Shared Cooling Loop for Battery Packs and PCS Heat Reuse
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Solution Overview
Problem
Existing energy storage systems with separate liquid-cooling systems for power conversion systems and battery packs result in large size, high weight, high cost, and low energy efficiency.
Innovation Solution
A thermal management apparatus with a shared cooling module for a battery pack group and a power conversion system group, where the power conversion system is located downstream, allowing for adjustable flow rates and integrated air-cooling and refrigerant units to optimize cooling and heating based on temperature tolerance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate liquid-cooling systems are provided for power conversion system and battery pack, then thermal management reliability is improved, but device size increases
Solution Approach 1:
The patent merges two separate liquid-cooling systems into a single integrated cooling system that serves both the power conversion system and battery pack. The cooling pump, cooling medium circulation path, and temperature control mechanisms are consolidated into one system, reducing device size while maintaining thermal management reliability through centralized monitoring and control.
Solution Approach 2:
The integrated cooling system is designed to perform multiple functions simultaneously - cooling the power conversion system components and cooling the battery pack. The system uses a single cooling medium circulation loop that can be distributed to multiple heat sources, making the cooling apparatus universal and multi-functional rather than dedicated to a single component.
2Reliability
If two separate liquid-cooling systems are provided for power conversion system and battery pack, then thermal management effectiveness is improved, but system weight increases
Solution Approach 1:
The patent combines two separate cooling systems into one integrated system, consolidating the cooling pump, piping, and control mechanisms. This merging eliminates duplicate components and reduces overall system weight while maintaining the thermal management effectiveness needed for both the power conversion system and battery pack.
Solution Approach 2:
The integrated cooling system is designed as a universal system that can cool multiple different components (power conversion system and battery pack) using a single apparatus. This multi-functionality eliminates the need for separate dedicated cooling systems, thereby reducing total system weight.
3Reliability
If two separate liquid-cooling systems are provided for power conversion system and battery pack, then cooling coverage is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges two separate cooling systems into a single integrated system, reducing the total number of components that need to be manufactured, assembled, and tested. This consolidation lowers manufacturing costs through economies of scale, reduced assembly complexity, and simplified supply chain requirements while maintaining comprehensive cooling coverage.
Solution Approach 2:
The integrated cooling system is designed to provide universal cooling capability for multiple components, which simplifies manufacturing by using a single standardized system rather than multiple specialized systems. This reduces tooling costs, assembly procedures, and quality control complexity.
4Measurement precision
If two separate liquid-cooling systems are provided for power conversion system and battery pack, then thermal control precision is improved, but energy efficiency ratio decreases
Solution Approach 1:
The patent applies the blessing in disguise principle by converting the heat generated by the power conversion system (which would be waste heat) into a useful resource for preheating the battery pack. The cooling medium absorbs heat from the power conversion system and uses it to warm the battery pack, especially beneficial in cold environments. This reduces the energy required for battery heating while maintaining thermal control precision.
Solution Approach 2:
The integrated cooling system merges the thermal management of the power conversion system and battery pack into a single coordinated system. This allows for heat exchange between the two components, improving overall energy efficiency by reducing the need for separate heating and cooling operations while maintaining precise thermal control through centralized monitoring and adjustment.
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
Reduces size, weight, and cost while improving energy efficiency by utilizing the power conversion system's heat to preheat the battery pack, minimizing energy consumption, and enhancing thermal management accuracy.
Implementation Method 1
a cooling module configured to provide a cooling medium to cool the heat exchange module
Implementation Method 2
the power conversion system heats the cooling medium, and the heated cooling medium heats the battery pack group
Data Source
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AI summary
Disclosed in the present invention are an energy storage system and a thermal management apparatus thereof. The thermal management apparatus of the energy storage system comprises: at least one heat exchange module, and a cooling module, which is used for providing a cooling medium and cooling the heat exchange module, wherein the heat exchange module comprises a battery pack group and a power conversion system group, which are connected in series; and in a cooling path, the power conversion system group is located downstream of the battery pack group. The thermal management apparatus of the energy storage system effectively reduces the size, weight and cost of the entire thermal management apparatus, improves the cooling effect, and also increases the energy efficiency ratio; and when a battery pack group needs to be heated, a cooling medium is heated during the process of same flowing through the power conversion system group, such that the energy consumption required for heating the battery pack group is reduced, and the energy efficiency ratio is further increased.