THERMOELECTRIC-BASED THERMAL MANAGEMENT OF ELECTRICAL DEVICES

• US 20150372356A1
• Filed: 01/13/2014
• Published: 12/24/2015
• Est. Priority Date: 01/14/2013
• Status: Active Grant

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: KOSSAKOVSKI, Dmitri, PIGGOTT, Alfred
• Granted Patent: US 10,170,811 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/625 Vehicles
• CPC Class Codes: H01M 10/633 characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/6572 Peltier elements or thermoelectric devices
• CPC Class Codes: H01M 2220/20 Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H05K 7/20 Modifications to facilitate cooling, ventilating, or heating
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y10T 29/49119 Brush

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.

Claims

1. A thermal management system configured to manage temperature in a temperature-sensitive region of an electrical device, the system comprising:

a thermoelectric device 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 substantial thermal communication with an electrical conductor, wherein the electrical conductor is configured to deliver electric power to or from an electrical device, and wherein the electrical conductor is capable of serving as a conduit for conducting thermal energy between a temperature-sensitive region of the electrical device and the thermoelectric device;

a controller comprising a control algorithm configured to monitor a thermal gradient created during operation of the electrical device across the temperature sensitive region and to adjust electric power delivered to the thermoelectric device such that the thermal energy transferred to or away from the temperature-sensitive region of the electrical device reduces or eliminates the thermal gradient created during operation of the electrical device across the temperature sensitive region.

2. The thermal management system of claim 1, further comprising a sensor in thermal communication with the electrical device and in electrical communication with the controller, wherein the controller is configured to monitor an input from the sensor and electric current directed in or out of the electrical device under thermal management and adjust electric power delivered to the thermoelectric device to reduce or eliminate the thermal gradient created during operation of the electrical device across the temperature sensitive region.

3. The thermal management system of claim 1, wherein the electric power delivered to the thermoelectric device in response to the input to reduce or eliminate the thermal gradient created during operation of the electrical device across the temperature sensitive region is adjusted between two or more nonzero levels of electric power.

4. The thermal management system of claim 1, wherein the control algorithm is further configured to monitor a thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device and to adjust electric power delivered to the thermoelectric device such that the thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device reduces or eliminates the thermal gradient created during operation of the electrical device across the temperature sensitive region.

5. The thermal management system of claim 1, wherein the thermoelectric device comprises a first operating mode and a second operating mode, wherein in the first operating mode, the thermoelectric device is configured to transfer a maximum amount of thermal energy allowed by the thermoelectric device, and wherein in the second operating mode, the thermoelectric device is configured to transfer an amount of thermal energy such that the thermal gradient created by the transfer of thermal energy balances with the thermal gradient created during operation of the electrical device across the temperature sensitive region to reduce or eliminate a resultant thermal gradient across the temperature sensitive region.

6. The thermal management system of claims 1-5, wherein an input configured to be monitored by the controller comprises at least one of:

temperature of the electrical device, charge state of the electrical device, health of the electrical device, voltage of the electrical device, resistance of the electrical device, current of the electrical device, load on the electrical device, temperature of an environment, weather forecast, time of day, terrain information, and geometry of the temperature sensitive region.

7. The thermal management system of any of claims 1-5, wherein the controller is integrated with a battery management system configured to administer control functions to a battery pack.

8. The thermal management system of any of claims 1-5, wherein the electrical device is a battery, and the temperature sensitive region is a cell of the battery.

9. The thermal management system of any of claims 1-5, wherein the thermal gradient across the temperature sensitive region of the electrical device is reduced to less than or equal to about 10 degrees C.

10. The thermal management system of any of claims 1-5, wherein the thermoelectric device is powered by the electrical device.

11. A method for thermally managing an electrical device, the method comprising:

establishing substantial thermal communication between a thermoelectric device and an electrical conductor that is in thermal and electrical communication with a temperature sensitive region of an electrical device;

monitoring an input from a temperature sensor in thermal communication with the temperature-sensitive region of the electrical device and electrical communication with a controller that comprises a control algorithm provided to monitor the input, wherein the input comprises a thermal gradient created during operation of the electrical device across the temperature sensitive region; and

adjusting the current directed in or out of the thermoelectric device in response to the input to reduce or eliminate the thermal gradient created during operation of the electrical device across the temperature sensitive region.

12. The method of claim 11, wherein adjusting the current directed in or out of the thermoelectric device in response to the input to reduce or eliminate a thermal gradient created during operation of the electrical device across the temperature-sensitive region comprises adjusting the current between two or more nonzero levels.

13. The method of claim 11, wherein the control algorithm is further configured to monitor a thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device and to adjust electric power delivered to the thermoelectric device such that the thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device combines with the thermal gradient created during operation of the electrical device across the temperature sensitive region such that a resulting thermal gradient of the electrical device is eliminated or reduced.

14. The method of claim 11, further comprising operating the thermoelectric device in a first mode and a second mode, wherein in the first mode, the thermoelectric device is configured to transfer a maximum amount of thermal energy allowed by the thermoelectric device, and wherein in the second operating mode, the thermoelectric device is configured to transfer an amount of thermal energy such that the thermal gradient created by the transfer of thermal energy balances with the thermal gradient created during operation of the electrical device across the temperature sensitive region to reduce or eliminate a resultant thermal gradient across the temperature sensitive region.

15. The method of any of claims 11-14, wherein an input configured to be monitored by the controller comprises at least one of:

temperature of the electrical device, charge state of the electrical device, health of the electrical device, voltage of the electrical device, resistance of the electrical device, current of the electrical device, load on the electrical device, temperature of an environment, weather forecast, time of day, terrain information, and geometry of the temperature sensitive region.

16. The method of any of claims 11-14, wherein the controller is integrated with a battery management system configured to administer control functions to a battery pack.

17. The method of any of claims 11-14, wherein the electrical device is a battery, and the temperature sensitive region is a cell of the battery.

18. The method of any of claims 11-14, wherein the thermal gradient across the temperature sensitive region of the electrical device is reduced to less than or equal to about 10 degrees C.

19. The method of any of claims 11-14, wherein the thermoelectric device is powered by the electrical device.

20. A method of manufacturing a thermal management system for thermally managing an electrical device, the method comprising:

connecting a thermoelectric device to an electrical conductor that is in thermal and electrical communication with a temperature sensitive region of an electrical device;

positioning a sensor on the electrical device such that the sensor is capable of measuring an input comprising a thermal gradient of the temperature sensitive region of the electrical device; and

connecting the sensor to a control system comprising a control algorithm configured to adjust electric power delivered to the thermoelectric device in response to the input from the sensor such that thermal energy transferred to or away from the temperature sensitive region of the electrical device reduces or eliminates a thermal gradient created during operation of the electrical device across the temperature sensitive region.

21. The method of claim 20, wherein the control algorithm is further configured to monitor a thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device and to adjust electric power delivered to the thermoelectric device such that the thermal gradient produced as a result of the thermal energy transferred to or away from the temperature sensitive region of the electrical device combines with the thermal gradient created during operation of the electrical device across the temperature sensitive region such that a resulting thermal gradient of the electrical device is eliminated or reduced.

22. The method of any of claims 20-21, wherein the input from the sensor comprises at least one of:

temperature of the electrical device, charge state of the electrical device, health of the electrical device, voltage of the electrical device, resistance of the electrical device, current of the electrical device, load on the electrical device, temperature of an environment, weather forecast, time of day, terrain information, and geometry of the temperature sensitive region.

23. The method of any of claims 20-21, further comprising integrating the control system with a battery management system configured to administer control functions to a battery pack

24. The method of any of claims 20-21, wherein the electrical device is a battery, and the temperature sensitive region is a cell of the battery.

25. The method of any of claims 20-21, wherein the thermal gradient across the temperature sensitive region of the electrical device is reduced to less than or equal to about 10 degrees C.

26. The method of any of claims 20-21, wherein the thermoelectric device is configured to be powered by the electrical device.