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.

What is claimed is: 
     
         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.