Modular Thermal Management Layout for Higher-Density Energy Storage
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Solution Overview
Problem
The conventional energy storage system's thermal management unit has limited flexibility and contour dimensions, resulting in low overall power density due to its one-piece design, which restricts the spatial layout and efficiency of the system.
Innovation Solution
The energy storage system divides the thermal management unit into separate liquid cooling, air-cooling heat dissipation, and liquid cooling management modules, allowing for a split arrangement within the structural cabinet, optimizing space utilization and increasing power density by enabling more battery modules in a limited space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece thermal management unit is used, then the structure is simple, but the flexibility of arrangement and spatial layout is limited, resulting in low power density
Solution Approach 1:
The thermal management unit is divided into multiple independent modules: liquid cooling modules (including liquid cooling pumps and heat exchangers), air cooling modules (including air cooling fans and heat dissipation structures), and control modules. These modules are separately arranged in the structural cabinet, allowing flexible spatial configuration that improves power density while maintaining manageable system complexity
2Ease of manufacture
If a one-piece thermal management unit is used, then the manufacturing process is simple, but the contour dimensions cannot meet customized requirements, limiting arrangement flexibility
Solution Approach 1:
The thermal management unit is segmented into standardized modular components (liquid cooling modules, air cooling modules, control modules) that can be independently manufactured and then assembled in various configurations. This modularity enables customization of contour dimensions and arrangement plans while keeping each module's manufacturing process simple and standardized
Solution Approach 2:
The modular design creates universal interface standards that allow the same type of thermal management modules to be used across different energy storage system configurations. The modules can be adapted to various contour dimensions and arrangement requirements through different组合 combinations, maintaining ease of manufacture through standardized production
3Device complexity
If the thermal management unit is arranged in a fixed configuration, then the layout is simple, but the overall spatial layout cannot be effectively improved, resulting in low power density
Solution Approach 1:
By segmenting the thermal management unit into independent modules (liquid cooling, air cooling, control), the system enables flexible spatial arrangement where modules can be positioned to optimize space utilization. The modular components can be distributed throughout the structural cabinet rather than occupying a single fixed location, improving overall space efficiency and power density
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 modular approach enhances the integration level of the energy storage system, improving power density by effectively utilizing available space and facilitating better thermal management through independent module configurations.
Implementation Method 1
a liquid cooling unit... used for cooling the battery module
Implementation Method 2
an air-cooling heat dissipation module... arranged at a top of the structural cabinet
Implementation Method 3
a liquid cooling management module used for managing the distribution of a cooling liquid of the liquid cooling unit
Data Source
Figure 1~2
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Figure 5~6
AI summary
An energy storage system is provided, which includes a structural cabinet, and a battery module and a thermal management unit mounted in the structural cabinet. The thermal management unit includes a liquid cooling unit, an air-cooling heat dissipation module, and a liquid cooling management module for managing the distribution of a cooling liquid of the liquid cooling unit. The liquid cooling unit, the air-cooling heat dissipation module, and the liquid cooling management module are separately mounted and arranged in a split manner in the structural cabinet. Compared with the conventional one-piece thermal management unit, the energy storage system is divided into three functional modules, the size of each functional module is greatly reduced, which facilitates the arrangement and the full utilization of available space of the structural cabinet, and ultimately facilitates the improvement of the integration level of the entire energy storage system, in this way, more battery modules can be arranged in a limited space, that is, the overall power density of the entire energy storage system is improved.