U.S. patent application number 17/528355 was filed with the patent office on 2022-03-10 for vehicle thermal management system and heat exchangers.
The applicant listed for this patent is Apple Inc.. Invention is credited to Mark R. Hoehne, Vincent G. Johnston, Donald P. Yuhasz.
Application Number | 20220072928 17/528355 |
Document ID | / |
Family ID | |
Filed Date | 2022-03-10 |
United States Patent
Application |
20220072928 |
Kind Code |
A1 |
Johnston; Vincent G. ; et
al. |
March 10, 2022 |
Vehicle Thermal Management System and Heat Exchangers
Abstract
A thermal management system and methods for thermal management
include selective use of heat exchange between thermal loops for
heating, cooling, battery, and refrigerant in order to increase
temperature control and efficiency of the thermal management
system.
Inventors: |
Johnston; Vincent G.; (Half
Moon Bay, CA) ; Yuhasz; Donald P.; (Sunnyvale,
CA) ; Hoehne; Mark R.; (Los Gatos, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Apple Inc. |
Cupertino |
CA |
US |
|
|
Appl. No.: |
17/528355 |
Filed: |
November 17, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16089641 |
Sep 28, 2018 |
11207939 |
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PCT/US2017/049348 |
Aug 30, 2017 |
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17528355 |
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62533949 |
Jul 18, 2017 |
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62382794 |
Sep 2, 2016 |
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International
Class: |
B60H 1/00 20060101
B60H001/00; B60H 1/14 20060101 B60H001/14; F25B 25/00 20060101
F25B025/00; H01M 10/625 20060101 H01M010/625; F25B 40/00 20060101
F25B040/00; H01M 10/66 20060101 H01M010/66; B60L 58/26 20060101
B60L058/26; B60L 58/27 20060101 B60L058/27; B60H 1/32 20060101
B60H001/32 |
Claims
1. A thermal management system for a vehicle, comprising: a heating
loop through which a heating loop coolant flows; a refrigerant loop
having a first heat exchanger in thermal communication with the
heating loop and through which a refrigerant flows, the first heat
exchanger configured to increase a temperature of the heating loop
coolant using the refrigerant; a second heat exchanger in the
heating loop downstream of the first heat exchanger through which
the heating loop coolant flows; and a cabin blower configured to
force air across the second heat exchanger and into a passenger
cabin of a vehicle, heating the passenger cabin and decreasing a
temperature of the heating loop coolant.
2. The thermal management system of claim 1, further comprising: a
third heat exchanger in the heating loop downstream of the second
heat exchanger through which the heating loop coolant flows; and a
battery loop in thermal communication with the third heat exchanger
and through which a battery loop coolant flows, the third heat
exchanger configured to increase a temperature of the battery loop
coolant.
3. The thermal management system of claim 1, further comprising: an
electric heater in the heating loop upstream of the second heat
exchanger and through which the heating loop coolant flows, the
electric heater configured to increase a temperature of the heating
loop coolant.
4. The thermal management system of claim 1, wherein the first heat
exchanger is a gas cooler.
5. The thermal management system of claim 1, wherein the first heat
exchanger is a liquid-cooled gas cooler, and wherein the second
heat exchanger is a heater core of a heating and ventilation system
of the vehicle.
6. A method for thermal management, the method comprising:
measuring a temperature of a battery loop coolant flowing through a
battery loop; comparing the temperature to a predetermined
temperature range; upon a condition that the temperature is below
the predetermined temperature range, directing a flow of the
battery loop coolant for thermal communication with a heating loop
having a heating loop coolant flowing therethrough; upon a
condition that the temperature is above the predetermined
temperature range, directing a flow of the battery loop coolant for
thermal communication with a cooling loop having a cooling loop
coolant flowing therethrough; and upon a condition that the
temperature is at or within the predetermined temperature range,
directing a flow of the battery loop coolant to bypass the heating
loop and to bypass the cooling loop.
7. The method of claim 6, further comprising: controlling a valve
to selectively direct the flow of the battery loop coolant to at
least one of the heating loop, to the cooling loop, or the battery
loop.
8. The method of claim 6, further comprising: upon a condition that
the temperature is below the predetermined temperature range,
directing a portion of the battery loop coolant for thermal
communication with a gas cooler in a refrigerant loop having a
refrigerant flowing therethrough.
9. The method of claim 8, wherein the battery loop coolant and the
refrigerant are in thermal not fluid communication through separate
conduits in the gas cooler.
10. The method of claim 9, further comprising: upon a condition
that the temperature is at or within the predetermined temperature
range, directing a flow of the battery loop coolant to bypass the
heating loop, bypass the cooling loop, and bypass the refrigerant
loop.
11. The method of claim 6, further comprising: upon a condition
that the temperature is above the predetermined temperature range,
directing a portion of the battery loop coolant for thermal
communication with a chiller in a refrigerant loop having a
refrigerant flowing therethrough.
12. The method of claim 11, wherein the battery loop coolant and
the refrigerant are in thermal not fluid communication through
separate conduits in the chiller.
13. The method of claim 11, further comprising: upon a condition
that the temperature is at or within the predetermined temperature
range, directing a flow of the battery loop coolant to bypass the
heating loop, bypass the cooling loop, and bypass the refrigerant
loop.
14. The method of claim 6, further comprising: upon a condition
that the temperature is at or within the predetermined temperature
range, sending a command configured to reduce a speed of a battery
loop pump to reduce a speed of the flow of the battery loop coolant
through the battery loop.
15. A method for thermal management, the method comprising:
measuring a temperature of a battery loop coolant flowing through a
battery loop; comparing the temperature to a predetermined
temperature range; and upon a condition that the temperature is
below the predetermined temperature range: directing a first
portion of the battery loop coolant for thermal communication with
a heating loop having a heating loop coolant flowing therethrough;
directing a second portion of the battery loop coolant for thermal
communication with a refrigerant loop having a refrigerant flowing
therethrough; and directing a third portion of the battery loop
coolant to recirculate within the battery loop.
16. The method of claim 15, further comprising: controlling a valve
to selectively direct the flow of the battery loop coolant to the
heating loop, the refrigerant loop, and the battery loop.
17. The method of claim 15, wherein the second portion is directed
for thermal, not fluid communication with a gas cooler in the
refrigerant loop.
18. The method of claim 15, further comprising: upon a condition
that the temperature is at or within the predetermined temperature
range, sending a command configured to reduce a speed of a battery
loop pump to reduce a speed of the flow of the battery loop coolant
through the battery loop.
19. The method of claim 15, further comprising: upon a condition
that the temperature is above the predetermined temperature range:
directing a first portion of the battery loop coolant for thermal
communication with a cooling loop; directing a second portion of
the battery loop coolant for thermal communication with the
refrigerant loop; and directing a third portion of the battery loop
coolant to recirculate within the battery loop.
20. The method of claim 19, wherein upon the condition that the
temperature is above the predetermined temperature range, the
second portion is directed for thermal, not fluid communication
with a chiller in the refrigerant loop.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/089,641 (filed Sep. 28, 2018) which claims
priority to and the benefit of International Patent Application No.
PCT/US2017/049348 (filed Aug. 30, 2017), U.S. Provisional
Application No. 62/533,949 (filed Jul. 18, 2017), and U.S.
Provisional Application No. 62/382,794 (filed Sep. 2, 2016), the
entire disclosures of which are incorporated by reference
herein.
TECHNICAL FIELD
[0002] This application generally relates to thermal management of
vehicle systems and heat exchangers.
BACKGROUND
[0003] Battery-powered electric or hybrid vehicles have become an
increasingly popular choice by consumers for their fuel efficiency
and low impact on the environment. With limits in technology on
battery performance and consumer demand for maximum range between
vehicle charging, there is an increased need for more efficient
power management systems, particularly in the area of vehicle
thermal management. The heating and cooling of vehicle operation
systems has a significant impact on vehicle efficiency and
performance. The heating, cooling and conditioning of the passenger
cabin environment is important to passenger comfort and vehicle
enjoyment.
[0004] Traditional electric and hybrid vehicles employed
independent heating and cooling systems using dedicated heating and
cooling devices to support the specific vehicle system. For
example, if the vehicle battery system required heating at start up
in cold temperatures, but cooling during extended operation for
optimum battery efficiency, traditional vehicle battery systems
employed dedicated heating and cooling devices to support the
battery system. These independent systems and dedicated components
for each thermal management subsystem consume more power, are less
efficient, and add complexity, packaging space, weight, and overall
cost to the vehicle.
SUMMARY
[0005] One aspect of the disclosure is a vehicle thermal management
system. The thermal management system includes a refrigerant
subsystem or loop, a heating loop, a cooling loop, a battery loop,
and a powertrain loop. In one aspect, each of the heating, cooling,
battery, and powertrain loops includes a heat exchanger in
communication with another of the subsystem loops to provide
selective heating or cooling between the communicating loops. In
another aspect, only the cooling loop and powertrain loop share a
common, dedicated heat exchanger to assist in cooling the
powertrain loop coolant.
[0006] In another aspect of the disclosure, a modular,
self-contained thermal management refrigerant subsystem or loop is
disclosed. The modular refrigerant subsystem can be assembled,
pre-charged, pre-tested, and delivered as a unit to a vehicle
assembly plant or system integrator for efficient hook-up to other
vehicle subsystems. In one example, the refrigerant subsystem uses
R744 refrigerant.
[0007] In another aspect of the disclosure, a thermal management
heating subsystem or loop using a liquid cooled gas cooler (LCGC)
is disclosed. The LCGC draws heat from the refrigerant subsystem to
supplement heat energy in the heating subsystem. In one example, a
3-port valve can be used to selectively add heat to the heating
loop coolant for use in heating a passenger cabin or to expel
excess heat from the refrigerant system via a low temperature
radiator based on a flow position of the 3-port valve. In another
aspect, the 3-port valve can blend or direct a flow of the heating
loop coolant to both heat the passenger cabin and expel heat to the
low temperature radiator to further control temperature in the
heating and refrigerant loops. In another example, the LCGC can be
the sole source of heat energy provided to the heating loop.
[0008] In another aspect of the disclosure, a thermal management
battery subsystem or loop is disclosed. In one aspect, the battery
loop selectively uses a heat exchanger in communication with the
heating loop and a heat exchanger in thermal communication with a
cooling loop to selectively provide heat to, or remove heat from,
the battery loop coolant as needed for efficient battery module
operation. In another aspect, the battery loop selectively adds
heat directly from the LCGC, selectively removes heat directly by a
chiller without the need for additional heat exchangers between the
battery loop and the heating and cooling loops. In one example, a
4-port valve can be used to selectively provide heat, remove heat,
bypass additional heating or cooling, or provide a blend of bypass
with heat addition or removal based on a flow position of the
4-port valve to increase the level of temperature control of the
battery loop and the battery module.
[0009] In another aspect of the disclosure, a thermal management
powertrain subsystem or loop is disclosed. The powertrain loop uses
a heat exchanger in thermal communication with the cooling loop for
efficient cooling of the powertrain subsystem. In one example, a
4-port valve can be employed to selectively use one of two cooling
devices in thermal communication with the powertrain loop, provide
a bypass to one or both cooling devices, or provide a blend of one
of the cooling devices and the bypass based on a flow position of
the 4-port valve to increase the level of temperature control of
the powertrain loop and powertrain drive components. In another
aspect of the disclosure, excess cooling capacity of the
refrigeration system is transferred to the powertrain subsystem in
order to increase the LCGC heat generation for heating loop
heating, even when the powertrain loop does not require additional
cooling.
[0010] In another aspect of the disclosure, a process for thermal
management of the battery loop is disclosed. The process
selectively provides heat or removes heat from the battery loop
through selected use of two heat exchangers in respective thermal
communication with the heating loop and the cooling loop. In
another aspect, the addition or removal of heat is respectively
provided directly by the LCGC or the chiller rather than separate
heat exchangers. In another aspect, a bypass can be used to
maintain a measured temperature of the battery loop coolant.
[0011] In another aspect, a process for increasing the temperature
of a heating loop coolant is disclosed. The process selectively
provides heat to the heating loop through use of the LCGC which
transfers heat expelled from the refrigerant loop.
[0012] In another aspect, a method is provided for thermal
management of a battery module through use of a battery loop having
a battery loop coolant flowing through the battery loop. The method
includes measuring a temperature of the battery loop coolant,
increasing the temperature of the battery loop coolant, and
decreasing the temperature of the battery loop coolant. The step of
increasing the temperature of the battery loop coolant flowing to
the battery module includes directing a flow of the battery loop
coolant to one of a heating loop heat exchanger in thermal
communication with a heating loop or a liquid cooled gas cooler
(LCGC) in thermal communication with a refrigerant loop. The step
of decreasing the temperature of the battery loop coolant flowing
to the battery module includes directing the flow of the battery
loop coolant to one of a cooling loop heat exchanger in thermal
communication with a cooling loop or a chiller in thermal
communication with the refrigerant loop.
[0013] In another aspect, a thermal management system includes a
refrigerant loop, a heating loop, a cooling loop, and a battery
loop. The refrigerant loop includes a refrigerant flowing
therethrough, a liquid cooled gas cooler (LCGC), and a chiller, the
LCGC and the chiller being in fluid communication by the
refrigerant. The heating loop includes a heating loop coolant
flowing therethrough, the heating loop being in fluid communication
with the LCGC by the heating loop coolant. The cooling loop
includes a cooling loop coolant flowing therethrough, the cooling
loop being in fluid communication with the chiller by the cooling
loop coolant. The battery loop includes a battery loop coolant
flowing therethrough, a battery loop valve, and a battery module,
the battery loop valve and the battery module being in fluid
communication by the battery loop coolant. The battery loop valve
includes flow configurations for directing the battery loop coolant
to (a) one of the LCGC, or a heating loop heat exchanger that is in
fluid communication with the heating loop by the heating loop
coolant, to increase a temperature of the battery loop coolant
upstream of the battery module, and (b) one of the chiller, or a
cooling loop heat exchanger that is in fluid communication with the
cooling loop by the cooling loop coolant, to decrease the
temperature of the battery loop coolant upstream of the battery
module.
[0014] In another aspect, a heat exchanger is provided for
exchanging heat between at least three fluids that are fluidically
separated. The heat exchanger includes refrigerant passes, primary
coolant passes, and a secondary coolant pass. The refrigerant
passes are configured for a refrigerant to flow serially
therethrough. The primary coolant passes are configured for a first
coolant to flow serially therethrough. The secondary coolant pass
is configured for a second coolant to flow therethrough. The
refrigerant passes are configured to exchange heat directly with
the primary coolant passes, the primary coolant passes are
configured to exchange heat directly with the secondary coolant
pass, and the refrigerant passes do not exchange heat directly with
the secondary coolant pass.
[0015] In another aspect, a heat exchanger includes a refrigerant
passage, a primary coolant passage, and a secondary coolant
passage. The refrigerant passage is for connecting to a refrigerant
loop of a thermal management system for receiving from and
transferring thereto a refrigerant. The refrigerant passage is
cooperatively defined by refrigerant tubes. The primary coolant
passage is for connecting to a primary coolant loop of the thermal
management system for receiving from and transferring thereto a
primary coolant. The primary the primary coolant passage is
cooperatively defined by at least two primary coolant cavities of a
core structure of the heat exchanger. The secondary coolant passage
is for connecting to a secondary coolant loop of the thermal
management system for receiving from and transferring thereto a
secondary coolant. The secondary coolant passage is formed by a
secondary coolant cavity of the core structure. The refrigerant
tubes extend in a serpentine manner through the two primary coolant
cavities to exchange heat directly between the refrigerant and the
primary coolant and do not extend through the secondary coolant
cavity.
[0016] A thermal management system includes a refrigerant loop, a
first primary coolant loop, a second primary coolant loop, a
secondary coolant loop, a first heat exchanger, and a second heat
exchanger. The refrigerant loop carries a refrigerant therethrough.
The first primary coolant loop carries a first primary coolant
therethrough. The second primary coolant loop carries a second
primary coolant therethrough. The secondary coolant loop carries a
secondary coolant therethrough.
[0017] The first heat exchanger is connected to the refrigerant
loop, the first primary coolant loop, and the secondary coolant
loop for the refrigerant, the first primary coolant, and the
secondary coolant, respectively, to flow through the heat
exchanger. The first heat exchanger includes a primary coolant
passage, a secondary coolant passage, and a refrigerant passage.
The first primary coolant flows serially in a first primary coolant
pass and a second primary coolant pass of the primary coolant
passage. The secondary coolant flows in a secondary coolant pass of
the secondary coolant passage. The refrigerant flows serially in at
least four refrigerant passes of the refrigerant passage. Heat is
exchanged directly between the refrigerant in a first two of the
refrigerant passes and the first primary coolant in the first
primary coolant pass and directly between the refrigerant in a
second two of the refrigerant passes and the first primary coolant
in the second primary coolant pass. The second heat exchanger is
connected to the refrigerant loop, the second primary coolant loop,
and the secondary coolant loop for the refrigerant, the second
primary coolant, and the secondary coolant, respectively, to flow
through the second heat exchanger. The second heat exchanger
includes another primary coolant passage, another secondary coolant
passage, and a refrigerant passage. The second primary coolant
flows serially in another first primary coolant pass, another a
second primary coolant pass, and a third primary coolant pass of
the other primary coolant passage. The secondary coolant flows in
another secondary coolant pass of the other secondary coolant
passage. The refrigerant flows serially in at least another six
refrigerant passes of the other refrigerant passage. Heat is
exchanged directly between the refrigerant in another first two of
the other six refrigerant passes and the second primary coolant in
the other first primary coolant pass, directly between the
refrigerant in another second two of the six refrigerant passes and
the second primary coolant in the other second primary coolant
pass, and directly between the refrigerant in a third two of the
six refrigerant passes and the second primary coolant in the third
primary coolant pass.
[0018] For example, in the first heat exchanger, heat may be
transferred directly from the secondary coolant to the first
primary coolant, and directly from the first primary coolant to the
refrigerant. In the second heat exchanger, heat may be transferred
directly from the refrigerant to the second primary coolant, and
directly from the second primary coolant to the secondary
coolant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a schematic of one example of a thermal management
system.
[0020] FIG. 2 is a schematic of an alternate example of a thermal
management system similar to the thermal management system of FIG.
1.
[0021] FIG. 3 is a block diagram of an electronic control
system.
[0022] FIG. 4 is a flow chart of one example of a method of thermal
management of a vehicle battery module.
[0023] FIG. 5 is a schematic flow chart of one example of a method
of increasing the temperature of a heating loop coolant.
[0024] FIG. 6A is a top schematic view of a first embodiment of a
heat exchanger.
[0025] FIG. 6B is a front schematic view of the heat exchanger of
FIG. 6A.
[0026] FIG. 6C is a side schematic view of the heat exchanger of
FIG. 6A.
[0027] FIG. 6D is a partial cross-sectional view of the heat
exchanger taken along line 6D-6D in FIG. 6A and of which a
refrigerant passage is omitted for clarity.
[0028] FIG. 6E is a cross-sectional view of the heat exchanger
taken along line 6E-6E in FIG. 6A and of which the refrigerant
passage is shown.
[0029] FIG. 6F is a cross-sectional view of the heat exchanger
taken along line 6F-6F in FIG. 6A.
[0030] FIG. 6G is a cross-sectional view of the heat exchanger
taken along line 6G-6G in FIG. 6A.
[0031] FIG. 6H is a cross-sectional view of a refrigerant tube of
the refrigerant passage of the heat exchanger of 6A.
[0032] FIG. 7 is a cross-sectional view of another embodiment of a
heat exchanger, which is taken similar to the cross-sectional view
of FIG. 6F.
[0033] FIG. 8 is a cross-sectional view of another embodiment of a
heat exchanger, which is taken similar to the cross-sectional view
of FIG. 6F.
[0034] FIG. 9 is a cross-sectional view of another embodiment of a
heat exchanger, which is taken similar to the cross-sectional view
of FIG. 6F.
[0035] FIG. 10 is a cross-sectional view of another embodiment of a
heat exchanger, which is taken similar to the cross-sectional view
of FIG. 6F.
[0036] FIG. 11 is a cross-sectional view of another embodiment of a
heat exchanger, which is taken similar to the cross-sectional view
of FIG. 6E.
DETAILED DESCRIPTION
[0037] Thermal management systems are described in the context of
use with passenger vehicles. Heat exchange interfaces between
individual subsystems or loops can be leveraged to decrease power
consumption and increase efficiency of the individual loops and the
overall thermal management system. Thermal communication between
the respective loops can be conducted without direct communication
or mixing of refrigerant or coolant between the respective loops,
allowing for closed loop subsystems. Although described in
reference to passenger vehicles, these thermal management systems
can also be used in other applications.
[0038] Referring to the example in FIG. 1, a thermal management
system 100 is schematically shown for use in a passenger vehicle
having a front end 104, commonly referred to as an engine
compartment, a passenger compartment or cabin 108, and a rear end
120 typically housing the drivetrain components to power wheels for
motion.
[0039] In the example shown in FIG. 1, the system 100 includes a
refrigerant subsystem or loop 124, a heating subsystem or loop 128,
a cooling subsystem or loop 130, a battery subsystem or loop 134,
and a powertrain subsystem or loop 140 as generally shown. It is
understood that additional components, connecting conduit lines,
alternative conduit routing schemes, and additional or alternative
system loads can be included (not shown). FIG. 1 also illustrates a
heating, ventilation, and air conditioning (HVAC) unit 146 which
provides heating, cooling, and conditioning of air for the
passenger cabin 108 as described further below.
[0040] The refrigerant loop 124 includes an accumulator 150 (e.g.,
with an internal heat exchanger unit), a compressor 152, a
refrigerant line or conduit 154, a first pressure and temperature
sensor 158, a liquid cooled gas cooler (LCGC) 160, an expansion
valve 162, a chiller 166, and a second temperature and pressure
sensor 170 all in fluid communication along the conduit 154 as
generally shown. In one example, the refrigerant loop 124 uses R744
refrigerant. Other types of refrigerant, for example R-134a, can
also be used. Generally speaking, the term "fluid communication" is
used to refer to various components to and/or through which a
common fluid flows. For example, the LCGC 160 and the chiller 166
are in fluid communication by the refrigerant, which flows
therethrough.
[0041] In the FIG. 1 example, the compressor 152 compresses the
vapor phase refrigerant to high pressure and temperature and forces
the refrigerant toward the LCGC 160. The LCGC 160 is a
high-pressure refrigerant to coolant heat exchanger. As shown in
FIG. 1, the LCGC 160 is in thermal communication with the heating
loop 128, thereby providing a source of heat/thermal energy to the
heating loop 128 from heat expelled from the refrigerant loop 124.
The transfer of expelled heat from the refrigerant loop 124 to the
heating loop 128 can be made without direct communication or
contact between the refrigerant and the heating loop coolant as
discussed further below. Through use of R744 refrigerant, the
system 100 can operate as a heat generator in temperatures down to
-30.degree. Celsius. In this manner, the refrigerant loop 124
operates as a heat pump to generate heat from a refrigerant cycle.
Generally speaking, the term "thermal communication" refers to
loops and fluids and/or components thereof that transfer heat to
other loops and fluids and/or components thereof. For example, each
of the refrigerant loop 124, the refrigerant, and/or the LCGC 160
may be considered in thermal communication with the heating loop
128 and the heating loop coolant. Thermal communication may include
direct heat transfer.
[0042] On exiting the LCGC 160, the cooled refrigerant flows
through a refrigerant to refrigerant heat exchanger internal to the
accumulator 150 to lower the refrigerant temperature further. The
high pressure, low temperature vapor phase refrigerant then flows
through an expansion valve 162 that reduces the pressure of the
refrigerant, causing it to condense into a liquid phase
refrigerant. The refrigerant can be forced into the chiller 166 as
generally shown. In the FIG. 1 example, the liquid phase
refrigerant absorbs heat from the coolant loop coolant in the
chiller 166 as it evaporates back to a vapor phase refrigerant. The
refrigerant then flows through the accumulator 150 where any
residual liquid refrigerant can be stored and only vapor phase
refrigerant can be selectively moved to the compressor 152 to start
the cycle again. The remaining liquid phase refrigerant in the
accumulator 150 absorbs heat from the refrigerant to refrigerant
heat exchanger internal to the accumulator 150.
[0043] The refrigerant loop 124 in the FIG. 1 example can be an
independent, closed-loop system which cools or draws heat away from
the refrigerant through use of the LCGC 160 instead of using a
forced air to refrigerant condenser/gas cooler present in
conventional refrigeration systems. The LCGC 160 transfers the heat
from the refrigerant, thereby cooling the refrigerant and
transferring that heat into the heating loop coolant as further
discussed below. Through use of a self-contained refrigerant loop
124 which does not require a traditional air to refrigerant
condenser/gas cooler for removing heat, the refrigerant loop 124
can be preassembled, filled with refrigerant, tested, packaged, and
shipped directly to the final assembly facility or a systems
integrator for rapid installation in the partially assembled
vehicle.
[0044] Still referring to FIG. 1, an example of the heating loop
128 is shown. In the example, the heating loop 128 includes a
reservoir 180 for the storage of heating loop coolant, a pump 181
to force the heating loop coolant through a line or conduit 182 in
a closed loop, an electric heater 184, and a temperature sensor 186
to monitor the temperature of the heating loop coolant as generally
shown.
[0045] As discussed above for FIG. 1, the LCGC 160 can be
positioned to be in thermal communication, but not direct
refrigerant fluid to coolant fluid communication, with both the
heating loop 128 and the refrigerant loop 124. The LCGC 160 can
transfer heat expelled from the refrigerant to the heating loop
coolant for use by other vehicle systems requiring heated fluid,
for example, a heater core 188 that is part of the HVAC unit 146,
and can be used to selectively heat the passenger cabin 108. An
advantage of the heating loop 128 and use of the LCGC 160 is that
the system 100 can operate at a Coefficient of Performance (COP)
greater than 1. The COP is the ratio of thermal power to electrical
power.
[0046] In the FIG. 1 example, the electric heater 184 can be
included to selectively supply additional heat or thermal energy to
warm the flow of heating loop coolant flowing through the electric
heater 184 toward the heater core 188. The heating loop 128 can
also include a heating loop heat exchanger 190 in thermal
conductive communication with the battery loop 134 as generally
shown. The heat exchanger 190 selectively provides heat energy from
the heating loop coolant to the battery loop 134 as further
discussed below.
[0047] In the example of FIG. 1, the heating loop 128 includes a
valve 194 in alternative fluid communication with a heating conduit
196 and an exhaust conduit 200, both positioned downstream of the
valve 194 as generally shown. The heating conduit 196 provides a
path for the heating loop coolant to flow through heater core 188
and heat exchanger 190. The exhaust conduit 200 provides a path for
the heating loop coolant to flow through a low temperature radiator
204 (e.g., a heating loop radiator) to expel or dump heat to the
atmosphere as generally shown. The low temperature radiator 204
cools the heating loop coolant through convection or forced air as
further described below. Both the heating conduit 196 and the
exhaust conduit 200 return the heating loop coolant to the LCGC 160
in a closed loop as described above.
[0048] In the FIG. 1 example, the valve 194 can be a 3-port valve
which selectively directs the flow of the heating loop coolant
through the heating conduit 196 to the heater core 188 and the heat
exchanger 190 or through the exhaust conduit 200 to the low
temperature radiator 204 to exhaust heat from the heating loop
coolant to the atmosphere. In one aspect, the valve 194 includes
flow positions allowing it to mix or blend the flow of heating loop
coolant to both the heating conduit 196 and the exhaust conduit
200. For example, the valve 194 can simultaneously direct a portion
of the heating loop coolant to flow to the heating conduit 196 and
a portion of the heating loop coolant to flow to the exhaust
conduit 200 to further control the temperature of the heating loop
coolant as well as the refrigerant loop 124.
[0049] In the examples discussed herein, the term "coolant" is used
to include an automotive grade mixture of about equal parts of
ethylene glycol and water. It is understood that different fluids
and/or different mixtures of ethylene glycol and water can be
used.
[0050] Still referring to FIG. 1, an example of the cooling
subsystem or loop 130 is illustrated. In the example, the cooling
loop 130 includes a reservoir 210 for the storage of cooling loop
coolant and a pump 214 to selectively force the flow of cooling
loop coolant through a closed-loop cooling line or conduit 216 as
generally shown.
[0051] In the FIG. 1 example, the cooling loop conduit 216 is in
thermal communication with the refrigerant loop 124 through the
chiller 166. As described above, as the refrigerant of the
refrigerant loop 124 flows through the chiller 166, the refrigerant
draws or absorbs heat as it evaporates inside the chiller 166 which
in turn removes heat from the cooling loop conduit 216. In this
example, the cooling loop 130 includes a powertrain heat exchanger
220 in thermal communication with the powertrain loop 140 and a
battery heat exchanger 226 in thermal communication with the
battery loop 134 as generally shown. A temperature sensor 228 in
communication (e.g., thermal and/or fluid communication) with
cooling loop coolant can also be used to measure and monitor the
temperature and other conditions of the cooling loop coolant. The
cooling loop 130 can also extend through a cooling core 230
described further below in reference to the HVAC unit 146.
[0052] Additional operational and control components 232, for
example, computing and power distribution components, can also be
placed in fluid communication with the cooling loop 130. The FIG. 1
powertrain heat exchanger 220 and the battery heat exchanger 226
independently operate to respectively and selectively transfer heat
from the powertrain loop coolant and the battery loop coolant, for
example, through conduction with the cooling loop coolant, to
reduce the temperature of the battery loop coolant and the
powertrain loop coolant as further described below.
[0053] Still referring to FIG. 1, the HVAC unit 146 can be used to
filter air, cool and de-humidify air, and heat air to ventilate and
condition the passenger cabin 108. In the example shown, the HVAC
unit 146 includes an air filter 236, at least one cabin blower 238,
a recirculation air filter 240, and a distribution manifold 242 for
selective distribution of air to and from the passenger cabin 108.
The heating loop 128 and the cooling loop 130 are in fluid
communication with the heater core 188 and the cooling core 230 of
the HVAC unit 146 respectively. One or more of the cabin blowers
238 can be used to force air over the respective cores 188, 230 to
selectively heat or cool the passenger cabin 108. The air filter
236 can be positioned upstream of the cabin blower 238 in
communication with environmental air. The recirculation air filter
240 can also be used to filter both environmental air and
recirculated cabin air entering the HVAC unit 146. The heating and
cooling controls (not shown) for the passenger cabin 108 can be in
electronic communication with the cabin blowers 238 through control
units (not shown).
[0054] An advantage of the system 100 and use of the cooling loop
130 is the elimination of a dedicated air-to-refrigerant evaporator
core and refrigerant conduit connections inside the passenger cabin
108 required by prior designs that have the potential to leak
refrigerant into the cabin air. Use of the chiller 166 to remove
heat from the cooling loop coolant cools the cooling loop coolant
without the need for a separate, dedicated cooling/evaporator core
along the cooling loop 130.
[0055] FIG. 1 further illustrates the battery loop 134. In the
example, the battery loop 134 includes a reservoir 250 for the
storage of liquid battery loop coolant and a battery loop pump 252
to selectively force the flow of battery loop coolant through a
closed-loop cooling line or conduit 254 in fluid communication with
a battery module 260. The battery module 260 provides the principal
or supplemental power to drive motors which power the drive wheels
of the vehicle.
[0056] In the FIG. 1 example, a 4-port valve 266 can be positioned
in fluid communication with a heating conduit 270, a cooling
conduit 274, and a bypass conduit 280 as generally shown. The valve
266 is operable to selectively direct a flow of battery loop
coolant to the heating conduit 270 and through the heat exchanger
190 which will add heat to the battery loop coolant from the
heating loop 128. It can be desirable to temporarily heat the
battery module 260, for example, during start up and early
operation in cold environmental temperatures.
[0057] The valve 266 is also operable to selectively direct the
flow of battery loop coolant to the cooling conduit 274 and through
the battery heat exchanger 226 in thermal communication with the
cooling loop 130 to remove heat from the battery loop coolant to
reduce or maintain the temperature of the battery module 260.
Alternatively, the valve 266 is further operable to selectively
direct the flow of battery loop coolant to the bypass conduit 280
to avoid additional heating or cooling of the battery loop coolant
by the respective heat exchangers 190, 226. In one example, the
valve 266 includes additional flow positions in which a portion of
the battery loop coolant is directed to blend flow to both the
heating conduit 270 and the bypass conduit 280 or blend flow to
both the cooling conduit 274 and the bypass conduit 280 for
increased control of the temperature of the battery loop coolant
and of the battery module 260.
[0058] An advantage of the FIG. 1 system 100 and use of the battery
loop 134 is that a dedicated heater and a dedicated chiller/cooling
device is not needed along the battery loop 134 due to use of the
respective heat exchangers 190, 226.
[0059] FIG. 1 further shows an example of the powertrain loop 140.
The powertrain loop 140 includes a reservoir 290 for storage of
powertrain loop coolant, a pump 292 to selectively force flow of
the powertrain loop coolant through a line or conduit 294, a
temperature sensor 296 to measure and monitor the temperature of
the powertrain loop coolant, a battery charger 300, a control
circuit and power electronics module 304, a traction motor 310, and
a traction motor invertor 314 for the vehicle rear wheels as
generally shown.
[0060] In the FIG. 1 example, a 4-port valve 320 can be in fluid
communication with the powertrain loop conduit 294 and a cooling
conduit 324 in communication with the heat exchanger 220 on the
cooling loop 130 as previously described. Alternatively, the valve
320 can direct the flow of powertrain loop coolant to an exhaust
conduit 330 in communication with a high temperature radiator 334
(e.g., a powertrain radiator) positioned at the front end 104 of
the vehicle as generally shown. The high temperature radiator 334
can be operable to exhaust heat or remove heat from the powertrain
loop coolant to the atmosphere through forced air induced by a fan
336 or by movement of the vehicle.
[0061] The valve 320 can also be in communication with a bypass
conduit 338 which selectively keeps powertrain loop coolant from
being directed to the cooling conduit 324, the exhaust conduit 330,
and thus, the heat exchanger 220 or the high temperature radiator
334. In the FIG. 1 example, the valve 320 further includes a flow
position in which a portion of the powertrain loop coolant is
directed to blend flow to both the cooling conduit 324 and the
bypass conduit 338 or to blend flow to both the exhaust conduit 330
and the bypass conduit 338 for increased control of the temperature
of the powertrain loop coolant and components in fluid
communication with the powertrain loop 140. Although the traction
motor 310 and associated components are shown for the rear wheels
of the vehicle, it is understood that the powertrain loop 140 is
equally applicable to the front wheels of a vehicle or both the
front and rear wheels, for example, in a four-wheel drive
vehicle.
[0062] In one aspect of the powertrain loop 140, excess cooling
capacity of the refrigerant loop 124 is transferred to the
powertrain loop 140 in order to increase heat generation or output
by the LCGC 160 for heating the heating loop 128, even when the
powertrain loop 140 does not require additional heating. In other
words, the powertrain loop 140 and the valve 320 may be used to
continuously warm or transfer heat to the cooling loop 130 thereby
raising the temperature of the cooling loop coolant. This heat in
the cooling loop coolant is then transferred to the chiller 166 to
warm the refrigerant in the refrigerant loop 124 as described
above. This in turn causes an additional load on the refrigerant
loop compressor 152. Through additional load or running of the
compressor 152, more heat is generated or expelled through the LCGC
160 which may be used for additional heating of the passenger cabin
108 or the battery loop 134 as described above. In this manner, the
refrigerant loop 124 is effectively being used as a heat pump,
i.e., use of a refrigeration cycle or the refrigerant loop 124 to
generate heat. In this manner, the Coefficient of Performance for
heating may exceed 2 or 3.
[0063] Referring to FIG. 2, an alternate aspect of the thermal
management system 100 of FIG. 1 is shown. Where identical
components disclosed in FIG. 1 are included, the same reference
numbers are used and not further described except where noted. In
the FIG. 2 example, aspects of the refrigerant loop 124, the
heating loop 128, the cooling loop 130, the battery loop 134, the
powertrain loop 140, and the HVAC unit 146 are as generally
described above in FIG. 1. When the components are slightly
modified, the use of an "A" after the reference numeral is
employed.
[0064] An alternate refrigerant loop 124A, shown in FIG. 2,
includes an optional gas cooler radiator 161 (e.g., refrigerant
radiator) as generally shown in dotted line to further reduce the
temperature of the refrigerant flowing from the LCGC 160 to the
accumulator 150. A valve (not shown) or other device may be used to
bypass the gas cooler radiator 161 and selectively route
refrigerant directly from the LCGC 160 to the accumulator 150 as
shown in FIG. 1.
[0065] FIG. 2 also shows an alternate battery loop 134A. The
battery loop 134A includes a heating conduit 270A routed directly
to, and in thermal communication with, the LCGC 160 as generally
shown without the separate heat exchanger 190 as described in FIG.
1. When the valve 266 is selectively positioned to direct battery
coolant to the heating conduit 270A, the LCGC 160 provides
additional heat directly to the battery coolant in the manner
generally described in FIG. 1.
[0066] The battery loop 134A of FIG. 2 also includes a cooling
conduit 274A routed directly to, and in thermal communication with,
the chiller 166 as generally shown without the separate heat
exchanger 226 described in FIG. 1. When the valve 266 is
selectively positioned to direct battery coolant to the cooling
conduit 274A, the chiller 166 removes heat from or cools the
battery coolant in the manner generally described in FIG. 1. The
bypass conduit 280 is used with the heating conduit 270A and the
cooling conduit 274A, as well as with various positions of the
valve 266, to blend the battery coolant flow to both the heating
conduit 270A or the cooling conduit 274A with the bypass conduit
280 as described for FIG. 1. The FIG. 2 example is advantageous in
that the heat exchangers 190 and 226 of FIG. 1 are eliminated and
replaced by expanded use of the LCGC 160 and the chiller 166.
[0067] In an example of the structure of the LCGC 160 as configured
in FIG. 2, the battery loop heating conduit 270A carrying the
battery coolant is placed in thermal communication with the
refrigerant conduit 154 carrying the high pressure and high
temperature refrigerant. In addition, the heating loop conduit 182
is placed in thermal communication with the refrigerant conduit
154. The position of the battery loop valve 266, the position of
the heating loop valve 194, and operation of the compressor 152
determine which, if any, of the fluids are actively flowing through
the LCGC 160 depending on the demands or loads on the system 100A.
Examples of heat exchangers that may be used as the LCGC 160 of the
thermal management system 100A are discussed further below with
reference to FIGS. 6A-10.
[0068] The construction of the chiller 166 as configured in FIG. 2
would be the same as for the LCGC 160 described above. Further, the
construction of the LCGC 160 and the chiller 166 in the FIG. 1
example would be similar in the FIG. 2 example except that the
battery loop heating conduit 270A and the battery loop cooling
conduit 274A would not be included in either the LCGC 160 or the
chiller 166 in the FIG. 1 configuration. Examples of heat
exchangers that may be used as the chiller 166 of the thermal
management system 100A are discussed further below with reference
to FIGS. 6A-10.
[0069] It should be understood that the various valves disclosed
herein may be different types of valves and/or be formed of
multiple valves. Furthermore, the flow positions of such valves may
also be referred to as configurations accounting for the different
types of valves and/or combinations of valves that may provide
similar flow paths.
[0070] Referring to FIG. 3, an electronic control system 350 is
shown which includes, or is in electronic and digital communication
with, a processor 352, a programmable controller 354, and a
temporary and/or permanent memory device 356 for storing
algorithms, computer code instructions and data. These components
are all in communication with each other through a bus 358 or other
similar device. A human machine interface (HMI) and other
components (not shown) can also be included and connected through a
bus interface 360. The electronic control system 350 can be part of
a vehicle electronic control unit (ECU) (not shown) or can be
separate and in communication with the vehicle ECU. Although
described in use with FIG. 1 system 100 below, it is understood
system 350 is equally applicable to the system 100A example shown
in FIG. 2.
[0071] The previously described temperature and/or pressure sensors
(collectively shown as 362) for each of the thermal management
subsystem loops 124, 128, 130, 134, 140 are also in electronic
and/or digital communication with the electronic control system
350. In one example of the system 100, the electronic control
system 350 monitors the temperature and/pressure sensor signals and
data generated by the sensors 362 and adjusts the respective valves
194, 266, 320 (collectively shown as 364) to the appropriate flow
position according to pre-programmed and stored software or coded
instructions in the electronic control system 350. In a similar
manner, the various pumps 214, 252, 292, the compressor 152, and
other components which are selectively operable as previously
described can be in electronic and/or digital communication with
the electronic control system 350 through the bus interface 624 for
operation, coordination, sequencing, and control of the functions
and operations described herein.
[0072] For example, if the temperature sensor 284 on the battery
loop 134 measures the temperature of the battery loop coolant to be
above a preprogrammed temperature target or range, the electronic
control system 350 can automatically and electronically adjust the
valve 266 to a flow position that directs the battery loop coolant
to the cooling conduit 274 through the battery heat exchanger 226
to cool or remove thermal heat from the battery loop 134, reducing
the temperature of the battery loop coolant and the battery module
260 to within the predetermined temperature target or range. A
similar process can be executed if the temperature sensor 284
measures the temperature of the battery loop coolant to be below a
preprogrammed temperature target or range. The electronic control
system 350 can adjust the flow position of the valve 266 to direct
the flow of battery loop coolant toward the heating conduit 270 and
the heat exchanger 190 to add thermal heat to the battery loop
coolant. Alternatively, the bypass conduit 280 or various
combinations of the cooling conduit 274, the heating conduit 270,
and the bypass conduit 280 described above can receive the battery
loop coolant based on the flow position of the valve 266 and
depending on the preprogrammed ranges and measured operating
conditions of the battery loop 134.
[0073] A similar loop sensor measurement and valve control
operation or process can be used for the heating loop 128 to add
heat through the LCGC 160 or expel heat through the low temperature
radiator 204. A similar loop sensor measurement and valve control
operation or process can be used for the powertrain loop 140 to
cool or bypass the cooling and exhaust conduits 324, 330. Other
devices and methods of monitoring and controlling the flow position
of the valves 364 and the flow of refrigerant or coolant can be
used. In another example, the electronic control system 350 can
further monitor and control the operation of the refrigerant loop
124 through adjusting and controlling operation of the compressor
152 speed and expansion valve 162 position to control the
temperature and pressure of the refrigerant for the refrigerant
loop 124 and the coolant for the loops 128, 130, 134, 140 in
communication with refrigerant loop 124.
[0074] In other examples, different valve or fluid control devices
(not shown) for controlling the flow of coolant through the
heating, cooling, battery, and powertrain loops 128, 130, 134, 140
can be used. Further, different conduit numbers, configurations and
routing for each loop can be made to suit the particular
application. Different heat transfer devices than the disclosed
heat exchangers 190, 220, 226, the chiller 166, and the LCGC 160
can also be used to obtain the disclosed features and
functions.
[0075] Referring to FIG. 4, a process 400 for monitoring and
altering the temperature of the thermal management battery
subsystem or loops 134, 134A is illustrated. In the example,
process step 410 monitors the temperature of the battery loop
coolant in the battery loops 134, 134A. In the example shown in
FIGS. 1 and 2, the temperature sensor 284 measures the temperature
of the battery loop coolant and transfers temperature management
data to the electronic control system 350 of FIG. 3.
[0076] In step 420, the measured received battery loop coolant
temperature data can be compared to a preprogrammed temperature
target or temperature range that can be pre-stored in the memory
device 356 connected to the electronic control system 350. In one
example, the stored temperature target is an acceptable value or
range for optimal performance of the battery module 260. It is
understood that this comparison step 420 can be eliminated and
replaced with a less sophisticated temperature measurement device
and/or system.
[0077] In step 430, the electronic control system 350 automatically
adjusts the flow position of the battery loop coolant flow valve
266 to add heat, remove heat, or maintain the measured temperature
of the battery loop coolant. The valve 266 can be adjusted to a
variety of positions as described in the alternative sub-steps
below.
[0078] In sub-step 440, on determination that the measured battery
loop coolant temperature is below the preprogrammed temperature
target or range, the flow position of the valve 266 can be
automatically adjusted to add heat to the battery coolant as
described above and generally illustrated. For example, the valve
266 can direct the flow of the battery loop coolant to the heating
conduit 270 and through the heat exchanger 190 as shown in FIG. 1
or to the heating conduit 270A and through the LCGC 160 as shown in
FIG. 2 to add thermal heat to the battery coolant.
[0079] In alternative sub-step 450, on determination that the
measured battery loop coolant temperature is above a preprogrammed
target value or range, the flow position of the valve 266 can be
automatically adjusted to remove heat or cool the battery coolant
as described above and generally illustrated. For example, the
valve 266 can direct the battery loop coolant to the cooling
conduit 274 and through the heat exchanger 226 in communication
with the cooling loop 130 as shown in FIG. 1 or to the cooling
conduit 274A and the chiller 166 as shown in FIG. 2 to remove
thermal heat from the battery loop coolant.
[0080] In alternative sub-step 460, on determination that the
measured battery loop coolant temperature is at the target value or
within the target/acceptable range, the flow position of the valve
266 can be automatically adjusted to direct the flow of battery
loop coolant to the bypass conduit 280 to avoid the flow of battery
loop coolant to either of the heat exchangers 190, 226 in FIG. 1,
or the LCGC 160 or the chiller 166 in FIG. 2, to avoid adding or
removing thermal heat from the battery loop coolant. In another
alternative sub-step (not shown), the speed of the battery loop
pump 252 can be reduced, increased, or stopped, temporarily idling
the flow of battery loop coolant through the battery loop 134. The
activation, change in speed, or idling of the other pumps discussed
and illustrated in the other system loops may also be controlled by
electronic control system 350.
[0081] In another alternative sub-step 470, the flow position of
the valve 266 can be automatically adjusted to a position so as to
direct the battery loop coolant to partially flow to both the
heating conduits 270, 270A and the bypass conduit 280 or to both
the cooling conduits 274, 274A and the bypass conduit 280 for
increased control of the temperature of the battery loop
coolant.
[0082] Referring to FIG. 5, a process 500 for heating the heating
loop 128 and/or the battery loops 134, 134A using the refrigerant
loops 124, 124A is illustrated. In step 510, refrigerant is
compressed in the refrigerant loops 124, 124A. In one example, the
compressor 152 is used to compress the refrigerant to a high
pressure and high temperature.
[0083] In step 520, the compressed refrigerant flows through the
LCGC 160. In the FIG. 1 and FIG. 2 examples, the heating loop
coolant from the heating loop 128 draws heat from the refrigerant
conduit 154 in the LCGC 160. In the FIG. 2 example, the battery
loop coolant from the battery loop 134A may also draw heat from the
refrigerant conduit 154 in the LCGC 160.
[0084] In step 530, in the FIG. 1 and FIG. 2 examples, the LCGC 160
transfers thermal energy in the form of heat to the heating loop
128, that is, to the heating loop coolant which draws or absorbs
the expelled heat, thereby increasing the temperature of the
heating loop coolant. In the FIG. 2 example, the LCGC 160 may also
transfer thermal energy in the form of heat to the battery loop
coolant from the battery loop 134A. The steps 520 and 530 can occur
simultaneously.
[0085] In optional step 535, applicable to the example in FIGS. 1
and 2, increasing the temperature of the heating loop coolant is
possible through use of the electric heater 184 in thermal
communication with the heating loop coolant.
[0086] In optional step 540, applicable to the example in FIGS. 1
and 2, the increased temperature heating loop coolant can be used
to selectively heat the passenger cabin 108. As disclosed above,
the HVAC unit 146 includes the heater core 188 in fluid
communication with the heating loop 128, and the cabin blower 238
can be used to selectively provide heated air to the passenger
cabin 108 by forcing the air across the heater core 188.
[0087] In optional, alternative step 550, applicable to the example
in FIG. 1, selectively heating the battery loop coolant is possible
by sending the increased-temperature heating loop coolant through
the heat exchanger 190 in thermal communication with the battery
loop coolant. It is understood that additional steps and a
different ordering of the disclosed steps in the process 500 is
also possible.
[0088] Referring to FIGS. 6A-6G, a heat exchanger 600 is configured
to exchange or transfer heat between at least three fluids of
various loops flowing therethrough. The heat exchanger 600 may, for
example, be configured and used as the chiller 166 and/or the LCGC
160 of the thermal management system 100A. For example, the thermal
management system 100A may include two of the heat exchangers 600,
which are used as the chiller 166 and the LCGC 160 and which may
have different configurations.
[0089] Referring to FIGS. 6A-6C, the heat exchanger 600 includes a
core 602 (e.g., structure or core structure) that defines passages
through which the fluids flow and various manifold structures 604
that connect the heat exchanger 600 to a thermal management system,
such as the thermal management system 100A. Referring to FIGS.
6D-6G, more particularly, the heat exchanger 600 includes a
refrigerant passage 620 through which refrigerant 620a flows, a
primary coolant passage 640 through which a primary coolant 640'
flows, and a secondary coolant passage 660 through which a
secondary coolant 660' flows. Fluidic separation is maintained
between the refrigerant 620a, the primary coolant 640', and the
secondary coolant 660', while heat is transferred therebetween. The
core 602, including the refrigerant passage 620, the primary
coolant passage 640, and the secondary coolant passage 660 thereof,
are discussed in further detail below. The manifolds are also
discussed in further detail below. In the figures, the passages,
the passes thereof, the fluid flowing therethrough, and the
direction of the fluid flow may generally be indicated by arrows
and/or cross-hatching of which down-right angled cross-hatching
indicates flow into the page and up-right angled cross-hatching
indicates flow out of the page.
[0090] The heat exchanger 600 may be configured, among other
considerations, according to a number of passes the refrigerant
passage 620, the primary coolant passage 640, and the secondary
coolant passage 660 each make through the heat exchanger 600, as
well as which passes of the refrigerant passage 620, the primary
coolant passage 640, and the secondary coolant passage 660 transfer
heat directly between each other. The term "pass" generally refers
a portion of a respective passage, or the fluid flowing
therethrough, which extends across the width or the length, or
substantial majorities thereof of the heat exchanger 600 or the
core 602 thereof. A single pass may be cooperatively formed by
parallel flows of a fluid (e.g., in different tube structures or
cavities, as discussed below). Direct heat transfer is generally
considered heat transfer between two fluids without heat transfer
through an intermediate fluid but may occur through an intermediate
structure (e.g., a wall structure or a tube structure). Direct heat
transfer may be referred to as occurring between passes of fluids
or between the fluids of the passes. Indirect heat transfer is
generally considered heat transfer between two fluids via one or
more intermediate fluids.
[0091] For example, in the heat exchanger 600, the refrigerant
passage 620 includes six refrigerant passes 620a, 620b, 620c, 620d,
620e, 620f, the primary coolant passage 640 includes two primary
coolant passes 640a, 640b, and the secondary coolant passage 660
includes one secondary coolant pass 660a. Three of the refrigerant
passes 620a, 620b, and 620c extend through and transfer heat
directly with a first of the coolant passes 640a, the three other
refrigerant passes 620d, 620e, and 620f extend through are transfer
heat directly with a second of the primary coolant pass 640b, and
the secondary coolant pass 660a transfers heat directly with both
the primary coolant passes 640a, 640b. Variations of the heat
exchanger 600 are discussed with reference to FIGS. 7-10 below,
which include a heat exchanger 700 having three primary coolant
passes, and a heat exchanger 800 having seven refrigerant passes,
but which may include more or fewer primary coolant passes (e.g.,
one, four, or five), and more or fewer refrigerant passes (e.g.,
fewer than six or more than seven).
[0092] The core 602 includes wall structures that define various
cavities that form the primary coolant passage 640 and the
secondary coolant passage 660. The core 602 additionally includes
refrigerant tubes 622 that cooperatively form the refrigerant
passage 620 and which extend through the cavities. Referring to
FIG. 6D, more particularly, the core 602 includes a first primary
coolant cavity 642a and a second primary coolant cavity 642b, which
cooperatively form the primary coolant passage 640 and which
individually form the first primary coolant pass 640a and the
second primary coolant pass 640b, respectively. The first primary
coolant cavity 642a and the second primary coolant cavity 642b are
fluidically connected, such that the primary coolant 640' flows
serially therethrough in opposite directions. The wall structures
are formed of a metal material (e.g., aluminum) or other suitable
material, which facilitates heat transfer between the primary
coolant passage 640 and the secondary coolant passage 660 (e.g.,
via conduction therethrough). The refrigerant tubes 622 are
discussed in further detail below.
[0093] The primary coolant cavities 642a, 642b are generally
rectangular in cross-section. The first primary coolant cavity 642a
is formed by (e.g., defined between) by a top wall 602a and a first
intermediate wall 602b opposite and parallel thereto, a first side
wall 602c and a second side wall 602d opposite and parallel
thereto, and a first end wall 602e and a second end wall 602f. The
second primary coolant cavity 642b is also formed by various wall
structures of the core 602, which may be common with those wall
structures forming the first primary coolant cavity 642a. More
particularly, the second primary coolant cavity 642b is formed by a
bottom wall 602g and a second intermediate wall 602h opposite and
parallel thereto, the first side wall 602c and the second side wall
602d, and the first end wall 602e and the second end wall 602f. The
first end wall 602e and/or the second end wall 602f, or portions
thereof, may be omitted in some embodiments as discussed in further
detail below. The intermediate walls 602b, 602h may, for example,
be referred to as a coolant plate, as they facilitate heat transfer
between fluids (e.g., the primary coolant 640' and the secondary
coolant 660') flowing on either side thereof as discussed in
further detail below. The intermediate walls 602b, 602h, as well as
the top wall 602a and the bottom wall 602g, each have a width and a
length that generally corresponds to the width and the length,
respectively of the core 602 (e.g., between 250 and 290 mm, such as
approximately 270 mm). Furthermore, the length of the core 602 and
the intermediate walls 602b, 602h, as well as the top wall 602a and
the bottom wall 602g, account for the number, width, and spacing of
the refrigerant tubes 622 discussed below.
[0094] The core 602 may, for example, have a height measured
between the top wall 602a and the bottom wall 602g of between
approximately 40 and 50 mm (e.g., approximately 46 mm), a width
measured between the first side wall 602c and the second side wall
602d of between approximately 250 and 290 mm (e.g., approximately
270 mm), and a length measured between the first end wall 602e and
the second end wall 602f of between approximately 250 and 290 mm
(e.g., approximately 270 mm). The manifold structures 604 may, for
example, be arranged on each side and one end of the core 602 and
have widths of between approximately 10 and 40 mm (e.g.,
approximately 30 mm and 20 mm, respectively). As a result, the heat
exchanger 600 may have an overall length measured between the
manifold structures 604 on each end (e.g., adjacent the end walls
602e, 602f) of between approximately 290 and 370 mm (e.g.,
approximately 330 mm), and an overall width measured between the
manifold structure 604 at one side and the second side wall 602d of
between approximately 260 and 310 mm (e.g., approximately 290 mm).
The heat exchanger 600 may, however, have different dimensions
overall, of the core 602, and/or of the manifold structures 604
(e.g., taller or shorter, wider or narrower, longer or shorter).
Furthermore, while the various wall structures are referred to with
directional terms for reference purposes, it should be understood
that the heat exchanger 600 may, in use, be arranged in different
orientations. For example, in one preferred orientation, the heat
exchanger 600 may be arranged such that gravity is in the direction
of the width (e.g., such that second side wall 602d may be an
upper, horizontal surface while, while the top wall 602a and the
bottom wall 602g are side, vertical surfaces).
[0095] As referenced above, the primary coolant 640' flows serially
through the first primary coolant cavity 642a, forming the first
primary coolant pass 640a, and then through the second primary
coolant cavity 642b, forming the second primary coolant pass 640b.
Referring additionally to FIG. 6G, the first primary coolant cavity
642a receives the primary coolant 640' at a first end thereof from
an inlet structure (e.g., a primary inlet manifold 644a, as
discussed in further detail below), for example, through the first
end wall 602e. The primary coolant 640' flows through the first
primary coolant cavity 642a in a first direction from the first end
to a second end thereof. The primary coolant 640' then flows from
the second end of the first primary coolant cavity 642a, for
example, through the second end wall 602f, to a first end of the
second primary coolant cavity 642b. The first primary coolant
cavity 642 and the second primary coolant cavity 642b may, for
example, be fluidically connected by one or more primary coolant
tubes 646 extending therebetween (e.g., between the second end and
the first end, respectively, thereof), which may be arranged in or
formed by one of the manifold structures 604. The primary coolant
640' then flows through the second primary coolant cavity 642b in a
second direction from the first end to the second end thereof,
which is substantially opposite the first direction. The primary
coolant 640' is expelled from the second end of the second primary
coolant cavity 642b, for example, through the first end wall 602e,
to an outlet structure (e.g., a primary outlet manifold 644b, as
discussed in further detail below). The first primary coolant
cavity 642a and the second primary coolant cavity 642b may be
fluidically connected in other suitable manners, for example, by a
chamber (e.g., formed by one of the manifold structures 604).
[0096] The secondary coolant cavity 662 is arranged between the
primary coolant cavities 642a, 642b to facilitate heat transfer
between the secondary coolant 660' and the primary coolant 640',
respectively, flowing therethrough. More particularly, the
secondary coolant cavity 662 is defined between the first
intermediate wall 602b, which also defines the first primary
coolant cavity 642a, and the second intermediate wall 602h, which
also defines the second primary coolant cavity 642b. Heat is,
thereby, transferred between the secondary coolant 660' and the
primary coolant 640' in the first primary coolant cavity 642a and
the second primary coolant cavity 642b via the first intermediate
wall 602b and the second intermediate wall 602h. In this
arrangement, the secondary coolant passage 660, in effect,
insulates the first primary coolant pass 640a from the second
primary coolant pass 664b to prevent direct heat transfer
therebetween through a wall structure.
[0097] The secondary coolant cavity 662 is generally rectangular in
cross-section. The secondary coolant cavity 662 may, for example,
have similar (e.g., substantially equal) cross-sectional dimensions
in one plane (e.g., width and length) as the primary coolant
cavities 642a, 642b, while having a different dimension in a
perpendicular plane (e.g., having a lesser height). The secondary
coolant cavity 662, as described above, is formed by the first
intermediate wall 602b and the second intermediate wall 602h, and
additionally by the first side wall 602c and the second side wall
602d, and the first end wall 602e and the second end wall 602f.
[0098] The secondary coolant 660' flows through the secondary
coolant cavity 662 in a single pass. The secondary coolant cavity
662 receives the secondary coolant 660' at a first end thereof from
an inlet structure (e.g., a secondary inlet manifold 664a, as
discussed in further detail below), for example, through the first
end wall 602e. The secondary coolant 660' then flows through the
secondary coolant cavity 662 from the first end to a second end
thereof in the same direction (i.e., the first direction) as the
primary coolant 640' flows through the first primary coolant cavity
642a. The secondary coolant 660' is expelled from the second end of
the primary coolant cavity 642a, for example, through the second
end wall 602f, to an outlet structure (e.g., a secondary outlet
manifold 664b, as discussed in further detail below).
Alternatively, the secondary coolant 660' may flow through the
secondary coolant cavity 662 in the same direction as the primary
coolant 640' flows through the second primary coolant cavity 642b
(i.e., in the second direction), or may flow perpendicular thereto
(e.g., between the first side wall 602c and the second side wall
602d).
[0099] Referring to FIGS. 6E-6F, the refrigerant passage 620 is
cooperatively formed by the refrigerant tubes 622 (e.g., n number
of refrigerant tubes 622.sub.1to 622.sub.n) that are spaced apart
laterally (e.g., along the first side wall 602c) and extend
substantially parallel with each other. The heat exchanger 600 may,
for example, include between 20 and 60 refrigerant tubes 622 (e.g.,
between 25 and 35 refrigerant tubes 622, such as 28 refrigerant
tubes 622). It should be noted that in FIG. 6E only 13 refrigerant
tubes 622 are illustrated for clarity purposes, while the vertical
jagged line indicates that additional refrigerant tubes 622 may be
included and that the core 602 may have different dimensions to
accommodate additional refrigerant tubes 622. The refrigerant tubes
622 may also be referred to as refrigerant lines.
[0100] The refrigerant tubes 622 extend through the core 602 in a
serpentine manner to form the multiple refrigerant passes. More
specifically, each of the refrigerant tubes 622 includes six tube
segments 622a, 622b, 622c, 622d, 622e, and 622f (e.g., straight
segments) through which the refrigerant 620' flows serially. The
tube segments 622a-622f extend through the first primary coolant
cavity 642a and the second primary coolant cavity 642b from the
first side wall 602c to the second side wall 602d, for example,
parallel with the top wall 602a and the first end wall 602e. For
example, in the heat exchanger 600, three of the tube segments
622a, 622b, and 622c extend through the first primary coolant
cavity 642a, while the other three of the tube segments 622d, 622e,
and 622f extend through the second primary coolant cavity 642b. The
refrigerant tubes 622 additionally include connecting segments
(e.g., curved segments; not labeled), which extend outside the
primary coolant cavities 642a, 642b (e.g., through the first side
wall 602c and the second side wall 602d) and interconnect the tube
segments 622a-622f for the refrigerant 620' to flow serially
therethrough. The refrigerant tubes 622 may protrude through the
first side wall 602c and the second side wall 602d and, for
example, be supported thereby and/or be sealingly connected thereto
(e.g., to prevent the primary coolant 640' and the secondary
coolant 660' from leaking between the side walls 602c, 602d and the
refrigerant tubes 622). Alternatively, the refrigerant tubes 622,
including the curved segments, may be contained within the primary
coolant cavities 642a, 642b (i.e., between the first side wall 602c
and the second side wall 602d) with, for example, only the first
and the second end thereof (i.e., formed by the first and the sixth
of the tube segments 622a, 622f extending through the first side
wall 602c). The tube segments 622a-622f have a length that
generally corresponds to a width of the core 602 (e.g., between 250
and 290 mm, such as approximately 270 mm).
[0101] The refrigerant 620' flows through the refrigerant passage
620 in six passes (i.e., formed by the tube segments 622a-622f)
back and forth in opposing directions, which are perpendicular to
the first direction and the second direction that the primary
coolant 640' flows through the primary coolant cavities 642a, 642b.
The refrigerant tubes 622 each receive the refrigerant 620' at a
first end thereof (e.g., formed by a first of the tube segments
622a) from an inlet structure (e.g., a refrigerant inlet manifold
664a, a discussed in further detail below), for example, through
the first side wall 602c. The refrigerant 620' then flows serially
through the tube segments 622a-622f and the connecting segments
therebetween in a serpentine manner (i.e., back and forth
directions) to a second end thereof (e.g., formed by a sixth or
last of the tube segments 622f). The refrigerant 620' is expelled
from the second ends of the refrigerant tubes 622, for example,
through the second side wall 602d, to an outlet structure (e.g., a
refrigerant outlet manifold 624b).
[0102] The refrigerant tubes 622 are, for example, configured to
carry the refrigerant 620' (e.g., CO.sub.2, such as R744), under
high pressure. The refrigerant tubes 622 may, for example, each be
continuously formed of a metal material (e.g., aluminum), for
example, being extruded and bent to form the tube segments
622a-622f and the connection segments therebetween. Referring to
FIG. 6H, in one example, each of the refrigerant tubes 622 includes
therein a series of channels 622' (e.g., channels, for example,
three) that are spaced apart laterally and extend therethrough from
the first end to the second end thereof. In cross-section, the
refrigerant tube 622 may be substantially rectangular in
cross-section, for example, having a width of approximately 6.3 mm
and a height of approximately 1.4 mm, or be larger or smaller in
width or height. As is shown, the larger dimension of the
refrigerant tube 622 (e.g., the width as shown) may be arranged in
the primary coolant cavities 642a, 642b substantially parallel with
the direction of flow of the primary coolant 640'. The channels
622' may, for example, be circular and have a diameter of between
0.5 and 1.3 mm (e.g., 1.3 mm), or may have another shape (e.g.,
triangular, rectangular, oval, etc.) and/or have another size. The
refrigerant tube 622 may be still configured in other manners, for
example, having a few or more channels 622' (e.g., one, two, four,
or more), have a different cross-sectional shape (e.g., circular),
and/or be configured for other fluids (e.g., a low pressure
refrigerant or coolant). As a result, the refrigerant tubes 622 may
collectively include, for example, between approximately 60 and 180
the channels 622' (e.g., 84 of the channels 622'), which
cooperatively form the refrigerant passage 620.
[0103] With the refrigerant tubes 622 extending through the primary
coolant cavities 642a, 642b, the primary coolant 640' flows in
contact therewith, such that heat may be transferred between the
refrigerant 620' and the primary coolant 640' via the material
forming the refrigerant tubes 622. Moreover, heat may be
transferred indirectly between the refrigerant 620' and the
secondary coolant 660' via the primary coolant 640', which
exchanges heat directly with the refrigerant 620' and the secondary
coolant 660'.
[0104] Additionally, with the primary coolant cavities 642a, 642b
having the refrigerant tubes 622 (i.e., the tube segments 622a-622f
thereof) extend therethrough and the secondary coolant cavity 662
being arranged therebetween, the heat exchanger 600 may be
considered to have fluid layers. The heat exchanger 600 includes 15
fluid layers, which include six refrigerant layers (i.e., formed by
the six tube segments 622a-622f), eight primary coolant layers
(i.e., defined above, below, and between the six tube segments
622a-622f within the primary coolant cavities 642a, 642b, and which
may have the same or different height as each other), and one
secondary coolant layer (i.e., defined by the secondary coolant
cavity 662, which may have the same or different height as the
primary coolant layers).
[0105] The refrigerant inlet manifold 624a is configured to connect
to a refrigerant input, for example at a refrigerant inlet 624a',
and is connected to the refrigerant passage 620. The refrigerant
inlet manifold 624a may be formed by and/or contained in one of the
manifold structures 604. The refrigerant inlet manifold 624a is,
for example, configured as a tubular structure that is connected to
the first ends (e.g., the first tube segments 622a) each of the
refrigerant tubes 622 that cooperatively form the refrigerant
passage 620. The refrigerant inlet manifold 624a receives the
refrigerant 620' from the refrigerant input and passes the
refrigerant 620' to the refrigerant passage 620 and, in particular,
distribute the refrigerant 620' to each of the refrigerant tubes
622.
[0106] The refrigerant outlet manifold 624b is configured to
connect to a refrigerant output, for example at a refrigerant
outlet 624b'. The refrigerant outlet manifold 624b is a tubular
structure that is connected to the second ends (e.g., the sixth
tube segments 622f) of each of the refrigerant tubes 622. The
refrigerant outlet manifold 624b may be formed by one of the
manifold structures 604. The refrigerant outlet manifold 624b
receives the refrigerant 620' from the refrigerant tubes 622 and
passes the refrigerant 620' to the refrigerant output. The
refrigerant input and the refrigerant output may be a common
refrigerant loop. For example, when the heat exchanger 600 is
configured and used as either the chiller 166 or the LCGC 160 in
the thermal management system 100A, the refrigerant passage 620 is
connected to the refrigerant loop 124A via the refrigerant inlet
manifold 624a and the refrigerant outlet manifold 624b.
[0107] As shown, the refrigerant inlet manifold 624a and the
refrigerant outlet manifold 624b are arranged on a common side of
the heat exchanger 600, which corresponds to an even number
refrigerant passes (i.e., six as shown) of the refrigerant passage
620. The refrigerant inlet manifold 624a and the refrigerant outlet
manifold 624b each extend substantially parallel with and adjacent
to the first side wall 602c of the core 602. The refrigerant inlet
manifold 624a and the refrigerant outlet manifold 624b are each
made of a compatible material (e.g., aluminum) for being connected
to the refrigerant tubes 622 and reliably handle the pressure
associated with refrigerant 620'. The refrigerant inlet manifold
624a and the refrigerant outlet manifold 624b are additionally
configured to connect to the refrigerant input and refrigerant
output, respectively, in a suitable manner, such as with releasable
connections (e.g., fittings) or with permanent connections (e.g.,
brazed).
[0108] The primary inlet manifold 644a is configured to connect to
a primary coolant input, for example at a primary inlet 644a', and
is connected to the primary coolant passage 640. The primary inlet
manifold 644a is, for example, configured as a chamber in fluid
communication with the first end of the first primary coolant
cavity 642a, for example, through one or more apertures (not
labeled) in the first end wall 602e of the core 602. Alternatively,
the first end wall 602e may be omitted. The primary inlet manifold
644a receives the primary coolant 640' from the primary coolant
input and passes the primary coolant 640' to the primary coolant
passage 640 and, may additionally, distribute the primary coolant
640' across the first end of the first primary coolant cavity
642a.
[0109] The primary outlet manifold 644b is configured to connect to
a primary coolant output, for example at a primary outlet 644b'.
The primary outlet manifold 644b is, for example, configured as
another chamber in fluid communication with the second end of the
second primary coolant cavity 642b. The primary outlet manifold
644b receives the primary coolant 640' from the second primary
coolant cavity 642b and passes the primary coolant 640' to the
primary coolant output. The primary coolant input and the primary
coolant output may be a common coolant loop. For example, when the
heat exchanger 600 is configured and used as the chiller 166, the
primary coolant passage 640 is connected to the cooling loop 130
via the primary inlet manifold 644a and the primary outlet manifold
644b. When instead configured and used as the LCGC 160 of the
thermal management system 100A, the primary coolant passage 640 is
connected to the heating loop 128 via the primary inlet manifold
644a and the primary outlet manifold 644b.
[0110] As shown, the primary inlet 644a' and the primary outlet
644b' are arranged on a common side of the heat exchanger 600,
which corresponds to an even number of primary coolant passes
(i.e., two as shown) of the primary coolant passage 640. It may
also be preferred to orient the primary inlet 644a' to be lower
than the primary outlet 644b' (e.g., when installed in the thermal
management system 100A). The primary inlet manifold 644a and the
primary outlet manifold 644b each extend substantially parallel
with and adjacent to the first end wall 602e of the core 602. The
primary inlet manifold 644a and the primary outlet manifold 644b
are each made of a compatible material (e.g., aluminum) for being
connected to the core 602 and for carrying the primary coolant 640'
therein (e.g., 50/50 mixture of water and ethylene glycol)., and
may be formed separately or continuously with other portions of the
core 602. The primary inlet manifold 644a and the primary outlet
manifold 644b are additionally configured to connect to the primary
coolant input and primary coolant output, respectively, in a
suitable manner, such as with releasable connections (e.g.,
fittings) or with permanent connections (e.g., brazed).
[0111] The secondary inlet manifold 664a is configured to connect
to a secondary coolant input, for example at a secondary inlet
664a', and is connected to the secondary coolant passage 660. The
secondary inlet manifold 664a is, for example, configured as a
chamber in fluid communication with the first end of the secondary
coolant cavity 662a, for example, through one or more apertures
(not labeled) in the first end wall 602e of the core 602.
Alternatively, the first end wall 602e may be omitted. The
secondary inlet manifold 664a receives the secondary coolant 660'
from the secondary coolant input and transfers the secondary
coolant 660' to the secondary coolant passage 660 and, may
additionally, distribute the secondary coolant 660' across the
first end of the secondary coolant cavity 662.
[0112] The secondary outlet manifold 664b is configured to connect
to a secondary coolant output, for example at a secondary outlet
664b', and is connected to the secondary coolant passage 660. The
secondary outlet manifold 664b is, for example, configured as
another chamber in fluid communication with the second end of the
secondary coolant cavity 662. The secondary outlet manifold 664b
receives the secondary coolant 660' from the secondary coolant
cavity 662 and transfers the secondary coolant 660' to the
secondary coolant output. The secondary coolant input and the
secondary coolant output may be a common coolant loop. For example,
when the heat exchanger 600 is configured and used as either the
chiller 166 or the LCGC 160, the secondary coolant passage 660 is
connected to the battery loop 134A via the secondary inlet manifold
664a and the secondary outlet manifold 664b. It may be preferred to
locate the secondary inlet 664a' below the secondary outlet 664b',
for example, in the thermal management system 100A.
[0113] As shown, the secondary inlet manifold 664a and the
secondary outlet manifold 664b are arranged on different sides of
the heat exchanger 600, which corresponds to an odd number of
secondary coolant passes 660a (i.e., one as shown) of the secondary
coolant passage 660. The secondary inlet manifold 664a and the
secondary outlet manifold 664b extend substantially parallel with
and adjacent to the first end wall 602e and the second end wall
602f, respectively, of the core 602. The secondary inlet manifold
664a and the secondary outlet manifold 664b are each made of a
compatible material (e.g., aluminum) for being connected to the
core 602 and for carrying the secondary coolant 660' therein (e.g.,
a 50/50 mixture of water and ethylene glycol)., and may be formed
separately or continuously with other portions of the core 602
and/or the primary inlet manifold 644a and/or the primary outlet
manifold 644b. The secondary inlet manifold 664a and the secondary
outlet manifold 664b are additionally configured to connect to the
secondary coolant input and secondary coolant output, respectively,
in a suitable manner, such as with releasable connections (e.g.,
fittings) or with permanent connections (e.g., brazed).
[0114] Additionally, the various manifolds and passages may be
configured for the primary refrigerant 620' and the primary coolant
640' to transfer heat therebetween either as both enter the heat
exchanger 600 or as one fluid enters and the other fluid exits the
heat exchanger 600. For example, when configured and used as a the
LCGC 160, heat is transferred from the refrigerant 620' to the
primary coolant 640' and in turn to the secondary coolant 660'. The
refrigerant 620' decreases in temperature flowing therethrough and,
thereby, has a maximum refrigerant temperature at the refrigerant
inlet 624a' and a minimum temperature at the refrigerant outlet
624b'. The primary coolant 640' and the secondary coolant 660' each
increase in temperature flowing through the heat exchanger 600 to
have minimum temperatures at the respective inlets 644a', 664a' and
maximum temperatures at the respective outlets 644b', 664b'. The
manifolds and passages may be arranged such that the highest
temperature refrigerant 620' (i.e., in those tube segments
622a-622c after entering through the inlet 624a') transfers heat to
that primary coolant 640' with the lowest temperature (i.e., in the
first primary coolant cavity 642a after entering through the inlet
644a') or that primary coolant 640' with the highest temperature
(i.e., in the second primary coolant cavity 642b prior to exiting
through the outlet 644b'). Conversely, when configured and used as
the chiller 166, heat is transferred from the primary coolant 640'
to the refrigerant 620'. The heat exchanger 600 may be configured
for the highest temperature primary coolant 640' (i.e., in the
first primary coolant cavity 642a after entering through the inlet
644a') to transfer heat to the lowest temperature refrigerant 620'
(i.e., in those tube segments 622a-622c after entering through the
inlet 624a') or the highest temperature refrigerant 620' (i.e., in
those tube segments 622d-622f before exiting through the outlet
624b').
[0115] Referring to FIG. 7, a heat exchanger 700 is a variation of
the heat exchanger 600. The heat exchanger 700 may, for example, be
used as the chiller 166 in the thermal management system 100A
and/or use as the LCGC 160 in the thermal management system 100A.
For example, in one preferred embodiment, the thermal management
system 100A may include the heat exchanger 600 as the chiller 166
(e.g., transfer heat from the battery loop coolant to the
refrigerant, for example, indirectly via the cooling loop coolant,
thereby decreasing the temperature of the battery loop coolant) and
may include the heat exchanger 700 as the LCGC 160 (e.g., to
transfer heat to the battery loop coolant from the refrigerant, for
example, indirectly via the heating loop coolant, thereby
increasing the temperature of the battery loop coolant).
[0116] For brevity, differences between the heat exchanger 600 and
the heat exchanger 700 are described below. For further
understanding of the heat exchanger 700, refer to the discussion of
the heat exchanger 600 above. The heat exchanger 700 includes six
refrigerant passes 720a-720f, three primary coolant passes
740a-740c, and one secondary coolant pass 760a. Two of the
refrigerant passes 720a-720f extend through and transfer heat
directly with one of the three primary coolant passes 740a-740c.
The three primary coolant passes 740a-740c additionally transfer
heat directly with the secondary coolant pass 760a.
[0117] For example, the heat exchanger 700 includes a core 702,
along with a refrigerant passage 720, a primary coolant passage
740, and a secondary coolant passage 760. The refrigerant passage
720 is formed by a series of refrigerant tubes 722. The refrigerant
passage 720 includes six passes 720a-720f, which are each formed by
tube segments 722a-722f of the refrigerant tubes 722.
[0118] The primary coolant passage 740 includes three passes 740a,
740b, 740c, which are, respectively, formed by a first cavity 742a
(defined between first and second intermediate walls 704h, 704i of
the core 702), a second cavity 742b (defined between third and
fourth intermediate walls 704j, 704k), and a third cavity 742c
(defined between the fifth and sixth intermediate walls 704l,
704m). The second cavity 742b is connected to the first cavity 742a
and the third cavity 742c for serial flow therethrough (e.g., with
connecting tubes or another suitable manner, as described above
with respect to the primary coolant passage 640). The first and
third passes 740a, 740c flow in a first direction (i.e., into the
page as indicated by down-right angled cross-hatching), while the
second pass 740b flows opposite the first direction (i.e., out of
the page as indicated by up-right angled cross-hatching). A primary
inlet manifold may be configured substantially similar to the
primary inlet manifold 644a described previously, while a primary
outlet manifold may be configured substantially similar to the
second primary outlet manifold 644b but is arranged on an opposite
side of the heat exchanger 700 relative to the primary inlet
manifold.
[0119] The secondary coolant passage 760 forms a single pass 760a,
which is cooperatively formed by four secondary coolant cavities
762a-762d (i.e., parallel flow occurs through the four secondary
coolant cavities 762a-762d). The four secondary coolant cavities
762a-762d are, respectively, defined between a top wall 704a and
the first intermediate wall 704h, between the second and third
intermediate walls 704i, 704j, between the fourth and fifth
intermediate walls 704k, 7041k, and between the sixth intermediate
wall 704m and a bottom wall 704b of the core 702. A secondary inlet
manifold and a secondary outlet manifold (not shown) are,
respectively, configured to, respectively, distribute and collect
the secondary coolant (not labeled) to and from the four secondary
coolant cavities 762a-762d.
[0120] Heat transfer occurs directly between two of the refrigerant
passes 720a-720f and each of the three primary coolant passes
740a-740c (i.e., through the material forming the refrigerant tubes
722). More particularly, two of the tube segments 722a-722f extend
through each of the primary coolant cavities 742a-742c.
[0121] Heat transfer additionally occurs directly between the
secondary coolant pass 760a in two of the secondary coolant
cavities 762a-762d and each of the primary coolant passes
740a-740c. More particularly, two of the secondary coolant cavities
762a-762d surround each of the primary coolant cavities 742a-742c
and share a common one of the intermediate walls 704h-704m
therewith. For example, the secondary coolant pass 760a flows
through the first primary coolant cavity 742a, which is surrounded
by the first and second secondary coolant cavities 762a, 762b and
shares the first and second intermediate walls 704h, 704i,
respectively, therewith.
[0122] Furthermore, the first and fourth secondary coolant cavities
762a, 762d are defined, in part, by the top wall 704a and the
bottom wall 704b, which may be exposed to ambient air. Thus, heat
may additionally be transferred between the secondary coolant pass
760a flowing through the first and fourth secondary coolant
cavities 762a, 762d and ambient air. Moreover, the secondary
coolant cavities 762a, 762d may insulate the primary coolant
passage 740 from ambient air, which may prevent condensation that
might otherwise form on outer surfaces of the heat exchanger 700
from humidity of the ambient air condensing as heat is transferred
from the ambient air to the primary coolant 740'.
[0123] As a result of the configuration described above and shown
in FIG. 7, the heat exchanger 700 includes 19 fluid layers, which
include six refrigerant layers (i.e., formed by the six tube
segments 722a-722g), nine primary coolant layers (i.e., formed in
the primary coolant cavities 742a-742c between and outside of the
six tube segments 722a-722g extending therethrough), and four
secondary coolant layers (i.e., formed by the secondary coolant
cavities 762a-762d, which extend outside of and between the three
primary coolant cavities 742a-742c).
[0124] The core 702 may, for example, have a height of between
approximately 55 and 65 mm (e.g., approximately 60 mm), a width of
between approximately 250 and 290 mm (e.g., approximately 270 mm),
and/or a length of between approximately 190 and 230 mm (e.g.,
approximately 210 mm). The heat exchanger 700, accounting for
manifold structures configured as described previously, may have an
overall height of between 55 and 65 mm (e.g., approximately 60 mm),
an overall width of between 290 and 370 mm (e.g., approximately 330
mm), and an overall length of between approximately 200 and 270 mm
(e.g., approximately 230 mm). The heat exchanger 700 and the core
702 may, however, be configured with other dimensions. Furthermore,
in preferred usage scenarios, gravity may extend in the direction
of the width (e.g., in either direction in which the refrigerant
720' flows through the refrigerant passage 720) or in the direction
of the length (e.g., in either direction in which the primary
coolant 740' flows through the primary coolant passage 740).
[0125] Referring to FIG. 8, a heat exchanger 800 is a variation of
the heat exchanger 600. For brevity, differences between the heat
exchanger 600 and the heat exchanger 800 are described below. For
further understanding of the heat exchanger 800, refer to the
discussion of the heat exchanger 600 above. The heat exchanger 800
includes a refrigerant passage 820 having seven refrigerant passes
820a-820g, a primary coolant passage 840 having two primary coolant
passes 840a-840b, and one secondary coolant passage 860 having one
secondary coolant pass 860a. By having an odd number of refrigerant
passes (i.e., seven), the refrigerant 820' enters and exits the
heat exchanger 800, respectively, through a refrigerant inlet
manifold 824a and a refrigerant outlet manifold 824b that are
positioned on opposites sides of the heat exchanger 800.
[0126] Three of the refrigerant passes 820a-820f extend through and
exchange heat directly with one of the two primary coolant passes
840a-840b. Another of the refrigerant passes 820g extends through
and transfer heat directly with the secondary coolant pass 860a.
The first primary coolant pass 840a and the second primary coolant
pass 840b may exchange heat directly with each other (e.g., by
sharing a intermediate wall 840m common therebetween). The second
primary coolant pass 840b and the secondary coolant pass 860a may
additionally exchange heat directly with each other (e.g., by
sharing another intermediate wall 804n common therebetween). The
first primary coolant pass 840a may additionally exchange heat
directly with ambient air (e.g., through a top wall 804a). The
secondary coolant pass 860a may additionally exchange heat directly
with ambient air via a bottom wall 804b).
[0127] As a result, the heat exchanger 800 may include 17 fluid
layers, which include seven refrigerant layers (i.e., formed by the
seven refrigerant passes 820a-820g), eight primary coolant layers
(i.e., formed by the two primary coolant passes 840a-840b above,
below, and between six of the refrigerant passes 820a-820f), and
two secondary coolant layers (i.e., formed by the secondary coolant
pass 860a above and below the seventh refrigerant pass 820g).
[0128] Referring to FIG. 9, a heat exchanger 900 is a variation of
the heat exchanger 600. For brevity, differences between the heat
exchanger 600 and the heat exchanger 900 are described below. For
further understanding of the heat exchanger 900, refer to the
discussion of the heat exchanger 600 above. The heat exchanger 900
includes six refrigerant passes 920a-920f, two primary coolant
passes 940a-940b, and one secondary coolant pass 960a that is
divided into three parallel cavities. Three of the refrigerant
passes 920a-920f extend through and exchange heat directly with one
of the two primary coolant passes 940a-940b. The first primary
coolant pass 940a exchanges heat directly with two of the three
secondary coolant passes 960a-960b (e.g., by sharing intermediate
walls therewith). The second primary coolant pass 940b exchanges
heat directly with two of the three secondary coolant passes
960b-960c (e.g., by sharing two intermediate walls therewith). The
first primary coolant pass 940a and the second primary coolant pass
940b do not exchange heat directly with each other or with ambient
air. The secondary coolant pass 960a may additionally exchange heat
directly with ambient air via a top wall 904a and a bottom wall
904b. Variations of the heat exchangers 600, 700, and 800 may
similarly include a refrigerant pass configured to exchange heat
directly with a secondary coolant pass.
[0129] As a result, the heat exchanger 900 may include 17 fluid
layers, which include six refrigerant layers (i.e., formed by the
six refrigerant passes 920a-920f), eight primary coolant layers
(i.e., formed by the two primary coolant passes 940a-940b above,
below, and between the six refrigerant passes 920a-920f), and three
secondary coolant layers (i.e., formed by the secondary coolant
pass 960a, below, and between the first primary coolant pass 940a
and the second primary coolant pass 940b.
[0130] Referring to FIG. 10, a heat exchanger 1000 is a variation
of the heat exchanger 600 and the heat exchanger 800. For brevity,
differences between the heat exchangers 600, 800 and the heat
exchanger 1000 are described below. For further understanding of
the heat exchanger 1000, refer to the discussion of the heat
exchangers 600, 800 above. The heat exchanger 1000 includes a
refrigerant passage 1020 having seven refrigerant passes
1020a-1020g, a primary coolant passage 1040 having two primary
coolant passes 1040a-1040b, one secondary coolant pass 1060a, and
an insulating chamber 1080. Three of the refrigerant passes
1020a-1020f extend through and exchange heat directly with one of
the two primary coolant passes 1040a-1040b. The first primary
coolant pass 1040a and the second primary coolant pass 1040b may
exchange heat directly with each other (e.g., by sharing an
intermediate wall 1040m therewith). The seventh refrigerant pass
1020g may exchange heat directly with the secondary coolant pass
1060a (e.g., by sharing another intermediate wall 1040n therewith).
The insulating chamber 1080 has no fluid flow therethrough and
insulates the second primary coolant pass 1040b from the secondary
coolant pass 1060a, for example, by sharing different intermediate
walls 1040o, 1040p therewith and forming an air gap therebetween.
The insulating chamber 1080 may be incorporated into variations of
the heat exchangers 600, 700, 800, and 900 described above.
[0131] As a result, the heat exchanger 1000 may include 17 fluid
layers, which include seven refrigerant layers (i.e., formed by the
seven refrigerant passes 1020a-1020g), eight primary coolant layers
(i.e., formed by the two primary coolant passes 1040a-1040b above,
below, and between the six of the refrigerant passes 1020a-1020f),
one secondary coolant layer (i.e., formed by the secondary coolant
pass 1060a), and one insulating layer (i.e., formed by the
insulating chamber 1080 and having a static fluid, such as air,
contained therein).
[0132] Referring to FIG. 11, which is a cross-sectional view taken
similar to FIG. 6E, a heat exchanger 1100 is a variation of the
heat exchanger 600. The heat exchanger includes a passage 1120, a
primary coolant passage 1140, and a secondary coolant passage 1160.
The passage 1120, rather than being formed by tubes, is instead
formed by cavities 1122a-f (e.g., six as shown), which form two
passes 1120a, 1120b for a refrigerant, which may be the high
pressure coolant described previously or another refrigerant (e.g.,
R134a), or another coolant. That is flow through a first set of
three of the cavities 1122a-c and another set of three of the
cavities 1122d-f is in parallel, and flow is serial from the first
set to the second set. Alternatively, the passage 1120 may be
provided with fewer or more cavities 1122a-f and fewer or more
passes (e.g., the six cavities being connected serially to form six
passes). The primary coolant passage 1140 is formed by eight
cavities 1142a-h, which form two passes 1140a, 1140b. The secondary
coolant passage 1160 is formed by a single cavity 1162, which forms
a single pass 1160a. The first pass 1120a of the passage 1120
exchanges heat directly with the first pass 1140a of the primary
coolant passage 1140, the first cavity 1142a of which insulates the
first pass 1120a of the passage 1120 from ambient air and the
fourth cavity 1142d of which insulates the first pass 1120a of the
passage 1120 from the secondary coolant passage 1160. The second
pass 1120b of the passage 1120 exchanges heat directly with the
second pass 1140b of the primary coolant passage 1140, the last
cavity 1142h of which insulates the second pass 1120a of the
passage 1120 from ambient air and the fifth cavity 1142e of which
insulates the first pass 1120a of the passage 1120 from the
secondary coolant passage 1160. The pass 1160a of the secondary
coolant passage 1160 exchanges heat directly with the first pass
1140a and the second pass 1140b of the primary coolant passage
1140.
[0133] As a result, the heat exchanger 1100 includes 15 fluid
layers, which include eight primary coolant layers, one secondary
coolant layers, and six layers of the refrigerant or additional
coolant.
[0134] Furthermore, the construction of the heat exchanger 1100
with cavities instead of refrigerant tubes may be applied to the
other heat exchangers described previously. Each refrigerant pass
would instead be formed by one or more cavities, and each primary
coolant layer would be formed by a distinct cavity (i.e., rather
than multiple layers being formed by one cavity).
* * * * *