AC Battery Pack with Integrated Cooling and Power Conversion
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Solution Overview
Problem
Conventional electrically powered transport refrigeration units face challenges with centralized power conversion units that occupy large space, produce high harmonic output waveforms, and require big sine filters, making them inefficient and space-intensive.
Innovation Solution
A transport refrigeration unit utilizing an AC battery pack with three phase groups of battery modules, each configured to provide AC electricity shaped as a stair step sine wave, along with a coolant circulation system to manage heat, and battery management modules for efficient power conversion and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a centralized power conversion unit is used, then power conversion is simplified, but the device occupies large space and produces high harmonic output waveforms
Solution Approach 1:
The patent divides the battery pack into multiple modular units, each containing battery cells and integrated power conversion electronics. This segmentation eliminates the need for a large centralized power conversion unit, reducing overall device volume while distributing power conversion functions across multiple smaller modules.
Solution Approach 2:
The patent combines battery cells and power conversion electronics into integrated modules, merging previously separate components (battery storage and power conversion) into a single compact unit. This integration reduces the total volume occupied by eliminating the need for separate centralized power conversion equipment and associated filtering components.
2Device complexity
If a centralized power conversion unit is used, then power conversion is simplified, but big sine filters are required occupying additional space
Solution Approach 1:
The patent segments the power conversion function across multiple distributed inverters within modular units, eliminating the need for a single large sine filter. Each inverter handles a portion of the power conversion, allowing for smaller, more efficient filtering that reduces total filter area and eliminates high harmonic output waveforms through distributed processing.
3Quantity of substance
If traditional AC battery pack configuration is used, then power storage is achieved, but space efficiency is reduced and cooling integration is difficult
Solution Approach 1:
The patent merges battery cells with power conversion electronics and cooling systems into integrated modular units. This consolidation maintains full electricity storage capacity while reducing total volume by eliminating separate compartments and interconnections for battery racks, power conversion equipment, and cooling infrastructure.
Solution Approach 2:
The modular units serve multiple functions simultaneously: energy storage, power conversion, and thermal management. Each module acts as a self-contained system that performs all three functions, eliminating the need for separate dedicated components and reducing overall system volume while maintaining full storage capacity.
4Device complexity
If centralized power conversion is used, then system structure is simplified, but cooling integration becomes difficult
Solution Approach 1:
The patent segments the system into modular units with integrated cooling, where each module manages its own thermal requirements locally. This segmentation enables straightforward cooling integration through standardized interfaces while maintaining simplified overall system architecture through modular scalability.
Solution Approach 2:
The patent combines power conversion electronics and cooling systems into integrated modules, merging thermal management functions directly with power conversion components. This integration simplifies cooling system design by eliminating the need for complex external cooling infrastructure while maintaining ease of operation through standardized modular interfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces the need for large sine filters, optimizes space usage, and enhances the efficiency of power conversion and distribution, providing a more compact and effective electrically driven refrigeration system.
Implementation Method 1
a DC-to-AC inverter configured to convert the DC electricity to the AC electricity
Implementation Method 2
a coolant circulation system in thermal communication with the battery modules, the coolant circulation system configured to remove heat from the battery modules
Implementation Method 3
The coolant circulation system is configured to remove heat from the battery modules using coolant from the transport refrigeration unit
Data Source
Figure 1
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AI summary
A transport refrigeration unit 22 is configured to provide conditioned air to a refrigerated cargo space 119 and includes: an AC battery pack 400 configured to store and convert DC electricity to AC electricity and provide the AC electricity to power the transport refrigeration unit 22 as three phase electrical power, the AC battery pack 400 includes: a first phase group 410 including a first plurality of battery modules 440, the first phase group 410 being configured to provide the AC electricity in a first phase; a second phase group 420 including a second plurality of battery modules 440, the second phase group 420 being configured to provide the AC electricity in a second phase; and a third phase group 430 including a third plurality of battery modules 440, the third phase group 430 being configured to provide the AC electricity in a third phase. The first phase, the second phase, and the third phase are each shaped as a stair step sine wave.