Portable Power Station Battery Module Thermal Management
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Solution Overview
Problem
Existing portable power stations lack efficient charging mechanisms that allow for fast-charging and thermal management of battery modules, limiting their operational capacity and reliability, especially in situations where urgent power demands arise.
Innovation Solution
A portable power station equipped with a battery management system (BMS) that selectively connects and disconnects battery modules from charging and load circuits, allowing for intelligent charging, thermal management, and efficient power distribution, including the use of mains electricity to bypass battery modules when necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If battery modules are charged using conventional charging devices, then charging is performed safely, but charging speed is limited and fast-charging capability is not achieved
Solution Approach 1:
The battery system is divided into multiple independently controllable battery modules, each with its own charging control. The BMS can selectively charge individual modules or groups of modules, enabling parallel charging paths that increase overall charging speed while maintaining safety through modular isolation.
Solution Approach 2:
The charging system dynamically adjusts charging parameters and selectively connects/disconnects battery modules based on real-time conditions. The BMS monitors module states and dynamically reconfigures charging circuits to optimize charging speed while preventing overheating and ensuring safety through adaptive control.
2Productivity
If all battery modules are connected to charging current, then charging efficiency is maximized, but thermal management becomes difficult and overheating risk increases
Solution Approach 1:
The battery system is segmented into multiple independently controllable modules. The BMS can selectively connect or disconnect individual modules from charging based on their thermal state, allowing continued charging of cooler modules while thermally managing hotter ones, thus maintaining overall charging efficiency while preventing system-wide overheating.
Solution Approach 2:
Different thermal management strategies are applied to different battery modules based on their individual temperature conditions. The BMS monitors each module's temperature and applies localized charging control, enabling some modules to charge at higher rates while others receive reduced or no charging, optimizing both efficiency and thermal safety.
3Duration of action of stationary object
If battery modules are operated continuously without selective disconnection, then power supply is maintained, but battery life is reduced due to uneven depletion and thermal stress
Solution Approach 1:
The battery system is divided into multiple independently controllable modules. The BMS monitors the state of charge and health of each module individually, enabling selective disconnection and reconnection of modules. This allows the system to rotate usage among modules, distributing wear and thermal stress evenly across all modules, thereby extending overall battery system life while maintaining continuous power supply.
Solution Approach 2:
The BMS periodically monitors and rotates the usage of different battery modules. Modules are cycled through charging, discharging, and rest periods in a rotating fashion, ensuring that no single module is over-stressed. This periodic rotation of module usage distributes cumulative stress evenly, extending battery life while maintaining continuous operational capability.
Data Source
AI summary
A method of operating a portable power station including a plurality of battery modules and a battery management system operably connected to the plurality of battery modules, includes supplying at least one first battery module of the plurality of battery modules with a charging current generated from mains electricity operably connected to an AC input connection of the portable power station using the battery management system, and electrically connecting at least one second battery module of the plurality of battery modules to a load to supply the load with an operating current using the battery management system. The method further includes electrically disconnecting at least one third battery module of the plurality of battery modules from the charging current and the load to manage thermally the at least one third battery module using the battery management system.