U.S. patent application number 12/433155 was filed with the patent office on 2010-11-04 for cooling system for a battery system and a method for cooling the battery system.
This patent application is currently assigned to LG CHEM, LTD.. Invention is credited to William Koetting, Josh Payne, Kwok Tom.
Application Number | 20100275619 12/433155 |
Document ID | / |
Family ID | 43029365 |
Filed Date | 2010-11-04 |
United States Patent
Application |
20100275619 |
Kind Code |
A1 |
Koetting; William ; et
al. |
November 4, 2010 |
COOLING SYSTEM FOR A BATTERY SYSTEM AND A METHOD FOR COOLING THE
BATTERY SYSTEM
Abstract
A cooling system for a battery system and a method for cooling
the battery system are provided. The cooling system includes a
housing having first and second enclosed portions, and a first
evaporator and a first evaporator fan disposed in the first
enclosed portion that recirculates air in a first closed flow path
loop within the first enclosed portion. The first evaporator
extracts heat energy from the air in the first closed flow path
loop to reduce a temperature level of a first battery module in the
first enclosed portion. The cooling system further includes a
condenser disposed in the second enclosed portion and fluidly
coupled to the first evaporator, which receives heat energy in a
refrigerant from the first evaporator and dissipates the heat
energy. The cooling system further includes a compressor disposed
in the second enclosed portion that recirculates the refrigerant
through the first evaporator and the condenser.
Inventors: |
Koetting; William;
(Davisburg, MI) ; Payne; Josh; (Royal Oak, MI)
; Tom; Kwok; (Madison Heights, MI) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
LG CHEM, LTD.
Seoul
KR
|
Family ID: |
43029365 |
Appl. No.: |
12/433155 |
Filed: |
April 30, 2009 |
Current U.S.
Class: |
62/79 ; 62/115;
62/129; 62/259.2 |
Current CPC
Class: |
F25D 29/00 20130101;
H01M 10/613 20150401; F25D 2317/0682 20130101; H01M 50/20 20210101;
H01M 10/633 20150401; H01M 10/6569 20150401; H01M 10/486 20130101;
F25D 2700/16 20130101; H01M 10/6563 20150401; Y02E 60/10
20130101 |
Class at
Publication: |
62/79 ; 62/259.2;
62/129; 62/115 |
International
Class: |
F25B 7/00 20060101
F25B007/00 |
Claims
1. A cooling system for a battery system, comprising: a housing
having a first enclosed portion and a second enclosed portion, the
first enclosed portion configured to receive a first battery module
therein; a first evaporator disposed in the first enclosed portion;
a first evaporator fan disposed proximate to the first evaporator
in the first enclosed portion configured to recirculate air in a
first closed flow path loop within the first enclosed portion, the
first evaporator configured to extract heat energy from the air in
the first closed flow path loop to reduce a temperature level of
the first battery module; a condenser disposed in the second
enclosed portion and fluidly coupled to the first evaporator, the
condenser configured to receive heat energy in a refrigerant from
the first evaporator and to dissipate the heat energy; and a
compressor disposed in the second enclosed portion that
recirculates the refrigerant through the first evaporator and the
condenser.
2. The cooling system of claim 1, wherein the first closed flow
path loop comprises a flow path through the first evaporator fan
and past the first evaporator and then through air flow channels in
the first battery module and then back through the first evaporator
fan.
3. The cooling system of claim 1, further comprising a first
temperature sensor generating a first signal indicative of a
temperature level of the first battery module.
4. The cooling system of claim 3, further comprising: a condenser
fan disposed in the second enclosed portion; a microprocessor
operably coupled to the first temperature sensor that receives the
first signal, the microprocessor configured to generate a second
signal to induce the compressor to recirculate the refrigerant
through the first evaporator and the condenser to cool the first
battery module when the first signal indicates the temperature
level of the first battery module is greater than a threshold
temperature level; the microprocessor further configured to
generate a third signal to induce the first evaporator fan to
recirculate air in the first closed flow path loop within the first
enclosed portion when the first signal indicates the temperature
level of the first battery module is greater than the threshold
temperature level; and the microprocessor further configured to
generate a fourth signal to induce the condenser fan to urge air
past the condenser to induce the condenser to dissipate heat energy
when the first signal indicates the temperature level of the first
battery module is greater than the threshold temperature level.
5. The cooling system of claim 1, further comprising: a second
evaporator disposed in the first enclosed portion, the second
evaporator fluidly coupled to the condenser; a second evaporator
fan disposed proximate to the second evaporator in the first
enclosed portion, the second evaporator fan configured to
recirculate air in a second closed flow path loop within the first
enclosed portion, the second evaporator configured to extract heat
energy from the air in the second closed flow path loop to reduce a
temperature level of a second battery module disposed in the first
enclosed portion; the condenser further fluidly coupled to the
second evaporator, the condenser further configured to receive heat
energy in refrigerant from the first and second evaporators and to
dissipate the heat energy; and the compressor further configured to
recirculate the refrigerant through the first and second
evaporators and the condenser.
6. The cooling system of claim 5, wherein the second closed flow
path loop comprises a flow path through the second evaporator fan
and past the second evaporator and then through air flow channels
in the second battery module and then back through the second
evaporator fan.
7. The cooling system of claim 5, further comprising: a first
temperature sensor generating a first signal indicative of a
temperature level of the first battery module, and a second
temperature sensor generating a second signal indicative of a
temperature level of the second battery module.
8. The cooling system of claim 7, further comprising: a condenser
fan disposed in the second enclosed portion; a microprocessor
operably coupled to the first and second temperature sensors that
receives the first and second signals, respectively; the
microprocessor configured to determine a first temperature
difference value by subtracting the first signal from the second
signal; the microprocessor further configured to generate a third
signal to induce the compressor to recirculate the refrigerant
through the first evaporator, the second evaporator, and the
condenser to cool the second battery module when the first
temperature difference value is greater than a threshold difference
value; the microprocessor further configured to generate a fourth
signal to induce the second evaporator fan to recirculate air in
the second closed flow path loop within the first enclosed portion
when the first temperature difference value is greater than the
threshold difference value; and the microprocessor further
configured to generate a fifth signal to induce the condenser fan
to urge air past the condenser to induce the condenser to dissipate
heat energy in the refrigerant when the first temperature
difference value is greater than the threshold difference
value.
9. The cooling system of claim 7, further comprising: a condenser
fan disposed in the second enclosed portion; a microprocessor
operably coupled to the first and second temperature sensors that
receives the first and second signals, respectively; the
microprocessor configured to determine a first temperature
difference value by subtracting the second signal from the first
signal; the microprocessor further configured to generate a third
signal to induce the compressor to recirculate the refrigerant
through the first evaporator, the second evaporator, and the
condenser to cool the first battery module when the first
temperature difference value is greater than a threshold difference
value; the microprocessor further configured to generate a fourth
signal to induce the first evaporator fan to recirculate air in the
first closed flow path loop within the first enclosed portion when
the first temperature difference value is greater than the
threshold difference value; and the microprocessor further
configured to generate a fifth signal to induce the condenser fan
to urge air past the condenser to induce the condenser to dissipate
the heat energy in the refrigerant when the first temperature
difference value is greater than the threshold difference
value.
10. The cooling system of claim 1, further comprising a cooling
coil that receives a liquid therein to remove heat energy from the
refrigerant in the condenser.
11. The cooling system of claim 1, wherein the first enclosed
portion is an airtight enclosed portion.
12. A method for cooling a battery system utilizing a cooling
system, the cooling system having a housing, a first evaporator, a
first evaporator fan, and a condenser, the housing having a first
enclosed portion and a second enclosed portion, the first enclosed
portion configured to receive a first battery module therein, the
method comprising: recirculating air in a first closed flow path
loop within the first enclosed portion utilizing the first
evaporator fan, the first evaporator configured to extract heat
energy from the air in the first closed flow path loop to reduce a
temperature level of the first battery module in the first enclosed
portion of the housing; receiving heat energy in a refrigerant from
the first evaporator in a condenser disposed in the second enclosed
portion of the housing and dissipating the heat energy utilizing
the condenser; and recirculating the refrigerant through the first
evaporator and the condenser utilizing a compressor disposed in the
second enclosed portion.
13. The method of claim 12, wherein the cooling system further has
a condenser fan, a temperature sensor, and a microprocessor, the
method further comprising: generating a first signal indicative of
a temperature level of the first battery module utilizing a
temperature sensor; generating a second signal to induce the
compressor to recirculate the refrigerant through the first
evaporator and the condenser to cool the first battery module
utilizing the microprocessor when the first signal indicates the
temperature level of the first battery module is greater than a
threshold temperature level; generating a third signal to induce
the first evaporator fan to recirculate air in the first closed
flow path loop within the first enclosed portion when the first
signal indicates the temperature level of the first battery module
is greater than the threshold temperature level; and generating a
fourth signal to induce the condenser fan to urge air past the
condenser to induce the condenser to dissipate heat energy when the
first signal indicates the temperature level of the first battery
module is greater than the threshold temperature level.
14. The method of claim 12, wherein the cooling system further
comprises a second evaporator and a second evaporator fan disposed
in the first enclosed portion, the second evaporator fluidly
coupled to the condenser, the first enclosed portion configured to
receive a second battery module therein, further comprising:
recirculating air in a second closed flow path loop within the
first enclosed portion utilizing the second evaporator fan, the
second evaporator configured to extract heat energy from the air in
the second closed flow path loop to reduce a temperature level of
the second battery module in the first enclosed portion; receiving
heat energy in refrigerant from the first and second evaporators in
the condenser disposed in the second enclosed portion and
dissipating the heat energy in the refrigerant utilizing the
condenser; and recirculating the refrigerant through the first
evaporator, the second evaporator, and the condenser utilizing the
compressor disposed in the second enclosed portion.
15. The method of claim 12, wherein the first enclosed portion is
an airtight enclosed portion.
Description
TECHNICAL FIELD
[0001] This application relates to a cooling system for a battery
system and a method for cooling the battery system.
BACKGROUND OF THE INVENTION
[0002] In a typical air-cooled battery pack, ambient air from
ambient atmosphere is directed across battery cells in the battery
pack and is subsequently exhausted from the battery pack. However,
the typical air-cooled battery pack has a major challenge in
maintaining a temperature of the battery pack within a desired
temperature range.
[0003] In particular, a maximum operating temperature of the
battery cells can often be less than a temperature of ambient air
utilized to cool the batteries. In this situation, it is impossible
to maintain the battery cells within a desired temperature range in
an air-cooled battery pack.
[0004] Accordingly, the inventors herein have recognized a need for
an improved battery cell assembly that minimizes and/or eliminates
the above-mentioned deficiency.
SUMMARY OF THE INVENTION
[0005] A cooling system for a battery system in accordance with an
exemplary embodiment is provided. The cooling system includes a
housing having a first enclosed portion and a second enclosed
portion. The first enclosed portion is configured to receive a
first battery module therein. The cooling system further includes a
first evaporator disposed in the first enclosed portion. The
cooling system further includes a first evaporator fan disposed
proximate to the first evaporator in the first enclosed portion
configured to recirculate air in a first closed flow path loop
within the first enclosed portion. The first evaporator is
configured to extract heat energy from the air in the first closed
flow path loop to reduce a temperature level of the first battery
module. The cooling system further includes a condenser disposed in
the second enclosed portion and fluidly coupled to the first
evaporator. The condenser is configured to receive heat energy in a
refrigerant from the first evaporator and to dissipate the heat
energy. The cooling system further includes a compressor disposed
in the second enclosed portion that recirculates the refrigerant
through the first evaporator and the condenser.
[0006] A method for cooling a battery system utilizing a cooling
system in accordance with another exemplary embodiment is provided.
The cooling system has a housing, a first evaporator, a first
evaporator fan, and a condenser. The housing has a first enclosed
portion and a second enclosed portion. The first enclosed portion
is configured to receive a first battery module therein. The method
includes recirculating air in a first closed flow path loop within
the first enclosed portion utilizing the first evaporator fan. The
first evaporator is configured to extract heat energy from the air
in the first closed flow path loop to reduce a temperature level of
the first battery module in the first enclosed portion of the
housing. The method further includes receiving heat energy in a
refrigerant from the first evaporator in a condenser disposed in
the second enclosed portion of the housing and dissipating the heat
energy utilizing the condenser. The method further includes
recirculating the refrigerant through the first evaporator and the
condenser utilizing a compressor disposed in the second enclosed
portion.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a schematic of a power generation system having a
battery system and a cooling system in accordance with an exemplary
embodiment;
[0008] FIG. 2 is a schematic of a portion of a housing, battery
modules, and the cooling system utilized in the power generation
system of FIG. 1;
[0009] FIG. 3 is a schematic of a top view of the housing, battery
modules, and the cooling system utilized in the power generation
system of FIG. 1;
[0010] FIG. 4 is a cross-sectional schematic of the power
generation system of FIG. 1;
[0011] FIG. 5 is a block diagram of components of the cooling
system utilized in the power generation system of FIG. 1;
[0012] FIG. 6 is a schematic of a portion of the housing and the
cooling system utilized in the power generation system of FIG.
1;
[0013] FIG. 7 is another schematic of a portion of the housing and
the cooling system utilized in the power generation system of FIG.
1;
[0014] FIG. 8 is another schematic of a portion of the housing,
battery modules, and the cooling system utilized in the power
generation system of FIG. 1;
[0015] FIG. 9 is another schematic of a portion of a housing,
battery modules, and the cooling system utilized in the power
generation system of FIG. 1;
[0016] FIG. 10 is an enlarged schematic of a portion of one battery
module shown in FIG. 9;
[0017] FIG. 11 is another schematic of a portion of the housing,
battery modules, and the cooling system utilized in the power
generation system of FIG. 1;
[0018] FIGS. 12-19 are flowcharts of a method for cooling a battery
system in accordance with another exemplary embodiment; and
[0019] FIG. 20 is a schematic of a portion of a housing, battery
modules, and the cooling system utilized in another power
generation system in accordance with another exemplary
embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0020] Referring to FIGS. 1-3, a power generation system 10 for
outputting electrical power in accordance with an exemplary
embodiment is illustrated. The power generation system 10 includes
a battery system 20 and a cooling system 22.
[0021] The battery system 20 is provided to output electrical
power. The battery system 20 includes the battery modules 24, 26.
Each of the battery modules 24, 26 has a similar structure and
includes a plurality of battery cell assemblies that can be
electrically connected in series to one another or in parallel to
one another. For purposes of brevity, only a portion of the battery
cell assemblies in the battery module 24 will be described in
detail. For example, referring to FIGS. 8-10, the battery module 24
includes battery cell assemblies 28, 29, 30, 31, 32, 33, 34, 36,
38, 40 and 42 and flow channel manifolds 60, 62, 64, 66, 68, 70,
72, 74, 76 and 78. Each of the battery cell assemblies has a
battery cell therein that generates an operational voltage between
a pair of electrodes extending therefrom. In one exemplary
embodiment, each battery cell is a lithium-ion battery cell. In
alternative embodiments, the battery cells could be nickel-cadmium
battery cells or nickel metal hydride battery cells for example. Of
course, other types of battery cells known to those skilled in the
art could be utilized.
[0022] The flow channel manifolds are provided to allow air to flow
through air channels defined in each flow channel manifold. The air
that flows through a flow channel manifold that is disposed between
adjacent battery cell assemblies, extracts heat energy from the
adjacent battery cell assemblies.
[0023] For example, referring to FIG. 4, a brief explanation of the
flow channel manifold 60 will be provided. It should be noted that
the structure of flow channel manifolds 62, 64, 66, 68, 70, 72, 74,
76 and 78 have the same structure as flow channel manifold 60. As
shown, the flow channel manifold 60 has an upper rail member 82, a
lower rail member 84, and a plurality of vertical members 86. The
upper rail member 82 and the lower rail member 84 are disposed
substantially parallel to each another. The plurality of vertical
members 86 are connected between the upper rail member 82 and the
lower rail member 84 and are disposed substantially parallel to
each other. The plurality of vertical members 86 are spaced apart
from each other and define a plurality of air flow channels
therein. For example, some of the vertical members 86 define air
flow channels 100, 102, 104 (on a right side of FIG. 4) in the flow
channel manifold 60. Further, some of the vertical members 86
define air flow channels 106, 108, 110 (on a left side of FIG. 4)
in the flow channel manifold 60.
[0024] Referring to FIG. 10, the flow channel manifold 60 is
disposed between the battery cell assemblies 28, 29, and the flow
channel manifold 62 is disposed between the battery cell assemblies
29, 30. Further, the flow channel manifold 64 is disposed between
the battery cell assemblies 30, 31, and the flow channel manifold
66 is disposed between the battery cell assemblies 31, 32. Further,
the flow channel manifold 68 is disposed between the battery cell
assemblies 32, 33 and the flow channel manifold 70 is disposed
between the battery cell assemblies 33, 34. Further, the flow
channel manifold 72 is disposed between the battery cell assemblies
34, 36, and the flow channel manifold 74 is disposed between the
battery cell assemblies 36, 38. Further, the flow channel manifold
76 is disposed between the battery cell assemblies 38, 40, and the
flow channel manifold 78 is disposed between the battery cell
assemblies 40, 42.
[0025] Referring to FIGS. 2, 3 and 5-8, the cooling system 22 is
provided to maintain a battery system 20 within a desired
temperature range, and in particular below a threshold temperature
level in accordance with an exemplary embodiment is provided. The
cooling system 22 includes a housing 130, evaporator fans 132, 134,
evaporators 136, 138, flow balancing baffles 140, 142, a support
member 144, conduit portions 146, 148, 150, flow balancing trays
160, 162, inner side walls 170, 172, 174, a dividing wall 176, a
condenser 190, a condenser fan 192, the compressor 194, conduit
portions 196, 198, 200, temperature sensors 210, 212, and a
microprocessor 220. In one exemplary embodiment, the cooling system
22 can maintain the battery modules 24, 26 within a desired
temperature range of 15.degree.-35.degree. Celsius. Of course,
other temperature ranges could also be utilized. In another
exemplary embodiment, the cooling system 22 can maintain the
battery modules 24, 26 at a temperature level less than a threshold
temperature level of 40.degree. Celsius. Of course, another
threshold temperature level could be utilized.
[0026] Referring to FIG. 1, the housing 130 is provided to enclose
the battery system 20 and the cooling system 22 therein. The
housing 130 includes a base member 230, a top cover 232 configured
to be coupled to the base member 230, and standoff members 234, 236
that are disposed on the bottom surface of the base member 230. In
one exemplary embodiment, the housing 130 is constructed from
plastic. However, in alternative embodiments other materials known
to those skilled in the art could be utilized to construct the
housing 130.
[0027] Referring to FIGS. 1, 6 and 8, the evaporators 136, 138 are
provided to extract heat energy from the battery modules 24, 26,
respectively. The evaporators 136, 138 are disposed on the base
member 230 of the housing 130. Further, the evaporators 136, 138
are disposed in an enclosed portion or space 180 within the housing
130. The evaporator 136 is configured to extract heat energy from
air in a first closed flow path loop (described below) into a
refrigerant flowing through the evaporator 136 to reduce a
temperature level of the battery module 24. Similarly, the
evaporator 138 is configured to extract heat energy from air in a
second closed flow path loop (described below) into a refrigerant
flowing through the evaporator 138 to reduce a temperature level of
the battery module 26. Exemplary refrigerants include R-11, R-12,
R-22, R-134A, R-407C and R-410A for example. Of course, other types
of refrigerants known to those skilled in the art could be
utilized.
[0028] Referring to FIGS. 3, 4 and 6, a refrigerant flow path in
the cooling system 22 will now be explained. As shown, the
evaporator 136 is fluidly coupled to the compressor 194 via the
conduit portions 200, 146. Further, the evaporator 136 is fluidly
coupled to the evaporator 138 via the conduit portion 148. Further,
the evaporator 138 is fluidly coupled to the condenser 190 via the
conduit portions 150, 196. Further, the condenser 190 is fluidly
coupled to the compressor 194 via the conduit portion 198. During
operation, the compressor 194 pumps the refrigerant through a
closed loop including the conduit portions 200, 146, the evaporator
136, the conduit portion 148, the evaporator 138, the conduit
portions 150, 196, the condenser 190, the conduit portion 198 and
back to the compressor 194.
[0029] Referring to FIGS. 4 and 6, the evaporator fan 132 is
disposed on the base member 230 of the housing 130. The evaporator
fan 132 is configured to recirculate air in a closed flow path loop
240 within the first enclosed portion 180 of the housing 130. The
closed flow path loop 240 includes a flow path through the
evaporator fan 132, and past the evaporator 136 and then through
air flow channels in the battery module 24 and then back through
the evaporator fan 132.
[0030] The evaporator fan 134 is disposed on the base member 230 of
the housing 130. The evaporator fan 134 is configured to
recirculate air in a closed flow path loop 242 within the enclosed
portion 182 of the housing 130. The closed flow path loop 242
includes a flow path through the evaporator fan 134, and past the
evaporator 136 and then through air flow channels in the battery
module 26 and then back through the evaporator fan 134.
[0031] The flow balancing baffle 140 is disposed proximate to the
evaporator fan 132 on the base member 230 of the housing 130. The
flow balancing baffle 140 is configured to allow a substantially
equal amount of air flow through each aperture in the baffle 140
such than air flow is evenly distributed across a surface of the
evaporator 136. In one exemplary embodiment the flow balancing
baffle 140 is substantially u-shaped with a plurality of apertures
extending therethrough and is constructed from plastic.
[0032] The flow balancing baffle 142 is disposed proximate to the
evaporator fan 134 on the base member 230 of the housing 130. The
flow balancing baffle 142 is configured to allow a substantially
equal amount of air flow through each aperture in the baffle 142
such than air flow is evenly distributed across a surface of the
evaporator 138. In one exemplary embodiment, the flow balancing
baffle 142 is substantially u-shaped with a plurality of apertures
extending therethrough and is constructed from plastic.
[0033] The support member 144 is disposed on the base member 230 of
the housing 130 between the evaporators 136, 138. In one exemplary
embodiment, the support member 144 is substantially u-shaped and is
constructed from plastic.
[0034] Referring to FIG. 6, the conduit portion 146 is fluidly
coupled to a first end of the evaporator 136. The conduit portion
148 is fluidly coupled between a second end of the evaporator 136
and a first end of the evaporator 138. Further, the conduit 150 is
fluidly coupled to a second end of the evaporator 138. Thus,
refrigerant can flow through the conduit portion 160, the
evaporator 136, the conduit portion 148, the evaporator 138, and
the conduit 150.
[0035] Referring to FIG. 7, the flow balancing tray 160 is disposed
on the flow balancing baffles 140, 142 and the support member 144
in the enclosed portion 180 of the housing 130. The flow balancing
tray 160 is configured to allow a substantially equal amount of air
flow through each aperture in the tray 160 such that air flow is
evenly distributed across lower surfaces of the battery modules 24,
26. Further, the flow balancing tray 160 is configured to hold the
battery modules 24, 26 thereon. In one exemplary embodiment, the
flow balancing tray 160 has a plurality of apertures extending
therethrough and is constructed from plastic.
[0036] Referring to FIG. 11, the flow balancing tray 162 is
disposed on a top surface of the battery modules 24, 26 in the
housing 130. The flow balancing tray 162 is configured to allow a
substantially equal amount of air flow through each aperture in the
tray 162 such than air flow is evenly distributed from the battery
modules 24, 26 through the flow balancing tray 162. In one
exemplary embodiment, the flow balancing tray 162 has a plurality
of apertures extending therethrough and is constructed from
plastic.
[0037] Referring to FIGS. 1 and 11, the inner side walls 170, 172,
174 and the dividing wall 176 are disposed proximate to side walls
of the battery modules 24, 26. The dividing wall 176 has a sealing
gasket 177 disposed on an outer periphery of the dividing wall 176
to form an airtight seal with the base member 230 and the top cover
232 that contact the outer periphery of the dividing wall 176.
Further, the base member 230, the top cover 232 and the dividing
wall 176 define an enclosed portion 180 having the battery modules
24, 26 disposed therein. It should be noted that the enclosed
portion 180 is an airtight enclosed portion. Further, the base
member 230, the top cover 232 and the dividing wall 176 define an
enclosed portion 184. In one exemplary embodiment, the enclosed
portion 184 fluidly communicates with ambient air external to the
housing 130. In one exemplary embodiment, the inner side walls 170,
172, 174 and the dividing wall 176 are constructed from
plastic.
[0038] Referring to FIGS. 3 and 6, the condenser 190 is disposed in
the enclosed portion 182 of the housing 130 and is fluidly coupled
to the evaporators 136, 138 and the compressor 194. As shown, the
condenser 190 is fluidly coupled to the evaporator 138 via the
conduit portions 150, 196. Further, the condenser 190 is fluidly
coupled to the compressor 194 via the conduit portion 198. The
condenser 190 is configured to receive heat energy in a refrigerant
from the evaporators 136, 138 and to dissipate the heat energy in
the received refrigerant such that the heat energy is removed from
the refrigerant for cooling the battery modules 24, 26.
[0039] Referring to FIGS. 3 and 5, the condenser fan 192 is
configured to urge air past the condenser 190 to induce the
condenser 190 to dissipate heat energy in response to a control
signal from the microprocessor 220. As shown, the condenser fan 192
is disposed proximate to the condenser 190 in the enclosed region
182.
[0040] Referring to FIGS. 3, 5 and 6, the compressor 194 is
configured to pump and recirculate refrigerant through the
evaporators 136, 138 in response to a control signal from the
microprocessor 220. In particular, the compressor 194 pumps the
refrigerant through a closed loop including the conduit portions
200, 146, the evaporator 136, the conduit portion 148, the
evaporator 138, the conduit portions 150, 190, the condenser 190,
and the conduit portion 198 back to the compressor 194. As shown,
the compressor 194 is disposed in the enclosed region 182.
[0041] Referring to FIGS. 3 and 5, the temperature sensor 210 is
electrically coupled to the microprocessor 220 and is disposed
proximate to the battery module 24. The temperature sensor 210 is
configured to generate a signal indicative of a temperature of the
battery module 24 that is received by the microprocessor 220.
[0042] The temperature sensor 212 is electrically coupled to the
microprocessor 220 and is disposed proximate to the battery module
26. The temperature sensor 212 is configured to generate a signal
indicative of a temperature of the battery module 26 that is
received by the microprocessor 220.
[0043] The microprocessor 212 is configured to control operation of
the cooling system 22. As shown, the microprocessor 212 is
electrically coupled to the evaporator fans 132, 134, the condenser
fan 192, the compressor 194, and the temperature sensors 210, 212.
During operation, the microprocessor 212 receive signals from the
temperature sensors 210, 212 indicative of temperatures of the
battery modules 24, 26, respectively. Based on the received signals
from the temperature sensors 210, 212, the microprocessor 212
generates control signals for controlling operation of the
evaporator fans 132, 134, the condenser fan 192, and the compressor
194, as will be explained in greater detail below.
[0044] Referring to FIGS. 12-19, a flowchart of a method for
cooling the battery system 20 will now be explained.
[0045] At step 260, the microprocessor 220 initializes the
following flags: flag1 equals "false"; flag2 equals "false"; flag3
equals "false"; and flag4 equals "false." After step 260, the
method advances to step 262.
[0046] At step 262, the temperature sensor 210 generates a first
signal indicative of a temperature of the battery module 24
disposed in the enclosed portion 180 of the housing 130 that is
received by the microprocessor 220. After step 262, the method
advances to step 264.
[0047] At step 264, the temperature sensor 212 generates a second
signal indicative of a temperature of the battery module 26
disposed in the enclosed portion 180 of the housing 130 that is
received by the microprocessor 220. After step 264, the method
advances to step 266.
[0048] At step 266, the microprocessor 220 makes a determination as
to whether the first signal from the temperature sensor 210
indicates that a temperature level of the battery module 24 is
greater than a threshold temperature level. If the value of step
266 equals "yes", the method advances to step 268. Otherwise, the
method advances to step 286.
[0049] At step 268, the microprocessor 220 sets flag1 equal to
"true." After step 268, the method advances to step 270.
[0050] At step 270, the microprocessor 220 generates a signal to
turn on the compressor 194 to recirculate refrigerant through
evaporators 132, 134 disposed proximate to battery module 24, 26,
respectively in the enclosed portion 180 of the housing 130, and
through the condenser 190 disposed in the enclosed portion 182 of
the housing 130. After step 270, the method advances to step
280.
[0051] At step 280, the microprocessor 220 generates a signal to
turn on the evaporator fan 132 to recirculate air in a first closed
flow path loop 240 (shown in FIG. 4) within the enclosed portion
180. The first closed flow path loop 240 includes a flow path
through the evaporator fan 132 and past the evaporator 136 and then
through air flow channels in the battery module 24 and then back
through the evaporator fan 132. After step 280, the method advances
to step 282.
[0052] At step 282, the evaporator 136 extracts heat energy from
the air in the first closed flow path loop 240 to the refrigerant
flowing through the evaporator 136 to reduce a temperature of the
battery module 24 in the enclosed portion 180. After step 282, the
method advances to step 284.
[0053] At step 284, the microprocessor 220 generates a signal to
turn on the condenser fan 192 to urge air past the condenser 190 in
the enclosed portion 182 that further induces the condenser 190 to
dissipate heat energy from the refrigerant flowing from the
evaporator 136. After step 284, the method advances to step
304.
[0054] Referring again to step 266, when the value of step 266
equals "no", the method advances to step 286. At step 286, the
microprocessor 220 sets flag1 equal to "false." After step 286, the
method advances to step 288.
[0055] At step 288, the microprocessor 220 makes a determination as
to whether the flag4 equals "false." If the value of step 288
equals "yes", the method advances to step 290. Otherwise, the
method advances to step 292.
[0056] At step 290, the microprocessor 220 removes a signal from
the evaporator fan 132 to turn off the evaporator fan 132. After
step 290, the method advances to step 292.
[0057] At step 292, the microprocessor 220 makes a determination as
to whether the flag2 equals "false"; flag3 equals "false" and flag4
equals "false." If the value of step 292 equals "yes", the method
advances to step 300. Otherwise, the method advances to step
304.
[0058] At step 300, the microprocessor 220 removes a signal from
the compressor 194 to turn off the compressor 194. After step 300,
the method advances to step 302.
[0059] At step 302, the microprocessor 220 removes a signal from
the condenser fan 192 to turn off the condenser fan 192. After step
302, the method advances to step 304.
[0060] At step 304, the microprocessor 220 makes a determination as
to whether the second signal from temperature sensor 212 indicates
that a temperature level of the battery module 26 is greater than
the threshold temperature level. If the value of step 304 equals
"yes", the method advances to step 306. Otherwise, the method
advances to step 316.
[0061] At step 306, the microprocessor 220 sets flag2 equal to
"true." After step 306, the method advances to step 308.
[0062] At step 308, the microprocessor 220 generates a signal to
turn on the compressor 194 to recirculate refrigerant through the
evaporator 136, the evaporator 138, and the condenser 190. After
step 308, the method advances to step 310.
[0063] At step 310, the microprocessor 220 generates a signal to
turn on the evaporator fan 134 to recirculate air in a second
closed flow path loop 242 (shown in FIG. 4) within the enclosed
portion 180. The second closed flow path loop 242 includes a flow
path through the evaporator fan 134 and past the evaporator 138 and
then through air flow channels in the battery module 26 and then
back through the evaporator fan 134. After step 310, the method
advances to step 312.
[0064] At step 312, the evaporator 138 extracts heat energy from
the air in the second closed flow path loop 242 to the refrigerant
flowing through the evaporator 138 to reduce a temperature of the
battery module 26 in the enclosed portion 180. After step 312, the
method advances to step 314.
[0065] At step 314, the microprocessor 220 generates a signal to
turn on the condenser fan 192 to urge air past the condenser 190 in
the enclosed portion 182 that further induces the condenser 190 to
dissipate heat energy from the refrigerant flowing from the
evaporator 138. After step 314, the method advances to step
330.
[0066] Referring again to step 304, if the value of step 304 equals
"no", the method advances to step 316. At step 316, the
microprocessor 220 sets flag2 equal to "false." After step 316, the
method advances to step 318.
[0067] At step 318, the microprocessor 220 makes a determination as
to whether the flag3 equals "false." If the value of step 318
equals "yes", the method advances to step 320. Otherwise, the
method advances to step 322.
[0068] At step 320, the microprocessor 220 removes a signal from
the evaporator fan 134 to turn off the evaporator fan 134. After
step 320, the method advances to step 322.
[0069] At step 322, the microprocessor 220 makes a determination as
to whether the flag1 equals "false"; flag3 equals "false"; and
flag4 equals "false." If the value of step 322 equals "yes", the
method advances to step 324. Otherwise, the method advances to step
330.
[0070] At step 324, the microprocessor 220 removes a signal from
the compressor 194 to turn off the compressor 194. After step 324,
the method advances to step 326.
[0071] At step 326, the microprocessor 220 removes a signal from
the condenser fan 192 to turn off the condenser fan 192. After step
326, the method advances to step 330.
[0072] At step 330, the microprocessor 220 calculates a first
temperature difference value utilizing the following equation:
first temperature difference value=second signal-first signal.
After step 330, the method advances to step 332.
[0073] At step 332, the microprocessor 220 makes a determination as
to whether the first temperature difference value is greater than a
threshold difference value. If the value of step 332 equals "yes",
the method advances to step 334. Otherwise, the method advances to
step 340.
[0074] At step 334, the microprocessor 220 sets flag3 equal to
"true." After step 334, the method advances to step 335.
[0075] At step 335, the microprocessor 220 generates a signal to
turn on the compressor 194 to recirculate refrigerant through the
evaporator 136, the evaporator 138, and the condenser 190. After
step 335, the method advances to step 336.
[0076] At step 336, the microprocessor 220 generates a signal to
turn on the evaporator fan 134 to recirculate air in the second
closed flow path loop 242 within the enclosed portion 180. After
step 336, the method advances to step 337.
[0077] At step 337, the evaporator 138 extracts heat energy from
the air in the second closed flow path loop 242 to the refrigerant
flowing through the evaporator 138 to reduce a temperature of the
battery module 26 in the enclosed portion 180. After step 337, the
method advances to step 338.
[0078] At step 338, the microprocessor 220 generates a signal to
turn on the condenser fan 192 to urge air past the condenser 190 in
the enclosed portion 182 of the housing 130 that further induces
the condenser 190 to dissipate heat energy from the refrigerant
flowing from the evaporator 138. After step 338, the method
advances to step 360.
[0079] Referring again to step 332, when the value of step 332
equals "no", the method advances to step 340. At step 340, the
microprocessor 220 sets flag3 equal to "false." After step 340, the
method advances to step 342.
[0080] At step 342, the microprocessor 220 makes a determination as
to whether the flag2 equals "false." If the value of step 342
equals "yes", the method advances to step 344. Otherwise, the
method advances to step 346.
[0081] At step 344, the microprocessor 220 removes a signal from
the evaporator fan 134 to turn off the evaporator fan 134. After
step 344, the method advances to step 346.
[0082] At step 346, the microprocessor makes a determination as to
whether the flag1 equals "false"; flag2 equals "false"; and flag4
equals "false." If the value of step 346 equals "yes", the method
advances to step 348. Otherwise, the method advances to step
360.
[0083] At step 348, the microprocessor 220 removes a signal from
the compressor 194 to turn off the compressor 194. After step 348,
the method advances to step 350.
[0084] At step 350, the microprocessor 220 removes a signal from
the condenser fan 192 to turn off the condenser fan 192. After step
350, the method advances to step 360.
[0085] At step 360, the microprocessor 220 calculates a second
temperature difference value utilizing the following equation:
second temperature difference value=first signal-second signal.
After step 360, the method advances to step 362.
[0086] At step 362, the microprocessor makes a determination as to
whether the second temperature difference value is greater than a
threshold difference value. If the value of step 362 equals "yes",
the method advances to step 364. Otherwise, the method advances to
step 380.
[0087] At step 364, the microprocessor 220 sets flag4 equal to
"true." After step 364, the method advances to step 366.
[0088] At step 366, the microprocessor 220 generates a signal to
turn on the compressor 194 to recirculate refrigerant through the
evaporator 136, the evaporator 138, and the condenser 190. After
step 366, the method advances to step 368.
[0089] At step 368, the microprocessor 220 generates a signal to
turn on the evaporator fan 132 to recirculate air in the first
closed flow path loop 240 within the enclosed portion 180. After
step 368, the method advances to step 370.
[0090] At step 370, the evaporator 136 extracts heat energy from
the air in the first closed flow path loop 240 to the refrigerant
flowing through the evaporator 136 to reduce a temperature of the
battery module 24 in the enclosed portion 180. After step 370, the
method advances to step 372.
[0091] At step 372, the microprocessor 220 generates a signal to
turn on the condenser fan 192 to urge air past the condenser 190 in
the enclosed portion 182 of the housing 130 that further induces
the condenser 190 to dissipate heat energy from the refrigerant
flowing from the evaporator 136. After step 372, the method returns
to step 262.
[0092] Referring again to step 362, if the value of step 362 equals
"no", the method advances to step 380. At step 380, the
microprocessor 220 sets flag4 equal to "false." After step 380, the
method advances to step 382.
[0093] At step 382, the microprocessor 220 makes a determination as
to whether flag1 equals "false." After step 382, the method
advances to step 384.
[0094] At step 384, the microprocessor 220 removes a signal from
the evaporator fan 132 to turn off the evaporator fan 132. After
step 384, the method advances to step 386.
[0095] At step 386, the microprocessor 220 makes a determination as
to whether flag1 equals "false"; and flag2 equals "false"; and
flag3 equals "false." If the value of step 386 equals "yes", the
method advances to step 388. Otherwise, the method returns to step
262.
[0096] At step 388, the microprocessor 220 removes a signal from
the compressor 194 to turn off the compressor 194. After step 388,
the method advances to step 390.
[0097] At step 390, the microprocessor 220 removes a signal from
the condenser fan 192 to turn off the condenser fan 192. After step
390, the method returns to step 262.
[0098] Referring to FIG. 20, a power generation system 418 for
outputting electrical power in accordance with another exemplary
embodiment is illustrated. The power generation system 418 includes
a battery system 420 and a cooling system 422. The battery system
420 has a substantially similar configuration as the battery system
20. The cooling system 422 has a cooling coil 424 and a condenser
490, and further includes the other components of the cooling
system 22 described above except for the condenser fan 192 and the
condenser 190. The cooling coil 424 is utilized to cool the
refrigerant and replaces the condenser fan 192 utilized in the
system 10. The condenser 490 replaces the condenser 190 utilized in
the cooling system 22. In operation, the cooling coil 424 receives
a liquid from an external liquid source which cools the refrigerant
flowing therethrough. It should be noted that the operation of the
cooling system 422 is similar to the operation of the cooling
system 22 described above, except that the cooling coil 424 is
utilized instead of a condenser fan to cool the refrigerant.
[0099] The cooling system for a battery system and the method for
cooling the battery system provide a substantial advantage over
other cooling systems and methods. In particular, the cooling
system and method provide a technical effect of recirculating air
in a closed flow path loop within a housing of the cooling system
to reduce a temperature level of the battery modules in the battery
system. The closed flow path loop is within an airtight enclosed
portion of the housing that allows the system and the method to
utilize less power and have a smaller size than other systems and
methods.
[0100] While the invention has been described with reference to
exemplary embodiments, it will be understood by those skilled in
the art that various changes may be made and equivalents may be
substituted for elements thereof without departing from the scope
of the invention. In addition, many modifications may be made to
adapt a particular situation or material to the teachings of the
invention without departing from the essential scope thereof.
Therefore, it is intended that the invention not be limited to the
particular embodiment disclosed for carrying this invention, but
that the invention will include all embodiments falling within the
scope of the appended claims. Moreover, the use of the terms,
first, second, etc. are used to distinguish one element from
another. Further, the use of the terms a, an, etc. do not denote a
limitation of quantity, but rather denote the presence of at least
one of the referenced items.
* * * * *