Thermal management systems and methods Number:7,147,071 from the United States Patent and Trademark Office (PTO) owispatent

Title: Thermal management systems and methods

Abstract: A thermal management system for a vehicle includes a heat exchanger having a thermal energy storage material provided therein, a first coolant loop thermally coupled to an electrochemical storage device located within the first coolant loop and to the heat exchanger, and a second coolant loop thermally coupled to the heat exchanger. The first and second coolant loops are configured to carry distinct thermal energy transfer media. The thermal management system also includes an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electrochemical storage device. Thermal management methods are also provided.

Patent Number: 7,147,071 Issued on 12/12/2006 to Gering,   et al.

---

Inventors:	Gering; Kevin L. (Idaho Falls, ID), Haefner; Daryl R. (Idaho Falls, ID)
Assignee:	Battelle Energy Alliance, LLC (Idaho Falls, ID)
Appl. No.:	10/772,762
Filed:	February 4, 2004

---

Current U.S. Class:	180/65.2 ; 429/120
Current International Class:	B60K 1/00 (20060101)

---

References Cited [Referenced By]

---

U.S. Patent Documents

	2282923		May 1942		Ambruster
	2405144		August 1946		Holthouse
	2666091		January 1954		Martin et al.
	3905884		September 1975		Parenti et al.
	4007315		February 1977		Brinkmann et al.
	4057101		November 1977		Ruka et al.
	4415847		November 1983		Galloway
	4582765		April 1986		Kothmann
	4691766		September 1987		Wurz et al.
	5239839		August 1993		James
	5449571		September 1995		Longardner et al.
	5678760		October 1997		Muso et al.
	5687706		November 1997		Goswami et al.
	5735133		April 1998		Voss et al.
	5834132		November 1998		Hasegawa et al.
	5871041		February 1999		Rafalovich et al.
	5952815		September 1999		Rouillard et al.
	6059016		May 2000		Rafalovich et al.
	6087036		July 2000		Rouillard et al.
	6239502		May 2001		Grewe et al.
	6276166		August 2001		Sarkisian et al.
	6357541		March 2002		Matsuda et al.
	6464027		October 2002		Dage et al.
	6512347		January 2003		Hellmann et al.
	6705101		March 2004		Brotz et al.
	6793012		September 2004		Fang et al.
	6932153		August 2005		Ko et al.
	6963131		November 2005		Frisch et al.
	7007501		March 2006		Hu

Primary Examiner: Ellis; Christopher P.
Assistant Examiner: Bottorff; Christopher
Attorney, Agent or Firm: Wells St. John P.S.

---

Government Interests

---

GOVERNMENT RIGHTS

This invention was made with Government support under Contract No. DE-AC07-99ID13727 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.

---

Claims

---

What is claimed is:

1. A thermal management system for a vehicle, comprising: a heat exchanger having a thermal energy storage material provided therein; a first coolant loop thermally coupled to an electro-chemical storage device located within the first coolant loop and to the heat exchanger; a second coolant loop thermally coupled to the heat exchanger, the first and second loops configured to carry distinct thermal energy transfer media; an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electro-chemical storage device; and a second heat exchanger provided in the first coolant loop.

2. The system of claim 1, wherein the heat generated by the internal combustion engine is provided to the first mentioned heat exchanger to regenerate the thermal energy storage material, and the electro-chemical storage device comprises one or more batteries, capacitors, fuel cells, or combinations thereof.

3. The system of claim 2, wherein regenerating the thermal energy storage material includes converting the thermal energy storage material from a solid state to a liquid state.

4. The system of claim 1, wherein the first coolant loop comprises a coolant mixture that is different from the thermal energy transfer medium flowing through the second loop.

5. The system of claim 4, wherein the thermal energy transfer medium flowing through the second loop comprises a coolant used in association with the internal combustion engine.

6. The system of claim 5, wherein the interface comprises one or more fluid supply paths in fluid communication with the second coolant loop.

7. The system of claim 6, wherein the heat generated by the internal combustion engine is provided to the heat exchanger via at least one of the fluid supply paths and the second coolant loop, the fluid supply paths being thermally coupled to a radiator core of the vehicle, and upon providing the heat to the first mentioned heat exchanger, at least one of a sensible heat or a latent heat of fusion of the thermal energy storage material is increased from a thermal state to a higher different thermal state.

8. The system of claim 6, wherein the heat generated by the internal combustion engine is provided to the heat exchanger via at least one of the fluid supply paths and the second coolant loop, the fluid supply paths being adapted to be thermally coupled to a radiator core of the vehicle, and upon providing the heat to the first mentioned heat exchanger, a sensible heat as well as a latent heat of fusion of the thermal energy storage material are increased from a thermal state to a higher different thermal state.

9. The system of claim 1, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle via the second coolant loop, or delivered to the electro-chemical storage device via the first coolant loop to increase a temperature of the electro-chemical storage device.

10. The system of claim 1, wherein the thermal energy storage material comprises a phase change material configured to change from a solid state to a liquid state and vice-versa during select conditions.

11. The system of claim 1, wherein the heat generated by the internal combustion engine is stored in the thermal energy storage material for use during cold-start conditions of the vehicle to increase a temperature T.sub.Batt of the electro-chemical storage device.

12. The system of claim 1, wherein the first mentioned heat exchanger is configured to preheat the electro-chemical storage device and a passenger cabin of the vehicle to enhance performance of the electro-chemical storage device and enhance cabin comfort of the passenger cabin.

13. The system of claim 1, wherein the thermal energy storage material provided within the heat exchanger is encapsulated in spheres in a baffled framework within the heat exchanger.

14. A thermal management system for a vehicle, comprising: a heat exchanger having a thermal energy storage material provided therein; a first coolant loop thermally coupled to an electro-chemical storage device located within the first coolant loop and to the heat exchanger; a second coolant loop thermally coupled to the heat exchanger, the first and second loops configured to carry distinct thermal energy transfer media; an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electro-chemical storage device; a second heat exchanger provided in the first coolant loop, wherein, in operation, thermal energy transfer medium flowing in the first coolant loop is selectively flowed through the second heat exchanger to reduce a temperature T.sub.Batt to within a predetermined temperature range; a bypass fluid path configured to deliver the thermal energy transfer medium circulating in the first coolant loop, bypassing the heat exchanger, to the electro-chemical storage device; and first and second pumps to enable circulation of the thermal energy transfer media provided in the respective first and second coolant loops.

15. The system of claim 14, further comprising a plurality of three-way valves configured to selectively permit the thermal energy transfer medium flowing in the first coolant loop to flow through the heat exchanger or the bypass fluid path.

16. The system of claim 14, wherein the thermal energy transfer medium flowing in the first coolant loop is flowed via the bypass fluid path if a temperature T.sub.Batt of the electro-chemical storage device is above a predetermined maximum threshold temperature T.sub.max.

17. The system of claim 14, wherein the thermal energy transfer medium flowing in the first coolant loop is enabled to flow through the heat exchanger if a temperature T.sub.Batt of the electro-chemical storage device is below a predetermined minimum threshold temperature T.sub.min.

18. The system of claim 14, wherein the second heat exchanger comprises air-to-glycol mixture heat exchanger.

19. The system of claim 14, wherein the first mentioned heat exchanger comprises a liquid-to-liquid heat exchanger.

20. The system of claim 14, wherein the first mentioned heat exchanger comprises: heat exchange tubing configured to exchange heat between the thermal energy storage material and the respective thermal energy transfer media circulating in the first and second coolant loops; and heat exchange fins configured to enhance the heat exchange, wherein the thermal energy storage material is encapsulated in one or more sections of flexible tubing comprised in the heat exchanger, wherein encapsulation in the one or more sections of the flexible tubing reduces a ratio of encapsulant volume relative to volume of the thermal energy storage material.

21. The system of claim 14, wherein the first mentioned heat exchanger is configured to control heat supplied to components of the vehicle during select phases of vehicular operation including cold-start conditions, normal operating conditions, and hot-operating conditions.

22. A thermal management system for a hybrid electric vehicle, comprising: a first fluid loop having a first coolant mixture flowing therein; a battery module located in the first fluid loop; a second fluid loop having a second coolant mixture flowing therein, the second coolant mixture being distinct from the first coolant mixture; a heat exchanger including: a wall defining a chamber; a fluid flow passage inside the chamber, the fluid flow passage defining a portion of the first fluid loop; heat exchange tubing defining a portion of the second fluid loop, the heat exchange tubing being inside the chamber but not being in fluid communication with the fluid flow passage inside the chamber; a flexible pouch in the chamber, and phase change material in the pouch, the pouch being capable of expanding and contracting as the phase change material therein undergoes changes in density because of phase transitions; and phase change material in the flexible pouch; and a thermal interface configured to transfer heat produced by an internal combustion engine of the vehicle to the heat exchanger.

23. The system of claim 22, further comprising: a second heat exchanger thermally coupled to the first fluid loop; and a bypass fluid path configured to deliver the first coolant mixture to the second heat exchanger bypassing the heat exchanger in order to dissipate heat carried by the first coolant mixture and to reduce a temperature T.sub.Batt of the battery module below a maximum desirable temperature T.sub.max.

24. The system of claim 23, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger via the second fluid loop and stored therein, and the heat stored in the heat exchanger is selectively delivered to the battery module via the first fluid loop.

25. The system of claim 22, wherein the heat generated by the internal combustion engine is transferred to the heat exchanger to regenerate the phase change material.

26. The system of claim 22, wherein the heat generated by the internal combustion engine is transfeffed to the heat exchanger via a fluid path configured to be thermally coupled to the second fluid loop and a radiator core of the vehicle, and further wherein after receiving the heat generated by the internal combustion engine, at least one of a sensible heat or a latent heat of fusion of the phase change material is increased from a thermal state to a higher different thermal state.

27. The system of claim 22, wherein the heat generated by the internal combustion engine is transfeffed to the heat exchanger via a fluid path configured to be thermally coupled to the second fluid loop and a radiator core of the vehicle, and further wherein after receiving the heat generated by the internal combustion engine, a sensible heat as well as a latent heat of fusion of the phase change material are increased from a thermal state to a higher different thermal state.

28. The system of claim 22, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle, the passenger cabin being thermally coupled to the heat exchanger via the second fluid loop.

29. A thermal management system for a vehicle, comprising: a heat exchanger means having a means for storing thermal energy; a first coolant loop thermally coupled to an electrical energy storage means located within the first coolant loop; a second coolant loop, the first and second coolant loops being thermally coupled to the heat exchanger means and configured to carry a thermal energy transfer medium; an interface means for enabling transfer of heat generated by an internal combustion engine to the heat exchanger means in order to selectively deliver the heat to the electro-chemical storage means; and a second heat exchanger means provided in the first coolant loop.

30. The system of claim 29, further comprising: a bypass fluid path for delivering a first coolant mixture, provided in the first coolant loop, to the second heat exchanger means, bypassing the heat exchanger means in order to dissipate heat carried by the first coolant mixture to reduce a temperature T.sub.Batt of the electrical energy storage means to within a predetermined maximum temperature T.sub.max.

31. The system of claim 29, wherein the interface means comprises a fluid path that is thermally coupled to the second fluid loop, and a radiator core of the vehicle is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the first mentioned heat exchanger means, and at least one of a sensible heat or a latent heat of fusion of the phase change material is increased from a thermal state to a higher different thermal state after receiving the heat generated by the internal combustion engine.

32. The system of claim 29, wherein the interface means comprising a fluid path that is thermally coupled to the second fluid loop, and a radiator core of the vehicle is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the first mentioned heat exchanger means, further wherein a sensible heat and a latent heat of fusion of the phase change material are increased from a thermal state to a higher different thermal state after receiving the heat generated by the internal combustion engine.

33. The system of claim 29, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle, wherein the passenger cabin is thermally coupled to the first mentioned heat exchanger means via the second coolant loop.

34. A vehicle comprising: a heat exchanger; a first coolant loop thermally coupled to an electro-chemical storage device located within the first coolant loop and to the heat exchanger; a second coolant loop thermally coupled to the heat exchanger, the first and second loops configured to carry distinct thermal energy transfer media; an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electro-chemical storage device; a second heat exchanger provided in the first coolant loop, wherein, in operation, thermal energy transfer medium flowing in the first coolant loop is selectively flowed through the second heat exchanger to reduce a temperature T.sub.Batt to within a predetermined temperature range; a bypass fluid path configured to selectively deliver the thermal energy transfer medium circulating in the first coolant loop, bypassing the heat exchanger, to the electro-chemical storage device; and first and second pumps to enable circulation of the thermal energy transfer media provided in the respective first and second coolant loops.

35. The vehicle of claim 34, further comprising a plurality of three-way valves configured to selectively permit the thermal energy transfer medium flowing in the first coolant loop to flow through the heat exchanger or the bypass fluid path.

36. The vehicle of claim 34, wherein the thermal energy transfer medium flowing in the first coolant loop is flowed via the bypass fluid path if a temperature T.sub.Batt of the electro-chemical storage device is above a predetermined maximum threshold temperature T.sub.max.

37. The vehicle of claim 34, wherein the thermal energy transfer medium flowing in the first coolant loop is enabled to flow through the heat exchanger if a temperature T.sub.Batt of the electro-chemical storage device is below a predetermined minimum threshold temperature T.sub.min.

38. The vehicle of claim 34, wherein the second heat exchanger comprises air-to-glycol mixture heat exchanger.

39. A vehicle comprising: an internal combustion engine; a heat exchanger; a first coolant loop thermally coupled to a battery located within the first coolant loop; a second coolant loop, the first and second coolant loops being thermally coupled to the heat exchanger and configured to carry a thermal energy transfer medium; an interface for enabling transfer of heat generated by the internal combustion engine to the heat exchanger in order to selectively deliver the heat from the engine to the battery; and a second heat exchanger provided in the first coolant loop.

40. The vehicle of claim 39, further comprising a bypass fluid path for delivering a first coolant mixture, provided in the first coolant loop, to the second heat exchanger, bypassing the first mentioned heat exchanger in order to dissipate heat carried by the first coolant mixture to reduce a temperature T.sub.Batt of the battery to within a predetermined maximum temperature T.sub.ma.

41. The vehicle of claim 39, and further comprising a radiator core, wherein the interface comprises a fluid path that is thermally coupled to the second fluid loop, and wherein the radiator core is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the first mentioned heat exchanger.

42. The vehicle of claim 39, and further comprising a radiator core, wherein the interface comprises a fluid path that is thermally coupled to the second fluid loop, and the radiator core is configured to be thermally coupled to the fluid path to transfer the heat generated by the internal combustion engine to the first mentioned heat exchanger.

43. The vehicle of claim 39, wherein the heat generated by the internal combustion engine is selectively delivered to heat a passenger cabin of the vehicle, and wherein the passenger cabin is thermally coupled to the first mentioned heat exchanger via the second coolant loop.

---

Description

---

TECHNICAL FIELD

Aspects of the invention generally relate to thermal management systems (TMSs) and methods.

BACKGROUND OF THE INVENTION

Hybrid electric vehicles (HEVs) and electric vehicles (EVs) provide improved fuel economy and reduced air emissions over conventional vehicles. The performance of HEVs and EVs depend on energy storage systems such as batteries. Battery performance influences, for example, acceleration, fuel economy, and charge acceptance during recovery from regenerative braking. As the cost of the batteries, durability, and life-cycle affect the cost and reliability of a vehicle using the batteries for vehicular operation, parameters that affect the efficiency of the batteries may have to be optimized to achieve optimized vehicular performance.

It is known that temperature has an influence over battery performance. Battery modules carrying batteries are preferred to operate within an optimum temperature range that is suitable for a particular electrochemical pair. For example, the desired operating temperature for a lead acid battery is 25.degree. C. to 45.degree. C. Battery modules may also have to be operated at uniform temperatures as uneven temperature distribution may result in varied charge-discharge behavior. Such varied charge-discharge behavior may lead to electrically unbalanced modules and reduced battery performance.

HEVs may be less reliable in northern latitudes due to cold temperature constraints imposed on the batteries carried by the HEVs. Lithium ion batteries have been a candidate for use in HEVs, and such batteries have optimum performance when operating from 0 40.degree. C. Below 0.degree. C., power output of the batteries diminishes and the effect of temperature becomes more severe as the level of discharge increases. Conversely, as temperatures exceed above 40.degree. C., detrimental cathode corrosion and other irreversible reactions may occur resulting in shortened battery life.

Accordingly, a battery thermal management system (TMS) is needed to achieve desired and reliable performance in varied climatic conditions while minimizing temperature excursions outside a desired temperature range.

SUMMARY OF THE INVENTION

Aspects of the invention also relate to a comprehensive thermal management system for hybrid electric vehicles which include both an internal combustion engine and battery based locomotion (example, lithium-ion, or nickel metal hydride). Aspects of the invention also disclose a thermal management system configured to provide a mechanism to pre-warm a vehicle's battery module, having a plurality of individual cells, in cold conditions, provide auxiliary warmth to the module as needed, and remove heat from it as the batteries heat up due to normal ohmic discharge and recharge.

In some embodiments, a thermal management system for a vehicle includes a heat exchanger having a thermal energy storage material provided therein. The thermal management system includes a first coolant loop thermally coupled to an electro-chemical storage device located within the first coolant loop and to the heat exchanger, a second coolant loop, thermally coupled to the heat exchanger, the first and second loops configured to carry distinct thermal energy transfer media. The thermal management system also includes an interface configured to facilitate transfer of heat generated by an internal combustion engine to the heat exchanger via the second coolant loop in order to selectively deliver the heat to the electrochemical storage device. Thermal management methods are also provided.

In other embodiments, a thermal management system for a hybrid electric vehicle includes a heat exchanger having a phase change material provided therein, a first fluid loop having a first coolant mixture flowing therein, and a second fluid loop having a second coolant mixture flowing therein, the second coolant mixture being distinct from the first coolant mixture. The first and second fluid loops are configured to be in thermal communication with the heat exchanger, the heat exchanger being configured to flow only the first coolant mixture within the heat exchanger. The thermal management system also includes a thermal interface configured to transfer heat produced by an internal combustion engine of the vehicle to the heat exchanger, the heat exchanger being configured to store the heat generated by the internal combustion engine and selectively provide the stored heat to control thermal characteristics of various components of the vehicle including the battery module.

In yet other embodiments, a thermal management method for a vehicle includes providing a heat exchanger having a thermal energy storage material disposed therein, providing first and second coolant loops to circulate distinct coolant mixtures through the respective first and second coolant loops, thermally coupling the first coolant loop to a battery module located within the first coolant loop, thermally coupling the second coolant loop to the heat exchanger, and providing an interface in close proximity to the second coolant loop. The interface is configured to transfer heat generated by an internal combustion engine of the vehicle to the heat exchanger, via the second coolant loop, for storage within the thermal energy storage material. The method also includes selectively performing one or more of preheating the battery module, heating a passenger cabin of the vehicle, increasing sensible heat or latent heat of fusion of the material from a first thermal state to a higher second thermal state using the heat stored within the thermal energy storage material.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the following accompanying drawings.

FIG. 1 shows a schematic of a vehicle in accordance with various embodiments of the invention.

FIG. 2 is a schematic of a thermal management system as shown in FIG. 1 in accordance with various embodiments of the invention.

FIG. 3A is a schematic of a heat exchanger shown in FIG. 2 in accordance with some embodiments of the invention.

FIG. 3B is a schematic of a heat exchanger shown in FIG. 2 in accordance with other embodiments of the invention.

FIG. 4 is a graph illustrating a thermal cycle for a phase change material that is stored in a heat exchanger in accordance with various embodiments of the invention.

FIG. 5 is a graph illustrating temperature history of a phase change material and battery cooling fluid in accordance with various embodiments of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws "to promote the progress of science and useful arts" (Article 1, Section 8).

The following terminology as described below is used to define terms that are used in this application.

The following operational parameters and control strategy may be used in various embodiments:

Measured Temperatures. T.sub.Batt: average or representative temperature within battery module of battery 110. T.sub.Cab: representative temperature of coolant within the internal combustion engine cabin (ICE cabin) heater core 118. T.sub.PCM: average or representative temperature within phase change material (PCM) module 214, 218 of heat exchanger (HX) 116. T.sub.Rad: representative temperature of the internal combustion engine radiator coolant/fluid in loop 104.

Set-Point Temperatures. T.sub.min: minimum desirable battery temperature. T.sub.max: maximum desirable battery temperature. T*: minimum desirable temperature of cabin heater core. T**: phase change material melting temperature plus a margin of 5 to 10.degree. C.

Control Strategy in Accordance with Various Embodiments of the Invention. V1--full open to heat exchanger 106: T.sub.Batt>T.sub.max; otherwise closed to heat exchanger 106. V2--full open to Bypass: T.sub.Batt>T.sub.max; otherwise closed to Bypass. V3--full open to cabin core: [(T.sub.Batt>T.sub.min) and (T.sub.Batt<T.sub.max)] and (T.sub.Cab<T*) and (T.sub.Rad<T*) and (T.sub.PCM>T.sub.Cab); otherwise open to internal combustion engine radiator 120. FAN 108--On at T.sub.Batt>T.sub.max; otherwise Off. P1--On: (T.sub.Batt<T.sub.min) or (T.sub.Batt>T.sub.max). Off: (T.sub.Batt>T.sub.min) and (T.sub.Batt<T.sub.max). P2--On: (a) using internal combustion engine coolant/fluid in loop 104 to help warm batteries 110 (T.sub.Batt<T.sub.min) and (T.sub.PCM<T.sub.min) and (T.sub.Rad>T.sub.PCM). (b) sending excess heat to cabin heater core 118 [(T.sub.Batt>T.sub.min) and (T.sub.Batt<T.sub.max)] and (T.sub.PCM>T.sub.Cab) and (T.sub.Cab<T*) and (T.sub.Rad<T*). (c) remelting phase change material (214, 218) and increasing sensible heat of the phase change material (214, 218) {[(T.sub.Batt>T.sub.min) and (T.sub.Batt<T.sub.max)] or (T.sub.Batt>T.sub.max)} and (T.sub.PCM>T**) Otherwise Off.

FIG. 1 shows a vehicle 10 embodying the invention. The vehicle 10 includes a thermal management system 100 and an on-board processor (and memory) or processor 101 in communication with the thermal management system 100.

The thermal management system 100 is configured to manage heat (e.g., thermal management of electro-chemical energy storage device 110 (e.g., battery module or battery)) (FIG. 2) of vehicle 10 during various phases of vehicular operation, such as for example, cold-start conditions, normal conditions, and hot environmental conditions. The device 110 is generally referred to herein as battery 110. The device 110 may also be provided as an electro-chemical energy storage device module. Further details of the thermal management system 100 are set forth and described below with reference to FIG. 2. Exemplary embodiments of battery types include lithium-ion, nickel-metal-hydride, and lead-acid. The electro-chemical energy storage device may comprise one or more batteries, capacitors, fuel cells, or combinations thereof.

The on-board processor 101 is configured to control various operations of the vehicle 10 including controlling of various sensors (not shown) of the vehicle 10. The on-board processor 101 may also be configured to control heat (e.g., heat supplied/discharged to/from the battery 110 (FIG. 2)) together with the thermal management system 100, during various phases of vehicular operation as noted above. In some embodiments, the processor 101 may comprise circuitry configured to execute provided programming. For example, the processor 101 may be implemented as a microprocessor or other structure configured to execute executable instructions of programming including, for example, software or firmware instructions. Other exemplary embodiments of the processor 101 include hardware logic, PGA, FPGA, ASIC, or other structures. These examples of the processor 101 are illustrative. As such, other configurations are possible for implementing operations performed by the processor 101.

In some embodiments, a separate processor is used in connection with the thermal management system 100 than the on-board processor.

In other embodiments, the processor 101 may be programmed with predetermined temperature value(s) in a desired temperature range (e.g., of battery 110 (FIG. 2)) corresponding to various phases of vehicular operation as noted above. The processor 101 is configured to compare the stored value(s) with measured temperature value(s) and provide instructions, based on the comparison, to the thermal management system 100 configured to manage heat of the battery 110 during various phases of operation of the vehicle 10. Further details of such heat management are set forth below with reference to FIG. 2.

FIG. 2 is a schematic of the thermal management system 100 as shown in FIG. 1. The thermal management system 100 includes heat exchanging fluid loops 102, 104, heat exchangers 106, 116, a fan 108 corresponding to the heat exchanger 106, a battery 110 (e.g., a lithium-ion battery or battery bank), a coolant expansion tank (ET) 112, pumps P1 and P2, a bypass loop 114, an internal combustion engine cabin heater core 118 (referred to herein as internal combustion engine cabin), an internal combustion engine radiator 120, and an interface 122. The thermal management system 100 also includes a plurality of valves V1 V7 (e.g., control valves V1 V3 and check valves V4 V7).

The loop 102 (shown to the left of heat exchanger 116) is configured as a battery side coolant loop for flowing or recirculating coolant or a fluid or a thermal energy transfer medium from the expansion tank 112 to add or remove heat from the battery 110 of the vehicle 10. The loop 102 is alternatively referred to herein as "battery fluid loop". In some embodiments, coolant flowing in the loop 102 is circulated via the loop 114 bypassing the heat exchanger 116. In other embodiments, coolant flowing in the loop 102 flows through the heat exchanger 116 without flowing via the loop 114. The control valve V2 is appropriately controlled (e.g., opened or closed) to achieve such functionality.

The loop 104 (shown to the right side of heat exchanger 116) is configured as an internal combustion engine side coolant loop 104 for flowing or recirculating heat exchanging fluid or a coolant via the heat exchanger 116, the internal combustion engine cabin 118 in some embodiments. In other embodiments, the loop 104 is configured for flowing or recirculating the heat exchanging fluid via the heat exchanger 116 and the internal combustion engine radiator 120 bypassing the internal combustion engine cabin 118. The heat exchanging fluid flowing through the loop 104 may be a coolant used for cooling the internal combustion engine (not shown), whereas the fluid flowing through the loop 102 can be of a different composition, compared to the fluid in the loop 104, to achieve unique heat transfer performance for the loop 102.

The heat exchanger 106 together with the fan 108 is configured to control temperature of the battery 110 to be within a predetermined optimal range. In one embodiment, fluid in the loop 102 is recirculated through the heat exchanger 106 in order to control excessive temperatures of the fluid in the loop 102, the fluid being circulated through the battery 110.

Battery 110 includes energy storage batteries configured to provide energy for operation of the vehicle 10. The battery 110 may be configured to have the loop 102 passing through the battery 110 to control thermal characteristics of the battery 110. It will be appreciated that the battery 110 may be configured to include a module to house a fluid (e.g., coolant) and such module may be configured to be coupled to the loop 102.

The expansion tank 112 may be configured as a coolant expansion tank for housing the fluid that is circulated in the loop 102.

The loop 114 is configured as a bypass loop for the fluid recirculating in the loop 102. Fluid in the loop 102 may be flowed through the loop 114 bypassing the heat exchanger 116 in some embodiments.

The heat exchanger 116 is configured as a well-insulated heat exchanger vessel to store a fixed volume of phase change material (reference numerals 214, 218 of FIGS. 3A, 3B) and a small volume of fluid (e.g., coolant) that is pre-warmed from a prior operation of the vehicle 10. The phase change material of the heat exchanger 116 provides latent and sensible heat that may be transferred to the fluid flowing through the heat exchanger 116 in some embodiments.

The heat exchanger 116 is further configured to facilitate heat transfer to control thermal characteristics of the battery 110 as well as controlling a temperature of a passenger cabin of the vehicle 10 by flowing the fluid in the loop 104 via the internal combustion engine cabin 118 in some embodiments. Further design details of the heat exchanger 116 are set forth below with reference to FIGS. 3A 3B.

The internal combustion engine cabin heater core 118 is configured to provide heat to the passenger cabin of the vehicle 10 to maintain a temperature of the passenger cabin within a predetermined temperature range.

The internal combustion engine radiator 120 is configured to control the temperature of the internal combustion engine.

The interface 122 is configured as an interface between the thermal management system 100 and the internal combustion engine (not shown) of the vehicle 10. For example, the interface 122 is designed to transport heat transfer fluids containing waste heat generated by the internal combustion engine to control the temperature of the battery 110 provided in the loop 102. Waste heat generated by the internal combustion engine may be transferred to the heat exchanger 116 via the loop 104, and the heat transferred to the heat exchanger 116 is stored in the phase change material resident in the heat exchanger 116. Such heat stored in the phase change material resident in the heat exchanger 116 is then provided to the battery 110 via the loop 102 to increase the temperature T.sub.Batt of the battery 110.

Phase change materials are desirable in a thermal management system due to exothermic heat of phase change, or latent heat, that is released as the phase change material undergoes a transition from one state (e.g., liquid) to another state (e.g., solid). Phase change materials are also desirable as a thermal cycle of most phase change materials is reversible, thus enabling the phase change material to be regenerated from a solid state to a liquid state by the addition of external heat. With regeneration, a phase change material may be used as a reliable heat source for multiple times. The combination of the phase change material latent heat and sensible heat (e.g., heat above that which is required to achieve phase change material melting) increases the overall heating value per mass.

The phase change materials used in various embodiments of the invention are desired to have the following characteristics: (i) Undergo fusion/melting within the desired temperature range (e.g., melting below 90 degrees C. and fusion (crystallization) at no lower than -20 degrees C.); (ii) limited or controlled supercooling so that nucleation would occur on demand;

(iii) high heat of fusion;

(iv) rapid crystallization so that heat is generated at a useable rate;

(v) ability to undergo numerous cycles without degradation or diminished performance;

(vi) be inexpensive, readily available, non-toxic, non-flammable, non-reactive, and non-corrosive.

The inventors have determined the materials as listed in Table I to be viable phase change material candidates for various embodiments of the invention.

TABLE-US-00001 TABLE I Melting Autonucleation Phase Change Material Temperature, .degree. C. Temperature, .degree. C. Sodium acetate 3.6-hydrate 58 -10 to -18 Sodium acetate 4.0-hydrate 58 -14 to -18 Sodium acetate/magnesium 58 -17 to -21 acetate (1 wt % Mg) 3.5-hydrate Sodium acetate/magnesium 58 -14 to -20 acetate (5 wt % Mg) 3.5-hydrate Ethylene carbonate 36 8.2 Ethylene carbonate/propylene 36 -0.5 carbonate (3.7 mole % PC) Ethylene carbonate/propylene 36 3.4 carbonate (5.6 mole % PC) Ethylene carbonate/propylene 36 12.8 carbonate (6.7 mole % PC) Calcium chloride 6.0-hydrate 30 2 Sodium hydrogen phosphate 12- 35 20 to 25 (ambient) hydrate

In accordance with various embodiments, the thermal management system 100 is configured to maintain temperatures of the battery 110 within an optimal range while providing heat for cabin comforts under cold environmental conditions. For example, an optimal range may be chosen to be between 0 40 degrees Centigrade. Such a temperature range was found to be favorable for Lithium-ion batteries.

During the operation of the thermal management system 100, fluids within the loops 102, 104 are circulated to add or remove heat according to a predetermined thermal protocol (e.g., predetermined values or established conditions) of the vehicle 10. Valves V1 V3 (e.g., control valves) and valves V4 V7 (e.g., one-way check valves) are configured to ensure that respective fluids in the loops 102, 104 flow through desired fluid paths. Valves V1 and V2 are specified as thermostatic, wherein their actuation is driven by the temperature of the fluid flowing through each. Valve V3 is electronically actuated based on control logic resident within the processor 101 and relevant temperature inputs described herein. The operation of the thermal management system 100 may be described by the following exemplary modes of operation: (1) cold-start conditions, (2) normal conditions, (3) hot mode. Each mode of operation is controlled by defined control parameters as described below.

Under cold-start conditions, the temperature (T.sub.Batt) of the battery 110 may not be within a predetermined temperature range. In some embodiments, if T.sub.Batt is beneath the predetermined temperature range, then the pump P1 is operated (e.g., turned ON) and valve V2 is controlled to circulate the fluid (e.g., coolant) from the battery 110 to the heat exchanger 116, whereupon sensible heat (e.g., heat stored in the fluid present in the heat exchanger 116) is transferred to the fluid circulating in the loop 102 and flowing through the heat exchanger 116. For example, after pump P1 is operated, fluid from the battery 110 and flowing in the loop 102 flows to the heat exchanger 116 and displaces the pre-warmed fluid therein. The pre-warmed fluid is circulated to the battery 110 by appropriately operating the valves V4 and V1. In other embodiments, latent heat from the phase change material resident in the heat exchanger 116 can also be transferred if the fluid circulating in the loop 102 and in contact with the phase change material (reference numerals 214, 218 of FIGS. 3A, 3B) in the heat exchanger 116 is sufficiently cold to initiate autonucleation of the phase change material 214, 218.

However, if the heat exchanger 116 is unable to provide sufficient heat (e.g., to the fluid circulating in the loop 102 through the heat exchanger 116) to increase T.sub.Batt due to the low temperature T.sub.PCM of the phase change material (214, 218), then pump P2 is operated (e.g., turned ON) to circulate fluid (e.g., internal combustion engine coolant) from the internal combustion engine (not shown) to the heat exchanger 116 via the interface 122 (e.g., internal combustion engine-heat exchanger interface). In this case, waste heat generated by the internal combustion engine is transferred to the heat exchanger 116. For example, if the fluid in the internal combustion engine is warmer than T.sub.PCM and {(T.sub.Batt<T.sub.min) and (T.sub.PCM<T.sub.min)}, then the pump P2 is turned ON to circulate warm fluid from the internal combustion engine to the heat exchanger 116 via the interface 122. After the pump P2 is turned ON, the pump P1 is operated to circulate fluid, present in the loop 102, through the heat exchanger 116 until the temperature of the battery 110 is restored to be within the predetermined temperature range.

Operation of thermal management system 100 under normal conditions is now described. Normal conditions described herein are defined by the temperature T.sub.Batt of the battery 110 being within the predetermined temperature range. Under the normal conditions, the pump P1 remains OFF. However, the pump P2 may recirculate fluid in the loop 104 to the heat exchanger 116 in order to remove excess heat from the heat exchanger 116 if the temperature (T.sub.PCM) of the phase change material (214, 216) resident in the heat exchanger 116 is greater than the temperature of the fluid circulating in the loop 104. After the excess heat from the phase change material (214, 216) is transferred to the fluid in the loop 104, valves V5 and V3 are appropriately controlled to route the fluid from the heat exchanger 116, with the received excess heat, to the internal combustion engine cabin 118 if the temperature of the internal combustion engine cabin 118 is less than a predetermined temperature range.

However, if the temperature of the internal combustion engine cabin 118 is within a predetermined temperature range, then valve V3 is controlled to route the fluid from the heat exchanger 116, with the received excess heat, to the internal combustion engine radiator 120 and bypassing the internal combustion engine cabin 118. Circulating the fluid that is received from the heat exchanger 116 to flow through the internal combustion engine radiator 120 further increases the temperature of the fluid that is circulated in the loop 104. The fluid flowing from the internal combustion engine radiator and circulating in the loop 104 is flowed through the heat exchanger 116, by controlling the valve V7 and the pump P2, to remelt the phase change material (214, 218) resident in the heat exchanger 116, thereby increasing the thermal energy of the phase change material. This process ensures that the phase change material is remelted at the first opportunity, thereby reactivating the phase change material and keeping it ready for subsequent use under cold-start conditions as explained above.

It will be appreciated that normal conditions may occur under cold ambient conditions since the battery 110 and the heat exchanger 116 are sufficiently insulated to render the thermal management system 100 operable within predetermined optimal temperature ranges. The types and methods of insulation used may depend on maximum acceptable heat loss rates for the battery 110 and the heat exchanger 116. Such heat loss rates may depend on vehicle-dependent factors as well as regional weather characteristics. In some embodiments, the battery 110 and the heat exchanger 116 are designed such that T.sub.Batt is above 0 degrees C. and T.sub.PCM is above 40 degrees C. over a period of thirty-six hours of inactivity of the vehicle 10.

Operation of the thermal management system 100 under hot conditions is now described. Hot conditions occur when temperature (T.sub.Batt) of the battery 110 exceeds the optimal temperature range due to normal ohmic discharge and recharging of the battery 110. Under hot conditions, fluid in the loop 102 is made to bypass the heat exchanger 116 by controlling (e.g., closing valve to heat exchanger 116 and opening valve to bypass loop 114) the valve V2. The valve V1 controls the fluid in the loop 102 to flow through the heat exchanger 106 (e.g., air cooled heat exchanger). After receiving the fluid in the heat exchanger 106, the fan 108 is turned ON until T.sub.Batt drops below the maximum optimal temperature (e.g., 40 degrees C.). Under the hot conditions, and in some embodiments, the pump P2 may be turned ON while the valve V3 is configured to direct the fluid in the loop 104 to circulate between the internal combustion engine radiator 120 and the heat exchanger 116 to heat the phase change material (214, 218) resident in the heat exchanger 116 as described above.

FIG. 3A is a cross-sectional schematic of the heat exchanger 116 shown n in FIG. 2, in accordance with some embodiments. The heat exchanger 116 includes the fluid circulation loops 102, 104, insulation 202, a fluid (e.g., coolant) filled chamber 204, a plurality of heat exchange fins 208, heat exchange tubing 210, 211, a baffle member 212, and a phase change material filled pouch 214.

The fluid circulation loops 102, 104 are configured to circulate fluid to control, for example, the thermal characteristics of the battery 110, temperature of the internal combustion engine cabin 118, and the heat content of the phase change material resident in the heat exchanger 116. Such have been described above with reference to FIG. 2 and therefore will not be repeated.

The chamber 204 is configured to circulate fluids received from the loops 102, 104, respectively in order to control the temperature of the circulating fluids to be within predetermined temperature ranges. The fluid circulating in the loop 102 flows within the heat exchanger 116 and the chamber 204 while fluid circulating in the loop 104 flows through the tubing 211 without flowing through the chamber 204.

The heat exchange fins 208 and the heat exchange tubing 210, 211 may be provided within the pouch 214 (e.g., heavy-gauge polymer pouch) filled with phase change material. In one embodiment, the pouch 214 is configured to expand and contract as the phase change material disposed therein undergoes changes in density during phase transitions. In one embodiment, heat exchange tubing 210, 211 may share the heat exchange fins 208. As noted above, fluid circulating in the loop 104 and flowing via the tubing 211 remains within the tubing 211 during its passage through the heat exchanger 116. However, fluid circulating in the loop 102 and flowing via the tubing 210 passes from the tubing 210 into the chamber or void space 204 provided between the phase change material pouch 214 and an internal wall bounded by the insulation 202 of the heat exchanger 116.

The baffle 212 blocks the pathway of the fluid circulating in the loop 102, the tubing 210, and the chamber 204 such that the fluid is forced to travel around the pouch 214 before it is allowed to leave the heat exchanger 116, thereby facilitating increased heat absorption by the phase change material resident in the heat exchanger 116.

The embodiment shown in FIG. 3A may be desired where heat transfer rate to and from the phase change material provided in the pouch 214 is desired to be maintained at a predetermined level. Further, the embodiment shown in FIG. 3A may be used where an auxiliary device or a nucleation triggering device (not shown) is desired to be placed in close proximity with the phase change material filled pouch 214 to promote forced nucleation.

In another embodiment, a "nucleation triggering device" may be provided within the phase change material (PCM) reservoir in order to activate the phase change material (e.g., 214, 218) on demand. This mode of activation may be provided as an alternative to autonucleation, and may be performed per the control logic (e.g., processor 101) resident in the vehicle. Enabling the phase change material to be activated on demand provides more consistent and timely nucleation of the phase change material. For example, the auxiliary device or nucleation triggering device may be employed within the tubular encapsulated phase change material within heat exchanger 1116 (FIG. 3B). An exemplary embodiment of such triggering device is a fixed stainless steel disc (e.g., fixed within a short, rigid tubular enclosure) having a slight concavity, that has several parallel thin slits cut into its interior. Upon flexure of the disc through a mechanical trigger, the interfacial dynamics between the disc and liquid phase change material induce phase change material crystallization. The inventors have demonstrated and found to be effective a device comprised solely of the stainless steel disc (having exemplary dimensions of 5/8 inch diameter by 0.02 inch thickness) to be effective for nucleating PCM materials such as sodium acetate trihydrate, ethylene carbonate, and calcium chloride hexahydrate. Stainless steel nucleators having other designs are possible.

FIG. 3B is a cross-sectional schematic of the heat exchanger 116 in accordance with some embodiments wherein elements like those shown in FIG. 3A are identified using similar reference numerals, but with a prefix "1" added.

In a preferred embodiment of the invention, the phase change material of the heat exchanger 1116 may be encapsulated in section(s) of flexible tubing instead of being encapsulated in spheres 218. The flexible tubing may be configured to conform to the internal space of the heat exchanger 1116 (e.g., coils, serpentine, or straight sections, etc.). The inventors have discovered that by using the flexible tubing instead of the spheres, a lower volume of encapsulant material is used for a similar volume of the phase change material. The ratio of encapsulant volume to the volume of the phase change material may be further reduced by using the flexible tubing with a thinner wall thickness. Exemplary selection criteria for the encapsulant tubing include high thermal conductivity, chemical compatibility, thermal compatibility, expandable/contractible properties of the tubing with phase change material phase changes, and increased lifetime. If wide variations of phase change material density are anticipated, then ends of the tubing may be heat-sealed or capped to allow a small volume of air to be trapped within the tubing.

The heat exchanger 1116 includes fluid circulation loops 1102 and 1104, an insulation 1202, a plurality of heat exchange fins 1208, a heat exchange tubing 1211, a baffled section 220 having phase change material encapsulated in spheres 218. The encapsulating material may be polypropylene in one case. In one embodiment, the baffled section 220 with the phase change material spheres 218 is configured to surround the tubing 1211. Fluid in the circulation loop 1102 flows in the baffled pathway indicated by the arrows. The fluid in the loop 1102 is provided in intimate contact with the phase change material spheres 218. However, the fluid in the loop 1102 does not flow to disperse within the baffled section 220.

The embodiment shown in FIG. 3B may be desired where the phase change material resident in the heat exchanger 1116 has an autonucleation point within a predetermined temperature range (e.g., 0 40 degrees C.). The heat exchanger 1116 shown in FIG. 3B may be easier to service, and is configured to use different phase change materials as the phase change material is encapsulated in spheres.

The embodiments of the heat exchanger shown in FIGS. 3A and 3B are exemplary. Other arrangements (e.g., a plate-and-frame design with external fins) of the heat exchanger are possible. An oval or cylindrical profile of the overall heat exchanger may be preferred for some other vehicle applications. Performance of the heat exchanger (e.g., heat exchanger 116) may be optimized by using an intelligent selection of phase change materials, such as for example, organic carbonates or hydrated inorganic salts shown in Table I as above. The choice of a phase change material may be based on the vehicle type and the geographic region of the vehicle's intended use.

FIG. 4 is a graph illustrating a thermal cycle for a phase change material stored in a heat exchanger (e.g., heat exchanger 116) in accordance with various embodiments of the invention. The thermal cycle path A-B-C shown in the graph indicates a normal thermal cycle, while the path A-B'-C indicates a shortened thermal cycle resulting in an incomplete release of heat from the phase change material resident in the heat exchanger 116. The general steps for the phase change material utilization cycle in accordance with the various embodiments are shown in Table II as below:

TABLE-US-00002 TABLE II Temperature Step Change Description/Requirements 1. Activation At T.sub.a May occur at any temperature lower than at low the melting point (T.sub.m) but above the glass ambient transition temperature (T.sub.g) of a metastable temperature phase change material, provided the phase (T.sub.a) change material is in the liquid state. It is preferred to activate