Thermoelectric-based thermal management of electrical devices

• US 9,671,142 B2
• Filed: 05/09/2014
• Issued: 06/06/2017
• Est. Priority Date: 07/11/2011
• Status: Active Grant

• Current Assignee: Gentherm Incorporated
• Original Assignee: Gentherm Incorporated
• Inventors: Kossakovski, Dmitri, Barnhart, Todd Robert, Piggott, Alfred
• Primary Examiner(s): Crepeau, Jonathan
• Application Number:
  US14/274,578
• Publication Number:
  US 20140331688A1
• Time in Patent Office: 1,124 Days
• Field of Search: None
• CPC Class Codes: F25B 21/04 reversible
• CPC Class Codes: H01M 10/425 Structural combination with electronic components, e.g. electronic circuits integrated to the outside of the casing printed circuits H05K1/00
• CPC Class Codes: H01M 10/443 in response to temperature
• CPC Class Codes: H01M 10/486 for measuring temperature
• CPC Class Codes: H01M 10/60 Heating or cooling; Temperature control
• CPC Class Codes: H01M 10/643 Cylindrical cells
• CPC Class Codes: H01M 10/6572 Peltier elements or thermoelectric devices
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

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

connecting a heat transfer device that comprises an electrically conductive portion and an electrically insulating portion to a plurality of electrical conductors of an electrical device;

establishing substantial thermal communication between the heat transfer device and a main surface of a thermoelectric device; and

establishing substantial thermal communication between a liquid heat exchanger and a waste surface of the thermoelectric device.

2. The method of claim 1, further comprising:

establishing substantial thermal communication between a first thermoelectric device and a first electrical conductor in thermal and electrical communication with a first electrical component of the electrical device; and

establishing substantial thermal communication between a second thermoelectric device and a second electrical conductor in thermal and electrical communication with a second electrical component of the electrical device.

6. The method of claim 1, further comprising operatively connecting a controller to control a polarity of electric current supplied to the thermoelectric device, wherein a first polarity of electric current is supplied in a cooling mode and wherein a second polarity opposite the first polarity of electric current is supplied in a heating mode.

7. The method of claim 6, further comprising thermally connecting a temperature sensor to the electrical device and electrically connecting the temperature sensor to the controller, wherein the controller is configured to monitor inputs from the temperature sensor and electric current directed in or out of the electrical device under thermal management and adjust electric power supplied to the thermoelectric device.

8. The method of claim 1, further comprising connecting a thermal insulator to an electrical conductor of the plurality of electrical conductors to substantially thermally isolate the thermoelectric device from a second electrical device that is in electrical communication with the electrical conductor.

9. The method of claim 1, wherein the electrical device comprises at least one of a battery, an insulated-gate bipolar transistor, or a power amplifier.

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

using a heat transfer device that comprises an electrically conductive portion connected to an electrical conductor that is in thermal and electrical communication with an electrical device;

operating a thermoelectric device in substantial thermal communication with the heat transfer device and in substantial thermal communication with a liquid heat exchanger; and

heating or cooling the electrical device by adjusting a polarity of electric current provided to the thermoelectric device.

4. The method of claim 3, further comprising:

monitoring inputs from a temperature sensor and electric current directed in or out of the electrical device and adjusting the current directed in or out of the thermoelectric device in response to the inputs.

5. The method of claim 3, further comprising:

operating a first thermoelectric device in substantial thermal communication with a first electrical conductor in thermal and electrical communication with a first electrical component of the electrical device;

operating a second thermoelectric device in substantial thermal communication with a second electrical conductor in thermal and electrical communication with a second electrical component of the electrical device; and

applying thermal management to the first electrical component independent of thermal management applied to the second electrical component.

10. The method of claim 3, wherein the thermoelectric device is isolated from a second electrical device that is in electrical communication with the electrical conductor.

11. A thermal management system for thermally managing an electrical device, the thermal management system comprising:

a heat transfer device comprising an electrically conductive portion and an electrically insulating portion connected to a plurality of electrical conductors of an electrical device;

a liquid heat exchanger configured to transfer thermal energy via a liquid working fluid; and

a thermoelectric device comprising a main surface and a waste surface, wherein the main surface is in substantial thermal communication with the heat transfer device, and wherein the waste surface is in substantial thermal communication with the liquid heat exchanger.

12. The thermal management system of claim 11, further comprising:

a first thermoelectric device in substantial thermal communication with a first electrical conductor in thermal and electrical communication with a first electrical component of the electrical device; and

a second thermoelectric device in substantial thermal communication with a second electrical conductor in thermal and electrical communication with a second electrical component of the electrical device.

13. The thermal management system of claim 11, wherein the plurality of electrical conductors is configured to deliver electric power to or from the electrical device such that the plurality of electrical conductors serves as a conduit for conducting thermal energy between the electrical device and the thermoelectric device.

14. The thermal management system of claim 11, further comprising a controller 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 operation and wherein a second polarity opposite the first polarity of electric current is provided in a heating mode of operation.

15. The thermal management system of claim 14, wherein the controller is integrated with a device management system configured to administer control functions to the electrical device.

16. The thermal management system of claim 14, further comprising a temperature sensor in thermal communication with the electrical device and in electrical communication with the controller.

17. The thermal management system of claim 16, wherein the controller is configured to monitor inputs from the temperature sensor and electric current directed in or out of the electrical device under thermal management and adjust electric power delivered to the thermoelectric device.

18. The thermal management system of claim 11, wherein the electrical device comprises a battery.

19. The thermal management system of claim 11, wherein the electrical device comprises at least one of an insulated-gate bipolar transistor or a power amplifier.

20. The thermal management system of claim 11, wherein the electrical device comprises an electrical circuit that is configured to have an electrode of the electrical circuit be in electrical and thermal communication with an electrode of a battery.

21. The thermal management system of claim 11, wherein the liquid heat exchanger extends along at least a portion of a surface of the electrical device between rows of electrical conductors of the plurality of electrical conductors.

22. The thermal management system of claim 11, wherein the liquid heat exchanger directly contacts a surface of the electrical device.

23. The thermal management system of claim 11, wherein the liquid heat exchanger does not touch a surface of the electrical device.

24. The thermal management system of claim 11, wherein the liquid heat exchanger includes electrically conductive portions and electrically insulating portions.

25. The thermal management system of claim 11, further comprising:

another thermoelectric device configured to transfer thermal energy between a main surface of the other thermoelectric device and a waste surface of the other thermoelectric device upon application of electric power to the other thermoelectric device, wherein the main surface of the other thermoelectric device is in substantial thermal communication with another heat transfer device,

wherein the waste surface of the other thermoelectric device is in substantial thermal communication with another liquid heat exchanger, and

wherein the liquid heat exchanger and the other liquid heat exchanger are positioned on different sides of the electrical device.

26. The thermal management system of claim 25, wherein the liquid heat exchanger and the other liquid heat exchanger directly contact the different sides of the electrical device.