Thermal Management System with Dual Mode Coolant Loops

• US 20120183815A1
• Filed: 03/23/2012
• Published: 07/19/2012
• Est. Priority Date: 06/04/2010
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Johnston, Vincent George, Baglino, Andrew David, Kohn, Scott Ira, Mehta, Vineet Haresh, O'Donnell, Curt Raymond, de Bruijn, Wulfer Adrijan, Gadda, Christopher David
• Granted Patent: US 8,402,776 B2
• Time in Patent Office: Days
• US Class Current: 429/50
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 11/02 with liquid cooling
• CPC Class Codes: B60K 11/04 Arrangement or mounting of radiators, radiator shutters, or radiator blinds B60K11/085 takes precedence
• CPC Class Codes: B60K 2001/003 with means for cooling the electrical propulsion units
• CPC Class Codes: B60K 2001/005 the electric storage means
• CPC Class Codes: B60K 2001/006 the electric motors
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• 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
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y02T 90/16 : Information or communication technologies improving the operation of electric vehicles

Abstract

A dual mode, thermal management system for use in a vehicle is provided. At a minimum, the system includes a first coolant loop in thermal communication with a battery system, a second coolant loop in thermal communication with at least one drive train component (e.g., electric motor, power electronics, inverter), a dual mode valve system that provides means for selecting between a first mode where the two coolant loops operate in parallel and a second mode where the two coolant loops operate in series, and a coolant reservoir that is coupled to both coolant loops when the two coolant loops are operating in series and only coupled to the drive train coolant loop when the two coolant loops are operating in parallel.

Claims

1. A dual mode, vehicle thermal management system, comprising:

a first coolant loop in thermal communication with a battery system, said first coolant loop comprising a first circulation pump for circulating a coolant within said first coolant loop;

a second coolant loop in thermal communication with at least one drive train component, said second coolant loop comprising a second circulation pump for circulating said coolant within said second coolant loop;

a dual mode valve system, wherein said first coolant loop operates in parallel with and separate from said second coolant loop when said valve system is configured in a first mode, and wherein said first coolant loop is serially coupled to said second coolant loop when said valve system is configured in a second mode; and

a coolant reservoir, wherein said coolant within said second coolant loop is coupled to said coolant reservoir when said valve system is configured in either said first mode or said second mode, wherein said coolant within said first coolant loop is coupled to said coolant reservoir when said valve system is configured in said second mode, and wherein said coolant within said first coolant loop is not coupled to said coolant reservoir when said valve system is configured in said first mode.

2. The dual mode, vehicle thermal management system of claim 1, wherein said dual mode valve system is comprised of a four-way valve, wherein said four-way valve configured in said first mode couples a first valve inlet to a first valve outlet and couples a second valve inlet to a second valve outlet, and wherein said four-way valve configured in said second mode couples said first valve inlet to said second valve outlet and couples said second valve inlet to said first valve outlet.

3. The dual mode, vehicle thermal management system of claim 1, wherein said dual mode valve system is comprised of a four-way valve, wherein said four-way valve configured in said first mode couples a first portion of said first coolant loop to a second portion of said first coolant loop and couples a first portion of said second coolant loop to a second portion of said second coolant loop, and wherein said four-way valve configured in said second mode couples said first portion of said first coolant loop to said second portion of said second coolant loop and couples said first portion of said second coolant loop to said second portion of said first coolant loop.

4. The dual mode, vehicle thermal management system of claim 1, wherein said dual mode valve system is comprised of a first three-way valve and a second three-way valve, wherein said first three-way valve couples a first portion of said first coolant loop to a second portion of said first coolant loop when said dual mode valve system is configured in said first mode, wherein said second three-way valve couples a first portion of said second coolant loop to a second portion of said second coolant loop when said dual mode valve system is configured in said first mode, wherein said first three-way valve couples said first portion of said first coolant loop to said second portion of said second coolant loop when said dual mode valve system is configured in said second mode, and wherein said second three-way valve couples said first portion of said second coolant loop to said second portion of said first coolant loop when said dual mode valve system is configured in said second mode.

5. The dual mode, vehicle thermal management system of claim 1, wherein said battery system is comprised of a plurality of batteries.

6. The dual mode, vehicle thermal management system of claim 1, further comprising a refrigeration subsystem in thermal communication with said first coolant loop.

7. The dual mode, vehicle thermal management system of claim 6, further comprising a heat exchanger, wherein said refrigeration subsystem is in thermal communication with said first coolant loop via said heat exchanger.

8. The dual mode, vehicle thermal management system of claim 6, further comprising a heat exchanger, wherein said refrigeration subsystem is in thermal communication with said first coolant loop via said heat exchanger, and wherein said refrigeration subsystem further comprises a refrigerant, a compressor, a condenser and a thermostatic expansion valve.

9. The dual mode, vehicle thermal management system of claim 1, said first coolant loop further comprising a heater.

10. The dual mode, vehicle thermal management system of claim 1, wherein said at least one drive train component is comprised of at least one of a drive motor and a drive electronics, said drive electronics comprising an inverter.

11. The dual mode, vehicle thermal management system of claim 1, further comprising a charger in thermal communication with said second coolant loop.

12. The dual mode, vehicle thermal management system of claim 1, said second coolant loop further comprising a radiator.

13. The dual mode, vehicle thermal management system of claim 1, said second coolant loop further comprising a bypass valve, wherein said bypass valve in a first position couples said second coolant loop to a radiator, and wherein said bypass valve in a second position decouples said radiator from said second coolant loop.

14. The dual mode, vehicle thermal management system of claim 1, further comprising:

a refrigeration subsystem comprising a heat exchanger, wherein said first coolant loop is in thermal communication with said refrigeration subsystem via said heat exchanger; and

a cabin heating, ventilation and cooling (HVAC) subsystem coupleable to said refrigeration subsystem.

15. A method of managing thermal loads within an electric vehicle, the method comprising the steps of:

selecting between a first mode and a second mode of circulating a coolant through a drive train coolant loop and a battery system coolant loop,

wherein in said first mode, the method further comprises the steps of;

circulating said coolant through said drive train coolant loop, said drive train coolant loop in thermal communication with at least one drive train component, wherein said drive train coolant loop is coupled to a coolant reservoir; and

circulating said coolant through said battery system coolant loop, said battery system coolant loop in thermal communication with a battery system, wherein said step of circulating said coolant through said battery system coolant loop is performed in parallel with said step of circulating said coolant through said drive train coolant loop, and wherein said battery system coolant loop is not coupled to said coolant reservoir; and

wherein in said second mode, the method further comprises the steps of;

serially circulating said coolant through said drive train coolant loop and said battery system coolant loop, wherein said drive train coolant loop and said battery system coolant loop are both coupled to said coolant reservoir.

16. The method of claim 15, wherein in said first mode the method comprises the steps of coupling a first portion of said drive train coolant loop to a second portion of said drive train coolant loop and coupling a first portion of said battery system coolant loop to a second portion of said battery system coolant loop, and wherein in said second mode the method comprises the steps of coupling said first portion of said drive train coolant loop to said second portion of said battery system coolant loop and coupling said first portion of said battery system coolant loop to said second portion of said drive train coolant loop.

17. The method of claim 16, wherein said selecting step further comprises the steps of positioning a four-way valve in either a first position corresponding to said first mode, or in a second position corresponding to said second mode.

18. The method of claim 16, wherein in said first mode the method further comprises the steps of positioning a first three-way valve in a first position and positioning a second three-way valve in a first position, and wherein in said second mode the method further comprises the steps of positioning said first three-way valve in a second position and positioning said second three-way valve in a second position.

19. The method of claim 15, further comprising the step of thermally coupling said drive train coolant loop to a charger.

20. The method of claim 15, further comprising the step of thermally coupling said battery system coolant loop to a refrigeration subsystem via a heat exchanger, wherein said step of thermally coupling said battery system coolant loop to said refrigeration subsystem is performed when additional battery system cooling is desired.

21. The method of claim 15, further comprising the step of thermally coupling said battery system coolant loop to a heater, wherein said step of thermally coupling said battery system coolant loop to said heater is performed when additional battery system heating is desired.

22. The method of claim 15, further comprising the step of coupling said drive train coolant loop to a radiator when additional drive train cooling is desired.

23. The method of claim 22, further said step of coupling said drive train coolant loop to said radiator is performed using a bypass valve.