the second mixing device is composed of symmetrical blades and a central shaft, and the blades rotate counterclockwise; the third mixing device is composed of symmetrical blades and a central shaft, and the blades rotate clockwise; the fourth mixing device is composed of symmetrical blades and a central shaft, and the blades rotate counterclockwise; the flow channel alignment directions of the first mixing device and the second mixing device are opposite to the flow channel alignment directions of the second mixing device and the third mixing device; the flow channel alignment directions of the second mixing device and the third mixing device are opposite to the flow channel alignment directions of the third mixing device and the fourth mixing device.

[0009] The gas-liquid mixer can be one or more. When there is one gas-liquid mixer, one end of the gas-liquid mixer is connected to a hydraulic connector threaded or flanged. The hydraulic connector threaded or flanged is connected to one end of the first vertical distribution manifold. The other end of the first vertical distribution manifold is threaded or flanged and connected to the rectifier core distributor head. The rectifier core distributor head is threaded or flanged and connected to the distributor pipeline. The distributor pipeline is threaded or flanged and connected to the direct cooling plate of the battery pack. One end of the gas-liquid mixer is connected to a hydraulic connector threaded or flanged. The hydraulic connector threaded or flanged is connected to one end of the second vertical distribution manifold. The other end of the second vertical distribution manifold is threaded or flanged and connected to the direct cooling unit. When there are multiple gas-liquid mixers, the leftmost one... One end of the gas-liquid mixer is connected to a hydraulic connector via a threaded or flanged connection. The hydraulic connector is then connected to one end of the first vertical lift distribution manifold via a threaded or flanged connection. The other end of the first vertical lift distribution manifold is connected to the rectifier core distributor head via a threaded or flanged connection. The rectifier core distributor head is connected to the distributor pipeline via a threaded or flanged connection. The distributor pipeline is connected to the direct cooling plate of the battery pack via a threaded or flanged connection. The rightmost gas-liquid mixer is connected to a hydraulic connector via a threaded or flanged connection. The hydraulic connector is then connected to one end of the second vertical lift distribution manifold via a threaded or flanged connection. The other end of the second vertical lift distribution manifold is connected to the direct cooling unit via a threaded or flanged connection. The gas-liquid mixers on the leftmost and rightmost sides are connected to each other via hydraulic connectors via threaded connections.

[0010] The first mixing device consists of a central shaft and two rectangular blades welded to the central shaft and twisted clockwise in parallel and symmetrically; the first mixing device divides the refrigerant into two fluid streams.

[0011] The second mixing device consists of four rectangular blades welded to the central shaft, which rotate counterclockwise in parallel and are symmetrical to each other; the second mixing device divides the two fluid streams into four fluid streams from the first mixing device.

[0012] The third mixing device consists of a central shaft and two rectangular blades welded to the central shaft and twisted in a clockwise parallel and symmetrical manner; the third mixing device mixes the four fluids divided by the second mixing device through opposite flow channel opening directions.

[0013] The fourth mixing device consists of a central shaft and six rectangular blades welded to the central shaft and twisted counterclockwise in parallel and symmetrical manner; the fourth mixing device divides the fluid mixed by the third mixing device into six streams and outputs them.

[0014] The rectangular blades of the first mixing device have a torsion angle greater than or equal to 90 degrees; the rectangular blades of the second mixing device have a torsion angle greater than or equal to 90 degrees; the rectangular blades of the third mixing device have a torsion angle greater than or equal to 90 degrees; and the rectangular blades of the fourth mixing device have a torsion angle greater than or equal to 90 degrees.

[0015] The rectangular blades of the first mixing device, the second mixing device, the third mixing device, and the fourth mixing device have the same torsion angle.

[0016] The length L of the gas-liquid mixing outer cylinder is greater than or equal to 3 times the pipe diameter D.

[0017] The flow channel area of ​​the rectifier core distributor head is greater than or equal to 1.2 times the flow channel area of ​​the gas-liquid mixer hydraulic connector.

[0018] A method for manufacturing a refrigerant direct cooling gas-liquid mixing pipeline, characterized by the following specific steps: Step s1: Periodically optimize and iterate the operation process of the refrigerant direct cooling gas-liquid mixing pipeline to obtain the liquid distribution pipeline size; set the initial heat load conditions and refrigerant parameters, and design the rectifier core liquid distribution head flow channel structure parameters required for uniform refrigerant distribution based on the initial heat load conditions and refrigerant parameters. Step s2: Connect the rectifier core distributor to the gas-liquid mixer, use simulation to adjust the key parameters of the gas-liquid mixer to test the refrigerant distribution, and record the distributor pipeline specifications and gas-liquid mixer parameters when the refrigerant is evenly distributed in the gas-liquid mixer. Step s3: Change the heat load conditions and refrigerant parameters, repeat steps s1 and s2, record the specifications of the liquid distribution pipeline and the parameters of the gas-liquid mixer under different heat load conditions, and establish a four-dimensional correlation database of "heat load - refrigerant characteristics - key parameters of gas-liquid mixer - specifications of rectifier core liquid distribution head". Step s4: Manufacture the rectifier core distributor and gas-liquid mixer that meet the requirements according to the data of the four-dimensional relational database; reserve standardized interfaces on the rectifier core distributor and gas-liquid mixer to match the first vertical distribution manifold and the second vertical distribution manifold, and assemble the rectifier core distributor, the distribution pipeline, the gas-liquid mixer, the first vertical distribution manifold and the second vertical distribution manifold to complete the manufacturing of the refrigerant direct cooling gas-liquid mixing pipeline.

[0019] The specific steps of the periodic optimization iteration are as follows: Step s1.1: Using a simulation system, the shape of the rectifier core distributor head remains unchanged, while the diameter and length of the rectifier core distributor head are changed. The dimensional parameters of the rectifier core distributor head outlet when balanced distribution is achieved under different given total flow rates are designed. Step s1.2: Based on the dimensional parameters of the rectifier core distributor outlet when balanced distribution is achieved, fabricate the corresponding test distributor and conduct a balanced flow test on the rectifier core distributor. Step s1.3: Based on the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor outlet when balanced distribution is achieved as simulated in step s1.1, optimize the dimensions and resubmit them to step s1.1 for simulation loop; when the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor outlet when balanced distribution is achieved as simulated in step s1.1 is less than 4%~6%, convergence is considered achieved, and the final dimensions of the distributor outlet of the distribution pipeline are output.

[0020] The balanced flow test involves applying a specific flow rate to the inlet of the rectifier core distributor, connecting a flow sensor to each outlet of the rectifier core distributor, stabilizing the flow rate for a period of time, measuring the sensor readings, and comparing them with the simulated balanced flow rate distribution at the outlet of the rectifier core distributor to determine if they are the same.

[0021] The structural parameters of the rectifier core distributor in step s1 include the cross-sectional dimensions of the distributor, the orifice distribution, and the number of distributor branches.

[0022] The refrigerant parameters in step s1 include refrigerant type and gas-liquid ratio.

[0023] The parameters of the gas-liquid mixer in step s2 include length, pipe diameter, rectangular blade angle, and number of rectangular blades.

[0024] In step s2, the simulation is performed, and the specific steps are as follows: Step s2.1: Under different given total simulated flow rates, adjust the gas-liquid mixer parameters and record the simulated rectifier core distributor outlet flow rate, rectifier core distributor specifications, and gas-liquid mixer parameters when the refrigerant is redistributed evenly in the simulated environment; Step s2.2: Manufacture a gas-liquid mixer based on the gas-liquid mixer parameters when the refrigerant is redistributed evenly. Test the outlet flow rate of each rectifier core distributor head for different total inlet flow rates of the gas-liquid mixer. When the deviation between the actual outlet flow rate of the rectifier core distributor head and the simulated outlet flow rate of the rectifier core distributor head is less than 4%~6%, it is considered to have converged, and the final dimensions are output; otherwise, optimize the dimensions of the gas-liquid mixer and re-perform the simulation.

[0025] The advantages of using this invention are: I. Compared with the prior art, the gas-liquid mixer of the present invention adopts a combination of a first mixing device, a second mixing device, a third mixing device and a fourth mixing device, and designs a nonlinear flow channel segmentation and alternating swirl direction to fully stir and premix the refrigerant, and assists the liquid distributor head in distributing the dryness and flow of the refrigerant, thereby reducing the distribution difference between the gas phase and the liquid phase caused by uneven flow velocity and uneven phase distribution.

[0026] Second, compared with the prior art, the first, second, third, and fourth mixing devices of the present invention employ combinations of two clockwise fan blades, four counterclockwise fan blades, two clockwise fan blades, and six counterclockwise fan blades to divide the nonlinear flow channel. This design breaks the periodic motion of conventional spiral flow channels, repeatedly folding the gaseous and liquid refrigerants to ensure that the refrigerant state flowing into each distribution pipe is exactly the same, thereby ensuring consistent cooling of all battery packs.

[0027] Third, this invention establishes a four-dimensional database that includes heat load, refrigerant characteristics, key parameters of gas-liquid mixer, and specifications of rectifier core distributor. By simply querying the database, the blade angle of the mixer can be finely adjusted or the corresponding distributor module can be replaced, which greatly extends the service life of the system.

[0028] Fourth, the length L of the gas-liquid mixing outer cylinder is greater than or equal to 3 times the pipe diameter D. Under the premise of ensuring uniform mixing, unnecessary pressure loss is reduced, making the refrigerant transport smoother and helping to improve the energy efficiency ratio of the entire energy storage temperature control system. Attached Figure Description

[0029] Figure 1 This is a three-dimensional structural diagram of the refrigerant distributor and piping of the present invention; Figure 2 This is a cross-sectional view of the refrigerant distributor and piping of the present invention; Figure 3 This is a half-sectional view of the gas-liquid mixer of the present invention; Figure 4 This is a schematic diagram of a combination of multiple gas-liquid mixers according to the present invention; Figure 5 This is a schematic diagram of the shape of the hybrid component of the present invention; Figure 6 This is a schematic diagram showing the length-to-diameter ratio of the outer cylinder for gas-liquid mixing in this invention; Figure 7 This is a flowchart of the gas-liquid mixing design, assembly, and adaptation method of the present invention.

[0030] Reference numerals: 1. Gas-liquid mixer; 2. Hydraulic connector; 3. First vertical lifting distribution manifold; 4. Rectifier core distributor head; 5. Distributor pipe; 6. Second vertical lifting distribution manifold; 7. Gas-liquid mixing outer cylinder; 8. Mixing assembly; 9. First mixing device; 10. Second mixing device; 11. Third mixing device; 12. Fourth mixing device; 13. Central shaft; 14. Rectangular blade; 15. Connector. Detailed Implementation

[0031] Example 1 A refrigerant direct cooling gas-liquid mixing pipeline includes a liquid distribution pipeline 5, a rectifier core liquid distribution head 4, a first vertical distribution main pipe 3, a gas-liquid mixer 1, and a second vertical distribution main pipe 6, which are fixedly connected in sequence. The gas-liquid mixer 1 includes a gas-liquid mixing outer cylinder 7 and a mixing assembly 8 fixedly sleeved inside the mixing outer cylinder. The mixing assembly 8 includes a fourth mixing device 12, a third mixing device 11, a second mixing device 10, and a first mixing device 9, which are fixedly connected end-to-end along the refrigerant flow direction. The first mixing device 9 is composed of symmetrical blades and a central shaft, and the blades rotate clockwise. The second mixing device 10 is composed of symmetrical blades and a central shaft, with the blades rotating counterclockwise; the third mixing device 11 is composed of symmetrical blades and a central shaft, with the blades rotating clockwise; the fourth mixing device 12 is composed of symmetrical blades and a central shaft, with the blades rotating counterclockwise; the flow channel alignment directions of the first mixing device 9 and the second mixing device 10 are opposite to those of the second mixing device 10 and the third mixing device 11; the flow channel alignment directions of the second mixing device 10 and the third mixing device 11 are opposite to those of the third mixing device 11 and the fourth mixing device 12.

[0032] The gas-liquid mixer 1 can be one or more. When there is only one gas-liquid mixer 1, the connector 15 at one end of the gas-liquid mixer 1 is threaded or flanged to the hydraulic connector 2. The hydraulic connector 2 is threaded or flanged to one end of the first vertical lifting distribution main pipe 3. The other end of the first vertical lifting distribution main pipe 3 is threaded or flanged to the rectifier core distributor 4. The rectifier core distributor 4 is threaded or flanged to the distributor pipe 5. The distributor pipe 5 is threaded or flanged to the direct cooling plate of the battery pack. The connector 15 at one end of the gas-liquid mixer 1 is threaded or flanged to the hydraulic connector 2. The hydraulic connector 2 is threaded or flanged to one end of the second vertical lifting distribution main pipe 6. The other end of the second vertical lifting distribution main pipe 6 is threaded or flanged to the direct cooling unit. When there are multiple gas-liquid mixers 1, the leftmost gas-liquid mixer 1... One end of the liquid mixer 1 is connected to the hydraulic connector 2 via a thread or flange. The hydraulic connector 2 is connected to one end of the first vertical lifting distribution manifold 3 via a thread or flange. The other end of the first vertical lifting distribution manifold 3 is connected to the rectifier core distributor 4 via a thread or flange. The rectifier core distributor 4 is connected to the distributor pipe 5 via a thread or flange. The distributor pipe 5 is connected to the direct cooling plate of the battery pack via a thread or flange. One end of the rightmost gas-liquid mixer 1 is connected to the hydraulic connector 2 via a thread or flange. The hydraulic connector 2 is connected to one end of the second vertical lifting distribution manifold 6 via a thread or flange. The other end of the second vertical lifting distribution manifold 6 is connected to the direct cooling unit via a thread or flange. The connectors 15 of the gas-liquid mixers 1 between the leftmost and rightmost gas-liquid mixers 1 are connected to each other via hydraulic connectors 2 via threads.

[0033] The first mixing device 9 is composed of a central shaft 13 and two rectangular blades 14 that are welded to the central shaft 13 and twisted in a clockwise parallel and symmetrical manner; the first mixing device 9 divides the refrigerant into two fluid streams.

[0034] The second mixing device 10 is composed of four rectangular blades 14 that are welded to the central shaft 13 and twisted counterclockwise in parallel and symmetrically to each other; the second mixing device 10 divides the two fluids divided by the first mixing device 9 into four fluids.

[0035] The third mixing device 11 consists of a central shaft 13 and two rectangular blades 14 that are welded to the central shaft 13 and twisted in a clockwise parallel and symmetrical manner; the third mixing device 11 mixes the four fluids divided by the second mixing device 10 through opposite flow channel opening directions.

[0036] The fourth mixing device 12 consists of a central shaft 13 and six rectangular blades 14 that are welded to the central shaft 13 and twisted counterclockwise in parallel and symmetrically to each other; the fourth mixing device 12 divides the fluid mixed by the third mixing device 11 into six streams and outputs them.

[0037] The rectangular blade 14 of the first mixing device 9 has a torsion angle greater than or equal to 90 degrees; the rectangular blade 14 of the second mixing device 10 has a torsion angle greater than or equal to 90 degrees; the rectangular blade 14 of the third mixing device 11 has a torsion angle greater than or equal to 90 degrees; and the rectangular blade 14 of the fourth mixing device 12 has a torsion angle greater than or equal to 90 degrees.

[0038] The rectangular blades 14 of the first mixing device 9, the second mixing device 10, the third mixing device 11 and the fourth mixing device 12 have the same twist angle.

[0039] The length L of the gas-liquid mixing outer cylinder 7 is greater than or equal to 3 times the pipe diameter D.

[0040] The flow channel area of ​​the rectifier core distributor 4 is greater than or equal to 1.2 times the flow channel area of ​​the hydraulic connector 2 of the gas-liquid mixer 1.

[0041] This invention provides a refrigerant direct cooling gas-liquid mixing pipeline, mainly to solve the problem of uneven refrigerant distribution in existing phase change direct cooling systems for energy storage systems.

[0042] This invention provides a refrigerant direct cooling gas-liquid mixing pipeline, mainly to solve the problem of uneven refrigerant distribution in existing phase change direct cooling systems for energy storage systems.

[0043] like Figure 3 and Figure 4 As shown, the entire structure consists of a liquid distribution pipe 5, a rectifier core liquid distribution head 4, a first vertical lifting distribution main pipe 3, a hydraulic connector 2, a gas-liquid mixer 1, and a second vertical lifting distribution main pipe 6, which are connected in sequence by means including but not limited to threads and flanges.

[0044] like Figure 5As shown, the gas-liquid mixer 1 of this patent includes a connector 15, a gas-liquid mixing outer cylinder 7, and a mixing component 8, which are connected sequentially by means including but not limited to threads and flanges. The mixing component 8 can be placed directly in the gas-liquid mixing outer cylinder 7 in a non-fixed manner to enhance the mixing effect and reduce the distribution deviation caused by uneven flow velocity and phase distribution of the two phases. The left connector 15 of the gas-liquid mixer is connected to a hydraulic connector 2, which is connected to the first vertical lifting distribution main pipe 3. The connection method includes but is not limited to threaded and flanged connections. The right connector 15 of the gas-liquid mixer is connected to a hydraulic connector 2, which is connected to the second vertical lifting distribution main pipe. The connection method includes but is not limited to threaded and flanged connections.

[0045] like Figure 6 As shown, the number of gas-liquid mixers 1 can be increased or decreased arbitrarily according to the working conditions, and multiple mixers can be connected through connectors 15.

[0046] like Figure 7 As shown, the first mixing device 9 of the mixing assembly 8 is obtained by rotating two symmetrical rectangular blades 14 welded to a cylinder clockwise by a certain degree; the second mixing device is obtained by rotating four symmetrical blades counterclockwise; the third mixing device 11 is obtained by rotating two symmetrical blades clockwise; and the fourth mixing device 12 is obtained by rotating six symmetrical blades counterclockwise. Each section is fixedly connected end to end. The structure is such that when the refrigerant gas-liquid mixture enters the gas-liquid mixer 1, it is first divided into two streams by the first mixing device 9, then into four streams by the second mixing device. When passing through the third mixing device 11, the flow channel alignment between the blades of the third mixing device 11 and the blades of the second mixing device is inconsistent with the flow channel alignment between the first mixing device 9 and the second mixing device, causing the fluid in the third mixing device 11 to randomly mix the four streams that passed through the second mixing device 10 together (similarly, the alignment between the third and fourth sections is inconsistent with that between the third and second sections). After passing through the blades of the fourth mixing device, it is further divided into six streams. The advantage is... The separated fluid employs a 2-4-2-6 nonlinear flow channel segmentation design for premixing throughout the liquid separation process. This breaks the periodic motion inherent in conventional single spiral flow channels. While conventional constant flow (e.g., 2-2-2) and multiplicative flow (e.g., 2-4-8) methods easily create stable laminar interfaces, this application achieves more thorough and uniform gas-liquid mixing through the asymmetric 2-4-2-6 flow channel variation. Combined with the different and alternating rotation directions between each blade section, the fluid disturbance effect is enhanced, forcing the gas and liquid phases to undergo intense radial displacement and shearing at the flow channel cross-section, introducing a chaotic mixing effect and effectively preventing gas-liquid stratification caused by excessive centrifugal force. Furthermore, the blade torsion degree of this invention can be freely designed, and the length and number of blades can be increased sequentially according to this rule, or the cycle can be repeated. As an option, the structure, shape, and size of the mixing component 8 are not limited in this invention.

[0047] The length L of the gas-liquid mixing outer cylinder 7 should be at least 3 times the pipe diameter D to ensure that the gas and liquid have sufficient length to flow and mix.

[0048] In operation, the second vertical distribution manifold is connected to the direct cooling unit. Refrigerant enters through the second vertical distribution manifold, is premixed by the gas-liquid mixer 1, and then enters the rectifier core distributor head 4 for uniform distribution. The evenly distributed refrigerant is then directed through the distributor head of the distribution pipeline 5 to different battery pack liquid cooling plates. The cooled refrigerant returns to the compressor and is then circulated by the direct cooling unit through the refrigerant distributor and pipelines, thereby reducing battery temperature and minimizing temperature inconsistencies between cells. In the pipeline system provided by this invention, the rectifier core distributor head 4 can be configured with different specifications and models depending on the operating conditions to achieve uniform refrigerant distribution.

[0049] Example 2 A method for manufacturing a refrigerant direct cooling gas-liquid mixing pipeline, characterized by the following specific steps: Step s1: Periodically optimize and iterate the operation process of the refrigerant direct cooling gas-liquid mixing pipeline to obtain the dimensions of the liquid distribution pipeline 5; set the initial heat load conditions and refrigerant parameters, and design the flow channel structure parameters of the rectifier core liquid distribution head 4 required for uniform refrigerant distribution based on the initial heat load conditions and refrigerant parameters. Step s2: Connect the rectifier core distributor 4 to the gas-liquid mixer 1. Use simulation to adjust the key parameters of the gas-liquid mixer 1 to test the refrigerant distribution. Record the specifications of the distributor 5 and the parameters of the gas-liquid mixer 1 when the refrigerant is evenly distributed in the gas-liquid mixer 1. Step s3: Change the heat load conditions and refrigerant parameters, repeat steps s1 and s2, record the specifications of the liquid distribution pipeline 5 and the parameters of the gas-liquid mixer 1 under different heat load conditions, and establish a four-dimensional correlation database of "heat load - refrigerant characteristics - key parameters of gas-liquid mixer - specifications of rectifier core liquid distribution head". Step s4: Manufacture the rectifier core distributor 4 and gas-liquid mixer 1 according to the data from the four-dimensional relational database; reserve standardized interfaces on the rectifier core distributor 4 and gas-liquid mixer 1 to match the first vertical distribution manifold 3 and the second vertical distribution manifold 6, and assemble the rectifier core distributor 4, the distribution pipeline 5, the gas-liquid mixer 1, the first vertical distribution manifold 3 and the second vertical distribution manifold 6 to complete the manufacturing of the refrigerant direct cooling gas-liquid mixing pipeline.

[0050] The specific steps of the periodic optimization iteration are as follows: Step s1.1: Using a simulation system, the shape of the rectifier core distributor 4 remains unchanged, while the diameter and length of the rectifier core distributor 4 are changed. The dimensional parameters of the outlet of the rectifier core distributor 4 are designed to achieve balanced distribution under different given total flow rates. Step s1.2: Based on the dimensional parameters of the outlet of the rectifier core distributor 4 when balanced distribution is achieved, a corresponding test distributor is made, and a balanced flow test is conducted on the rectifier core distributor 4. Step s1.3: Based on the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved as simulated in step s1.1, optimize the dimensions and resubmit them to step s1.1 for simulation loop; when the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved as simulated in step s1.1 is less than 4%~6%, convergence is considered achieved, and the final dimensions of the distributor outlet of the distribution pipeline 5 are output.

[0051] The balanced flow test involves giving a specific flow rate at the inlet of the rectifier core distributor 4, connecting a flow sensor to each outlet of the rectifier core distributor 4, stabilizing the flow rate for a period of time, measuring the sensor readings, and comparing whether the flow rates evenly distributed at the outlets of the rectifier core distributor 4 are the same during simulation.

[0052] The flow channel structure parameters of the rectifier core distributor 4 in step s1 include the flow channel cross-sectional dimensions, aperture distribution, and number of branch channels.

[0053] The refrigerant parameters in step s1 include refrigerant type and gas-liquid ratio.

[0054] The parameters of the gas-liquid mixer 1 in step s2 include length, pipe diameter, angle of rectangular blade 14, and number of rectangular blades 14.

[0055] In step s2, the simulation is performed, and the specific steps are as follows: Step s2.1: Under different given total simulation flow rates, adjust the parameters of gas-liquid mixer 1, and record the simulated rectifier core distributor outlet flow rate, rectifier core distributor 4 specifications, and gas-liquid mixer 1 parameters when the refrigerant is redistributed evenly under the simulation environment; Step s2.2: Based on the parameters of gas-liquid mixer 1 when the refrigerant is redistributed evenly, manufacture gas-liquid mixer 1. Given different total inlet flow rates of gas-liquid mixer 1, test the outlet flow rates of each rectifier core distributor head. When the deviation between the actual rectifier core distributor head outlet flow rate and the simulated rectifier core distributor head outlet flow rate is less than 4%~6%, it is considered converged, and the final dimensions are output. Otherwise, optimize the connection dimensions of gas-liquid mixer 1 and re-perform the simulation.

[0056] The specific steps are as follows: Step s1: The dimensions of the rectifier core distributor 4 are obtained by using a periodic iterative method of simulation analysis-pattern prototyping-experimental verification-optimization iteration; the initial heat load conditions and refrigerant parameters are set, including refrigerant type, gas-liquid ratio, etc., and the structural parameters of the rectifier core distributor 4 required for uniform refrigerant distribution are optimized. The structural specifications of the rectifier core distributor 4 should cover parameters such as flow channel cross-sectional dimensions, orifice distribution, and number of branch paths.

[0057] The cyclic iterations are performed by using a simulation system to simulate the rectifier core distributor 4 with its shape unchanged, while changing the diameter and length of the rectifier core distributor 4. The dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved under different given total flow rates are designed. Based on the dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved, the corresponding test distributor is made, and the balanced flow test of the rectifier core distributor 4 is carried out.

[0058] Based on the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved as simulated in step s1.1, the dimensions are optimized, and then resubmitted into step s1.1 for simulation. When the deviation between the balanced flow test results and the dimensional parameters of the rectifier core distributor 4 outlet when balanced distribution is achieved as simulated in step s1.1 is less than 4%~6%, convergence is considered achieved, and the final dimensions of the distributor outlet of the distribution pipeline 5 are output.

[0059] The balanced flow test involves applying a specific flow rate to the inlet of the rectifier core distributor 4, connecting a flow sensor to each outlet of the rectifier core distributor 4, stabilizing the flow rate for a period of time, measuring the sensor readings, and comparing them with the simulated balanced flow rate at the outlet of the rectifier core distributor 4 to determine if they are the same.

[0060] Step s2: Connect the gas-liquid mixer 1. Using simulation, adjust the key parameters of the gas-liquid mixer 1 under different given total flow rates. Record the current simulated rectifier core distributor outlet flow rate, rectifier core distributor 4 specifications, and mixer parameters when the refrigerant reaches a more even distribution. Based on the above parameters, manufacture a gas-liquid mixer prototype. Test the outlet flow rate of each distributor under different inlet total flow rates. When the deviation between the actual rectifier core distributor outlet flow rate and the simulated rectifier core distributor outlet flow rate is less than 4%~6%, convergence is considered achieved, and the final dimensions are output. Otherwise, optimize the dimensions of the gas-liquid mixer 1 and repeat the simulation. The mixer parameters include length, pipe diameter, and rectangular blade 14 parameters (angle, number, etc.). The design follows these principles: ① The diameter of the gas-liquid mixer 1 should meet the matching principle that the inlet flow channel area of ​​the rectifier core distributor 4 is ≥ 1.2 times the outlet flow channel area of ​​the mixer; ② The length L of the gas-liquid mixing outer cylinder 7 should be at least greater than or equal to 3 times the pipe diameter D to ensure that the gas and liquid have sufficient length to flow and mix. The higher the heat load and the more uneven the gas-liquid ratio, the longer the mixer needs to be designed.

[0061] ③ The number of rectangular blades 14 is set according to the mixing intensity requirements. The number of blade sections is ≥2. The flow channel division can be increased sequentially according to the rule of 2-4-2-6, or it can be re-cycled.

[0062] ④ The rectangular blade 14 has a twist angle of at least ≥90° to ensure that the refrigerant flow channel has sufficient disturbance strength, and to ensure that the refrigerant gas-liquid distribution is uniform after mixing, laying the foundation for the uniform distribution of the liquid by the rectifier core distributor 4.

[0063] Step s3: Change the heat load conditions and refrigerant parameters, repeat steps s1 and s2, record multiple sets of different specifications of the rectifier core distributor 4 and parameters of the gas-liquid mixer 1, and establish a four-dimensional relational database of "heat load - refrigerant characteristics - key parameters of gas-liquid mixer - specifications of rectifier core distributor", and support multi-dimensional fast retrieval and matching.

[0064] Step s4: Modularly integrate the liquid distribution pipe 5, rectifier core liquid distribution head 4, gas-liquid mixer 1, first vertical distribution main pipe 3 and second vertical distribution main pipe 6, reserve standardized interfaces, complete the rapid assembly of each module according to the collaborative design results, ensure that the installation position and connection method of gas-liquid mixer 1 and rectifier core liquid distribution head 4 meet the parameter matching requirements, and ensure initial compatibility. Connect one end of the second vertical distribution main pipe 6 to the direct cooling unit, and connect the liquid distribution pipe 5 to the direct cooling plates of different battery packs.

[0065] The adaptation process is as follows: Step s5: Turn on the energy storage system and run the direct cooling unit. The refrigerant flows in from the second vertical distribution main pipe 6, and after being pre-mixed by the gas-liquid mixer 1, it is evenly distributed by the rectifier core distributor head 4, and then enters different liquid cooling plates through the distributor pipe 5.

[0066] Step s6: Install sensors at key locations in the rectifier core distributor 4 channels or direct cooling plate to obtain the thermal load parameters of the battery pack in real time. Step s7: When the energy storage system undergoes module expansion, cell aging leading to significant changes in internal resistance, or generational changes in system operation strategy, resulting in a shift in the baseline heat load, shut down the system, stop the direct cooling unit, and achieve coordinated adaptation based on the heat load parameters and database association: ① When the shift is small, dynamically adjust the mixer blade angle and number of sections without replacing components; ② When the shift is large, simultaneously replace the corresponding specification rectifier core distributor 4, and match and adjust the mixer length (extend / shorten through modular splicing) or pipe diameter (replace the mixer section of the appropriate specification) to adjust the mixing effect and achieve the purpose of evenly distributing the refrigerant. Step s8: After the adjustment is completed, restart the energy storage system, start the direct cooling unit, and verify the temperature consistency of each direct cooling plate and the uniformity of refrigerant distribution through sensor testing. If the design standard is not met, return to step 7 for secondary fine-tuning. Step s9: Regularly review the operating data and iteratively update the compatibility between the mixer parameters and the specifications of the rectifier core distributor 4.

Claims

1. A refrigerant direct cooling gas-liquid mixing pipeline, characterized in that: The system includes a liquid distribution pipe (5), a rectifier core liquid distribution head (4), a first vertical distribution main pipe (3), a gas-liquid mixer (1), and a second vertical distribution main pipe (6) that are fixedly connected in sequence. The gas-liquid mixer (1) includes a gas-liquid mixing outer cylinder (7) and a mixing assembly (8) fixedly fitted inside the mixing outer cylinder. The mixing assembly (8) includes a fourth mixing device (12), a third mixing device (11), a second mixing device (10), and a first mixing device (9) that are fixedly connected end to end along the refrigerant flow direction. The first mixing device (9) is composed of symmetrical blades and a central shaft, and the blades rotate clockwise. The second mixing device (9) is composed of a fourth mixing device (12), a third mixing device (11), a second mixing device (10), and a third mixing device (9) that are fixedly connected end to end along the refrigerant flow direction. Device (10) is composed of symmetrical blades and a central shaft, with the blades rotating counterclockwise; third mixing device (11) is composed of symmetrical blades and a central shaft, with the blades rotating clockwise; fourth mixing device (12) is composed of symmetrical blades and a central shaft, with the blades rotating counterclockwise; the flow channel alignment direction of the first mixing device (9) and the second mixing device (10) is opposite to that of the second mixing device (10) and the third mixing device (11); the flow channel alignment direction of the second mixing device (10) and the third mixing device (11) is opposite to that of the third mixing device (11) and the fourth mixing device (12).

2. The refrigerant direct cooling gas-liquid mixing pipeline according to claim 1, characterized in that: The gas-liquid mixer (1) is one or more; when there is one gas-liquid mixer (1), the connector (15) at one end of the gas-liquid mixer (1) is threaded or flanged to the hydraulic connector (2), the hydraulic connector (2) is threaded or flanged to one end of the first vertical distribution main pipe (3), the other end of the first vertical distribution main pipe (3) is threaded or flanged to the rectifier core distributor (4), the rectifier core distributor (4) is threaded or flanged to the distributor pipe (5), and the distributor pipe (5) is threaded or flanged to the direct cooling plate of the battery pack; the connector (15) at one end of the gas-liquid mixer (1) is threaded or flanged to the hydraulic connector (2), the hydraulic connector (2) is threaded or flanged to one end of the second vertical distribution main pipe (6), and the other end of the second vertical distribution main pipe (6) is threaded or flanged to the direct cooling unit; when there are multiple gas-liquid mixers (1), the leftmost gas-liquid mixer is threaded or flanged to the first end of the second vertical distribution main pipe (6). The connector (15) at one end of the mixer (1) is threaded or flanged to the hydraulic connector (2). The hydraulic connector (2) is threaded or flanged to one end of the first vertical distribution main pipe (3). The other end of the first vertical distribution main pipe (3) is threaded or flanged to the rectifier core distributor head (4). The rectifier core distributor head (4) is threaded or flanged to the distributor pipeline (5). The distributor pipeline (5) is threaded or flanged to the direct cooling plate of the battery pack. The connector (15) at one end of the rightmost gas-liquid mixer (1) is threaded or flanged to the hydraulic connector (2). The hydraulic connector (2) is threaded or flanged to one end of the second vertical distribution main pipe (6). The other end of the second vertical distribution main pipe (6) is threaded or flanged to the direct cooling unit. The connectors (15) of the gas-liquid mixers (1) between the leftmost and rightmost gas-liquid mixers (1) are threaded together by the hydraulic connector (2).

3. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 2, characterized in that: The first mixing device (9) is composed of a central shaft (13) and two rectangular blades (14) that are welded to the central shaft (13) and twisted in a clockwise parallel and symmetrical manner; the first mixing device (9) divides the refrigerant into two fluids.

4. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 3, characterized in that: The second mixing device (10) is composed of four rectangular blades (14) that are welded to the central shaft (13) and rotated counterclockwise in parallel and are symmetrical to each other; the second mixing device (10) divides the two fluids into four fluids by the first mixing device (9).

5. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 4, characterized in that: The third mixing device (11) consists of a central shaft (13) and two rectangular blades (14) that are welded to the central shaft (13) and twisted in a clockwise parallel and symmetrical manner; the third mixing device (11) mixes the four streams of fluid divided by the second mixing device (10) through opposite flow channel opening directions.

6. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 5, characterized in that: The fourth mixing device (12) consists of a central shaft (13) and six rectangular blades (14) that are welded to the central shaft (13) and twisted counterclockwise in parallel and symmetrically to each other; the fourth mixing device (12) divides the fluid mixed by the third mixing device (11) into six streams and outputs them.

7. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 6, characterized in that: The rectangular blade (14) of the first mixing device (9) has a torsion angle greater than or equal to 90 degrees; the rectangular blade (14) of the second mixing device (10) has a torsion angle greater than or equal to 90 degrees; the rectangular blade (14) of the third mixing device (11) has a torsion angle greater than or equal to 90 degrees; and the rectangular blade (14) of the fourth mixing device (12) has a torsion angle greater than or equal to 90 degrees.

8. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 7, characterized in that: The rectangular blades (14) of the first mixing device (9), the second mixing device (10), the third mixing device (11) and the fourth mixing device (12) have the same twist angle.

9. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 2, characterized in that: The length L of the gas-liquid mixing outer cylinder (7) is greater than or equal to 3 times the pipe diameter D.

10. A refrigerant direct cooling gas-liquid mixing pipeline according to claim 9, characterized in that: The flow channel area of ​​the rectifier core distributor (4) is greater than or equal to 1.2 times that of the hydraulic connector (2) of the gas-liquid mixer (1).

11. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline, comprising manufacturing the direct-cooling gas-liquid mixing pipeline as described in any one of claims 1-10, characterized in that: The specific steps are as follows: Step s1: Periodically optimize and iterate the operation process of the refrigerant direct cooling gas-liquid mixing pipeline to obtain the size of the liquid distribution pipeline (5); set the initial heat load conditions and refrigerant parameters, and design the flow channel structure parameters of the rectifier core liquid distribution head (4) required for the uniform distribution of refrigerant according to the initial heat load conditions and refrigerant parameters. Step s2: Connect the rectifier core distributor (4) to the gas-liquid mixer (1), adjust the key parameters of the gas-liquid mixer (1) to test and observe the refrigerant distribution, and record the specifications of the distributor pipe (5) and the parameters of the gas-liquid mixer (1) when the refrigerant reaches an average distribution in the gas-liquid mixer (1). Step s3: Change the heat load conditions and refrigerant parameters, repeat steps s1 and s2, record the specifications of the liquid distribution pipeline (5) and the parameters of the gas-liquid mixer (1) under different heat load conditions, and establish a four-dimensional relational database of "heat load-refrigerant characteristics-gas-liquid mixer key parameters-rectifier core liquid distribution head specifications". Step s4: Manufacture a rectifier core distributor (4) and a gas-liquid mixer (1) that meet the requirements according to the data of the four-dimensional relational database; reserve standardized interfaces on the rectifier core distributor (4) and the gas-liquid mixer (1) to match the first vertical distribution main pipe (3) and the second vertical distribution main pipe (6), and assemble the rectifier core distributor (4), the distributor pipeline (5), the gas-liquid mixer (1), the first vertical distribution main pipe (3) and the second vertical distribution main pipe (6) to complete the manufacturing of the refrigerant direct cooling gas-liquid mixing pipeline.

12. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 11, characterized in that: The specific steps of the periodic optimization iteration are as follows: Step s1.1: Using a simulation system, the shape of the rectifier core distributor (4) remains unchanged, while the diameter and length of the rectifier core distributor (4) are changed. The size parameters of the rectifier core distributor (4) outlet when balanced distribution is achieved under different given total flow rates are designed. Step s1.2: Make the corresponding test distributor according to the size parameters of the outlet of the rectifier core distributor (4) when the distribution is balanced, and conduct a balanced flow test on the rectifier core distributor (4); Step s1.3: Based on the deviation between the test results of the balanced flow test and the size parameters of the rectifier core distributor (4) outlet when balanced distribution is achieved as simulated in step s1.1, optimize the size and resubmit it into step s1.1 for simulation cycle; when the deviation between the test results of the balanced flow test and the size parameters of the rectifier core distributor (4) outlet when balanced distribution is achieved as simulated in step s1.1 is less than 4%~6%, it is considered to have converged, and the final size of the distributor outlet of the distributor pipeline (5) is output.

13. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 12, characterized in that: The balanced flow test involves giving a specific flow rate at the inlet of the rectifier core distributor (4), connecting a flow sensor to each outlet of the rectifier core distributor (4), stabilizing the flow rate for a period of time, measuring the sensor readings, and comparing the flow rate with that of the simulated balanced distribution at the outlet of the rectifier core distributor (4).

14. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 13, characterized in that: The flow channel structure parameters of the rectifier core distributor (4) in step s1 include the flow channel cross-sectional dimensions, aperture distribution, and number of branch channels.

15. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 14, characterized in that: The refrigerant parameters in step s1 include refrigerant type and gas-liquid ratio.

16. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 15, characterized in that: The parameters of the gas-liquid mixer (1) in step s2 include length, pipe diameter, angle of rectangular blades (14) and number of rectangular blades (14).

17. A method for manufacturing a refrigerant direct-cooling gas-liquid mixing pipeline according to claim 16, characterized in that: In step s2, the simulation is performed, and the specific steps are as follows: Step s2.1: Under different given total simulated flow rates, adjust the parameters of the gas-liquid mixer (1), and record the simulated rectifier core distributor outlet flow rate, rectifier core distributor (4) specifications and gas-liquid mixer (1) parameters when the refrigerant is redistributed evenly in the simulated environment; Step s2.2: Based on the parameters of the gas-liquid mixer (1) when the refrigerant is redistributed evenly, manufacture the gas-liquid mixer (1). Given different total inlet flow rates of the gas-liquid mixer (1), test the outlet flow rates of each rectifier core distributor head. When the deviation between the actual outlet flow rate of the rectifier core distributor head and the simulated outlet flow rate of the rectifier core distributor head is less than 4%~6%, it is considered to have converged, and the final size is output. Otherwise, optimize the size of the gas-liquid mixer (1) and re-perform the simulation.

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