Electric vehicle thermal management system

• US 7,789,176 B2
• Filed: 04/11/2007
• Issued: 09/07/2010
• Est. Priority Date: 04/11/2007
• Status: Active Grant

• Current Assignee: Tesla Inc.
• Original Assignee: Tesla Motors Incorporated (Tesla Inc.)
• Inventors: Zhou, Peng
• Primary Examiner(s): Dickson; Paul N
• Assistant Examiner(s): COOLMAN, VAUGHN
• Application Number:
  US11/786,108
• Publication Number:
  US 20080251235A1
• Time in Patent Office: 1,245 Days
• Field of Search: 180/65.1, 180/65.31, 622/44, 429/26
• US Class Current: 180/65.1
• 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 1/00885 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 1/32281 comprising a single secondary circuit, e.g. at evaporator or condenser side
• CPC Class Codes: B60H 2001/00307 Component temperature regulation using a liquid flow
• CPC Class Codes: B60H 2001/00928 comprising a secondary circuit
• 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 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/662 Temperature
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

An efficient thermal management system (100) that utilizes a single heat exchanger (133) is provided. A refrigeration subsystem (103) cools the heat exchanger (133). A first coolant loop (139) in thermal communication with the heat exchanger (133) is used to cool the energy storage system (137). A second coolant loop (151) corresponding to the HVAC subsystem (107) is also in thermal communication with the heat exchanger (133). Preferably a third coolant loop (109) corresponding to the drive motor cooling subsystem (101) is coupleable to the HVAC coolant loop (151), thus providing an efficient means of providing heat to the HVAC subsystem (107).

Claims

1. An electric vehicle thermal management system comprising:

a refrigeration subsystem comprising a refrigerant and a heat exchanger;

a first coolant loop in thermal communication with an energy storage system and in thermal communication with said heat exchanger;

a heating, ventilation and cooling (HVAC) subsystem comprising a second coolant loop in thermal communication with said heat exchanger;

a power train cooling subsystem, said power train cooling subsystem comprising a third coolant loop in thermal communication with a vehicle drive motor and in thermal communication with a radiator; and

means for controllably and fluidly coupling said second coolant loop to said third coolant loop, wherein said means for controllably and fluidly coupling provides a means for allowing and preventing coolant fluid exchange between said second and third coolant loops.

2. The electric vehicle thermal management system of claim 1, said HVAC subsystem further comprising a radiator and a blower fan.

3. The electric vehicle thermal management system of claim 2, said second coolant loop further comprising a coolant pump.

4. The electric vehicle thermal management system of claim 2, further comprising a heater in thermal communication with said radiator.

5. The electric vehicle thermal management system of claim 1, said first coolant loop further comprising a coolant pump and a coolant reservoir.

6. The electric vehicle thermal management system of claim 5, further comprising a heater in thermal communication with said first coolant loop.

7. The electric vehicle thermal management system of claim 1, wherein said means for controllably and fluidly coupling means comprises a first flow control valve within said third coolant loop and a pair of flow control valves within said second coolant loop.

8. The electric vehicle thermal management system of claim 1, said refrigeration system further comprising a compressor, a condenser and a thermostatic expansion valve.

9. The electric vehicle thermal management system of claim 1, said energy storage system further comprising a plurality of batteries.

10. The electric vehicle thermal management system of claim 1, said third coolant loop further comprising a coolant pump and a coolant reservoir.

11. The electric vehicle thermal management system of claim 1, said power train cooling subsystem further comprising a power electronics module in thermal communication with said third coolant loop.