THERMOELECTRIC-BASED THERMAL MANAGEMENT SYSTEM

• US 20150357692A1
• Filed: 01/28/2014
• Published: 12/10/2015
• Est. Priority Date: 01/30/2013
• Status: Active Application

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Piggott, Alfred, Kossakovski, Dmitri, Barnhart, Todd Robert
• Granted Patent: US 10,270,141 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01M 10/613 Cooling or keeping cold
• CPC Class Codes: H01M 10/615 Heating or keeping warm
• CPC Class Codes: H01M 10/655 Solid structures for heat exchange or heat conduction
• CPC Class Codes: H01M 10/6572 Peltier elements or thermoelectric devices
• CPC Class Codes: H02J 7/0068 Battery or charger load switching, e.g. concurrent charging and load supply H02J7/0013 takes precedence
• CPC Class Codes: H05K 3/325 by abutting or pinching, i.e. without alloying process; mechanical auxiliary parts therefor adaptations of leads inserted in holes for press-fit connections H05K3/308
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49112 including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49131 by utilizing optical sighting device

Abstract

Disclosed embodiments include thermoelectric-based thermal management systems and methods configured to heat and/or cool an electrical device. Thermal management systems can include at least one electrical conductor in electrical and thermal communication with a temperature-sensitive region of the electrical device and at least one thermoelectric device in thermal communication with the at least one electrical conductor. Electric power can be directed to the thermoelectric device by the same electrical conductor or an external power supply, causing the thermoelectric device to provide controlled heating and/or cooling to the electrical device via the at least one electrical conductor. The thermoelectric management system can be integrated with the management system of the electrical device on a printed circuit substrate.

Claims

1. A thermoelectric battery thermal management system configured to manage temperature in a temperature-sensitive region of a battery cell, the system comprising:

a battery management controller configured to control charging and discharging of a battery cell;

a thermoelectric management controller configured to control electric power delivered to a thermoelectric device, wherein the thermoelectric device is configured to transfer thermal energy between a main surface and a waste surface upon application of electric power to the thermoelectric device, wherein the main surface of the thermoelectric device is attached to a bus bar, wherein the bus bar is in substantial thermal communication with an electrical conductor of the battery cell, wherein the electrical conductor is configured to deliver electric power to or from the battery cell, and wherein the electrical conductor serves as a conduit for conducting thermal energy between a temperature-sensitive region of the battery cell and the thermoelectric device;

a battery enclosure that encloses the battery cell; and

a printed circuit substrate comprising the battery management controller, the thermoelectric management controller, and a data connection between the battery management controller and the thermoelectric management controller, wherein the printed circuit substrate is positioned within the battery enclosure and comprises a power connection for supplying electric power to the thermoelectric device.

2. The thermoelectric battery thermal management system of claim 1, comprising a controller in electrical communication with the thermoelectric management controller and configured to control a polarity of electric current provided to the thermoelectric device, wherein a first polarity of electric current is provided in a cooling mode of system operation and wherein a second polarity opposite the first polarity of electric current is provided in a heating mode of system operation.

3. The thermoelectric battery thermal management system of claim 1, wherein the battery management controller is configured to administer control functions to the battery cell.

4. The thermoelectric battery thermal management system of claim 1, comprising a temperature sensor in thermal communication with the battery cell and in electrical communication with the thermoelectric management controller.

5. The thermoelectric battery thermal management system of claim 1, wherein the printed circuit substrate comprises a cutout portion configured to receive the thermoelectric device.

6. The thermoelectric battery thermal management system of any of claims 1-5, wherein a surface of the bus bar is in direct physical contact with a surface of the electrical conductor.

7. The thermoelectric battery thermal management system of any of claims 1-5, comprising a blower and duct assembly attached to the printed circuit substrate and configured to push or pull air across the waste surface of the thermoelectric device, wherein the blower and duct assembly comprises a controller in electrical communication with at least one of the battery management controller and thermoelectric management controller such that at least one of the battery management controller and thermoelectric management controller is configured to optimize system efficiency such that airflow from the blower is increased or decreased to match cooling or heating requirements of the battery cell.

8. The thermoelectric battery thermal management system of any of claims 1-5, wherein the bus bar comprises one or more mounting holes for mounting the bus bar to the printed circuit substrate and electrical conductor.

9. The thermoelectric battery thermal management system of any of claims 1-5, wherein the battery cell is sealed within an enclosure, the enclosure comprising a window of high thermal conductivity material abutting the thermoelectric device configured to provide access for substantial thermal communication between a portion of a waste heat removal system positioned outside the window and the waste surface of the thermoelectric device.

10. The thermoelectric battery thermal management system of any of claims 1-5, wherein thermoelectric devices are attached to both a top and bottom surface of the bus bar.

11. A method for thermally managing a battery cell, the method comprising:

controlling charging and discharging of a battery cell using a battery management controller attached to a printed circuit substrate;

controlling electric power delivered to a thermoelectric device using a thermoelectric management controller attached to the printed circuit substrate; and

supplying electric power to the thermoelectric device from a power connection attached to the printed circuit substrate;

wherein the thermoelectric device is configured to transfer thermal energy between a main surface and a waste surface upon application of electric power to the thermoelectric device;

wherein the main surface of the thermoelectric device is in physical contact with a bus bar;

wherein the bus bar is in thermal and electrical communication with an electrode of the battery cell;

wherein the electrode is configured to deliver electric power to or from the battery cell and to serve as a conduit for conducting thermal energy between a temperature-sensitive region of the battery cell and the thermoelectric device; and

wherein the battery cell is capable of being heated or cooled by adjusting a polarity of electric current delivered to the thermoelectric device.

12. The method of claim 11, wherein the thermoelectric management controller is configured to control the polarity of electric current provided to the thermoelectric device, wherein a first polarity of electric current is provided in a cooling mode of system operation, and wherein a second polarity opposite the first polarity of electric current is provided in a heating mode of system operation.

13. The method of claim 11, wherein the battery management controller is configured to manage the charging and discharging of the battery cell.

14. The method of claim 11, comprising a temperature sensor in thermal communication with the battery cell and in electrical communication with the thermoelectric management controller.

15. The method of claim 11, wherein the printed circuit substrate comprises a cutout portion configured to receive the thermoelectric device.

16. The method of any of claims 11-15, wherein a surface of the bus bar is in direct physical contact with a surface of the electrical conductor.

17. The method of any of claims 11-15, comprising a blower and duct assembly attached to the printed circuit substrate and configured to push or pull air across the waste surface of the thermoelectric device, wherein the blower and duct assembly comprises a controller in electrical communication with at least one of the battery management controller and thermoelectric management controller such that at least one of the battery management controller and thermoelectric management controller is configured to optimize system efficiency such that airflow from the blower is increased or decreased to match cooling or heating requirements of the battery cell.

18. The method of any of claims 11-15, wherein the bus bar comprises one or more mounting holes for mounting the bus bar to the printed circuit substrate and electrical conductor.

19. The method of any of claims 11-15, wherein the battery cell is sealed within an enclosure, the enclosure comprising a window abutting the thermoelectric device configured to provide access for substantial thermal communication between a portion of a waste heat removal system positioned outside the window and the waste surface of the thermoelectric device.

20. The method of any of claims 11-15, wherein thermoelectric devices are attached to both a top and bottom surface of the bus bar.

21. A method of manufacturing a thermoelectric battery thermal management system, the method comprising:

connecting a printed circuit substrate to a battery management system configured to control charging and discharging of a battery cell and to a thermoelectric management system configured to control electric power delivered to a thermoelectric device, wherein the thermoelectric device is configured to transfer thermal energy between a main surface and a waste surface upon application of electric power to the thermoelectric device

attaching the main surface of the thermoelectric device to a bus bar;

connecting the bus bar to an electrical conductor that is in thermal and electrical communication with the battery cell, wherein the electrical conductor is configured to deliver electric power to or from the battery cell such that the electrical conductor serves as a conduit for conducting thermal energy between a temperature-sensitive region of the battery cell and the thermoelectric device; and

connecting a power connection positioned on the printed circuit substrate to the thermoelectric device for supplying electric power to the thermoelectric device.

22. The method of claim 21, comprising connecting a controller to the thermoelectric management system, wherein the controller is configured to control a polarity of electric current provided to the thermoelectric device, wherein a first polarity of electric current is provided in a cooling mode of system operation and wherein a second polarity opposite the first polarity of electric current is provided in a heating mode of system operation.

23. The method of claim 21, comprising connecting a controller with the battery management system configured to administer control functions to the battery cell.

24. The method of claim 21, comprising connecting a temperature sensor in thermal communication with the battery cell and in electrical communication with the thermoelectric management controller.

25. The method of claim 21, comprising forming a cutout in the printed circuit configured to receive the thermoelectric device.

26. The method of any of claims 21-25, comprising connecting the bus bar to the electrical conductor such that a surface of the bus bar is in direct physical contact with a surface of the electrical conductor.

27. The method of any of claims 21-25, comprising attaching a blower and duct assembly to the printed circuit substrate, the blower and duct assembly configured to push or pull air across the waste surface of the thermoelectric device, wherein the blower and duct assembly comprises a controller in electrical communication with at least one of the battery management system and thermoelectric management system such that at least one of the battery management system and thermoelectric management system is configured to optimize system efficiency such that airflow from the blower is increased or decreased to match cooling or heating requirements of the battery cell.

28. The method of any of claims 21-25, comprising mounting the bus bar to the printed circuit substrate and electrical conductor.

29. The method of any of claims 21-25, comprising sealing the battery cell within an enclosure, the enclosure comprising a window abutting the thermoelectric device configured to provide access for substantial thermal communication between a portion of a waste heat removal system positioned outside the window and the waste surface of the thermoelectric device.

30. The method of any of claims 21-25, comprising attaching thermoelectric devices to both a top and bottom surface of the bus bar.