A thermal protection device

Abstract

The application discloses a kind of heat guarantee device.It includes cabinet, refrigeration cycle unit, water circulation unit, air circulation unit and electric control system.Cabinet forms enclosed containing space;Refrigeration cycle unit includes compressor, condenser, evaporator and expansion valve, and is sequentially communicated to form refrigeration cycle circuit by refrigerant pipeline;Water circulation unit includes water pump, heater, three-way valve, radiator and expansion tank, and is communicated to form cooling liquid circulation circuit by cooling liquid pipeline, and evaporator is heat exchange connected with cooling liquid circulation circuit;Air circulation unit includes fan, and fan is oppositely arranged with radiator.The application can realize the cooling and heating of power battery in high-altitude environment, has the beneficial effects of strong anti-ultraviolet ability, stable electrical performance, compact structure and small size.

Description

Technical Field

[0001] This invention relates to the field of power battery thermal management technology, and specifically to a thermal protection device. Background Technology

[0002] As the core energy source for vehicles, mobile energy storage devices, and other applications, the operating temperature of power batteries has a significant impact on their performance, lifespan, and safety. Batteries generate heat during charging and discharging; excessively high temperatures accelerate internal side reactions, leading to faster capacity decay and, in severe cases, thermal runaway. Conversely, at low temperatures, the battery's internal resistance increases significantly, and its usable capacity decreases, making it difficult to meet normal charging and discharging requirements. Therefore, a thermal protection device is needed to cool or heat the battery, ensuring it operates within a suitable temperature range to guarantee its performance and safety.

[0003] Existing thermal protection devices are typically designed for low-altitude, conventional environmental conditions, and are mostly only suitable for environments at altitudes of 2500 meters and below. However, with the increasing use of railway locomotives and mobile energy storage devices in high-altitude areas, existing thermal protection devices have revealed the following shortcomings in high-altitude environments: The intensity of ultraviolet radiation in high-altitude areas is much higher than that in low-altitude areas. Ordinary protective structures have poor weather resistance and are prone to aging and cracking after long-term exposure. They cannot effectively block ultraviolet radiation from damaging the internal power battery and electrical components, thus shortening the service life of the device and battery.

[0004] The air is thin at high altitudes, and the heat dissipation conditions are significantly different from those in plains. Ordinary thermal protection devices can only achieve basic temperature regulation functions and are insufficient in heating protection capabilities in low-temperature environments, making it difficult to meet the needs of rapid battery temperature rise. At the same time, ordinary thermal protection devices have a large overall structure, occupy a lot of space, and have poor installation adaptability, making them unsuitable for the compact installation space requirements of small mobile energy storage devices.

[0005] High-altitude, low-pressure environments can reduce the electrical performance of ordinary insulating materials, easily leading to safety hazards such as creepage and leakage, which in turn affects the safety of power batteries to operate stably in high-altitude environments.

[0006] In view of this, there is an urgent need for a power battery thermal protection device that can adapt to high-altitude environments, has both cooling and heating functions, stable electrical performance, and a compact structure. It should be noted that the above statements are only used to provide background information related to this invention and do not necessarily constitute prior art. Summary of the Invention

[0007] The purpose of this invention is to provide a thermal protection device to solve the technical problems of poor weather resistance, insufficient heating protection capacity, excessively large structure, and reduced electrical insulation performance of existing thermal protection devices in high-altitude environments.

[0008] To achieve the above objectives, the present invention provides the following technical solution: A thermal protection device includes: a cabinet forming an enclosed storage space; a refrigeration cycle unit including a compressor, a condenser, an evaporator, and an expansion valve, wherein the compressor, condenser, expansion valve, and evaporator are sequentially connected via refrigerant piping to form a refrigeration cycle loop; a water circulation unit including a water pump, a heater, a three-way valve, a radiator, and an expansion tank, wherein the water pump, heater, three-way valve, radiator, and expansion tank are connected via coolant piping to form a coolant cycle loop, and the evaporator is heat-exchange connected to the coolant cycle loop; an air circulation unit including a fan positioned opposite the radiator; and an electrical control system including a high-voltage pre-charge unit, a thermal relay assembly, a control box, an AC / DC power supply, and a power board.

[0009] Preferably, the compressor's exhaust port is connected to the condenser's inlet, the condenser's outlet is connected to the evaporator's inlet via the expansion valve, the evaporator's outlet is connected to the compressor's suction port, and the evaporator is connected to the coolant circulation loop for heat exchange, so that the coolant flowing through the evaporator is cooled.

[0010] Preferably, the heater is a PTC heater, which is connected in series in the coolant circulation loop to heat the coolant.

[0011] Preferably, the three-way valve is installed in the coolant circulation loop to switch the coolant circulation path according to the operating conditions, so as to switch between heating mode and cooling mode under different ambient temperatures.

[0012] Preferably, the high-voltage pre-charge unit is connected in series in the high-voltage electrical circuit to complete pre-charging before the thermal protection device is connected to the high-voltage circuit, so as to suppress the current surge at the moment of connection.

[0013] Preferably, the cabinet includes a cabinet weld and a cabinet cover, both of which are made of metal. The cabinet cover is assembled with the cabinet weld to form the enclosed storage space.

[0014] Preferably, the thermal protection device further includes a unit inlet water pipe assembly and a unit outlet water pipe assembly. The unit inlet water pipe assembly is used to transport the coolant after battery heat exchange back to the coolant circulation loop, and the unit outlet water pipe assembly is used to transport the treated coolant to the battery end.

[0015] Preferably, the electrical control system further includes a terminal block, which is used to centrally arrange the connection terminals of each line of the thermal protection device.

[0016] Preferably, the AC / DC power supply is used to convert the input AC power into DC power required for the operation of the thermal protection device, and the power board is used to provide operating voltage for each control component and execution component within the thermal protection device.

[0017] This invention discloses a thermal protection device, which has the following advantages: The cabinet forms a closed enclosure, and both the cabinet welding and the cabinet cover are made of metal, which can effectively isolate the internal battery electrical components and pipeline components from the strong ultraviolet rays in high-altitude areas, significantly improve the weather resistance of the device, and extend the service life of the device and the battery.

[0018] The refrigeration cycle unit cools the coolant through an evaporator, the water circulation unit heats the coolant through a heater, and the air circulation unit uses a fan to force-cool the radiator, enabling the device to simultaneously perform cooling and heating functions, meeting the heating requirements in high-altitude and low-temperature environments as well as the heat dissipation requirements in high-temperature environments.

[0019] The electrical control system is equipped with a high-voltage pre-charge unit to complete pre-charging before connecting to the high-voltage circuit, suppressing the large current surge at the moment of connection; the AC-DC power supply converts the input AC power into DC power required for the device to operate, and works with the thermal relay assembly to implement overcurrent and overheat protection, ensuring stable electrical insulation performance and safe operation of the device in high-altitude and low-pressure environments.

[0020] Each circulation unit is integrated into a closed cabinet, with a compact pipeline layout and small overall size, making it suitable for the compact installation space of small mobile energy storage devices and locomotive power batteries.

[0021] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention, specific embodiments of the present invention are described below. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0023] Figure 1 This is a general diagram of the present invention; Figure 2 This is a top view of the invention, showing the hidden cabinet cover. Figure 3 This is an axial view of the present invention, showing the hidden cabinet cover and the welded parts of the cabinet. Figure 4 This is an axial view of the present invention, showing the hidden cabinet cover and the welded parts of the cabinet. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below.

[0025] As shown in the figure, this embodiment provides a thermal protection device, which is a supporting component of the locomotive's power battery and is used for cooling and heating the battery. The thermal protection device consists of four parts: a refrigeration cycle, a water cycle, an air cycle, and an electronic control system. The specific structure and connection relationships of each part are described in detail below.

[0026] The cabinet consists of cabinet welding 1 and cabinet cover 2. Cabinet welding 1 is made of metal and serves as the main load-bearing structure of the entire device, supporting all internal components. Cabinet welding 1 is typically formed by welding metal sheets to create a frame and support structure with sufficient rigidity and strength. Cabinet cover 2 is also made of metal. When assembled with cabinet welding 1, cabinet cover 2 forms a closed thermal protection space, enclosing the components of the refrigeration cycle, water cycle, air cycle, and electrical control system. This enclosed cabinet structure, made of metal, provides reliable mechanical protection and structural support for the internal components. Furthermore, it effectively isolates the internal power battery, electrical components, and piping from intense ultraviolet radiation at high altitudes, preventing aging and cracking of the internal power battery, electrical components, and piping due to prolonged UV exposure. This significantly improves the overall weather resistance of the device and extends the lifespan of the device and battery.

[0027] The refrigeration cycle unit consists of components such as compressor 3, condenser 4, evaporator 5, and expansion valve 6. These components are connected sequentially via refrigerant piping to form a complete refrigeration cycle loop. Specifically, the discharge port of compressor 3 is connected to the inlet of condenser 4 via a refrigerant piping, the outlet of condenser 4 is connected to the inlet of evaporator 5 via expansion valve 6, and the outlet of evaporator 5 is connected to the suction port of compressor 3, thus forming a refrigerant circulation channel.

[0028] Compressor 3 is the power component of the refrigeration cycle, used to compress the low-temperature, low-pressure refrigerant vapor from evaporator 5 into high-temperature, high-pressure gas, and then deliver the high-temperature, high-pressure gas to condenser 4. Condenser 4 condenses the high-temperature, high-pressure refrigerant gas discharged from compressor 3 into liquid refrigerant, releasing heat to the outside during the condensation process. Expansion valve 6 throttles and reduces the pressure of the high-pressure liquid refrigerant from condenser 4, while simultaneously regulating the refrigerant flow into evaporator 5, controlling the refrigerant at the outlet of evaporator 5 to maintain a suitable superheat. This ensures that the heat exchange volume of evaporator 5 is fully utilized and prevents liquid slugging in compressor 3, thus guaranteeing stable and efficient operation of the refrigeration cycle. Evaporator 5 absorbs heat from the coolant side, cooling the high-temperature coolant flowing through it to a low-temperature coolant. Simultaneously, the low-pressure liquid refrigerant vaporizes within evaporator 5 through heat absorption, changing from a low-temperature, low-pressure state to a high-temperature, low-pressure state, and is then drawn into compressor 3 to enter the next refrigeration cycle.

[0029] The water circulation unit consists of a water pump 7, a PTC heater 9, a three-way valve 8, a radiator 11, an expansion tank 10, and corresponding piping. All components are connected via coolant piping to form a coolant circulation loop. The evaporator 5 is connected to this coolant circulation loop for heat exchange, meaning that the evaporator 5 can cool the coolant flowing through the coolant circulation loop.

[0030] Water pump 7 provides power for coolant circulation, driving the coolant to circulate between the heat-generating components and the device, thus achieving heat transfer and transport. Three-way valve 8 switches the coolant circulation path according to system operating conditions, meeting the thermal protection and regulation requirements under different ambient temperatures. PTC heater 9 heats the coolant in low-temperature conditions requiring rapid temperature rise, raising the operating temperature of the heat-generating components to meet operational requirements. Expansion tank 10 accommodates the volume of coolant that expands due to heat within the coolant circulation system, while also replenishing coolant lost from the system to maintain stable system pressure. Radiator 11 dissipates the heat carried by the coolant to the external environment when cooling is required.

[0031] The air circulation unit consists of components such as a fan 12, a condenser 4, and a radiator 11. The fan 12 is positioned opposite the radiator 11 to provide forced convection airflow to the radiator 11, enhancing its heat exchange efficiency and improving the overall heat dissipation capacity of the device. The condenser 4, while meeting the refrigerant condensation heat release requirements, also participates in air circulation heat exchange.

[0032] The electrical control system consists of components such as a high-voltage precharge unit 13, a thermal relay box assembly 14, a control box 16, an AC / DC power supply 17, a power board 15, and a terminal box 18.

[0033] The high-voltage pre-charge unit 13 is a key protection component in the high-voltage electrical system. Its core function is to protect the system from the impact caused by sudden high-voltage surges by controlling the flow of initial current. The high-voltage pre-charge unit 13 completes pre-charging before the device is connected to the high-voltage circuit, avoiding large current surges at the moment of connection, thus protecting the safety of circuit components. The thermal relay assembly 14 integrates a thermal protection relay for overcurrent and overheat protection of the circuit, promptly cutting off the circuit in case of a fault to prevent component damage. The control box 16 integrates the device's control logic unit, used to collect system parameters such as temperature and pressure, and control the operation of various components according to preset control logic. The AC / DC power supply 17 converts the input AC power into the DC power required for device operation. For example, it can convert AC380V main power input to DC500V, DC24V, and other different voltage levels to meet the power supply needs of different components. The power board 15 provides suitable operating voltages for various control and execution components within the device. The terminal box 18 centrally arranges the connection terminals of various lines, facilitating line layout, inspection, and maintenance.

[0034] The thermal protection device also includes a unit inlet water pipe assembly 19 and a unit outlet water pipe assembly 20. The unit inlet water pipe assembly 19 is the inlet water pipe of the thermal protection device, which is the connecting pipe for the coolant after battery heat exchange to flow back to the thermal protection device; the unit outlet water pipe assembly 20 is the outlet water pipe of the thermal protection device, through which the coolant that meets the requirements after being processed by the thermal protection device is transported to the battery end.

[0035] The cooling process of the thermal protection device in this embodiment is as follows: When cooling of the heat-generating components is required, the compressor refrigeration circuit is activated. Compressor 3 compresses the low-temperature, low-pressure refrigerant into a high-temperature, high-pressure gas and sends it to condenser 4. The high-temperature, high-pressure refrigerant gas condenses into liquid refrigerant in condenser 4. The liquid refrigerant is then throttled and depressurized by expansion valve 6 and sent to evaporator 5. The liquid refrigerant evaporates and absorbs heat in evaporator 5, cooling the coolant flowing through evaporator 5. The cooled coolant is then transported to the heat-generating component side, carrying away the heat generated by the heat-generating component, thereby achieving cooling of the heat-generating component.

[0036] When the device is in a low-temperature environment and the heating component needs to be heated, the compressor refrigeration circuit is cut off, the PTC heater 9 is started, the coolant flows through the PTC heater 9 and is heated before being sent to the side of the heating component, raising the temperature of the heating component to a suitable operating range, thereby meeting the thermal protection requirements.

[0037] Specifically, in low-temperature environments, the temperatures of heat-generating components such as the motor and battery are too low to meet normal operating requirements. At this time, the control box 16, based on the collected system temperature parameters, controls the three-way valve 8 to switch the coolant circulation path, allowing the coolant to enter the heating branch, and simultaneously controls the PTC heater 9 to power on. The PTC heater 9 uses a positive temperature coefficient thermistor as its heating element, rapidly heating up after being powered on and transferring heat to the coolant flowing through it. The water pump 7 drives the heated coolant to be transported to the battery end through the unit's outlet water pipe assembly 20 to heat the battery. Once the battery temperature reaches a suitable operating range, the control box 16 controls the PTC heater 9 to stop working or reduce its heating power, maintaining the battery within a suitable temperature range.

[0038] The PTC heater 9 has a self-limiting temperature characteristic: when its temperature rises to a certain value, the resistance of the positive temperature coefficient thermistor will increase rapidly, and the heating power will automatically decrease, thereby avoiding overheating and improving the safety of the heating process.

[0039] When the device is connected to the high-voltage circuit, the high-voltage pre-charge unit 13 first completes pre-charging. Specifically, before the main circuit of the device is connected to the high-voltage power supply, the high-voltage pre-charge unit 13 pre-charges the capacitors in the circuit through a pre-charging resistor, limiting the charging current; after the capacitor voltage approaches the power supply voltage, the main contactor is closed to formally connect the device to the high-voltage circuit. This pre-charging process avoids the large current surge caused by the initial zero voltage of the capacitors at the moment of formal connection, protecting electrical components such as rectifier inverters, relay contacts, and power modules. At the same time, this pre-charging design also adapts to the working conditions of reduced insulation strength in high-altitude, low-pressure environments, reducing the risk of creepage and leakage, and improving the electrical safety of the device in high-altitude environments.

[0040] The AC-DC power supply 17 converts the input AC380V main power supply into DC power of different voltage levels such as DC500V and DC24V to meet the power supply requirements of different components such as compressor 3, water pump 7, fan 12, and control box 16. The power board 15 performs secondary power distribution for each control and actuator, providing suitable operating voltages.

[0041] The control box 16 collects system parameters such as temperature and pressure in real time, and coordinates the operation of the compressor 3, PTC heater 9, three-way valve 8, water pump 7, and fan 12 according to preset control logic. When the battery temperature is detected to be higher than the set upper temperature limit, the control box 16 starts the cooling cycle and turns on the fan 12 to perform forced air cooling of the radiator 11; when the battery temperature is detected to be lower than the set lower temperature limit, the control box 16 switches to heating mode and starts the PTC heater 9; when the battery temperature is within a suitable temperature range, the control box 16 maintains the current operating state or puts the device into a low-power standby state.

[0042] The thermal relay assembly 14 provides overcurrent and overheat protection for the circuit. When the circuit is overloaded or the temperature rises abnormally, the thermal relay assembly 14 will cut off the circuit in time to prevent damage to the components, thereby further ensuring the safe operation of the device in high-altitude environments.

[0043] In this embodiment, each circulation unit of the device is integrated into a closed cabinet, with a compact piping layout, resulting in a compact overall structure and small size, suitable for the compact installation space of small mobile energy storage devices and locomotive power batteries. The closed cabinet made of metal can effectively block strong ultraviolet rays in high-altitude areas, ensuring the long-term stable operation of internal electrical components and preventing aging and cracking due to ultraviolet radiation.

[0044] Those skilled in the art will understand that the compressor 3, condenser 4, evaporator 5, and expansion valve 6 in the refrigeration cycle unit can all be implemented using conventional refrigeration components in the art, and their specific models and specifications can be selected according to the cooling capacity requirements of the device. The heater is preferably a PTC heater 9, but it is not limited to this; other heating elements capable of heating the coolant, such as electric heating tubes or heating elements, can also be used. The cabinet welding 1 and cabinet cover 2 can be made of metal materials such as steel plates or aluminum alloys, as long as they can form a closed enclosure and provide UV protection. The fan 12 can be an axial flow fan or a centrifugal fan, as long as it can provide forced convection airflow to the radiator 11.

[0045] The heat exchange relationships of the refrigeration cycle loop, coolant cycle loop, and air cycle in the device, as well as the control logic of the electronic control system, can all be adjusted and optimized according to actual needs. All equivalent substitutions or modifications described above do not depart from the technical concept of this invention and should be covered within the scope of protection defined by the claims of this invention.

[0046] In summary, the thermal protection device provided by this invention, by setting up a closed cabinet, a refrigeration circulation unit, a water circulation unit, an air circulation unit, and an electronic control system, can achieve cooling and heating of the power battery in high-altitude environments. It has the advantages of strong UV protection, stable electrical performance, compact structure, and small size. It effectively solves the technical problems of poor weather resistance, insufficient heating protection capacity, large structure, and decreased electrical insulation performance of existing thermal protection devices in high-altitude environments. It has high practical value and promising prospects for widespread application.

[0047] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Modifications or substitutions to the technical solutions described in the foregoing embodiments do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A thermal protection device, comprising: The cabinet forms an enclosed storage space; The system includes a refrigeration cycle unit comprising a compressor, a condenser, an evaporator, and an expansion valve, wherein the compressor, condenser, expansion valve, and evaporator are sequentially connected via refrigerant piping to form a refrigeration cycle loop; a water circulation unit comprising a water pump, a heater, a three-way valve, a radiator, and an expansion tank, wherein the water pump, heater, three-way valve, radiator, and expansion tank are connected via coolant piping to form a coolant circulation loop, and the evaporator is connected to the coolant circulation loop for heat exchange; an air circulation unit comprising a fan, wherein the fan is positioned opposite the radiator; and an electrical control system comprising a high-voltage pre-charge unit, a thermal relay assembly, a control box, an AC / DC power supply, and a power board.

2. The thermal protection device according to claim 1, wherein, The compressor's exhaust port is connected to the condenser's inlet, the condenser's outlet is connected to the evaporator's inlet via the expansion valve, the evaporator's outlet is connected to the compressor's suction port, and the evaporator is connected to the coolant circulation loop for heat exchange, so that the coolant flowing through the evaporator is cooled.

3. The thermal protection device according to claim 1, wherein, The heater is a PTC heater, which is connected in series in the coolant circulation loop to heat the coolant.

4. The thermal protection device according to claim 1, wherein, The three-way valve is installed in the coolant circulation loop and is used to switch the coolant circulation path according to the operating conditions, so as to switch between heating mode and cooling mode under different ambient temperatures.

5. The thermal protection device according to claim 1, wherein, The high-voltage pre-charge unit is connected in series in the high-voltage electrical circuit and is used to pre-charge the thermal protection device before it is connected to the high-voltage circuit in order to suppress the current surge at the moment of connection.

6. The thermal protection device according to claim 1, wherein, The cabinet includes a cabinet weld and a cabinet cover, both of which are made of metal. The cabinet cover is assembled with the cabinet weld to form the enclosed storage space.

7. The thermal protection device according to claim 1, wherein, It also includes a unit inlet water pipe assembly and a unit outlet water pipe assembly. The unit inlet water pipe assembly is used to transport the coolant after battery heat exchange back to the coolant circulation loop, and the unit outlet water pipe assembly is used to transport the treated coolant to the battery end.

8. The thermal protection device according to claim 1, wherein, The electrical control system also includes a terminal box, which is used to centrally arrange the connection terminals of each line of the thermal protection device.

9. The thermal protection device according to claim 1, wherein, The AC / DC power supply is used to convert the input AC power into DC power required for the operation of the thermal protection device, and the power board is used to provide operating voltage for the various control and execution components within the thermal protection device.

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