System and method for using exhaust gas to heat and charge a battery for a hybrid vehicle

1. A system for heating and charging a battery in a hybrid vehicle using exhaust gas comprising:

an exhaust gas heat recovery (EGHR) device having an EGHR heat exchanger configured to transfer thermal energy to a heat transfer fluid;

a temperature sensor configured to sense a temperature of the battery;

a state of charge indicator configured to indicate the state of charge of the battery;

a first heat exchanger configured to receive the thermal energy from the heat transfer fluid and transfer the thermal energy to the battery cover plate so that the temperature of the battery rises; and

a thermoelectric device configured to generate a current to charge the battery;

a second heat exchanger configured to receive the thermal energy from the heat transfer fluid and transfer the thermal energy to the thermoelectric device such that the thermal energy creates a temperature difference in the thermoelectric device which causes generation of the current to charge the battery so that the state of charge of the battery rises;

a controller configured to monitor the temperature of the battery from the temperature sensor and the state of charge of the battery from the state of charge indicator to determine whether to transfer the heat transfer fluid to at least one of the first and second heat exchangers;

a first fluid flow control valve configured to control the flow of the heat transfer fluid in response to the controller, and having a first position in which substantially all of the heat transfer fluid is transferred to the first heat exchanger, a second position in which the heat transfer fluid is transferred to both the first heat exchanger and the second heat exchanger, and a third position in which substantially all of the heat transfer fluid is transferred to the second heat exchanger;

a second fluid flow control valve configured to control the flow of the heat transfer fluid in response to the controller, and having a first position in which the heat transfer fluid is transferred to both the EGHR heat exchanger and the second heat exchanger, and a second position in which substantially all of the heat transfer fluid is transferred to the second heat exchanger;

wherein the controller is configured to:

signal the first fluid control valve to operate in the first position if the temperature of the battery is below a first predetermined temperature,

signal the first fluid control valve to operate in the second position if the temperature of the battery is between the first predetermined temperature and a second predetermined temperature and the state of charge of the battery is below a predetermined level,

signal the first fluid control valve to operate in the third position if the temperature of the battery is greater than the second predetermined temperature and the state of charge of the battery is below the predetermined level,

signal the second fluid control valve to operate in the first position if the temperature of the battery is between the first predetermined temperature and the second predetermined temperature and the state of charge of the battery is below the predetermined level, and

signal the second fluid control valve to operate in the second position if the temperature of the battery is above the second predetermined temperature and the state of charge of the battery is below the predetermined level.

2. The system of claim 1 wherein the controller signals a switch in the EGHR device for directing exhaust gas to the EGHR heat exchanger.

3. The system of claim 1 including a heat transfer loop having fluid lines wherein the heat transfer fluid is located in the fluid lines of the heat transfer loop and further including a pump for maintaining flow in the fluid lines of the heat transfer loop.

4. The system of claim 1 including an internal combustion engine to produce exhaust gas having thermal energy for use in the EGHR device.

5. The system of claim 4 wherein the EGHR device is mounted closer to the internal combustion engine than to the battery so as to provide more thermal energy to the heat transfer fluid.

6. The system of claim 1 wherein the first heat exchanger is a liquid stacked heat exchanger.

7. The system of claim 1 wherein the thermoelectric device is a Peltier generator.

8. The system of claim 7 wherein the Peltier generator includes a pair of plates that the temperature difference occurs between.

9. The system of claim 7 wherein the Peltier generator includes a pair of plates such that the thermal energy creates the temperature difference between the plates to build a difference in voltage which causes the generation of the current.

10. The system of claim 1 wherein the thermoelectric device includes a pair of plates that the temperature difference occurs between.

11. The system of claim 1 wherein the thermoelectric device includes a pair of plates with the thermal energy creating the temperature difference between the plates to build a difference in voltage which causes the generation of the current.

12. The system of claim 1 wherein the thermoelectric device includes a pair of plates, with the thermal energy creating the temperature difference between the plates to build a difference in voltage to directly generate the current.

13. The system of claim 1 wherein the first and second heat exchangers are disposed upstream to the thermoelectric device relative to the direction of flow of the heat transfer fluid.

14. The system of claim 1 wherein the first fluid flow control valve is disposed between the EGHR heat exchanger and the first heat exchanger in the direction of flow of the heat transfer fluid, and wherein the second fluid flow control valve is disposed between the first and second heat exchangers in the direction of flow of the heat transfer fluid.

15. The system of claim 1 wherein the thermoelectric device includes a material that creates the current when the thermal energy is introduced to the thermoelectric device from the second heat exchanger.

16. A method for heating and charging a battery having a battery cover plate in a hybrid vehicle using thermal energy recovered by an exhaust gas heat recovery (EGHR) device having an EGHR heat exchanger configured to transfer the thermal energy to a heat transfer fluid in a heat transfer loop including a first heat exchanger, a second heat exchanger and a thermoelectric device, the method comprising:

determining a temperature of the battery;

determining a state of charge of the battery;

thermally connecting the exhaust gas having thermal energy to the heat transfer fluid;

thermally connecting the first heat exchanger to the heat transfer fluid if the temperature of the battery is below one of a first predetermined temperature and a second predetermined temperature so that the first heat exchanger receives the heat transfer fluid and thermally connects to the battery cover plate so that the temperature of the battery rises; and

thermally connecting the second heat exchanger to the thermoelectric device such that the thermal energy from the second heat exchanger creates a temperature difference in the thermoelectric device which causes generation of a current to charge the battery so the state of charge of the battery rises;

wherein the heat transfer loop further includes a first fluid flow control valve configured to control the flow of the heat transfer fluid in response to a controller and a second fluid flow control valve configured to control the flow of the heat transfer fluid in response to the controller, the method further comprising:

opening the first fluid flow control valve to one of:

a first position if the temperature of the battery is below the first predetermined temperature which is lower than the second predetermined temperature such that substantially all of the heat transfer fluid flows to the first heat exchanger,

a second position if the temperature of the battery is higher than the first predetermined temperature and lower than the second predetermined temperature and the state of charge of the battery is below the predetermined level such that the heat transfer fluid flows to both of the first heat exchanger and the second heat exchanger, and

a third position if the temperature of the battery is greater than the second predetermined temperature and the state of charge of the battery is below the predetermined level such that substantially all of the heat transfer fluid flows to the second heat exchanger; and

opening the second fluid flow control valve to one of:

a first position in which the heat transfer fluid flows to both the EGHR heat exchanger and the second heat exchanger if the temperature of the battery is between the first predetermined temperature and the second predetermined temperature and the state of charge is below the predetermined level, and

a second position in which substantially all of the heat transfer fluid flows to the second heat exchanger if the temperature of the battery is above the second predetermined temperature and the state of charge is below the predetermined level.

17. The method of claim 16 wherein thermally connecting the first heat exchanger to the heat transfer fluid continues until the temperature of the battery is above the second predetermined temperature.

18. The method of claim 16 wherein thermally connecting the second heat exchanger to the heat transfer fluid continues until the state of charge of the battery is above the predetermined level.