Thermal management system with heat exchanger blending valve

• US 10,427,491 B2
• Filed: 04/28/2012
• Issued: 10/01/2019
• Est. Priority Date: 09/28/2011
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Inc.
• Inventors: Johnston, Vincent George, O'Donnell, Curt Raymond, de Bruijn, Wulfer Adrijan, Elkenkamp, Marco
• Primary Examiner(s): Jules, Frantz F
• Assistant Examiner(s): Tadesse, Martha
• Application Number:
  US13/459,112
• Publication Number:
  US 20130074525A1
• Time in Patent Office: 2,712 Days
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 1/00385 for vehicles having an electrical drive, e.g. hybrid or fuel cell
• CPC Class Codes: B60H 1/143 the heat being derived from cooling an electric component, e.g. electric motors, electric circuits, fuel cells or batteries
• CPC Class Codes: B60H 1/323 characterised by comprising auxiliary or multiple systems, e.g. plurality of evaporators, or by involving auxiliary cooling devices
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow

Abstract

A thermal management system and method of use are provided, the system including a heat exchanger, a refrigeration system, a coolant loop thermally coupled to the heat exchanger, and a by-pass valve that regulates the amount of coolant within the coolant loop that either passes through the heat exchanger or is diverted away from the heat exchanger. The coolant loop is thermally coupled to the battery pack of an electric vehicle.

Claims

1. A method of regulating thermal dissipation of a battery pack of a vehicle, the vehicle including a coolant loop coupled to and in thermal communication with the battery pack and a heat exchanger, a refrigeration system coupled to and in thermal communication with the heat exchanger and an evaporator, a coolant within the coolant loop, and a by-pass valve coupled to the coolant loop to regulate a first amount of the coolant that flows through the heat exchanger and a second amount of the coolant that is diverted around the heat exchanger, the method comprising:

determining a first temperature corresponding to the coolant;

comparing the first temperature to a first preset temperature range;

adjusting the by-pass valve at a first time based on comparing the first temperature to the first preset temperature range;

comparing a second temperature corresponding to an evaporator air outlet temperature before adjusting the by-pass valve at the first time to a third temperature corresponding to the evaporator air outlet temperature after adjusting the by-pass valve at the first time; and

adjusting the by-pass valve at a second time after the first time to decrease the first amount of the coolant that flows through the heat exchanger and increase the second amount of the coolant that is diverted around the heat exchanger if the second temperature and third temperature are not within a preset range.

2. The method of claim 1, further comprising monitoring a vehicle cabin temperature and adjusting an HVAC output based on the vehicle cabin temperature.

3. The method of claim 1, wherein monitoring a vehicle cabin temperature uses a cabin temperature sensor.

4. The method of claim 1, further comprising the step of comparing a fourth temperature corresponding to the evaporator air outlet temperature before adjusting the by-pass valve at the second time to a fifth temperature corresponding to the evaporator air outlet temperature after adjusting the by-pass valve at the second time.

5. The method of claim 1, wherein the refrigeration system is comprised of a gas-phase refrigerant compression system including a refrigerant, a refrigerant compressor, a condenser, and at least one thermal expansion valve.

6. The method of claim 1, wherein the step of determining the first temperature corresponding to the coolant, occurs after the coolant exists the heat exchanger and before the battery pack.

7. The method of claim 1, wherein a heater is thermally coupled to the coolant loop between the heat exchanger and the battery pack.

8. The method of claim 1, wherein the coolant loop further comprises a coolant reservoir.

9. A thermal management system comprising:

a coolant loop coupled to and in thermal communication with a battery pack and a heat exchanger;

a refrigeration system coupled to and in thermal communication with the heat exchanger and an evaporator;

a coolant with the coolant loop;

a by-pass valve coupled to the coolant loop to regulate a first amount of the coolant that flows through the heat exchanger and a second amount of the coolant that is diverted around the heat exchanger;

a temperature sensor; and

a controller operable to;

determine a first temperature corresponding to the coolant using the temperature sensor;

compare the first temperature to a first preset temperature range;

adjust the by-pass valve at a first time based on the first temperature and the first preset temperature range;

compare a second temperature corresponding to an evaporator air outlet temperature before the first time to a third temperature corresponding to the evaporator air outlet temperature after the first time; and

adjust the by-pass valve at a second time after the first time to decrease the first amount of the coolant that flows through the heat exchanger and increase the second amount of the coolant that is diverted around the heat exchanger if the second temperature and third temperature are not within a preset range.

10. The thermal management system of claim 9, further comprising a cabin temperature sensor and wherein the controller is further operable to monitor a vehicle cabin temperature using the cabin temperature sensor and adjust an HVAC output based on the vehicle cabin temperature.

11. The thermal management system of claim 9, wherein the controller is further operable to compare a fourth temperature corresponding to the evaporator air outlet temperature before the second time to a fifth temperature corresponding to the evaporator air outlet temperature after the second time.

12. The thermal management system of claim 9, wherein the refrigeration system is comprised of a gas-phase refrigerant compression system including a refrigerant, a refrigerant compressor, a condenser, and at least one thermal expansion valve.

13. The thermal management system of claim 9, wherein the temperature sensor is located after the heat exchanger and before the battery pack.

14. The thermal management system of claim 9, wherein a heater is thermally coupled to the coolant loop between the heat exchanger and the battery pack.

15. The thermal management system of claim 9, wherein the coolant loop further comprises a coolant reservoir.