Methods and apparatus for thermal management of vehicle systems and components

• US 20040118142A1
• Filed: 07/11/2003
• Published: 06/24/2004
• Est. Priority Date: 12/20/2002
• Status: Active Grant

• Current Assignee: UT-Battelle LLC
• Original Assignee: UT-Battelle LLC
• Inventors: Adams, Donald Joe, Marlino, Laura D., Ayers, Curtis W., Hsu, John Sheungchun, Coomer, Chester, Su, Gui-Jia
• Granted Patent: US 6,772,603 B2
• Time in Patent Office: Days
• US Class Current: 62/259.2
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 2001/003 with means for cooling the electrical propulsion units
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: F25B 31/008 by injecting a liquid
• CPC Class Codes: H01L 23/44 the complete device being wholly immersed in a fluid other than air H01L23/427 takes precedence
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00

Abstract

This disclosure provides an integrated thermal management system and methods for managing the cooling of electrical devices and components and the heating and cooling of the passengers'"'"' compartment in a hybrid or full electric vehicle to reduce the cost and volume of such systems.

Claims

1. An integrated thermal management system comprising;

a refrigeration subsystem having a refrigerant and multiple components,

an electrical subsystem having multiple components,

an electronic control subsystem having multiple components,

wherein said refrigeration subsystem is in thermal communication with at least one of the components of the electrical subsystem and at least one of the components of the electronic control subsystem,

wherein said electrical subsystem is in thermal communication with at least one of the components of the refrigeration subsystem and in electronic communication with at least one of the components of said electronic control subsystem, and

wherein said electronic control subsystem is in electronic communication with at least one of the components of the electrical subsystem and at least one of the components of the refrigeration system.

2. The integrated thermal management system of claim 1 wherein said thermal communication is direct refrigerant contact.

3. The integrated thermal management system of claim 1 wherein said electronic communication further comprises digital signal processing signals.

4. The integrated thermal management system of claim 1 wherein said refrigeration subsystem further comprises at least one device selected from the group consisting of refrigerant compressors, refrigerant control devices, refrigerant reservoirs, refrigerant condensers, refrigerant evaporators, and heat exchangers, each device responsive to said electronic control subsystem.

5. The integrated thermal management system of claim 1 wherein said electrical subsystem further comprises at least one device selected from the group consisting of inverters, traction motors, refrigerant compressor motors, fuel cells, auxiliary converters, gate drivers, and power electronic devices, each device responsive to said electronic control subsystem.

6. The integrated thermal management system of claim 5 wherein said refrigerant evaporates in direct contact with the windings and core of said traction motors.

7. The integrated thermal management system of claim 5 wherein said refrigerant evaporates in indirect contact with the windings and core of said traction motors.

8. The integrated thermal management system of claim 5 wherein said refrigerant evaporates in indirect contact with vehicle transmission oil.

9. The integrated thermal management system of claim 5 wherein said inverter is a four leg inverter using zero-sequence components to drive at least one motor selected from the group consisting of induction and brushless DC motors.

10. The integrated thermal management system of claim 5 wherein said inverter is a three and one-half leg inverter using zero-sequence components to drive at least one brushless DC motor.

11. The integrated thermal management system of claim 1 wherein said electronic control subsystem further comprises at least one device selected from the group consisting of digital signal processors, inverter controllers, sensors, and control wiring.

12. The integrated thermal management system of claim 11 wherein said sensors are selected from the group consisting of pressure sensors, temperature sensors, current sensors, and voltage sensors.

13. The integrated thermal management system of claim 1 wherein said electronic control subsystem controls the refrigeration subsystem devices and electrical subsystem devices within set limits of temperature, pressure, current, and voltage.

14. A method of managing the thermal environment of a vehicle comprising;

providing a refrigeration subsystem having a refrigerant and multiple components,

providing an electrical subsystem having multiple components,

providing an electronic control subsystem having multiple components,

wherein said refrigeration subsystem is in thermal communication with at least one of the components of the electrical subsystem and at least one of the components of the electronic control subsystem,

wherein said electrical subsystem is in thermal communication with at least one of the components of the refrigeration subsystem and in electronic communication with at least one of the components of said electronic control subsystem, and

wherein said electronic control subsystem is in electronic communication with at least one of the components of the electrical subsystem and at least one of the components of the refrigeration system.

15. The method of claim 14 wherein said thermal communication is direct refrigerant contact.

16. The method claim 14 wherein said electronic communication further comprises digital signal processing signals.

17. The method claim 14 wherein said refrigeration subsystem further comprises at least one device selected from the group consisting of refrigerant compressors, refrigerant control devices, refrigerant reservoirs, refrigerant condensers, refrigerant evaporators, and heat exchangers, each device responsive to said electronic control subsystem.

18. The method of claim 14 wherein said electrical subsystem further comprises at least one device selected from the group consisting of inverters, traction motors, refrigerant compressor motors, fuel cells, auxiliary converters, gate drivers, and power electronic devices, each device responsive to said electronic control subsystem.

19. The method of claim 18 wherein said refrigerant evaporates in direct contact with the windings and core of said traction motors.

20. The method of claim 18 wherein said refrigerant evaporates in indirect contact with the windings and core of said traction motors.

21. The method of claim 18 wherein said refrigerant evaporates in indirect contact with vehicle transmission oil.

22. The method of claim 18 wherein said inverter is a four leg inverter using zero-sequence components to drive at least one motor selected from the group consisting of induction and brushless DC motors.

23. The method of claim 18 wherein said inverter is a three and one-half leg inverter using zero-sequence components to drive at least one brushless DC motor.

24. The method of claim 14 wherein said electronic control subsystem further comprises at least one device selected from the group consisting of digital signal processors, inverter controllers, sensors, and control wiring.

25. The method of claim 24 wherein said sensors are selected from the group consisting of pressure sensors, temperature sensors, current sensors, and voltage sensors.

26. The method of claim 14 wherein said electronic control subsystem controls the refrigeration subsystem devices and electrical subsystem devices within set limits of temperature, pressure, current, and voltage.