The present invention relates to an energy storage system, particularly to a battery system, and more particularly to a valve-regulated type lead-acid battery system, that is capable of preventing self from overheating. The present invention further relates to a method for preventing overheat of the energy storage system.
As an energy storage system, a battery and a system thereof are means for storing electric energy so as to restore the energy when needed. Typically, a cell includes two electrodes arranged in the electrolyte, i.e. an anode and a cathode. As known in related technologies, an electrical apparatus to be operated is usually connected across the cathode and anode at two ends to obtain electrical energy from the cell.
Invented in 1859, the lead acid battery has more than 150 years of history. It still remains to be one of the most popular batteries nowadays and has been widely used in technical fields such as electricity, communication, railway, petroleum, aviation, irrigation, coal, geology, medical care, rail transportation, national defense facilities and so on.
A lead-acid battery as well as a system thereof is such a device that converts electrical energy into chemical energy for storage and then converts the chemical energy into electrical energy to be supplied to electrical apparatuses for use when needed. The cathode active substance in the lead-acid cell is PbO2, and the anode active substance is sponge-like lead (Pb), and the electrolyte is liquid H2SO4. The process of charging and discharging the lead-acid cell is achieved by electrochemical reactions. As shown in the following reaction equation, Pb (anode) and lead oxide (cathode) react with H2SO4 during the discharging process of the lead-acid cell to generate lead sulfate. The charging process exhibits a reverse reaction of the discharging process.
Cathode reaction: PbO2+4H++SO42−+2e−PbSO4+2H2O
Anode reaction: Pb+SO42−PbSO4+2e−
Overall reaction: Pbo2+Pb+2H2SO42PbSO4+2H2O
Currently, the lead acid battery is widely used all over the world with more than 50% of battery market share due to its reliability and low cost. Traditional lead-acid batteries are mostly used in small-scale and low-rate applications, such as those in auxiliary devices or back-up power, so the overheat and heat dissipation problems are not so noticeable, nor are there any particular solutions to these problems. However, with recent development of smart grid and the increasing amount of interest in renewable energy (e.g. wind power, solar energy and so on), the demand in large-scale energy storage system has never been more imperative. At present, lead-acid batteries have already been used in Uninterruptible Power Supplies (UPS). The emerging applications in technology pose new challenges to lead-acid batteries and other types of batteries. For example, overheating occurs in almost any large-scale applications that are usually of high rate and multi-cycle, which shortens the cycle life and sometimes even causes permanent damage to the batteries and especially to the lead acid batteries. Therefore, the thermal management technology is extremely important for the lead acid battery in large-scale applications in maintaining proper system health etc.
The conventional solution for overheating is to over-size the batteries, so that the relative discharge rate and the depth of discharge are smaller. But this, on the other hand, increases the total system cost tremendously.
The prior art lead-acid batteries are mainly classified into two types: flooded type and valve-regulated type. The heat dissipation problem is more severe in the valve-regulated type lead-acid batteries (VRLA batteries) than the flooded type lead-acid batteries because excess electrolyte in cells of the latter fills the three-dimensional space in the cells except for those occupied by the electrodes, thereby the thermal contact between internal members of the cells is enhanced. Gases are generated during charging and the gases remove heat from the cell via water loss and acid mist. In contrast, in a cell of a valve-regulated type lead-acid battery, the acid liquid is absorbed in saturation by a separator (e.g. absorptive glass fiber fabric), so there is no excess liquid electrolyte in the cell. The limited contact of the acid, separators and plates with the plastic case walls limits the heat transfer out of the cell because of the lack of a heat dissipation passage and therefore increases the operating temperature, which limits the cycle life of valve-regulated type lead-acid battery and thus their potential applications in large-scale.
Overheating of the valve-regulated type lead-acid battery, as a matter of fact, is mainly caused by heat release from chemical reactions and ohmic heat (resistance heat generated from grid plate, bus-bar, separator, terminal post and etc. of the cell due to their resistance). The chemical reaction is very intense, for example the oxygen recombination reaction during the charging process is exothermic with an enthalpy of 68.32 kcal/mol. When the temperature of the positive plate is increased, the rate of oxygen evolution increases rapidly and a bigger portion of oxygen recombines at the negative plate, giving rise of a further temperature rise there. The cell temperature can easily exceed 80° C. and the cell can go into ‘thermal runaway’ thus forcing the cell temperature even higher. In some instances thermal runaway can lead to softening or even burning of the polymer case. The ohmic heat (I2R) also comes from the inside of the cell. The shell of a cell is generally made of polymer materials, and the heat dissipation contact area is very limited through metallic components of a cell such as grid plate, bus-bar and terminal post, thus heat within the interior of the cell is not easy to be dissipated.
In high rate applications of a battery, according to Arrhenius Equation, reaction rate of any chemical reaction is generally increased to as much as two times with the increase of temperature by 10 degrees. This principle is applicable to product life approximation based on failure mode (chemical reaction, such as corrosion, oxygen recombination reaction and so on), in particular applicable to the life approximation of a lead-acid battery. According to IEEE Recommended practice for Maintenance, Testing and Replacement of Vented Lead-acid Batteries for Stationary Applications, IEEE power engineering society, IEEE std 450™-2002, 3 Apr., 2003, it is calculated that the life of a lead acid battery is shortened by 50% when the working temperature of the lead acid battery increases from 25 to 33.
In order to prevent overheating of a battery and its system and prolong life thereof, various solutions have been proposed at present for thermal control or thermal management during operation of the battery, wherein most of the solutions focus on thermal control or thermal management on a side or bottom of a cell, e.g. U.S. Pat. No. 7,967,256, U.S. Pat. No. 7,531,270, U.S. Pat. No. 6,533,031, U.S. Pat. No. 6,512,347, U.S. Pat. No. 6,407,553, U.S. Pat. No. 5,695,891, U.S. Pat. No. 5,385,793, U.S. Pat. No. 5,356,735, U.S. Pat. No. 4,913,985. These modified designs relate to built-in arrangements which are also technically challenging in maintenance and heat dissipation. As stated above, heat generated in a valve-regulated type lead-acid battery is difficult to be dissipated to the outside, so heat dissipation effect is not quite satisfactory when the prior art thermal control or thermal management method is applied to the valve-regulated type lead-acid battery.
U.S. Pat. No. 7,651,811 discloses a traction battery, comprising a ventilated plastic cover for covering an electrical connection strap, wherein a fan forces air to flow through the electrical connection strap of the battery to reduce the operating temperature of the battery. U.S. Pat. No. 3,834,945 discloses to use water to cool terminal posts and inter-cell electrical connection strap for a traction battery. No matter cooling is performed by air or water, improvement in heat exchange is not satisfactory due to the limited heat-exchanging area of the electrical connection strap. In addition, the design of a structure having a function of cooling the battery, e.g. the added water cooling system or a fan, etc., makes the entire structure of the battery more complex and the volume thereof large and heavy, which results in a complicated maintenance and installation process.
The above documents are incorporated herein in entirety by reference.
Therefore, the present invention is aimed to improve one or more defects in the prior art.
The objective of the present invention is to provide an energy storage system preventing self from overheating, having excellent heat dissipating effect to prevent excessively high working temperature during high rate charging and discharging so as to prolong life of the energy storage system.
The above objective is achieved by an energy storage system having the following features. The energy storage system, in particular a battery system, and more particularly a valve-regulated type lead-acid battery system comprising at least one energy storage unit (cell) each having two terminal posts extending outwards from the interior thereof; when there are at least two energy storage units, electrical connection therebetween is achieved by electrical connection elements that bridge the terminal posts of different energy storage units, and at least one of the terminal posts and/or the electrical connection elements is in thermal connection with a heat transfer surface enlarging structure made of solid heat conductive materials. The heat transfer surface enlarging structure serves to increase an effective heat dissipating area of an element to be cooled, such as the terminal posts and/or the electrical connection elements, so cooling effect is enhanced to effectively prevent overheat of the energy storage system.
Preferably, the heat transfer surface enlarging structure includes a plurality of fins which may be arranged in a linear form, a radial form, a two or three-dimensional web-shaped form or a honeycomb-shaped form. The fins can be mounted fixedly or removably.
The heat transfer surface enlarging structure of fin type can be designed and mounted simply, maintained easily and produce particularly remarkable effect of improving heat dissipation.
In an embodiment of the invention, the heat transfer surface enlarging structure has a radial fan-shaped form. Preferably, the radial fan shaped heat transfer surface enlarging structure is in indirect thermal connection with the terminal posts and/or the electrical connection elements by means of a heat pipe or a heat pipe through which cooling medium flows. The heat pipe, in the case of limited installation space, transfers heat to a larger available space from the terminal posts and/or the electrical connection elements to increase effective heat dissipating area, and moreover the cooling medium circulating in the heat pipe can absorb part of the heat rapidly, so that the energy storage system may produce better cooling effect. Therefore, the heat transfer surface enlarging structure thus configured exhibits better mounting flexibility and makes it possible to increase effective heat dissipating area and cooling speed more considerably and to further improve heat dissipating and cooling effects.
In another embodiment of the invention, the solid heat conductive materials are metallic materials, such as copper, aluminum, iron and alloy thereof. Because of the higher thermal conductivity of the metallic materials, the heat transfer surface enlarging structure made of the metallic materials facilitates transfer of heat from the energy storage system to be cooled and thus facilitates reducing working temperature thereof.
According to one aspect of the invention, a method for preventing overheat of an energy storage system e.g. a battery system, in particular a valve-regulated type lead-acid battery system, comprising at least one energy storage unit each having two terminal posts extending outwards from the interior; when there are at least two energy storage units, electrical connection therebetween is achieved by electrical connection elements that bridge the terminal posts of different energy storage units, the method comprising thermally connecting a heat transfer surface enlarging structure made of solid heat conductive materials to at least one of the terminal posts and/or the electrical connection elements.
In the energy storage system for overheat prevention and the method for preventing overheat of the energy storage system according to the invention, because the terminal posts and/or the electrical connection elements of the energy storage system are in thermal connection with the heat transfer surface enlarging structure, the effective heat dissipating area of the terminal posts and/or the electrical connection elements is enlarged, and heat dissipation capacity thereof is enhanced, and further the working temperature of the energy storage system is reduced and the life thereof is prolonged.
The drawings constitute a part of the description show the exemplary embodiments of the invention and are intended to construe the principle of the invention with the description, in which,
a-3e show different embodiments of the heat transfer surface enlarging structure of the invention in thermal connection with the electrical connection strap (electrical connection element);
A traditional electrical connection strap 13, as shown in
a-3e show different embodiments of a heat transfer surface enlarging structure 130 of the invention in thermal connection with the electrical connection strap 13. The heat transfer surface enlarging structure 130 includes a plurality of fins 1301 in thermal connection with an exposed surface of the electrical connection strap 13. The plurality of fins in the embodiment illustrated in
Thanks to the fins 1301 in the present invention, heat exchanging surface area of the terminal posts and/or the electrical connection straps is increased so that the heat exchange between the terminal posts and/or the electrical connection straps 13 and the ambient environment is greatly enhanced, thus facilitating the decrease of temperature of the terminal posts and/or the electrical connection straps. Because the electrical connection strap and the terminal post are also in thermal connection, the terminal post, which primarily functions for electrical conduction though, also serves to conduct heat from the interior of a battery unit to the outside due to its distinctiveness of position and material. Therefore, decrease in temperature of the electrical connection strap is helpful in conducting heat from the interior of a battery unit to the outside to reduce working temperature thereof.
In addition to the means of increasing the effective heat exchange surface of the electrical connection strap 13, in order to accelerate the speed of conducting heat from the interior of a battery unit to the outside, a fin may be provided on part of the surface of the terminal post 101, 102 exposed externally to the battery. In a heat transfer surface enlarging structure 110 shown in
The technical term “thermal connection” herein refers to a direct or indirect thermal contact between the heat transfer surface enlarging structure e.g. a fin, and an electrical connection strap (electrical connection element) and/or a terminal post to create a heat flow channel for transferring heat flow.
The arrangements of the fins in the heat transfer surface enlarging structure shown in
The fins may be fixed to the connection strap or the terminal post permanently or connected thereto removably. For instance, as shown in
In the event of limited installation space, a heat pipe or a heat pipe for circulating cooling medium therethrough may be taken into consideration to transfer heat from an electrical connection strap or a terminal post to a heat dissipation structure and/or circulating cooling medium arranged in available space to dissipate heat. In a heat dissipation structure 140 shown in
More preferably, the circulating cooling medium is allowed to flow through the heat pipe to absorb heat from the wall of the heat pipe. In this case, heat dissipation can be achieved simultaneously by two means, i.e. the plurality of fins of the radial fan-shaped heat transfer surface enlarging structure and the circulating cooling medium, so that the energy storage system is cooled rapidly and produces better cooling effect.
Preferably, the heat transfer surface enlarging structure, e.g. the fins or the radial fan-shaped heat transfer surface enlarging structure, may be made of a solid heat conductive material of excellent heat conductivity, .e.g. metallic materials. Preferably, the metallic materials may be selected from copper, aluminum, iron and alloy thereof.
The heat transfer surface enlarging structure in the present invention is not limited to the above fin structure or the radial fan-shaped heat transfer surface enlarging structure. For example, the heat transfer surface enlarging structure may also be a structure in a concave-convex configuration formed on the electrical connection strap or the terminal post, e.g. a groove, a pit or a bulge. The structure in a concave-convex configuration may be distributed over the exposed surface of the electrical connection strap or the terminal post in a certain manner or pattern, and also serves to increase available heat exchange area, and thus improves cooling or heat dissipation of the electrical connection strap or the terminal post.
Preferably, on an electrical connection strap or terminal post of a battery unit (an energy storage unit) at the center of the energy storage system, one or more heat transfer surface enlarging structures of the present invention are arranged, e.g. a fin structure or a radial fan-shaped heat transfer surface enlarging structure to enable substantially uniform working temperature of the battery units in different areas of the battery system so as to reduce heat accumulation of the system and decrease replacement or maintenance frequency of components of the battery system, thereby prolong life of the battery and its system.
In order to further enhance cooling effect of the electrical connection strap or the terminal post, the heat transfer surface enlarging structure according to the present invention may be used in combination with other conventional technical means of heat exchange enhancement. For example, a ventilation channel (hole) and a fan may be additionally provided on a transparent plastic cover of the battery for covering the electrical connection strap or the terminal post, to force air to flow rapidly through the heat transfer surface enlarging structure disposed on the electrical connection strap or the terminal post, thereby achieving the objective of improving heat transfer.
A flat electrical connection strap is taken as an example below in order to compare heat dissipation capacity (heat accumulation capacity) between a traditional electrical connection strap and an electrical connection strap in thermal connection with the heat transfer surface enlarging structure of the invention. In order to simulate temperature variation of different electrical connection straps that have absorbed equivalent amount of heat, first a fixed heat source is provided, and an equivalent amount of heat flow (the power of the heat source is 200 W) is allowed to flow through the traditional electrical connection strap and the electrical connection strap in thermal connection with the heat transfer surface enlarging structure of the invention; heat dissipation is performed at room temperature and surface areas of the electrical connection straps are measured in real time by means of thermoelectric couples.
As shown in
As shown in
As shown in
It is found from these tests that the electrical connection strap in thermal connection with the heat transfer surface enlarging structure of the invention has a surface temperature significantly lower than the traditional electrical connection strap, which means that the former has greater heat dissipation capacity than the latter.
In addition, a test is performed to compare a battery having an electrical connection strap in thermal connection with the radial fan-shaped heat transfer surface enlarging structure illustrated in
It is necessary to note that because the resistance of the electrical connection strap (electrical connection element) or terminal post itself is extremely small and the heat transfer surface enlarging structure is usually made of a material of high electrical conductivity, change in resistance heat of the electrical connection strap and/or of the terminal post is negligible in the case of being in thermal connection with the heat transfer surface enlarging structure.
Although the battery system illustrated in the above embodiments has a plurality of battery units (energy storage units), those skilled in the art should envisage that the heat transfer surface enlarging structure of the invention can be applied to a battery system having one battery unit (energy storage unit).
The above depiction is only preferred embodiments of the present invention and is not taken as limiting or restricting this invention since various modifications and variations may be made to the energy storage system of the invention without departing from the scope of the present invention through the exercise of those skilled in the art. Other embodiments may be obtained on the basis of disclosure in the description. The description and embodiments shall be considered exemplary only and the true scope of the invention is defined by the annexed claims and equivalents thereof.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/CN2012/074436 | 4/20/2012 | WO | 00 | 3/30/2015 |