Thermal dissipation system of an electric vehicle

• US 9,604,546 B2
• Filed: 12/14/2015
• Issued: 03/28/2017
• Est. Priority Date: 03/16/2015
• Status: Expired due to Fees

• Current Assignee: Thunder Power New Energy Vehicle Development Company Limited
• Original Assignee: Thunder Power Hong Kong Limited (Thunder Power Holdings Ltd.)
• Inventors: Chen, Yong-Syuan, Ho, Ming-Hui, Hsiao, Jen-Chieh
• Primary Examiner(s): WALTERS, JOHN DANIEL
• Application Number:
  US14/967,373
• Publication Number:
  US 20160272045A1
• Time in Patent Office: 470 Days
• Field of Search: 180/68.1, 180/68.2, 180/68.4
• US Class Current: 1/1
• CPC Class Codes: B32B 15/00 Layered products comprising a layer of metal
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 7/04 Interconnection of layers
• CPC Class Codes: B32B 7/05 the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 1/00392 for electric vehicles having only electric drive means
• CPC Class Codes: B60H 1/00564 of air ducts
• CPC Class Codes: B60H 1/00885 Controlling the flow of heating or cooling liquid, e.g. valves or pumps B60H1/00899 takes precedence; constructions of valves B60H1/00485
• 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: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 11/04 Arrangement or mounting of radiators, radiator shutters, or radiator blinds B60K11/085 takes precedence
• CPC Class Codes: B60K 11/085 with adjustable shutters or blinds
• CPC Class Codes: B60K 2001/005 the electric storage means
• CPC Class Codes: B60K 2001/006 the electric motors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/24 for controlling the temperature of batteries
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60Y 2200/91 : Electric vehicles
• CPC Class Codes: B60Y 2306/07 : Heating of passenger cabins
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: C09J 5/00 : Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: F16B 11/00 : Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding non-electric welding in general B23K; methods of using adhesives independently of the form of the surfaces joined C09J5/00
• CPC Class Codes: F16B 11/006 : by gluing gluing of plastics material B29C65/48
• CPC Class Codes: F16B 3/005 : the key being formed by solidification of injected material joining of preformed parts by applying molten plastics B29C65/40; non-disconnectible pipe joints obtained using a hardenable filler F16L13/11
• CPC Class Codes: F16B 5/04 : by means of riveting rivets F16B19/04
• CPC Class Codes: H01M 10/486 : for measuring temperature
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/63 : Control systems charging or discharging in response to temperature H01M10/44 , H01M10/443; measurement of temperature H01M10/48 , H01M10/486
• CPC Class Codes: H01M 10/6568 : characterised by flow circuits, e.g. loops, located externally to the cells or cell casings
• CPC Class Codes: H01M 10/663 : the system being an air-conditioner or an engine
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: H02J 7/0018 : using separate charge circuits
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/88 : Optimized components or subsystems, e.g. lighting, actively controlled glasses
• CPC Class Codes: Y10T 428/24347 : From both sides

Abstract

The present disclosure relates to a thermal dissipation system of an electric vehicle that includes: a heat exchanger arranged at the front part of the electric vehicle for providing heating or cooling to an air conditioning system of the electric vehicle; a first heat sink and a second heat sink, which are respectively arranged at the two sides of the front part of the heat exchanger; a number of rotatable and adjustable air deflectors for changing the flow direction of the air flowing through the heat dissipation system. Temperature sensors are included within the thermal dissipation system for sensing the working temperatures and the environmental temperatures of a battery pack and a motor of the electric vehicle. Opening and closing states of the air deflectors are adjusted in accordance with data provided by the temperature sensors.

Claims

1. A thermal dissipation system suitable for placement within a channel defined by a vehicle that draws ambient air through the channel during operation of the vehicle, the thermal dissipation system comprising:

a heat exchanger configured to provide cooling and heating for a cabin air conditioning system;

a first heat sink and a second heat sink arranged forward of and laterally shifted to opposing sides of the heat exchanger, each of the heat sinks configured to be in thermal contact with an operational heat emitting component of the vehicle; and

a plurality of air deflectors configured to alter a flow of the ambient air through the thermal dissipation system by transitioning between two or more configurations,

wherein the plurality of air deflectors comprises a first air deflector positioned in front of the heat exchanger and spanning the gap between the first and second heat sinks,

wherein in a first configuration the air deflectors are arranged to direct all the ambient air passing through the thermal dissipation system through one of the first and second heat sinks and then subsequently rejoin the ambient air after flowing through the heat exchanger and in a second configuration the air deflectors are arranged to allow a portion of the ambient air to flow directly to the heat exchanger by passing through a gap between the first heat sink and the second heat sink.

2. The thermal dissipation system as recited in claim 1, wherein the first configuration is a heating configuration for the cabin air conditioning system and the second configuration is a cooling configuration for the cabin air conditioning system.

3. The thermal dissipation system as recited in claim 1, wherein the plurality of air deflectors further comprises second air deflectors arranged to prevent air passing through the first and second heat sinks from flowing into the heat exchanger.

4. The thermal dissipation system of claim 3, wherein the plurality of air deflectors further comprises third air deflectors arranged to redirect air exiting the first and second heat sinks into an air intake of the heat exchanger.

5. The thermal dissipation system of claim 4, wherein in the first configuration the first deflector and the third deflectors are closed while the second deflectors are left open.

6. The thermal dissipation system of claim 4, wherein in the second configuration the first deflector and the third deflectors are left open while the second deflectors are closed.

7. The thermal dissipation system of claim 1, wherein the operational heat emitting components of the vehicle are a motor and a battery pack.

8. The thermal dissipation system of claim 7, further comprising:

a controller for adjusting the closing and opening of the plurality of air deflectors in accordance with an operating state of the heat exchanger and the temperatures of the motor and the battery pack.

9. The thermal dissipation system of claim 8, further comprising:

a first temperature sensor disposed within the battery pack; and

a second temperature sensor disposed within the motor,

wherein the first and second temperature sensors periodically send signals to the controller indicating temperature changes in the motor and the battery pack.

10. An electric vehicle, comprising:

a vehicle chassis defining an air inlet;

an air conditioning system configured to govern a temperature within the electric vehicle;

a motor;

a battery pack configured to provide energy to the motor; and

a thermal dissipation system positioned proximate the air inlet and configured to receive air entering the air inlet, the thermal dissipation system comprising;

a heat exchanger in thermal contact with the air conditioning system,

a first and a second heat sink in thermal contact with the motor and the battery pack respectively, the first and second heat sinks being positioned forward of and on opposing sides of the heat exchanger,

a plurality of air deflectors configured to switch between open and closed configurations, and

a controller configured to direct configuration changes of the plurality of air deflectors,

wherein when the thermal dissipation system is operating in a heating state the controller directs the plurality of air deflectors to divide the air received through the air inlet so that a first portion of the air passes through the first heat sink and a second portion of the air passes through the second heat sink and then the first and second portions of the air are subsequently recombined to pass through the heat exchanger.

11. The electric vehicle of claim 10, further comprising:

a battery pack heater in communication with the controller and configured to supply heating to the battery pack when the thermal dissipation system is in a heating mode.

12. The electric vehicle of claim 10, further comprising:

a battery pack temperature sensor arranged in the battery pack and connected to the controller for sensing a working temperature of the battery pack and sending a temperature signal to the controller;

a motor temperature sensor arranged in the motor and connected to the controller for sensing a working temperature of the motor and sending a temperature signal to the controller;

an air conditioner state input connected to the controller for sending a working state of the air conditioner to the controller;

a battery pack environment temperature sensor arranged at the outside of the battery pack and connected to the controller for sensing the environment temperature of the battery pack and sending a temperature signal to the controller; and

a motor environment temperature sensor arranged at the outside of the motor and connected to the controller for sensing the environment temperature of the motor and sending a temperature signal to the controller.

13. The electric vehicle of claim 10, further comprising:

a first air deflector drive, a second air deflector drive and a third air deflector drive, which are used for receiving the control signals of the controller and respectively controlling the opening and closing of a first air deflector (111), a second air deflector and a third air deflector of the plurality of air deflectors.

14. The electric vehicle of claim 13, wherein the operating modes of the air deflectors comprise at least four modes:

mode I;

the first air deflector and the third air deflectors are open, the second air deflectors are closed, and the air passes through the first heat sink, the heat exchanger and the second heat sink at the same time;

mode II;

the first air deflector and the second air deflectors are open, the third air deflectors are closed, part of the air first passes through the first heat sink and the second heat sink and then flows through the heat exchanger after being heated, and part of the air directly passes through the heat exchanger;

mode III;

the first air deflector and the second air deflectors are closed, the third air deflectors are open, the air only flows through the first heat sink and the second heat sink without passing through the heat exchanger;

mode IV;

the first air deflector and the third air deflectors are closed, the second air deflectors are open, and the air firstly flows through the first heat sink and the second heat sink and then flows through the heat exchanger after being heated.

15. A thermal dissipation system suitable for use within a vehicle, the thermal dissipation system comprising:

a heat exchanger;

a first heat sink and a second heat sink arranged forward of and laterally shifted to opposing sides of the heat exchanger;

a plurality of sensors configured to determine temperatures associated with operational components of the vehicle;

a plurality of air deflectors configured to alter a flow of the ambient air through the thermal dissipation system by transitioning between two or more configurations; and

a controller configured to direct a configuration of the plurality of air deflects to be changed in accordance with signals received from the plurality of sensors, the configuration change altering a flow of air through the thermal dissipation system,

wherein in a first configuration the air deflectors are arranged to divide the air passing through the thermal dissipation system so that a first portion of the air passes through the first heat sink and a second portion of the air passes through the second heat sinks and then the two portions of the air are subsequently rejoined while flowing through the heat exchanger.

16. The thermal dissipation system of claim 15, wherein in a second configuration the air deflectors are arranged to allow a portion of the ambient air to flow directly to the heat exchanger by passing through a gap between the first heat sink and the second heat sink.

17. The thermal dissipation system of claim 15, wherein the first heat sink is configured to be in thermal contact with a motor of the vehicle and the second heat sink is configured to be in thermal contact with a battery of the vehicle.

18. The thermal dissipation system of claim 15, wherein the heat exchanger is associated with a cabin air temperature system of the vehicle.