Thermal management systems and methods

• US 20050167169A1
• Filed: 02/04/2004
• Published: 08/04/2005
• Est. Priority Date: 02/04/2004
• Status: Active Grant

• Current Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Original Assignee: Battelle Energy Alliance LLC (Battelle Memorial Institute)
• Inventors: Gering, Kevin L., Haefner, Daryl R.
• Granted Patent: US 7,147,071 B2
• Time in Patent Office: Days
• US Class Current: 237/12.30B
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 1/004 for vehicles having a combustion engine and electric drive means, e.g. hybrid electric vehicles
• CPC Class Codes: B60H 1/00492 comprising regenerative heating or cooling means, e.g. heat accumulators
• CPC Class Codes: B60H 1/08 from other radiator than main radiator
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow
• CPC Class Codes: B60K 11/02 with liquid cooling
• CPC Class Codes: B60K 2001/005 the electric storage means
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: F01P 11/20 concerning atmospheric freezing conditions, e.g. automatically draining or heating during frosty weather
• CPC Class Codes: F01P 2011/205 using heat-accumulators
• CPC Class Codes: F01P 2050/24 Hybrid vehicles
• CPC Class Codes: F01P 2060/08 Cabin heater
• CPC Class Codes: F01P 2060/18 Heater
• CPC Class Codes: F01P 3/20 Cooling circuits not specific to a single part of engine or machine F01P3/22 takes precedence
• CPC Class Codes: F01P 7/165 characterised by systems with two or more loops
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

Abstract

A thermal management system for a vehicle includes a heat exchanger having a thermal energy storage material provided therein, a first coolant loop thermally coupled to an electrochemical storage device located within the first coolant loop and to the heat exchanger, and a second coolant loop thermally coupled to the heat exchanger. The first and second coolant loops are configured to carry distinct thermal energy transfer media. The thermal management system also includes an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electrochemical storage device. Thermal management methods are also provided.

Claims

1. A thermal management system for a vehicle, comprising:

a heat exchanger having a thermal energy storage material provided therein;

a first coolant loop thermally coupled to an electro-chemical storage device located within the first coolant loop and to the heat exchanger;

a second coolant loop thermally coupled to the heat exchanger, the first and second loops configured to carry distinct thermal energy transfer media; and

an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electro-chemical storage device.

2. The system of claim 1, wherein the heat generated by the internal combustion engine is provided to the heat exchanger to regenerate the thermal energy storage material, and the electro-chemical storage device comprises one or more batteries, capacitors, fuel cells, or combinations thereof.

3. The system of claim 2, wherein regenerating the thermal energy storage material includes converting the thermal energy storage material from a solid state to a liquid state.

4. The system of claim 1, wherein the first coolant loop comprises a coolant mixture that is different from the thermal energy transfer medium flowing through the second loop.

5. The system of claim 4, wherein the thermal energy transfer medium flowing through the second loop comprises a coolant used in association with the internal combustion engine.

6. The system of claim 5, wherein the interface comprises one or more fluid supply paths in fluid communication with the second coolant loop.

7. The system of claim 6, wherein the heat generated by the internal combustion engine is provided to the heat exchanger via at least one of the fluid supply paths and the second coolant loop, the fluid supply paths being thermally coupled to a radiator core of the vehicle, and upon providing the heat to the heat exchanger, at least one of a sensible heat or a latent heat of fusion of the thermal energy storage material is increased from a thermal state to a higher different thermal state.

8. The system of claim 6, wherein the heat generated by the internal combustion engine is provided to the heat exchanger via at least one of the fluid supply paths and the second coolant loop, the fluid supply paths being adapted to be thermally coupled to a radiator core of the vehicle, and upon providing the heat to the heat exchanger, a sensible heat as well as a latent heat of fusion of the thermal energy storage material are increased from a thermal state to a higher different thermal state.

9. The system of claim 1, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle via the second coolant loop, or delivered to the electro-chemical storage device via the first coolant loop to increase a temperature of the electrochemical storage device.

10. The system of claim 1, wherein the thermal energy storage material comprises a phase change material configured to change from a solid state to a liquid state and vice-versa during select conditions.

11. The system of claim 1, further comprising:

a second heat exchanger provided in the first coolant loop, the thermal energy transfer medium flowing in the first coolant loop is selectively flowed through the second heat exchanger to reduce a temperature T_Batt to within a predetermined temperature range;

a bypass fluid path configured to deliver the thermal energy transfer medium circulating in the first coolant loop, bypassing the heat exchanger, to the electrochemical storage device; and

first and second pumps to enable circulation of the thermal energy transfer media provided in the respective first and second coolant loops.

12. The system of claim 11, further comprising a plurality of three-way valves configured to selectively permit the thermal energy transfer medium flowing in the first coolant loop to flow through the heat exchanger or the bypass fluid path.

13. The system of claim 11, wherein the thermal energy transfer medium flowing in the first coolant loop is flowed via the bypass fluid path if a temperature T_Batt of the electro-chemical storage device is above a predetermined maximum threshold temperature T_max.

14. The system of claim 11, wherein the thermal energy transfer medium flowing in the first coolant loop is enabled to flow through the heat exchanger if a temperature T_Batt of the electro-chemical storage device is below a predetermined minimum threshold temperature T_min.

15. The system of claim 11, wherein the second heat exchanger comprises air-to-glycol mixture heat exchanger.

16. The system of claim 1, wherein the heat exchanger comprises a liquid-to-liquid heat exchanger.

17. The system of claim 16, wherein the heat exchanger comprises:

heat exchange tubing configured to exchange heat between the thermal energy storage material and the respective thermal energy transfer media circulating in the first and second coolant loops; and

heat exchange fins configured to enhance the heat exchange, wherein the thermal energy storage material is encapsulated in one or more sections of flexible tubing comprised in the heat exchanger, wherein encapsulation in the one or more sections of the flexible tubing reduces a ratio of encapsulant volume relative to volume of the thermal energy storage material.

18. The system of claim 16, wherein the heat exchanger is configured to control heat supplied to components of the vehicle during select phases of vehicular operation including cold-start conditions, normal operating conditions, and hot-operating conditions.

19. The system of claim 1, wherein the heat generated by the internal combustion engine is stored in the thermal energy storage material for use during cold-start conditions of the vehicle to increase a temperature T_Batt of the electrochemical storage device.

20. The system of claim 1, wherein the heat exchanger is configured to preheat the electro-chemical storage device and a passenger cabin of the vehicle to enhance performance of the electro-chemical storage device and enhance cabin comfort of the passenger cabin.

21. The system of claim 1, wherein the thermal energy storage material provided within the heat exchanger is encapsulated in spheres in a baffled framework within the heat exchanger.

22. A thermal management system for a hybrid electric vehicle, comprising:

a first fluid loop having a first coolant mixture flowing therein;

a battery module located in the first fluid loop;

a second fluid loop having a second coolant mixture flowing therein, the second coolant mixture being distinct from the first coolant mixture;

a heat exchanger having a phase change material provided therein;

the first and second fluid loops being configured to be in thermal communication with the heat exchanger, the heat exchanger being configured to flow only the first coolant mixture within the heat exchanger; and

a thermal interface configured to transfer heat produced by an internal combustion engine of the vehicle to the heat exchanger, the heat exchanger being configured to store the heat generated by the internal combustion engine and selectively provide the stored heat to control thermal characteristics of various components of the vehicle including the battery module.

23. The system of claim 22, further comprising:

a second heat exchanger thermally coupled to the first fluid loop; and

a bypass fluid path configured to deliver the first coolant mixture to the second heat exchanger bypassing the heat exchanger in order to dissipate heat carried by the first coolant mixture and to reduce a temperature T_Batt of the battery module below a maximum desirable temperature T_max.

24. The system of claim 23, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger via the second fluid loop and stored therein, and the heat stored in the heat exchanger is selectively delivered to the battery module via the first fluid loop.

25. The system of claim 22, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger to regenerate the phase change material.

26. The system of claim 22, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger via a fluid path configured to be thermally coupled to the second fluid loop and a radiator core of the vehicle, and further wherein after receiving the heat generated by the internal combustion engine, at least one of a sensible heat or a latent heat of fusion of the phase change material is increased from a thermal state to a higher different thermal state.

27. The system of claim 22, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger via a fluid path configured to be thermally coupled to the second fluid loop and a radiator core of the vehicle, and further wherein after receiving the heat generated by the internal combustion engine, a sensible heat as well as a latent heat of fusion of the phase change material are increased from a thermal state to a higher different thermal state.

28. The system of claim 22, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle, the passenger cabin being thermally coupled to the heat exchanger via the second fluid loop.

29. A thermal management system for a vehicle, comprising:

a heat exchanger means having a means for storing thermal energy;

a first coolant loop thermally coupled to an electrical energy storage means located within the first coolant loop;

a second coolant loop, the first and second coolant loops being thermally coupled to the heat exchanger means and configured to carry a thermal energy transfer medium; and

an interface means for enabling transfer of heat generated by an internal combustion engine to the heat exchanger means in order to selectively deliver the heat to the electro-chemical storage means.

30. The system of claim 29, further comprising:

a second heat exchanger means provided in the first coolant loop; and

a bypass fluid path for delivering a first coolant mixture, provided in the first coolant loop, to the second heat exchanger means bypassing the heat exchanger means in order to dissipate heat carried by the first coolant mixture to reduce a temperature T_Batt of the electrical energy storage means to within a predetermined maximum temperature T_max.

31. The system of claim 29, wherein the interface means comprising a fluid path that is thermally coupled to the second fluid loop, and a radiator core of the vehicle is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the heat exchanger means, and at least one of a sensible heat or a latent heat of fusion of the phase change material is increased from a thermal state to a higher different thermal state after receiving the heat generated by the internal combustion engine.

32. The system of claim 29, wherein the interface means comprising a fluid path that is thermally coupled to the second fluid loop, and a radiator core of the vehicle is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the heat exchanger means, further wherein a sensible heat and a latent heat of fusion of the phase change material are increased from a thermal state to a higher different thermal state after receiving the heat generated by the internal combustion engine.

33. The system of claim 29, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle, wherein the passenger cabin is thermally coupled to the heat exchanger means via the second coolant loop.

34. A thermal management method for a vehicle, comprising:

providing a heat exchanger having a thermal energy storage material disposed therein;

providing first and second coolant loops configured to circulate distinct coolant mixtures through the respective first and second coolant loops;

thermally coupling the first coolant loop to a battery module located within the first coolant loop;

thermally coupling the second coolant loop to the heat exchanger;

providing an interface in close proximity to the second coolant loop, wherein the interface is configured to transfer heat generated by an internal combustion engine of the vehicle to the heat exchanger, via the second coolant loop, for storage within the thermal energy storage material; and

selectively performing one or more of preheating the battery module, heating a passenger cabin of the vehicle, increasing sensible heat or latent heat of fusion of the material from a first thermal state to a higher second thermal state using the heat stored within the thermal energy storage material.

35. The method of claim 34, further comprising:

thermally coupling a second heat exchanger to the first coolant loop to cool the battery module; and

providing a bypass fluid path to deliver the first coolant mixture to the second heat exchanger bypassing the heat exchanger in order to cool the battery module by reducing a temperature T_Batt of the battery module below a maximum desirable temperature T_max.

36. The method of claim 35, further comprising:

transferring the heat generated by the internal combustion engine to the heat exchanger via the second fluid loop for storage in the heat exchanger; and

selectively delivering the heat stored in the heat exchanger to the battery module via the first fluid loop to increase the temperature T_Batt of the battery module.

37. The method of claim 36, further comprising:

transferring the heat generated by the internal combustion engine to the heat exchanger; and

after receiving the heat at the heat exchanger, one or more of sensible heat or latent heat of fusion of the phase change material is increased from a first thermal state to a higher different thermal state.

38. The method of claim 37, further comprising selectively delivering the heat generated by the internal combustion engine to heat a passenger cabin of the vehicle.