U.S. patent application number 13/388230 was filed with the patent office on 2012-05-24 for cooling system.
This patent application is currently assigned to CARRIER CORPORATION. Invention is credited to Gavin R. Blight, Timothy R. Campbell, Belin G. Czechowicz, Alan S. Drucker, Andreas Hille, XuQiang Liao, Daniel M. Maybury.
Application Number | 20120125022 13/388230 |
Document ID | / |
Family ID | 43529962 |
Filed Date | 2012-05-24 |
United States Patent
Application |
20120125022 |
Kind Code |
A1 |
Maybury; Daniel M. ; et
al. |
May 24, 2012 |
COOLING SYSTEM
Abstract
A cooling system for a heat source includes a heat source loop,
a refrigerant loop, and a controller. The heat source loop provides
a closed fluid path for a process fluid and fluidly connects a
valve, a bypass leg and/or a heat exchange leg having a heat
exchanger, and a pump. The process fluid is disposed within a
portion of the loop and is subject to heat transfer from the heat
source. The valve is disposed downstream of the heat source portion
of the loop, wherein the valve is selectively operable to direct
process fluid to the bypass leg and/or the heat exchanger leg. The
refrigerant loop provides a closed fluid path for a fluid
refrigerant and fluidly connects the heat exchanger, a refrigerant
compressor, a refrigerant condenser, and a refrigerant regulator.
The controller is in communication with the valve and is adapted to
control the valve to regulate an amount of process fluid entering
the bypass leg and the heat exchanger leg.
Inventors: |
Maybury; Daniel M.;
(Baldwinsville, NY) ; Drucker; Alan S.; (Syracuse,
NY) ; Liao; XuQiang; (Manlius, NY) ;
Czechowicz; Belin G.; (Jamesville, NY) ; Blight;
Gavin R.; (Bell Post Hill, AU) ; Hille; Andreas;
(Renningen, DE) ; Campbell; Timothy R.;
(Marcellus, NY) |
Assignee: |
CARRIER CORPORATION
Farmington
CT
|
Family ID: |
43529962 |
Appl. No.: |
13/388230 |
Filed: |
July 30, 2010 |
PCT Filed: |
July 30, 2010 |
PCT NO: |
PCT/US2010/043921 |
371 Date: |
January 31, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61230156 |
Jul 31, 2009 |
|
|
|
Current U.S.
Class: |
62/113 ;
62/196.1 |
Current CPC
Class: |
F25B 2600/021 20130101;
F25B 2400/04 20130101; Y02B 30/70 20130101; Y02E 60/10 20130101;
H01M 10/655 20150401; F25B 25/005 20130101; H01M 10/6568
20150401 |
Class at
Publication: |
62/113 ;
62/196.1 |
International
Class: |
F25B 39/04 20060101
F25B039/04; F25B 49/00 20060101 F25B049/00 |
Claims
1. A cooling system for a heat source, comprising: a heat source
loop that provides a closed fluid path for a process fluid, which
loop fluidly connects a valve, at least one of a bypass leg and a
heat exchange leg having a heat exchanger, and a pump, wherein the
process fluid disposed within a portion of the loop is subject to
heat transfer from the heat source, and the valve is disposed
downstream of the heat source portion of the loop, wherein the
valve is selectively operable to direct process fluid to at least
one of the bypass leg and the heat exchanger leg; a refrigerant
loop that provides a closed fluid path for a fluid refrigerant,
which refrigerant loop fluidly connects the heat exchanger, a
refrigerant compressor, a refrigerant condenser, and a refrigerant
regulator; and a controller in communication with the valve and
adapted to control the valve to regulate an amount of process fluid
entering the bypass leg and the heat exchanger leg.
2. The cooling system of claim 1, wherein the heat source is a
battery.
3. The cooling system of claim 1, wherein the heat source is an
electrical component.
4. The cooling system of claim 1, wherein the heat source loop
further includes a second heat exchange leg having an ambient air
heat exchanger.
5. The cooling system of claim 1, wherein the valve includes a
plurality of valves.
6. The cooling system of claim 1, wherein the valve is a three-way
valve.
7. The cooling system of claim 1, wherein the pump is a variable
speed pump.
8. The cooling system of claim 1, wherein the refrigerant
compressor is a variable speed compressor.
9. The cooling system of claim 8, wherein the controller is
configured in communication with the variable speed compressor for
regulating operational performance thereof.
10. The cooling system of claim 1, wherein the controller includes
a processor in signal communication with an inverter.
11. The cooling system of claim 10, wherein the inverter is
electrically coupled to the refrigerant compressor.
12. The cooling system of claim 1, wherein the refrigerant
regulator is configured as a thermal expansion valve.
13. The cooling system of claim 1, further comprising a fan
configured to facilitate airflow through the refrigerant
condenser.
14. The cooling system of claim 13, wherein the fan is a variable
speed fan.
15. The cooling system of claim 4, further comprising a fan
configured to facilitate airflow through the ambient air heat
exchanger.
16. The cooling system of claim 15, wherein the fan is a variable
speed fan.
17. A method for regulating temperature of a heat source,
comprising: providing a cooling system having a heat source loop, a
refrigerant loop and a controller, which heat source loop includes
a heat transfer portion thermally coupled to the heat source, a
bypass leg, and a heat exchanger, which refrigerant loop includes
the heat exchanger, a refrigerant compressor, a refrigerant
condenser, and a refrigerant regulator; circulating process fluid
through the heat source loop; selectively directing the process
fluid from the heat transfer portion of the heat source loop to at
least one of the bypass leg and the heat exchanger to regulate the
temperature of the heat source within a predetermined temperature
range; and circulating fluid refrigerant through the refrigerant
loop when at least a portion of the process fluid is directed to
the heat exchanger.
18. The method of claim 17, wherein the predetermined temperature
range is between sixty degrees and one hundred degrees
Fahrenheit.
19. The method of claim 17, wherein the process fluid is
selectively directed using a valve.
20. The method of claim 19, further comprising controlling the
valve using the controller.
Description
[0001] Applicant hereby claims priority benefits under 35 U.S.C.
.sctn.119(e) of U.S. Provisional Patent Application No. 61/230,156
filed Jul. 31, 2009, the disclosure of which is herein incorporated
by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] This disclosure relates generally to a cooling system and,
in particular, to a cooling system for regulating the temperature
of a heat source.
[0004] 2. Background Information
[0005] Heat exchange systems are widely used to regulate
environmental temperatures and conditions. For example, temperature
in certain portions of a hybrid power system (e.g., the batteries
in a hybrid vehicle) are regulated to improve system performance
and to reduce/prevent degradation and damage caused by
overheating.
[0006] Typically, there are two methods for regulating the
temperature (e.g. cooling) of batteries in a hybrid vehicle. In a
first method, heat is transferred from the batteries to a process
fluid disposed within a heat transfer jacket and thereafter from
the process fluid into ambient air via a radiator. This method may
be limited by the size of the radiator and the temperature of the
ambient air in contact with the radiator. In a second method, an
air conditioning system that includes refrigerant, a condenser, and
an evaporator, chills air passing within a supply duct. When the
chilled air passes around the battery, heat is transferred between
the battery and the airflow through radiation and convection. A
disadvantage of this method is that the air may be chilled to a
temperature (e.g., between 40.degree. and 60.degree. F.) that can
overcool the batteries and reduce their performance.
SUMMARY OF THE DISCLOSURE
[0007] In one embodiment of the invention, a cooling system for a
heat source includes a heat source loop, a refrigerant loop, and a
controller. The heat source loop provides a closed fluid path for a
process fluid and fluidly connects a valve, a bypass leg and/or a
heat exchange leg having a heat exchanger, and a pump. The process
fluid is disposed within a portion of the loop and is subject to
heat transfer from the heat source. The valve is disposed
downstream of the heat source portion of the loop, wherein the
valve is selectively operable to direct process fluid to the bypass
leg and/or the heat exchanger leg. The refrigerant loop provides a
closed fluid path for a fluid refrigerant and fluidly connects the
heat exchanger, a refrigerant compressor, a refrigerant condenser,
and a refrigerant regulator. The controller is in communication
with the valve and is adapted to control the valve to regulate an
amount of process fluid entering the bypass leg and the heat
exchanger leg.
[0008] In another embodiment of the invention, a method for
regulating temperature of a heat source includes the steps of: (1)
providing a cooling system having a heat source loop, a refrigerant
loop and a controller, which heat source loop includes a heat
transfer portion thermally coupled to the heat source, a bypass
leg, and a heat exchanger, which refrigerant loop includes the heat
exchanger, a refrigerant compressor, a refrigerant condenser, and a
refrigerant regulator; (2) circulating process fluid through the
heat source loop; (3) selectively directing the process fluid from
the heat transfer portion of the heat source loop to at least one
of the bypass leg and the heat exchanger to regulate the
temperature of the heat source within a predetermined temperature
range; and (4) circulating fluid refrigerant through the
refrigerant loop when at least a portion of the process fluid is
directed to the heat exchanger.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a diagrammatic illustration of one embodiment of a
cooling system.
[0010] FIG. 2 is a diagrammatic illustration of another embodiment
of the cooling system in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0011] FIG. 1 is a diagrammatic illustration of one embodiment of a
cooling system 10 for regulating the temperature of at least one
heat source such as, but not limited to, at least one battery 12
in, for example, a hybrid vehicle. Other heat sources may include,
but are not limited to motors and/or one or more electrical
components (e.g., an alternator, an inverter, a direct current
("dc") to alternating current ("ac") converter, etc.). The cooling
system 10 includes a heat source loop 14, a refrigerant loop 16 and
a controller 18.
[0012] The heat source loop 14 in this embodiment is a closed fluid
path for a process fluid such as, but not limited to, water, brine,
and/or antifreeze. The heat source loop 14 includes a heat transfer
portion 20, a valve 22, a bypass leg 24, an evaporator leg 26, and
a pump 28. In some embodiments, the heat source loop 14 further
includes an ambient heat exchange leg 30 (illustrated in FIG.
2).
[0013] The heat transfer portion 20 of the heat source loop 14
includes a heat transfer device 32 disposed between an inlet 21 and
an outlet 23. The heat transfer device 32 is operable to permit the
transfer of thermal energy from the heat source 12 (e.g., battery)
to a process fluid. An example of an acceptable heat transfer
device 32 is a jacket enclosure that includes a fluid passage
disposed between walls 27. One of the walls 27 is positioned in
close proximity to an exterior surface of the battery 12.
[0014] The valve 22 has a plurality of outlets and is operable to
selectively direct at least a portion of the process fluid to one
or more of the outlets. For example, in the embodiment illustrated
in FIG. 1, the valve 22 is a three-way valve having an inlet 29, a
first outlet 31, and a second outlet 33. Process fluid received
through the inlet 29 of the three-way valve is selectively directed
to one or both of the first outlet 31 and second outlet 33 of the
valve. The valve 22 is not limited to the aforesaid three-way
configuration, however. Other configurations may include a
plurality of independent valves (e.g., a first valve 34 and a
second valve 36 as is illustrated in FIG. 2), that may be
synchronously configured to selectively direct process fluid to one
or more of their outlets.
[0015] The bypass leg 24 extends between an inlet 35 and an outlet
37.
[0016] The evaporator leg 26 of the heat source loop 14 includes a
section that passes between an inlet 39 and an outlet 41 of a first
side 38 of an evaporator 40. The evaporator 40 has a second side 42
through which refrigerant passes as part of the refrigerant loop
16, as will be described below. The evaporator 40 is operable to
transfer thermal energy from the process fluid, to the evaporator
40, and subsequently to the refrigerant.
[0017] Referring now to FIG. 2, in those embodiments of the heat
source loop 14 that include an ambient heat exchange leg 30, the
ambient heat exchange leg 30 includes an ambient air heat exchanger
(e.g., a radiator 44) disposed between an inlet 43 and an outlet
45. The radiator 44 is operable to thermally couple the process
fluid flowing within the radiator 44 with ambient air flowing
through and/or around the radiator 44. For example, where the
process fluid is at a higher temperature than the ambient air,
thermal energy will be transferred out of the process fluid,
through walls of the radiator 44, and into the ambient air. In some
embodiments, a fan 25 (e.g., a variable speed fan) is used to
facilitate the flow of the ambient air through and/or around the
radiator 44.
[0018] The refrigerant loop 16 is a closed fluid path for a fluid
refrigerant ("refrigerant") such as, but not limited to, R134a,
etc. The refrigerant loop 16 includes an evaporator 40, a
compressor 46, a condenser 48, and a refrigerant regulator 50 in
line with one another to form the closed loop.
[0019] The refrigerant loop 16 includes a section that passes
through the second side 42 of the evaporator 40, which section
includes a second side inlet 47 and a second side outlet 49. As
stated above, the evaporator 40 is operable to transfer thermal
energy from the process fluid, to the evaporator 40, and
subsequently to the refrigerant.
[0020] The compressor 46 has an inlet 51 and an outlet 53 and is
operable to compress the refrigerant from an inlet pressure to a
higher exit pressure. An example of an acceptable compressor 46 is
a variable speed compressor.
[0021] The refrigerant loop 16 includes a section that passes
through the condenser 48 via a condenser inlet 55 and a condenser
outlet 57. The condenser 48 is operable to process the refrigerant
in a manner that causes heat to transfer out of the refrigerant,
through the condenser 48, and into ambient air. In some
embodiments, a condenser fan 75 (e.g., a variable speed condenser
fan) is used to facilitate the flow of ambient air through and/or
around the condenser 48.
[0022] The refrigerant regulator 50 has an inlet 59 and an outlet
61 and is operable to meter refrigerant flowing therethrough. In
some embodiments, a thermal expansion valve ("TXV") may be used as
a refrigerant regulator 50.
[0023] The controller 18 monitors and dynamically controls the
cooling system 10 in order to regulate one or both of the
temperature of the heat source (e.g., the battery 12) and the
operational performance of one or more components of the cooling
system 10. For example, the controller 18 is adapted to receive one
or more feedback signals, and utilizing those feedback signals, the
controller 18 is adapted to provide one or more control signals
indicative of different modes of operation to one or more
components of the cooling system 10. The feedback signals may
include, but are not limited to, a signal indicative of the
temperature of the heat source (e.g., the battery 12) and/or a
signal indicative of the operational performance of components
(e.g., the compressor 46) within the refrigerant loop 16. The
present cooling system 10 may be operated in a variety of different
modes of operation; e.g., the cooling system 10 may be operated
based on the temperature of the process fluid disposed within the
heat source loop 14, or based on the performance of the refrigerant
loop 16, or some combination thereof. Referring to the embodiment
in FIG. 2, the controller 18 includes a processor 52 in signal
communication with an inverter 54 operable to selectively and
incrementally provide power to and thereby control components
including one or more of the valve(s), pump 28, compressor 46, and
the condenser fan 75.
[0024] Referring to the embodiment shown in FIG. 1, the outlet 23
of the heat transfer portion 20 is connected (e.g. through a fluid
coupling) in the heat source loop 14 to the inlet 29 of the
three-way valve 22. The first outlet 31 of the three-way valve 22
is connected to the inlet 35 of the bypass leg 24, and the second
outlet 33 is connected to the inlet 39 of the first side 38 of the
evaporator 40. The outlet 37 of the bypass leg 24 and the outlet 41
of the evaporator 40 are connected to the inlet 21 of the heat
transfer portion 20 through the pump 28.
[0025] In the embodiment of the heat source loop 14 shown in FIG.
2, the outlet 23 of the heat transfer portion 20 is connected to
the inlet 63 of the first valve 34. The first outlet 65 of the
first valve 34 is connected to the inlet 35 of the bypass leg 24,
and the second outlet 67 of the first valve 34 is connected to the
inlet 69 of the second valve 36. The first outlet 71 of the second
valve 36 is connected to the inlet 39 of the first side 38 of the
evaporator 40, and the second outlet 73 is connected to the inlet
43 of the ambient heat exchange leg 30. The outlets 37, 41, 45 of
the bypass leg 24, the evaporator 40, and the ambient heat exchange
leg 30 are connected to the inlet 21 of the heat transfer portion
20 through the pump 28.
[0026] Referring now to both FIGS. 1 and 2, in the refrigerant loop
16, the outlet 49 of the second side 42 of the evaporator 40 is
connected to the inlet 51 of the compressor 46. The outlet 53 of
the compressor 46 is connected to the inlet 55 of the condenser 48.
The outlet 57 of the condenser 48 is connected to the inlet 59 of
the refrigerant regulator 50. The outlet 61 of the refrigerant
regulator 50 is connected to the inlet 47 of the evaporator 40.
[0027] The heat source loop 14 and the refrigerant loop 16 are
thermally connected to one another through the first and the second
sections of the evaporator 40. Examples of acceptable evaporators
include counter-flow evaporators and braised plate heat exchanger
evaporators ("braised plate evaporator") having first and second
fluid paths. Counter-flow and braised plate evaporators are known
in the art, and therefore will not be discussed in further detail.
The present invention is not limited to any particular type of
evaporator, however.
[0028] The controller 18 is in communication with the components of
the cooling system 10 such that it may operatively control the
configuration of one or more of the valve 22 (or valves in the
embodiment in FIG. 2) and the speed/output of the pump 28, the
compressor 46, and/or the fan(s) 75, 25 coupled with the condenser
48 and radiator 44. For example, in the embodiment in FIG. 2, the
inverter 54 is electrically coupled to the pump 28 and the
compressor 46 such that the processor 52 may control the pump 28
and/or the compressor 46 by regulating the power to the inverter
54, which in turn controls the pump 28 and/or compressor 46.
[0029] During operation of the cooling system 10 embodiment shown
in FIG. 2, the pump 28 responds to a pump control signal from the
controller 18, and circulates the process fluid within the heat
source loop 14. Heat transfers from the battery 12, through the
heat transfer jacket 32, and into the process fluid. The now heated
process fluid flows from the heat transfer portion 20 and into the
first valve 34.
[0030] In a first mode of operation, the first valve 34 responds to
a valve control signal from the controller 18, and directs at least
a portion of the heated process fluid towards the second valve 36.
The second valve 36 responses to another valve control signal from
the controller 18, and directs at least a portion of the heated
process fluid into the first side 38 of the evaporator 40. Heat
from the heated process fluid is transferred through the first and
the second sides 38, 42 of the evaporator 40 into the refrigerant
disposed within the refrigerant loop 16. The now cooled process
fluid flows from the evaporator leg 26 back towards the pump 28,
where it is recirculated.
[0031] In the refrigerant loop 16, the now heated refrigerant flows
from the evaporator 40 and into the compressor 46, where the heated
refrigerant is compressed. The now heated and compressed
refrigerant flows from the compressor 46 and into the condenser 48.
Heat from the refrigerant is transferred, through the condenser 48,
into ambient air directed through and/or around the condenser 48
via the condenser fan 75. The now cooled and lower pressure
refrigerant flows from the condenser 48 and into the refrigerant
regulator 50, where the regulator meters the quantity of the
refrigerant that flows back into the evaporator 40, where the cycle
begins again. In some embodiments, one or more of the compressor 46
and the condenser fan 75 are responsive to a control signal(s) from
the controller 18 to increase or decrease their speed/output, which
thereby increases or decreases the rate at which heat is
transferred from the refrigerant to the ambient air.
[0032] In a second mode of operation, in the heat source loop 14,
the first valve 34 responds to another valve control signal from
the controller 18, and directs at least a portion of the heated
process fluid towards the second valve 36. The second valve 36
responds to another valve control signal from the controller 18,
and directs at least a portion of the heated process fluid into the
radiator 44 disposed within the ambient heat exchange leg 30. As
the process fluid passes through the radiator 44, heat transfers
from the process fluid, through the radiator 44, into the ambient
air directed through and/or around the radiator 44 via the radiator
fan 25. The now cooled process fluid exits the radiator 44 and
flows toward the pump 28, where it is recirculated. In some
embodiments, the radiator fan 25 responds to a control signal from
the controller 18 to increase or decrease its speed/output, which
thereby increases or decreases the rate at which heat is
transferred from the process fluid to the ambient air.
[0033] In a third mode of operation, in the heat source loop 14,
the first valve 34 responds to another valve control signal from
the controller 18, and directs at least a portion of the process
fluid into the bypass leg 24. The process fluid flows through the
bypass leg 24 and back towards the pump 28, where it is
recirculated.
[0034] The controller 18 regulates the temperature of the battery
12 within a predetermined range, for example, by utilizing at least
one of the aforesaid three modes of operation. For example, where
the battery 12 has a high temperature (relative to ambient), the
controller 18 may signal the first valve 34 and the second valve 36
in the heat source loop 14 to direct the majority (e.g. greater
than fifty percent) of the heated process fluid through the
evaporator 40 where it is cooled by the refrigerant passing through
the opposite side of the evaporator 40. The remaining heated
process fluid passes through the ambient heat exchange leg 30. In
another example, where the battery 12 has a slightly elevated
temperature, the controller 18 may signal the first valve 34 and
the second valve 36 in the heat source loop 14 to direct the
majority (e.g. greater than fifty percent) of the heated process
fluid through the bypass leg 24, and the remaining portion of the
heated process fluid through the ambient heat exchange leg 30. The
predetermined temperature range, and the cooling path configuration
selected to best achieve that temperature, is selected to optimize
(i.e., increase) the performance and/or the efficiency of the heat
source. For example, the predetermined temperature range is set
between sixty and one hundred degrees Fahrenheit
(60.degree.-100.degree. F.) for battery types used in hybrid
vehicles. The present cooling system contemplates that the
controller 18 can control the process flow to flow in a variety of
different paths in a variety of different relative portions to
arrive at a desirable cooling configuration, and the present
invention is not limited to the examples described above.
[0035] The controller 18 may further regulate the operational
performance of the components of the cooling system. For example,
where the controller 18 receives a feedback signal which indicates
that the compressor 46 is operating beyond a predetermined
tolerance, the controller 18 turns the compressor 46 off by
signaling the inverter 54 to cutoff power thereto. The controller
18 may additionally signal the first and the second valves 34, 36
to direct the process fluid through the bypass leg 24 and the
ambient heat exchange leg 30, and not through the first side 38 of
the evaporator 40. In another example, the controller 18 may signal
the inverter 54 to increase or decrease power provided to the pump
28 to increase or decrease the flowrate of the process fluid
flowing through the heat source loop 14 to increase the efficiency
of the system.
[0036] While various embodiments of the present invention have been
disclosed, it will be apparent to those of ordinary skill in the
art that many more embodiments and implementations are possible
within the scope of the invention. Accordingly, the present
invention is not to be restricted except in light of the attached
claims and their equivalents.
* * * * *