A high power density energy storage system based on electric double layer capacitance
Patent Information
- Application Number
- CN202522225527.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-21
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-10-21
AI Technical Summary
Existing energy storage systems based on double-layer capacitors suffer from problems such as complex electrical connection structures, unreasonable heat dissipation and layout, limited power density, and insufficient system safety.
The energy storage module is constructed by connecting multiple capacitor clusters in parallel. The current sensor, current sharing resistor and contactor are mounted on the same structural mounting plate, which achieves compact electrical connection and simple heat dissipation path. Real-time monitoring and control are performed through the energy management module to ensure coordinated current distribution.
It achieves efficient energy storage and stable output at high power density, improves current sampling accuracy and response speed, simplifies system structure, optimizes layout, ensures safe operation, and increases power density.
Smart Images
Figure CN224934629U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of energy storage technology, and specifically relates to a high power density energy storage system based on double-layer capacitors. Background Technology
[0002] In existing technologies, energy storage systems based on double-layer capacitors typically rely on modular capacitor banks and bus structures, using series and parallel connections to meet the energy storage and rapid release requirements under high voltage and high current conditions. However, existing energy storage systems mostly use a split wiring method to connect units. The parallel system between each capacitor bank is usually completed by independent conductive copper busbars, contactors, and current-sharing resistors, which results in large distances between components and complex wiring arrangements. This not only increases installation space and manufacturing costs but also leads to uneven overall electrical connection paths, limited heat dissipation, and restricted power density improvement.
[0003] In this type of structure, current sensing elements and contact switch elements are mostly externally mounted modules. The current signal acquisition path is relatively long, and the signal delay and noise interference are more prominent, making it difficult to achieve rapid response and current sharing control for high-power charging and discharging processes. At the same time, due to the lack of a unified installation support structure between the parallel ports, the installation accuracy depends on manual adjustment, the heat distribution of the components is uneven, and problems such as local heating, poor contact and electrical stress concentration are likely to occur during long-term operation, resulting in insufficient safety and stability of system operation.
[0004] On the other hand, the heat dissipation design of existing capacitor modules is mainly based on the ventilation of the entire enclosure, with a single fan installation position and limited heat dissipation efficiency. When the system is running continuously under high power density conditions, the temperature rise of key components such as current sensors and current sharing resistors is significant, which can easily lead to measurement deviations and control lags. In addition, the traditional energy storage compartment layout is mainly based on centralized wiring, with unreasonable distribution of power modules and energy storage modules, low space utilization, and inconvenient maintenance and operation.
[0005] It is evident that existing technologies often suffer from problems such as complex electrical connection structures, unreasonable heat dissipation and layout, limited power density, and insufficient system safety. These are the shortcomings of existing technologies.
[0006] In view of this, it is very necessary to provide a high power density energy storage system based on double-layer capacitors to solve the above-mentioned defects in the prior art. Utility Model Content
[0007] The purpose of this invention is to address the shortcomings of the existing technology, such as complex electrical connection structure, unreasonable heat dissipation and layout, limited power density, and insufficient system safety, by providing a high power density energy storage system based on double-layer capacitors to solve the above-mentioned technical problems.
[0008] To achieve the above objectives, the present invention provides the following technical solution: A high power density energy storage system based on electric double-layer capacitors includes: The energy storage module includes multiple capacitor clusters connected in parallel. Each capacitor cluster includes multiple capacitor boxes. The capacitor boxes contain multiple double-layer capacitor cells connected in series and / or in parallel. Each parallel port of the energy storage module is connected in sequence to a current sensor, a current sharing resistor, and a contactor. The current sensor, current sharing resistor, and contactor are all mounted on the same structural mounting plate. The power conversion module is electrically connected to the energy storage module; The energy management module is electrically connected to the energy storage module.
[0009] By adopting the above technical solution, energy storage modules are constructed by connecting single double-layer capacitors in series and / or in parallel, and by connecting multiple capacitor clusters in parallel. This achieves efficient energy storage and stable output at high power density, and maintains compact electrical connections and simple heat dissipation paths within a limited space. It meets the requirements of simplified system structure, reasonable layout, safe operation, and increased power density.
[0010] Each parallel port within the energy storage module is sequentially equipped with a current sensor, a current sharing resistor, and a contactor. All components are mounted on the same structural mounting plate, giving the parallel branches a fixed and modular character. By shortening the conductive and signal paths, the current sampling accuracy and response speed are improved, resulting in more stable current sharing control and maintaining consistent output across capacitor clusters under high current conditions. The direct electrical connection between the energy storage module and the power conversion module ensures clear energy flow, concentrated impedance, and reduced path inductance, enabling the system to maintain high energy transfer efficiency, low loss, and balanced heat generation even under high-power charging and discharging conditions. The energy management module is electrically connected to the energy storage module, enabling real-time monitoring and control of the operating status of each parallel port. This results in more coordinated current distribution among the modules, ensuring the dynamic balance and operational stability of the capacitor clusters during charging and discharging cycles.
[0011] Preferably, the structural mounting plate is an insulating plate with heat dissipation channels and limiting structures, and the current sensor, current sharing resistor and contactor are installed sequentially along the heat dissipation channel.
[0012] Preferably, the energy storage module includes a positive connection structure and a negative connection structure. Each parallel port is fixed to the lateral mounting area of the positive connection structure and the negative connection structure, respectively. An isolation plate is set between the lateral mounting areas, and an insulating bracket is provided on the isolation plate. The insulating bracket is fixedly connected to the structural mounting plate.
[0013] Preferably, the current sharing resistor and the current sensor are connected by a bolt-copper busbar connection structure, and a copper braided strip is provided between the output end of the contactor and the input end of the capacitor cluster. The copper braided strip is fixed to the connection structure by an independent clamp.
[0014] Preferably, the capacitor box has a metal shell, a fan is provided in the width direction of the box, the fan is embedded in the mounting hole, a metal pressure ring is provided on the outside of the fan, and an elastic gasket is provided between the fan and the box.
[0015] Preferably, the end plate of the capacitor box is equipped with temperature and current sensors, which are connected to aviation sockets via wiring harnesses. The aviation sockets are installed in the unified interface area of the end plate.
[0016] Preferably, the energy storage module is located inside the container-type cabin, with each capacitor cluster arranged symmetrically along the longitudinal direction inside the cabin. The structural mounting plate is located in the middle of the cabin, and the power conversion module is located at one end of the cabin.
[0017] Preferably, the bottom of the cabin is provided with an air guide channel, and the fans of each capacitor box are arranged in the direction of the air guide channel. The air guide channel is connected to the air inlet of the cabin, and the air inlet, the fans and the air outlet of the cabin form a through airflow path.
[0018] Preferably, the energy management module is equipped with a control channel, each control channel corresponding to a capacitor cluster. The output terminal of the control channel is connected to the control terminal of each contactor, and the sampling harness of the control channel is connected to the signal terminal of the current sensor.
[0019] Preferably, the inner wall of the energy storage module's casing is equipped with a grounding copper busbar and a metal shielding mesh. The grounding copper busbar is electrically connected to the casing of the power conversion module, and the metal shielding mesh covers the installation area of each parallel port.
[0020] The beneficial effects of this utility model are that by connecting single double-layer capacitors in series and / or in parallel, and constructing an energy storage module by connecting multiple capacitor clusters in parallel, it achieves efficient energy storage and stable output under high power density. It can maintain compact electrical connections and simple heat dissipation paths in a limited space, and meet the requirements of simplified system structure, reasonable layout, safe operation and increased power density.
[0021] Furthermore, the design principle of this utility model is reliable, the structure is simple, and it has a very wide range of application prospects.
[0022] It is evident that this utility model has outstanding substantive features and significant progress compared with the prior art, and the beneficial effects of its implementation are also obvious. Attached Figure Description
[0023] To more clearly illustrate the technical solutions in the embodiments of this utility model 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 only embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.
[0024] Figure 1 This is a schematic diagram of a high power density energy storage system based on double-layer capacitors provided by this utility model; Figure 2 This is a schematic diagram of the structure of a capacitor standard box for a high power density energy storage system based on double-layer capacitors provided by this utility model; Figure 3 This is a structural schematic diagram of a mounting plate for a high power density energy storage system based on double-layer capacitors provided by this utility model; Figure 4 This is a schematic diagram of the structure of an energy storage module of a high power density energy storage system based on double-layer capacitors provided by this utility model; Figure 5 This is a schematic diagram of the air duct structure of a high power density energy storage system based on double-layer capacitors provided by this utility model.
[0025] Among them, 1. Energy storage module, 11. Capacitor cluster, 12. Capacitor box, 121. Fan, 122. Metal pressure ring, 13. Current sensor, 14. Current sharing resistor, 15. Contactor, 16. Structural mounting plate, 161. Heat dissipation channel, 162. Limiting structure, 17. Positive connection structure, 18. Negative connection structure, 19. Isolation plate, 191. Insulating bracket, 2. Power conversion module, 3. Energy management module, 4. Air guide channel, 41. Air inlet, 42. Air outlet. Detailed Implementation
[0026] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The following embodiments are explanations of the present invention, but the present invention is not limited to the following implementation methods.
[0027] To make the objectives, technical solutions, and advantages of this utility model clearer, the embodiments of this utility model will be described in further detail below with reference to the accompanying drawings.
[0028] like Figure 1 As shown, this embodiment provides a high power density energy storage system based on double-layer capacitors, including an energy storage module 1, a power conversion module 2 and an energy management module 3 electrically connected to the energy storage module 1.
[0029] Specifically, the energy storage module 1 consists of multiple capacitor clusters 11 connected in parallel. Each capacitor cluster 11 is composed of multiple capacitor boxes 12 connected in series or in parallel. Each capacitor box 12 is composed of several double-layer capacitor cells grouped in series and parallel. The individual capacitor cells are cylindrical, and their electrode-electrolyte interface energy storage characteristics result in low internal resistance and high cycle life, making them suitable for frequent charge-discharge and high-rate operation. The cells are arranged in an equidistant array within the energy storage module 1, with the terminal direction aligned with the internal airflow path, facilitating heat transfer to the ventilation channel along a fixed direction. For example, the rated voltage of a single cell is 3.0V, the operating voltage range is 1.95V to 2.80V, the capacitance is 3000F, the charge capacity is 2.5Ah, and the energy per cell is 3.75Wh. The individual cell dimensions are approximately 60mm in diameter and approximately 139–145mm in height. The maximum sustainable current at 15℃ and 40℃ is approximately 139A and 227A, respectively.
[0030] Meanwhile, the system adopts a hierarchical assembly and standardized parallel port structure, enabling multi-cluster energy storage units to operate stably under high voltage, high current and fast response conditions; the parallel port structure is set in the main combiner cabinet as a unified device unit for cluster-level access and exit, current sharing and detection, realizing controllable cluster-level access, parallel system current distribution and centralized heat dissipation at the device level.
[0031] A current sensor 13, a current sharing resistor 14, and a contactor 15 are sequentially installed at each parallel port of the energy storage module 1. The current sensor 13, the current sharing resistor 14, and the contactor 15 are fixedly mounted on the same structural mounting plate 16. The structural mounting plate 16 is located in the connection area between the energy storage module 1 and the main busbar, so that each capacitor cluster 11 can be connected to or disconnected from the parallel system in a standardized circuit unit.
[0032] By adopting the above technical solution, energy storage module 1 is constructed by connecting single double-layer capacitors in series and / or in parallel, and by connecting multiple capacitor clusters 11 in parallel. This achieves efficient energy storage and stable output at high power density, and maintains compact electrical connections and simple heat dissipation paths within a limited space. It meets the requirements of simplified system structure, reasonable layout, safe operation, and increased power density. Each parallel port in energy storage module 1 is sequentially equipped with a current sensor 13, a current sharing resistor 14, and a contactor 15. All components are mounted on the same structural mounting plate 16, giving the parallel branches fixed and modular characteristics. This shortens the conductive path and signal path. The system improves current sampling accuracy and response speed, achieving more stable current sharing control and maintaining consistent output of each capacitor cluster 11 under high current conditions. The direct electrical connection between the energy storage module 1 and the power conversion module 2 clarifies the energy flow, concentrates impedance, and reduces path inductance, thus enabling the system to maintain high energy transfer efficiency, low loss, and balanced heat generation under high-power charging and discharging conditions. The energy management module 3 is electrically connected to the energy storage module 1, and through real-time monitoring and control of the operating status of each parallel port, it makes the current distribution between modules more coordinated, ensuring the dynamic balance and operational stability of the capacitor cluster 11 during charging and discharging cycles.
[0033] In this embodiment, the capacitor box 12 is a basic series-parallel unit within the cluster. The box body adopts a metal shell and is equipped with a lateral airflow structure. The end plate of the box body is provided with a unified electrical and signal interface area to achieve quick insertion and connection with the wiring harness inside the cabin. The individual capacitors in the capacitor box 12 are equidistantly fastened and connected with low resistance through copper busbars or flexible connectors. Insulation and vibration damping components are provided between the individual capacitors and the box body to ensure structural stability under high current pulse and thermal cycling conditions. For example, the capacitor box 12 is grouped in a configuration of 48 series connections and 2 parallel connections to form a high-voltage submodule. The rated voltage of the capacitor box 12 is approximately 144V, the operating voltage range is approximately 93.6–134.4V, the equivalent capacitance is approximately 125F, the capacity is approximately 5Ah, and the energy storage is approximately 360Wh. The external dimensions of the capacitor box 12 are approximately 1028mm × 743mm × 150mm.
[0034] Furthermore, such as Figure 2 As shown, a dual-fan mounting position is provided on the width direction of the side wall of the capacitor box 12. The fan 121 is embedded along the thickness direction of the box and is fixed to the box with a metal pressure ring 122 on the outside. An elastic gasket is used between the fan 121 and the box to suppress the transmission of operating vibration and reduce the risk of resonance. The inlet and outlet of the fan 121 form a straight airflow in the box to shorten the air heat exchange path.
[0035] Furthermore, temperature and current sensors are provided on the end plate of the capacitor label box 12. The cables of the fan 121 and the temperature / current sensors are concentrated in the end plate interface area and connected to the internal wiring harness via an aviation socket for easy assembly and maintenance. For example, the fan 121 can be embedded in about 5mm and the pressure ring can be about 3mm thick. In standby or low-power discharge, only one fan 121 can be used to run at about 3000rpm while the other is shut down. In normal discharge conditions, both fans 121 can run at about 4600rpm simultaneously. In high-current discharge conditions, both fans 121 can run at about 5000rpm and report a "high temperature signal for the capacitor label box". The corresponding power consumption for the three levels is about 12W (single unit), 18.7W / unit, and 21W / unit, respectively. The operating noise can be controlled to within about 55dB(A).
[0036] The capacitor cluster 11 is composed of multiple capacitor banks 12 connected in series and parallel along the electrical direction. The positive and negative terminals of the capacitor cluster 11 are connected to the main busbar cabinet by flexible conductors. Each capacitor cluster 11 is symmetrically arranged in the depth direction within the compartment, and ventilation spacing is maintained between the clusters to facilitate longitudinal airflow through the array of capacitor banks 12 and the parallel port device area. For example, the capacitor cluster 11 consists of 11 capacitor banks 12, and the overall equivalent group can be 2P528S (528 in series and 2 in parallel), with an equivalent capacitance of approximately 11.4F, a capacity of approximately 5Ah, an energy storage of approximately 3.96kWh, and a calculated voltage level of approximately 1584V (theoretical value). The actual operating voltage is limited by the system voltage window.
[0037] The main busbar cabinet is used for the parallel connection of several capacitor clusters 11. Multiple parallel port device units are installed within the cabinet. Each parallel port device unit consists of a current sensor 13, a current-sharing resistor 14, and a contactor 15, forming a fixed electrical connection sequence on the same structural mounting plate 16. This device unit is connected to the main busbar via a detachable conductive connector, and its heat dissipation direction is consistent with the airflow direction of the cabin. This device unit serves as a unified hardware interface for cluster-level access / exit and branch current distribution. Through its structural features of "integrated on the same board, fixed sequence, and straight airflow path," it shortens the distance between the detection wires and the main circuit, reduces parasitic parameters, improves the current consistency of the parallel system, and significantly reduces the amount of disassembly and assembly work required for maintenance. For example, the device units are connected in series in a fixed order of "current sensor 13 on the side closest to the main busbar - current sharing resistor 14 in the middle - contactor 15 on the side furthest from the main busbar", and are connected to the cluster terminals and the main busbar through copper busbars and copper braided strips; the device units are arranged linearly in the cabinet according to the number of parallel branches.
[0038] Furthermore, such as Figure 5As shown, a guide channel 4 is formed at the bottom of the containerized cabin between the main junction box and the capacitor label box 12 area. The guide channel 4 is connected to the bottom air inlet 41 of the cabin. The fans 121 of each capacitor label box 12 are arranged in the direction of the guide channel 4. The air inlet 41, the fans 121 and the top exhaust vent 42 of the cabin form a through airflow passage. Cold air enters the semi-enclosed guide channel 4 from the bottom air inlet 41, is introduced by the side fans 121 of the capacitor label box 12, forms a directional airflow along the array of capacitor label boxes 12 and the surface of the device unit, and is discharged from the top exhaust vent 42.
[0039] In some embodiments of this application, the cabin may be equipped with grounding copper busbars and metal shielding components. The shielding components provide surface coverage in the main combiner cabinet and areas with dense wiring harnesses, using a multi-point grounding connection to reduce electromagnetic radiation and induced interference caused by high current pulses. For example, the cabin may adopt a 20-foot container structure, with the energy storage area, combiner area, and control area arranged sequentially along the longitudinal direction. The cross-section of the air duct 4 is configured to match the number of fans 121 with the number of heat-generating devices.
[0040] In some embodiments of this application, the energy storage module 1 can also be formed by several clusters connected in parallel to achieve the target power level. The main busbar and the DC terminal of the power conversion module 2 are connected through a high-voltage copper busbar. The spacing and creepage distance of the copper busbars meet the insulation requirements of the rated voltage level. Rounded corners are used at bends to reduce electric field concentration. Protective covers are provided at the connection ends and the tightening torque is marked. A dedicated grounding point is provided at the casing and reliably connected to the grounding copper busbar. For example, in one capacity level configuration, the system voltage window is approximately 1029.6–1478.4V, and the total energy storage is approximately 21.32kWh. In another high-power level configuration, the maximum system discharge power can reach approximately 2.5MW, with a duration of approximately 30s, and the maximum system discharge current is approximately 2428A. The maximum discharge current of a single unit according to the current distribution relationship is approximately 101A.
[0041] The power conversion module 2 is located in the control area of the cabin and is connected to the DC terminal of the main combiner cabinet via a busbar or a large-section conductor. Mechanical protection and indicator markings can be installed at the interface between the power conversion module 2 and the external power grid or load, and visual isolation and anti-accidental contact measures can be implemented at the DC terminal. The casing of the power conversion module 2 can be equipotentially connected to the cabin grounding copper busbar via a short grounding wire to form a complete grounding network. For example, the power conversion module 2 can be configured with two parallel units, each with a rated power of approximately 1250kW, to meet the target power level and grid connection interface requirements.
[0042] The energy management module 3 can be located on one side of the wiring terminal in the cabin control area, and connected to each parallel port device unit via a bundle of wires and terminal blocks. The casing, cable tray shielding layer, and grounding copper busbar of the energy management module 3 form a unified grounding system. Simultaneously, the energy management module 3 can have an independent control channel for each capacitor cluster 11. The output of the control channel is connected to the control terminal of the contactor 15 of the corresponding device unit, and the sampling terminal is connected to the current sensor 13 and the temperature / current detection interface of the capacitor label box 12 terminal board of the corresponding device unit. The wiring harness is arranged in layers, color-coded, and fixed with cable trays or cable ducts to avoid physical interference with the busbar and air duct 4. For example, the number of control channels corresponds to the number of clusters, and the sampling line uses a shielded cable and is grounded at the same point as the shielding mesh.
[0043] In this embodiment, to improve assembly consistency and maintainability, the capacitor label boxes 12 in the energy storage module 1 are assembled using a uniform positioning and sliding mechanism. A fixed ventilation distance is maintained between the capacitor label boxes 12. The plug-in interfaces on the end plates of the capacitor label boxes 12 use a uniform model and are marked with polarity. The wire harness is bound at the end plate by a limiter and clamp before entering the wire trough. The device units in the main busbar cabinet adopt a drawer-type or side-insertion installation structure. The device units are fixed on the structural mounting plate 16 with standard holes. The path for pulling out and inserting is consistent with the airflow direction to avoid disturbing adjacent device units. Exemplarily, the structural gap between the capacitor label boxes 12 can be set according to the air duct requirements. The device units are arranged in rows in the cabinet, with their heat dissipation surfaces facing the airflow direction.
[0044] During high-power operation, the energy from energy storage module 1 is fed into the main busbar via parallel branches and then sent to power conversion module 2. The current sharing resistor 14 in the parallel port device unit constitutes the current distribution network between branches, and the sampling value of current sensor 13 is used for cluster-level monitoring and fault identification. When the temperature detection device of capacitor bank 12 detects that the temperature rise inside the bank is close to the set threshold, the corresponding fan 121 maintains or switches to high-speed operation and transmits the high-temperature signal to the control area through the end board interface to facilitate the implementation of cluster-level access and exit operation sequences at the device level. For example, the three operating states of fan 121 of capacitor bank 12 correspond one-to-one with the discharge current range. When the discharge current is less than or equal to about 50A, a single fan 121 can be used for low-speed operation. When it is in the range of about 50–150A, dual fans 121 can be used for rated speed operation. When it exceeds about 150A, dual fans 121 can be used for high-speed operation and trigger the high-temperature reporting process.
[0045] Furthermore, considering electromagnetic compatibility and personnel safety within the cabin, in this embodiment, a metal shielding component is installed on the inner wall of the cabin and connected to the grounding copper busbar at multiple points. The shielding component covers the main busbar cabinet and areas with dense wiring harnesses. Transparent inspection windows or line-of-sight markers are provided near the busbar and device units to facilitate quick verification of serial numbers, polarity, and fastening points during maintenance. An operating clearance is reserved in front of the device unit to allow the drawer-type device unit to be disassembled and installed without touching live parts. Exemplarily, the shielding component and the grounding copper busbar are connected by surface contact or multi-point overlap, and the grounding point and the main grounding point of the cabin form a single equipotential network.
[0046] like Figure 4 As shown, in some embodiments of this application, the positive and negative connections of the energy storage module 1 can extend to the junction position in the form of a main busbar. The positive connection structure 17 and the negative connection structure 18 are arranged in parallel in the installation area, and an isolation plate 19 is provided between them. Several insulating brackets 191 are fixed on the isolation plate 19. The insulating brackets 191 are connected to the structural mounting plate 16, which limits the height, spacing and safety electrical clearance of the structural mounting plate 16 relative to the busbar and the outer casing.
[0047] The "single-path parallel port device unit" of the parallel system integrates a current sensor 13, a current sharing resistor 14, and a contactor 15 in a fixed order on the same structural mounting plate 16. This order is consistent with the connection direction of the main busbar and cluster terminals. Through the structural features of "integration on the same board, fixed sequence, short path connection, and straight airflow," the following technical effects can be achieved in terms of cluster-level access, branch current sharing, heat dissipation consistency, and maintenance efficiency: First, the proximity of the detection and main circuit reduces parasitic inductance and sampling noise, improving the consistency of the parallel system; second, the arrangement of the current sharing resistor 14 and contactor 15 along the air duct places the heat-generating devices in the main airflow channel, enhancing heat exchange capacity and reducing the temperature rise gradient of the devices; third, drawer-type or side-insertion installation allows replacement of a single cluster device unit without disassembling adjacent branches, shortening the maintenance path and reducing the probability of misoperation. For example, the electrical connection of the device unit adopts a combination of bolts—copper busbars—copper braided straps; and as... Figure 3 As shown, the structural mounting plate 16 is made of heat-resistant insulating board and has a heat dissipation channel 161. A limiting structure 162 is provided on one side of the device unit. The current sensor 13, the current sharing resistor 14 and the contactor 15 are sequentially integrated on the structural mounting plate 16 along the direction of the heat dissipation channel 161 through the limiting structure 162.
[0048] Meanwhile, power conversion module 2 and energy management module 3 are logically and physically separated from the aforementioned parallel port device unit through terminal blocks and wiring harnesses; the module housing, cable tray shielding layer, main busbar and cabin grounding copper busbar are connected by short grounding wires or copper busbars to form a continuous grounding path, reducing high voltage. Inductive coupling and ground loop under certain conditions. For example, terminal blocks may be installed on the side wall of the control area, and the sampling and control harnesses are color-coded according to the number of clusters corresponding to the number of paths. External communication and monitoring interfaces pass through the cabin through sealed joints to maintain the cabin's protection level.
[0049] In some other embodiments of this application, to meet different power and capacity targets, the number of clusters connected in parallel and the number of clusters arranged within the cabin can be expanded or reduced using standardized interfaces. Since the parallel ports adopt a unified device unit structure, expansion or reduction only involves adjusting the correspondence between device units and clusters, without changing the electrical connection order and heat dissipation direction within the device unit. For example, in one type of cluster configuration, approximately 12 clusters can be connected in parallel, corresponding to a system equivalent capacitance of approximately 136.4F and a total energy storage of approximately 21.32kWh; in another type of cluster configuration, approximately 20 clusters can be connected in parallel, corresponding to a system that can be used for short-term high-power output scenarios of approximately 2.5MW and approximately 30s.
[0050] In summary, this system integrates current sensor 13, current sharing resistor 14, and contactor 15 onto the same carrier board in a fixed order by introducing standardized parallel port device units based on structural mounting plate 16 into energy storage module 1, forming a cluster-level independent access and current sharing control structure. The overall system adopts a multi-cluster double-layer capacitor series-parallel topology, combined with embedded fan 121, air duct 4, and metal shielding grounding structure, to achieve high power density, fast response, and stable heat dissipation. Power conversion module 2 and energy management module 3 are connected via short-path busbars and shielded wiring harnesses to ensure safety and balance under high voltage and high current conditions, ultimately meeting the requirements of simplified system structure, reasonable layout, safe operation, and increased power density.
[0051] Those skilled in the art will understand that the component names and connection relationships used in the above embodiments correspond one-to-one with the reference numerals in the accompanying drawings; the terms "set," "connect," and "link" are all interpreted broadly, including fixed connection, detachable connection, integral connection, mechanical connection, electrical connection, direct connection, or indirect connection via intermediate components; adjustments to the structural shape, plate thickness, fastening method, and material grade, without changing the component names and the fixed connection order of the device unit, are all considered conventional modifications of the same device structure. For example, the resistance value, rated and pulse power of the current sharing resistor 14, the number of poles and main contact parameters of the contactor 15, and the range and bandwidth of the current sensor 13 can be selected according to the target power level and branch current distribution, while maintaining their relative positions and airflow direction within the device unit.
[0052] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0053] The above-disclosed embodiments are merely preferred embodiments of the present utility model, but the present utility model is not limited thereto. Any non-creative changes that can be conceived by those skilled in the art, as well as any improvements and modifications made without departing from the principle of the present utility model, should fall within the protection scope of the present utility model.
Claims
1. A high power density energy storage system based on double-layer capacitors, characterized in that, include: An energy storage module includes multiple capacitor clusters connected in parallel. Each capacitor cluster includes multiple capacitor boxes. Each capacitor box contains multiple double-layer capacitor cells connected in series and / or in parallel. Each parallel port of the energy storage module is connected in sequence to a current sensor, a current sharing resistor, and a contactor. The current sensor, the current sharing resistor, and the contactor are all mounted on the same structural mounting plate. A power conversion module is electrically connected to the energy storage module; An energy management module is electrically connected to the energy storage module.
2. The high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The structural mounting plate is an insulating plate and is provided with a heat dissipation channel and a limiting structure. The current sensor, the current sharing resistor and the contactor are installed sequentially along the direction of the heat dissipation channel.
3. A high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The energy storage module includes a positive electrode connection structure and a negative electrode connection structure. Each of the parallel ports is fixed to the lateral mounting area of the positive electrode connection structure and the negative electrode connection structure, respectively. An isolation plate is provided between the lateral mounting areas. An insulating bracket is provided on the isolation plate. The insulating bracket is fixedly connected to the structural mounting plate.
4. A high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The current sharing resistor is connected to the current sensor via a bolt-copper busbar connection structure. A copper braided strip is provided between the output end of the contactor and the input end of the capacitor cluster. The copper braided strip is fixed to the connection structure by an independent clamp.
5. A high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The capacitor box has a metal shell, and a fan is provided in the width direction of the box. The fan is embedded in the mounting hole, and a metal pressure ring is provided on the outside of the fan. An elastic gasket is provided between the fan and the box.
6. A high power density energy storage system based on double-layer capacitors as described in claim 5, characterized in that, The end plate of the capacitor box is equipped with a temperature sensor and a current sensor. The temperature sensor and the current sensor are connected to an aviation socket via a wiring harness. The aviation socket is installed in a unified interface area of the end plate.
7. A high power density energy storage system based on double-layer capacitors as described in claim 5, characterized in that, The energy storage module is located inside the container-type cabin, and the capacitor clusters are arranged symmetrically along the longitudinal direction inside the cabin. The structural mounting plate is located in the middle of the cabin, and the power conversion module is located at one end of the cabin.
8. A high power density energy storage system based on double-layer capacitors as described in claim 7, characterized in that, The bottom of the cabin is provided with an air guide channel, and the fans of each capacitor box are arranged facing the air guide channel. The air guide channel is connected to the air inlet of the cabin, and the air inlet, the fans and the exhaust port of the cabin form a through airflow path.
9. A high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The energy management module is provided with a control channel, each control channel corresponding to one of the capacitor clusters. The output terminal of the control channel is connected to the control terminal of each contactor, and the sampling harness of the control channel is connected to the signal terminal of the current sensor.
10. A high power density energy storage system based on double-layer capacitors as described in claim 1, characterized in that, The inner wall of the energy storage module's outer casing is provided with a grounding copper busbar and a metal shielding mesh. The grounding copper busbar is electrically connected to the casing of the power conversion module, and the metal shielding mesh covers the installation area of each of the parallel ports.