Vehicle cabin thermal management system and method

Patent metadata

Field	Value
Publication number	US-11230384-B2
Application number	US-202017033549-A
Country	US
Kind code	B2
Filing date	Sep 25, 2020
Priority date	Apr 23, 2019
Publication date	Jan 25, 2022
Grant date	Jan 25, 2022

Abstract

The system can include an on-board thermal management subsystem. The system 100 can optionally include an off-board (extravehicular) infrastructure subsystem. The on-board thermal management subsystem can include: a battery pack, one or more fluid loops, and an air manifold. The system 100 can additionally or alternatively include any other suitable components.

First claim

What is claimed is:

1. A system comprising:
an electric aircraft comprising a cabin defining an interior;
a plurality of battery cells on-board the electric aircraft;
a refrigeration system comprising a refrigerant;
a first fluid loop which is fluidly isolated form the refrigeration system, comprising:
a working fluid within the first fluid loop;
a first heat exchanger on-board the electric aircraft, the first heat exchanger configured to transfer heat between the interior of the cabin and the working fluid;
a condenser thermally coupling the working fluid to the refrigerant and configured to transfer thermal energy from the refrigerant to the working fluid, the condenser selectively fluidly coupled to the first heat exchanger;
a second heat exchanger thermally coupled to the plurality of battery cells;
an evaporator thermally coupling the working fluid to the refrigerant and configured to transfer thermal energy from the working fluid to the refrigerant, the evaporator selectively fluidly coupled to the second heat exchanger;
a first liquid pump configured to circulate the working fluid within the first fluid loop in a liquid state,
wherein the first fluid loop is configured such that the working fluid flows through the first heat exchanger, the condenser, the second heat exchanger, and the evaporator in the liquid state.

2. The system of claim 1 , further comprising a set of valves which fluidly decouple the second heat exchanger from the first heat exchanger in a cooling mode.

3. The system of claim 2 , wherein the first and second heat exchanger each comprise an inlet port and an outlet port, the inlet and outlet ports fluidly coupled to the working fluid within the first fluid loop, wherein the set of valves is operable between:
a cabin heating mode, wherein the set of valves connects the outlet of second heat exchanger to the inlet of the first heat exchanger and connects the outlet of the first heat exchanger outlet to the inlet of second heat exchanger; and
the cabin cooling mode, wherein the set of valves connects the outlet of the second heat exchanger to the inlet of the second heat exchanger and connects the outlet of the first heat exchanger to the inlet of the second heat exchanger.

4. The system of claim 3 , further comprising a second pump, wherein, in the cooling mode, a first portion of the working fluid is arranged within a first subloop which comprises the first heat exchanger, and a second portion of the working fluid is arranged within a second subloop which comprises the second heat exchanger, wherein the first and second pumps are arranged within the first and second subloops, respectively.

5. The system of claim 3 , wherein the set of valves comprises a four-way switch valve defining:
a first end associated with the inlet of the first heat exchanger;
a second end associated with the outlet of the first heat exchanger;
a third end associated with the inlet of the second heat exchanger; and
a fourth end associated with the outlet of the second heat exchanger.

6. The system of claim 1 , wherein the refrigeration system is isolated from an exterior airflow.

7. The system of claim 1 , further comprising a fluid coupling, the fluid coupling configured to selectively connect the first fluid loop to a ground-based infrastructure comprising the working fluid.

8. The system of claim 7 , wherein a charging mechanism is configured to fluidly connect the fluid coupling to the ground-based infrastructure and electrically connect the plurality of battery cells to the ground-based infrastructure.

9. The system of claim 1 , further comprising:
a first orifice defining an intake path from an aircraft exterior to the cabin interior,
a nozzle defining an exhaust path from the cabin interior to the aircraft exterior;
an air compressor arranged along the exhaust path, the air compressor configured to increase a pressure at the nozzle.

10. The system of claim 9 , wherein the exhaust path passes over avionics equipment.

11. The system of claim 1 , further comprising:
a second working fluid within a second fluid loop;
a heat exchanger thermally connected to the plurality of battery cells, the second fluid loop extending through an interior of the heat exchanger;
the second heat exchanger thermally connecting the second fluid loop to the first fluid loop; and
a second pump configured to circulate the second working fluid through the second fluid loop.

12. A method comprising:
flying the electric aircraft, the electric aircraft comprising: a cabin and a battery pack;
venting air out of the cabin through an exhaust nozzle, the venting comprising using a fan positioned at the exhaust nozzle to increase at least one of: air pressure at the exhaust nozzle or velocity at the exhaust nozzle;
cooling the cabin while flying the electric aircraft, comprising:
transferring, at a first heat exchanger, thermal energy between a first working fluid and the air within the cabin;
at a second heat exchanger, transferring the thermal energy from the first working fluid to a second working fluid, the second working fluid in thermal communication with the battery pack; and
storing the first portion of thermal energy within a thermal mass of the battery pack.

13. The method of claim 12 , further comprising: while the electric aircraft is grounded, pre-conditioning the aircraft comprising: replacing a first portion of the second working fluid with a second portion of the second working fluid from a ground-infrastructure.

14. The method of claim 12 , wherein the first working fluid is within a first fluid loop, wherein cooling the cabin further comprises:
in response to determining satisfaction of a cabin temperature threshold, dividing the first fluid loop into a first subloop and a second subloop, a first portion of the first working fluid contained within the first subloop, a second portion of the working fluid contained within the second subloop, wherein the first subloop comprises the first heat exchanger and the second subloop comprises the second heat exchanger; and
using a heat pump, transferring thermal energy from the first subloop to the second subloop.

15. The method of claim 14 , wherein a total thermal energy of a thermal system comprising the battery pack, the first working fluid, the second working fluid, and the cabin air continuously increases during flight.

16. The method of claim 12 , further comprising, during flight, regulating a flow of external air into the cabin, comprising:
using a turbine, regeneratively charging the battery pack and simultaneously reducing a thermal energy of the flow.

17. The method of claim 16 , further comprising, while flying the electric aircraft, equilibrating a pressure of the cabin air with an ambient pressure.

18. The method of claim 12 , further comprising, prior to venting the portion of cabin air, ducting the portion of cabin air across avionics equipment.

19. The method of claim 12 , wherein the battery pack comprises a first cell and a second cell, wherein cooling the cabin further comprises: using a third heat exchanger, convectively balancing thermal energy between the first and second cells.

Assignees

• Joby Aero Inc

Inventors

• Lynn Robert
• Villanueva Ernest
• Martin Nathaniel
• Bevirt Joeben
• Wagner Jonathan
• Witt Kevin
• Uznanski Brian
• Newman Austin

Classifications

• B64D13/08 Primary

  the air being heated or cooled · CPC title

• B60L1/02 Primary

  to electric heating circuits · CPC title

• B60L2240/545

  Temperature · CPC title

• B60L1/003

  to auxiliary motors, e.g. for pumps, compressors · CPC title

• H01M10/613

  Cooling or keeping cold · CPC title