Thermal management system and method of making and using the same

Patent metadata

Field	Value
Publication number	US-10116016-B2
Application number	US-201615161557-A
Country	US
Kind code	B2
Filing date	May 23, 2016
Priority date	May 23, 2016
Publication date	Oct 30, 2018
Grant date	Oct 30, 2018

Abstract

A number of variations may include a product including a thermal management component comprising a housing comprising a first polymer wherein the first polymer is constructed and arranged to provide thermal control of at least one neighbor component comprising an exterior surface in contact with the thermal management component wherein the first polymer comprises a heat generating polymer.

First claim

What is claimed is:

1. A product comprising:
a thermal management component comprising a housing comprising a first polymer wherein the thermal management component is constructed and arranged to provide thermal control of at least one neighbor component comprising an exterior surface in contact with the thermal management component wherein the first polymer comprises a heat generating polymer, and further comprising cooling tubes in the housing, and a phase change material in the cooling tubes, the phase change material being constructed and arranged to absorb thermal energy above a first temperature and to reversibly release thermal energy below a second temperature, and further comprising a plurality of batteries each having an external surface and wherein the housing is in contact with the external surface of each of the plurality of batteries, wherein the heat generating polymer comprises a PTC polymer, the PTC polymer comprising electrically conductive particles, the PTC polymer being constructed and arranged to change from a crystalline state to an amorphous tripped state once the PTC polymer reaches its trip temperature thereby causing a higher resistance due to the separation of the electrically conductive particles and as the mean distance between the conductive particles increases, causing a breaking of conductive pathways caused by the expansion of the PTC polymer in the amorphous state.

2. A product as set forth in claim 1 wherein the heat generating polymer comprises at least one of high density polyethylene (HDPE) with carbon black particulates, low density polyethylene (LDPE) with carbon black particulates, polyvinylidiene fluoride with carbon black particulates, HDPE with nickel particulates, HDPE with titanium carbide particulates, or heat conductive PTC polymer.

3. A product as set forth in claim 1 wherein each of the batteries comprises a lithium ion, nickel metal hydride (NiMH), lead acid, lithium polymer, lithium-oxygen, lithium sulfur, magnesium ion, or silicon battery.

4. The product as set forth in claim 1 wherein the thermal management component comprises the coolant material in cooling tubes.

5. A product as set forth in claim 1 wherein the thermal management component is constructed and arranged to maintain the temperature of the plurality of batteries in a range of 0° C.≥X≥50° C.

6. A product as set forth in claim 1 wherein the thermal management component further comprises a cooling channel and a coolant material in the cooling channel, and wherein the coolant material comprises at least one of oil, engine coolant, water, transmission fluid, battery fluid, air, paraffin, antifreeze, propylene glycol, carbon tetrachloride, trichlorofluoromethane, dichlorodifluoromethane, bromochlorodifluoromethane, dibromodifluoromethane, methane, hexachloroethane, pentachlorofluoroethane, trifluoromethane, dichloromethane, chlorofluoromethane, fluoromethane, hexachloroethane, pentachlorofluroethane, fluoroethane, ethane, dimethyl ether, ocafluoropropane, propane, chloropropane, ethoxyethane, pentane, isobutene, isopentane, butane, methyl formate, methylamine, ethylamine, hydrogen, helium, ammonia, nitrogen, oxygen, argon, carbon dioxide, nitrous oxide, sulfur dioxide, krypton, tetrafluoroethylene, trichloroethylene, chloroethylene, fluoroethylene, ethane, hexafluoropropylene, propene, a chlorofluorocarbon, a chlorofluoroolefin, a hydrochlorofluorocarbon, a hydrochlorofluoroolefin, a hydrofluorocarbon, a hydrofluoroolefin, a hydrochlorocarbon, a hydrochloroolefin, a hydrocarbon, a perfluorocarbon, a perfluoroolefin, a perchlorocarbon, a perchloroolefin, a halon, or ethylene glycol.

7. A product as set forth in claim 1 wherein the phase change material constructed and arranged to release thermal energy below 25° C. and to absorb thermal energy above 25° C.

8. The product of claim 1 wherein the phase change material comprises at least one of plant-based PCMs, pure salts, metals, metal hydrides, high molecular weight hydrocarbons, hydrated salts, hydrated salts in solution, paraffins, waxes, hydrogenated oils, polyglycols, fatty acids, methyl oleate, linoleic acid, ethyl laurate, methyl laurate, isopropyl myristate, isopropyl palmitate, oleic acid, isopropyl stearate, capric acid, lauric acid, propyl palmitate, caprylic acid, methyl myristate, dodecane, undecane, NaCl+H 2 O, Al(NO 3 )+H 2 O, KCL+H 2 O, diethylene glycol, triethylene glycol, H 2 O+polyacrylamide, heptadecane, hexadecane, glycerin, acetic acid, pentadecane, tetrabutyl ammoniumbromide (type A and type B), formic acid, tetradecane, tetrahydrofurano (THF), LiNO 3 +H 2 O, Zn(NO 3 )+H 2 O, CaCl 2 +H 2 O, CaBr 2 +H 2 O, or Magnesium Nitrate Hexahydrates.

9. A system comprising:
a thermal management component comprising a housing comprising a first polymer wherein the thermal management component is constructed and arranged to provide thermal control of a plurality of neighbor components comprising a plurality of exterior surfaces in contact with the housing simultaneously wherein the first polymer comprises a heat generating polymer, and further comprising cooling tubes in the housing, and a phase change material in the cooling tubes, the phase change material being constructed and arranged to absorb thermal energy above a first temperature and to reversibly release thermal energy below a second temperature, wherein the heat generating polymer comprises a PTC polymer, the PTC polymer comprising electrically conductive particles, the PTC polymer being constructed and arranged to change from a crystalline state to an amorphous tripped state once the PTC polymer reaches its trip temperature thereby causing a higher resistance due to the separation of the electrically conductive particles and as the mean distance between the conductive particles increases, causing a breaking of conductive pathways caused by the expansion of the PTC polymer in the amorphous state.

10. A system as set forth in claim 9 wherein the heat generating polymer comprises at least one of high density polyethylene (HDPE) with carbon black particulates, low density polyethylene (LDPE) with carbon black particulates, polyvinylidiene fluoride with carbon black particulates, HDPE with nickel particulates, HDPE with titanium carbide particulates, or heat conductive PTC polymer.

11. A system as set forth in claim 9 wherein the thermal management system is applied to a plurality of batteries comprising the plurality of exterior surfaces.

12. A system as set forth in claim 11 wherein the plurality of batteries comprises at least one lithium ion, nickel metal hydride (NiMH), lead acid, lithium polymer, lithium-oxygen, lithium sulfur, magnesium ion, or silicon battery.

13. A system as set forth in claim 9 wherein the phase change material constructed and arranged to release thermal energy below 25° C. and to absorb thermal energy above 25° C.

14. A method comprising:
providing a thermal management component comprising a housing comprising a first polymer wherein the thermal management component is constructed and arranged to provide thermal control of at least one neighbor component comprising an exterior surface in contact with the housing, and wherein the first polymer comprises a heat generating polymer, and further comprising cooling tubes in the housing, and a phase change material in the cooling tubes, the phase change material being constructed and arranged to absorb thermal energy above a first temperature and to reversibly release thermal energy below a second temperature, wherein the heat generating polymer comprises a PTC polymer, the PTC polymer comprising electrically conductive particles, the PTC polymer being c

Assignees

• Borgwarner Inc

Inventors

• Mott Philip J
• Sutherland Andrew Duncan
• Thomas Christopher P
• Myers Steven Michael

Classifications

• H01M2/1094

  Electricity · mapped topic

• H01M10/6557

  arranged between the cells · CPC title

• H01M10/659

  by heat storage or buffering, e.g. heat capacity or liquid-solid phase changes or transition · CPC title

• H01M10/617 Primary

  for achieving uniformity or desired distribution of temperature · CPC title

• H01M10/6556

  Solid parts with flow channel passages or pipes for heat exchange (closed pipes H01M10/6552) · CPC title