Thermal management system for vehicles with an electric powertrain
This patent application is directed to thermal management systems of vehicles with an electric powertrain. More specifically, the battery system and one or more powertrain components and/or cabin climate control components of a vehicle share the same thermal circuit as the battery module through which heat can be exchanged between the battery module and one or more powertrain or climate control components as needed.
1. A thermal management system for a vehicle with an electric drivetrain, the system comprising:
a battery system comprising at least one battery cell having a cycle life of at least 100 cycles;
an internal combustion engine (ICE);
at least one heat exchanger;
a shared thermal circuit thermally coupling the battery system and the ICE, comprising:
a working fluid,
at least one valve for directing the working fluid in the following direction:
from the battery system to the ICE,
from the ICE to the heat exchanger, and
from the heat exchanger to the battery system; and
a control system for controlling the heat exchange between the ICE and the battery system, wherein the control system actuates the at least one valve;
wherein the working fluid of the shared thermal circuit is shared among the battery system, the ICE, and optionally other components.
2. The thermal management system of claim 1 , wherein the control system is selected from a computer, a programmed chip, a microprocessor, or a logic circuit.
3. The thermal management system of claim 1 , further comprising at least one electric motor or generator connected to the shared thermal circuit.
4. The thermal management system of claim 1 , wherein the vehicle is a hybrid electric vehicle comprising the ICE and an electric motor.
5. The thermal management system of claim 1 , further comprising motor power electronics thermally coupled to the shared thermal circuit.
6. The thermal management system of claim 1 , further comprising a battery system charger.
7. The thermal management system of claim 1 , wherein the thermal management system is configured to dissipate heat from devices connected to the shared thermal circuit via the external heat exchanger.
8. The thermal management system of claim 1 , wherein the battery system has a cycle life of at least 100 cycles and is capable of operating at a temperature of 75° C. or higher.
9. The thermal management system of claim 1 , wherein the battery system has a cycle life of at least 100 cycles and is capable of operating at a temperature of 85° C. or higher.
10. The thermal management system of claim 1 , wherein the optimal operation comprises greater than 50% power output from the battery relative to the rated power output of the battery.
11. The thermal management system of claim 1 , wherein the battery system is configured to start the ICE.
12. The thermal management system of claim 1 , wherein the control system controls the transfer of the working fluid such that heat dissipated by the battery system transfers to one or more components on the shared thermal circuit, which are at a lower temperature than the battery system.
13. The thermal management system of claim 1 , further comprising a climate control module, wherein heat generated by the battery system or other components in the shared thermal circuit transfers to the interior of the vehicle.
14. The thermal management system of claim 1 , wherein the battery system comprises an enclosure, the enclosure having a floor surface thermally coupled to the shared thermal circuit and the external environment, the enclosure floor surface being configured to transfer heat between the working fluid and the external environment.
15. The thermal management system of claim 1 , wherein the external heat exchanger comprises one or more heat rejection devices configured to dissipate heat away from the thermal management system.
16. The thermal management system of claim 1 , comprising a powertrain component having an electric motor.
17. The thermal management system of claim 1 , wherein the at least one valve directs the working fluid in the following direction:
from the battery system to motor electronics,
from the motor electronics to a motor,
from the motor to the ICE,
from the ICE to the heat exchanger, and
from the heat exchanger to the battery system.
18. The thermal management system of claim 1 , wherein the vehicle does not comprise a second thermal management system comprising the battery system, the ICE and a motor or motor electronics.