Vehicle thermal management systems and methods

Patent metadata

Field	Value
Publication number	US-11458799-B2
Application number	US-202117557396-A
Country	US
Kind code	B2
Filing date	Dec 21, 2021
Priority date	Dec 22, 2020
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

An electric vehicle has a thermal management system that comprises a common radiator, a brake resistor loop, and an electric power source loop. The brake resistor loop comprises a brake resistor and a brake resistor controller that are coupled to the common radiator. The electric power source loop comprises an electric power source coupled to the common radiator. When the brake resistor loop is determined to be in operation, the common radiator is utilized by the brake resistor loop to absorb heat generated by the brake resistor loop. When the brake resistor loop is determined to not be in operation, the common radiator is utilized by the electric power source to absorb heat generated by the electric power source loop.

First claim

What is claimed is:

1. A thermal management system for a vehicle, comprising:
a common radiator;
at least one brake resistor coupled to the common radiator;
one or more batteries coupled to the common radiator; and
an alternate cooling system thermally coupled to the one or more batteries,
wherein, when the brake resistor is determined to be in operation, the common radiator absorbs heat generated by the brake resistor and the alternate cooling system absorbs heat generated by the one or more batteries, and
wherein, when the brake resistor is determined to not be in operation, the common radiator absorbs heat generated by the one or more batteries.

2. The thermal management system of claim 1 , wherein the alternate cooling system comprises a refrigeration system.

3. The thermal management system of claim 1 , further comprising:
a first 3-way valve coupled to the brake resistor, the one or more batteries, and the common radiator,
wherein, when the brake resistor is determined to be in operation, the first 3-way valve thermally couples the common radiator with the brake resistor, and
wherein, when the brake resistor is determined not to be in operation, the first 3-way valve thermally couples the common radiator to the one or more batteries.

4. The thermal management system of claim 3 , further comprising:
a refrigeration system coupled to the one or more batteries; and
a second valve coupled to the common radiator,
wherein the one or more batteries are coupled to the second valve,
wherein the refrigeration system is coupled to the second valve, and
wherein, when the brake resistor is determined to be in operation, the second valve thermally couples the refrigeration system with the one or more batteries and the refrigeration system absorbs heat generated by the one or more batteries.

5. The thermal management system of claim 4 , wherein the second valve is a 4-way valve.

6. The thermal management system of claim 5 , further comprising:
a shut-off valve coupled to the one or more batteries and the brake resistor,
wherein the brake resistor is coupled to the second valve, wherein the one or more batteries are coupled to the second valve, and wherein, when an ambient temperature is determined to be less than a first temperature threshold, the shut-off valve thermally couples the one or more batteries to the brake resistor and the 4-way valve thermally couples the brake resistor to one or more batteries.

7. The thermal management system of claim 6 , wherein the second valve is further coupled to a heating component, and wherein, when the ambient temperature is less than a first temperature threshold, the heating component pre-heats at least one of the one or more batteries.

8. The thermal management system of claim 1 , wherein the one or more batteries comprises three battery packs.

9. The thermal management system of claim 8 , wherein each of the three battery packs is coupled in parallel.

10. The thermal management system of claim 8 , wherein each of the three battery packs is coupled to a respective battery shut-off valve, and
wherein, when the battery shut-off valve is open, the respective battery is coupled to at least one other component of the thermal management system.

11. The thermal management system of claim 8 , wherein each of the three battery packs is further coupled to a check valve.

12. A method for thermal management of an electric vehicle, the method comprising:
determining if a brake resistor comprised within the vehicle is in operation, wherein the vehicle further comprises a common radiator and at least one battery pack;
when the brake resistor is in operation, utilizing the common radiator to cool the brake resistor; and
when the brake resistor is not in operation, utilizing the common radiator to cool the at least one battery pack,
wherein, responsive to a determination that the brake resistor is in operation, the method further comprises:
determining if the at least one battery pack is in operation; and
when the at least one battery pack is in operation, utilizing an alternate cooling system to cool the at least one battery pack.

13. The method of claim 12 , wherein utilizing an alternate cooling system to cool the at least one battery pack further comprises using a refrigeration system to cool the at least one battery pack.

14. The method of claim 12 , wherein responsive to a determination that the brake resistor is in operation, the method further comprises:
determining if an ambient temperature is greater than a second temperature threshold; and
when the ambient temperature is greater than a second temperature threshold, utilizing a refrigeration system to cool the at least one battery pack.

15. The method of claim 14 , wherein the second temperature threshold is between 25 degrees Celsius and 35 degrees Celsius.

16. A thermal management system, comprising:
a common radiator;
a brake resistor coupled to the common radiator;
three battery packs, wherein each battery pack is coupled in parallel with at least one other battery back, and wherein each of the three battery packs are coupled to the common radiator; and
a refrigeration system coupled to the three battery packs,
wherein, when the brake resistor is determined to be in operation, the common radiator absorbs heat generated by the brake resistor, and the refrigeration system absorbs heat generated by the three battery packs, and
wherein, when the brake resistor is determined to not be in operation, the common radiator absorbs heat generated by the three battery packs.

Assignees

• Nikola Corp

Inventors

• Cohan Aiden
• Cook Rachel
• Markan Akshit
• Shinn Mitchell
• Smith Katherine

Classifications

• B60L58/21

  having the same nominal voltage · CPC title

• B60L7/02

  Dynamic electric resistor braking (B60L7/22 takes precedence) · CPC title

• B60L2240/662

  Temperature · CPC title

• B60L2240/545

  Temperature · CPC title

• B60L2240/36

  Temperature of vehicle components or parts · CPC title