US20120168125A1 - Multi-Function Automotive Radiator and Condenser Airflow System - Google Patents
Multi-Function Automotive Radiator and Condenser Airflow System Download PDFInfo
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- US20120168125A1 US20120168125A1 US13/150,553 US201113150553A US2012168125A1 US 20120168125 A1 US20120168125 A1 US 20120168125A1 US 201113150553 A US201113150553 A US 201113150553A US 2012168125 A1 US2012168125 A1 US 2012168125A1
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- Prior art keywords
- heat exchanger
- adjustable louvers
- louvers
- adjustable
- management system
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60H—ARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
- B60H1/00—Heating, cooling or ventilating [HVAC] devices
- B60H1/32—Cooling devices
- B60H1/3204—Cooling devices using compression
- B60H1/3227—Cooling devices using compression characterised by the arrangement or the type of heat exchanger, e.g. condenser, evaporator
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K11/00—Arrangement in connection with cooling of propulsion units
- B60K11/02—Arrangement in connection with cooling of propulsion units with liquid cooling
- B60K11/04—Arrangement or mounting of radiators, radiator shutters, or radiator blinds
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
- F28D1/0408—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids
- F28D1/0426—Multi-circuit heat exchangers, e.g. integrating different heat exchange sections in the same unit or heat exchangers for more than two fluids with units having particular arrangement relative to the large body of fluid, e.g. with interleaved units or with adjacent heat exchange units in common air flow or with units extending at an angle to each other or with units arranged around a central element
- F28D1/0443—Combination of units extending one beside or one above the other
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
- F28F27/02—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus for controlling the distribution of heat-exchange media between different channels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K11/00—Arrangement in connection with cooling of propulsion units
- B60K11/08—Air inlets for cooling; Shutters or blinds therefor
- B60K11/085—Air inlets for cooling; Shutters or blinds therefor with adjustable shutters or blinds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60Y—INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
- B60Y2200/00—Type of vehicle
- B60Y2200/90—Vehicles comprising electric prime movers
- B60Y2200/91—Electric vehicles
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P3/00—Liquid cooling
- F01P3/18—Arrangements or mounting of liquid-to-air heat-exchangers
- F01P2003/185—Arrangements or mounting of liquid-to-air heat-exchangers arranged in parallel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01P—COOLING OF MACHINES OR ENGINES IN GENERAL; COOLING OF INTERNAL-COMBUSTION ENGINES
- F01P7/00—Controlling of coolant flow
- F01P7/02—Controlling of coolant flow the coolant being cooling-air
- F01P7/10—Controlling of coolant flow the coolant being cooling-air by throttling amount of air flowing through liquid-to-air heat exchangers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/80—Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
- Y02T10/88—Optimized components or subsystems, e.g. lighting, actively controlled glasses
Definitions
- the present invention relates generally to vehicles and, more particularly, to an automotive radiator and condenser airflow system.
- Vehicle cooling systems vary widely in complexity, depending primarily upon the thermal requirements of the various vehicle systems employed in the vehicle in question.
- these cooling systems utilize heat exchangers of one form or another to transfer the heat generated by the vehicle subsystems to the surrounding ambient environment.
- Such heat transfer may either be performed directly, for example in the case of a simple radiator coupled to a vehicle engine, or indirectly, for example in the case of a thermal management system utilizing multiple heat transfer circuits to transfer the heat through multiple stages in order to sufficiently lower the temperature of the component in question.
- vehicle heat exchangers are designed to exchange heat between two different fluids, or two similar fluids that are at different temperatures, thereby helping to maintain the various vehicle systems and components within a safe and effective operating range of temperatures.
- One of the fluids is typically composed of a refrigerant or water, the water often mixed with ethylene glycol or propylene glycol or a similar liquid that provides anti-freeze protection at low temperatures.
- the second fluid is air which is forced to flow through the heat exchanger, either as a result of vehicle movement or through the use of a fan.
- Exemplary heat exchangers include:
- a powertrain radiator in which a coolant-to-air heat exchanger is used to remove heat from an internal combustion engine or electric motor.
- a transmission oil cooler in which an oil-to-air heat exchanger is used to remove heat from the transmission via the transmission fluid.
- a steering pump oil cooler in which an oil-to-air heat exchanger is used to remove heat from the steering system via the steering fluid.
- a charge air cooler in which an air-to-air heat exchanger is used to remove heat from turbocharged (compressed) air used in the engine intake system.
- the performance of a fluid-to-fluid heat exchanger depends primarily on the surface area of the heat exchanger and the volume flow rate of the two fluids through the heat exchanger.
- Flow rate is commonly determined as the fluid velocity through the heat exchanger multiplied by the frontal area of the heat exchanger. Larger heat exchanger surface areas and mass flow rates result in greater heat transfer from the inner fluid to the outer fluid.
- An increase in these same variables also results in an increase in the hydraulic losses, or pressure drop losses, which are manifested in increased aerodynamic drag (i.e., vehicle motive power), pump power, and fan power.
- the transfer of heat between the two fluids increases as the temperature difference between the two fluids increases.
- a conventional vehicle utilizing multiple heat exchangers regardless of whether the vehicle utilizes a combustion engine, an electric motor, or a combination of both (i.e., a hybrid), the individual heat exchangers are typically positioned one in front of the other, followed by a fan, this configuration referred to as a “stack”.
- a stacking arrangement commonly the heat exchanger with the lowest outlet air temperature is located upstream, followed by higher temperature heat exchangers downstream.
- An example of such a configuration is a condenser followed directly by an engine radiator, followed by one or more fans. While this arrangement is more common with vehicles utilizing a combustion engine, hybrid vehicles may also use a stack of heat exchangers in order to provide cooling for the battery pack, power electronics and the motor.
- a principal drawback of the practice of stacking heat exchangers is an increase in hydraulic losses (i.e., fan power, aerodynamic drag) that result regardless of whether each heat exchanger in the stack is in active use. Additionally, since the temperature of the air entering the inner heat exchanger(s) will be the temperature of the air exiting the upstream heat exchanger which is typically higher than the ambient temperature, the efficiency and overall performance of the inner heat exchanger(s) is compromised. As a consequence, it is common practice to increase the surface area or thickness of the downstream heat exchangers to compensate for this decrease in expected performance which, in turn, adds weight and cost to the affected heat exchangers.
- thermal management system that maximizes heat transfer while minimizing the hydraulic power consumed in the process.
- the present invention provides such a thermal management system.
- a vehicle thermal management system is provided that is comprised of at least first and second heat exchangers configured in a non-stacked arrangement, wherein the first heat exchanger is coupled to a first vehicle cooling subsystem and the second heat exchanger is coupled to a second vehicle cooling subsystem; a first air inlet, wherein air flowing through the first air inlet flows directly into the first heat exchanger without first passing through the second heat exchanger; a second air inlet, wherein air flowing through the second air inlet flows directly into the second heat exchanger without first passing through the first heat exchanger; and a first set of adjustable louvers that controls air flowing directly through the first air inlet into the first heat exchanger.
- the system may further comprise a second set of adjustable louvers that controls air flowing directly through the second air inlet into the second heat exchanger.
- the second set of adjustable louvers may be located between the second heat exchanger's airflow entrance surface and the ambient environment.
- the first and second sets of adjustable louvers may each have a first, fully opened position and a second, fully closed position.
- the first and second sets of adjustable louvers may each be adjustable over a range of positions between fully opened and fully closed.
- the first and second sets of adjustable louvers may each be comprised of two or more groups of adjustable louvers that are independently operable from one another.
- an air duct couples at least a portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger. If there is a single set of adjustable louvers, they may be (i) positioned within the air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger, or (ii) positioned between the second heat exchanger's airflow entrance surface and the ambient environment.
- the system includes a second set of adjustable louvers
- the first set of adjustable louvers is positioned within the air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger and the second set of adjustable louvers is located between the second heat exchanger's airflow entrance surface and the ambient environment, for example adjacent to the second heat exchanger's airflow entrance surface.
- a fan may be positioned adjacent to the airflow exit surface of the second heat exchanger.
- the system further comprises a second set of adjustable louvers that controls air flowing directly through the second air inlet into the second heat exchanger; a third heat exchanger configured in a non-stacked arrangement with the first and second heat exchangers, wherein the third heat exchanger is coupled to a third vehicle cooling subsystem; a third air inlet, wherein air flowing through the third air inlet flows directly into the third heat exchanger without first passing through either the first or second heat exchangers; and a third set of adjustable louvers that controls air flowing directly through the third air inlet into the third heat exchanger that does not first pass through either the first or second heat exchangers.
- the first, second and third sets of adjustable louvers may each have a first, fully opened position and a second, fully closed position.
- the first, second and third sets of adjustable louvers may each be adjustable over a range of positions between fully opened and fully closed.
- the first, second and third sets of adjustable louvers may each be comprised of two or more groups of adjustable louvers that are independently operable from one another.
- the first, second and third vehicle cooling subsystems may be selected from battery cooling subsystems, refrigeration subsystems, passenger cabin HVAC subsystems, power electronics cooling subsystems, motor cooling subsystems, transmission cooling subsystems, and charging system cooling subsystems.
- the second and third vehicle cooling subsystems may be the same cooling subsystem.
- the system may further comprise a first air duct that couples at least a first portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger, and a second air duct that couples at least a second portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the third heat exchanger.
- the first set of adjustable louvers may be comprised of at least a first group and a second group of adjustable louvers, where the first group of adjustable louvers is positioned within the first air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger, and where the second group of adjustable louvers is positioned within the second air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the third heat exchanger.
- the second set of adjustable louvers may be located between the airflow entrance surface of the second heat exchanger and the ambient environment, for example adjacent to the airflow entrance surface of the second heat exchanger
- the third set of adjustable louvers may be located between the airflow entrance surface of the third heat exchanger and the ambient environment, for example adjacent to the airflow entrance surface of the third heat exchanger.
- the system may further comprise a first fan adjacent to the airflow exit surface of the second heat exchanger and a second fan adjacent to the airflow exit surface of the third heat exchanger.
- the system further comprises a third heat exchanger configured in a non-stacked arrangement with the first and second heat exchangers, wherein the third heat exchanger is coupled to a third vehicle cooling subsystem; a third air inlet, wherein air flowing through the third air inlet flows directly into the third heat exchanger without first passing through either the first or second heat exchangers; a first air duct that couples at least a first portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger; a second air duct that couples at least a second portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the third heat exchanger; a second set of adjustable louvers that controls air flowing directly through the third air inlet into the third heat exchanger that does not first pass through either the first or second heat exchangers, and wherein the first set of adjustable louvers controls air flowing directly through the second air inlet into the second heat exchanger that does not first pass through either the first or third heat exchangers.
- FIG. 1 provides a simplified view of a vehicle thermal management system in accordance with the invention
- FIG. 2 illustrates the vehicle thermal management system shown in FIG. 1 , modified to allow air to pass unimpeded through the central heat exchanger;
- FIG. 3 illustrates a preferred embodiment of the invention based on the thermal management system shown in FIG. 1 ;
- FIG. 4 illustrates a preferred embodiment of the invention based on the thermal management system shown in FIG. 2 ;
- FIG. 5 illustrates an alternate embodiment utilizing only a portion of the louvers shown in FIG. 3 ;
- FIG. 6 illustrates another alternate embodiment utilizing only a portion of the louvers shown in FIG. 3 ;
- FIG. 7 provides a first airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 8 provides a second airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 9 provides a third airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 10 provides a fourth airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 11 provides a fifth airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 12 provides a sixth airflow pattern for a given arrangement of the louvers shown in the thermal management system of FIG. 3 ;
- FIG. 13 illustrates an alternate embodiment of the thermal management system shown in FIG. 3 ;
- FIG. 14 provides a front, perspective view of a preferred embodiment of the thermal management system of the invention.
- FIG. 15 provides a rear, perspective view of the thermal management system shown in FIG. 14 ;
- FIG. 16 provides a top view of the thermal management system shown in FIGS. 14 and 15 ;
- FIG. 17 provides a high-level view of the primary vehicle subsystems involved in a thermal management system designed in accordance with a preferred embodiment of the invention.
- battery may be used interchangeably and may refer to any of a variety of different cell types, chemistries and configurations including, but not limited to, lithium ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel zinc, silver zinc, or other battery type/configuration.
- battery pack refers to multiple individual batteries contained within a single piece or multi-piece housing, the individual batteries electrically interconnected to achieve the desired voltage and capacity for a particular application.
- electric vehicle refers to either an all-electric vehicle, also referred to as an EV, plug-in hybrid vehicles, also referred to as a PHEV, or a hybrid vehicle (HEV), a hybrid vehicle utilizing multiple propulsion sources one of which is an electric drive system.
- EV all-electric vehicle
- plug-in hybrid vehicles also referred to as a PHEV
- HEV hybrid vehicle
- FIG. 1 provides a simplified view of a vehicle thermal management system in accordance with the invention.
- System 100 includes three heat exchangers 101 - 103 ; more specifically, central heat exchanger 101 and a pair of heat exchangers 102 / 103 that are mounted on either side of central heat exchanger 101 .
- Heat exchangers 101 - 103 are thermally coupled to one or more vehicle cooling subsystems (e.g., battery cooling subsystem, refrigeration subsystem, passenger cabin HVAC subsystem, power electronics cooling subsystem, motor and/or transmission cooling subsystem, charging system cooling subsystem, etc.).
- vehicle cooling subsystems e.g., battery cooling subsystem, refrigeration subsystem, passenger cabin HVAC subsystem, power electronics cooling subsystem, motor and/or transmission cooling subsystem, charging system cooling subsystem, etc.
- System 100 is designed to provide symmetry about central vehicular axis 105 . Note that in this configuration, forward vehicle motion is shown by arrow 107 , resulting in airflow through the heat exchangers in direction 109 .
- Thermal management system 100 includes a number of air ducts that control the flow of air through, or around, the heat exchangers.
- rear ducting 111 A prevents air from flowing unimpeded through heat exchanger 101 . Rather, the air that flows through the left side of heat exchanger 101 and exits rear heat exchanger surface 112 is forced to flow through heat exchanger 102 , following path 113 .
- rear ducting 111 B forces air flowing through the right side of heat exchanger 101 and exiting rear heat exchanger surface 112 to pass through heat exchanger 103 , following path 115 .
- ducting section 117 prevents air from flowing through the left side of heat exchanger 101 without also passing through heat exchanger 102 .
- ducting section 119 prevents air from flowing through the right side of heat exchanger 101 without also passing through heat exchanger 103 .
- Alternate embodiments eliminate ducting sections 117 / 119 , thus allowing air to flow through central heat exchanger 101 and then exit the system without also passing through one of the side-mounted heat exchangers 102 / 103 .
- adjustable louvers may be positioned at ducting sections 117 / 119 , thus allowing control over whether the air flowing through the central heat exchanger 101 passes through a side-mounted heat exchanger.
- the forward portions of the air ducting include a pair of air inlets 121 and 123 , shown in phantom, which are positioned in front of heat exchangers 102 and 103 , respectively. Additionally, the entrance 124 to the central heat exchanger 101 forms a third air inlet that provides a pathway for air to flow directly into heat exchanger 101 . Air duct inlet 121 provides an airflow path 125 that bypasses heat exchanger 101 as shown. Similarly, air duct inlet 123 allows air to flow directly through heat exchanger 103 without passing through central heat exchanger 101 , following path 127 .
- Thermal management system 200 illustrated in FIG. 2 , illustrates a minor modification of the air ducts of system 100 .
- at least a portion of rear ducting 111 A/ 111 B is modified to include air exhaust ports 201 and 202 .
- Outlets 201 and 202 allow air passing through heat exchanger 101 to flow out of the back of heat exchanger 101 without also passing through one or both heat exchangers 102 and 103 (e.g., pathways 203 / 204 ).
- air may or may not follow pathways 113 and 115 shown in FIG. 1 .
- air passing through inlets 121 / 123 will flow directly through the side heat exchangers without first passing through central heat exchanger 101 .
- FIG. 3 illustrates a preferred embodiment of the invention based on thermal management system 100 .
- System 300 includes four sets of louvers 301 - 304 that provide means for controlling the flow of air through heat exchangers 101 - 103 .
- louvers 301 - 304 are completely independent from one another, thereby providing even finer thermal management control.
- system 300 includes at least one fan, and more preferably at least two fans 305 / 306 , to augment airflow by drawing air through the heat exchangers or, in some embodiments, blowing air through the heat exchangers.
- FIG. 4 illustrates a preferred embodiment of the invention based on thermal management system 200 .
- the system not only includes louvers 301 - 304 , but also louvers 401 and 402 as shown. Louvers 401 and 402 control whether the air that passes through central heat exchanger 101 also passes through a side-mounted heat exchanger, i.e., heat exchanger 102 and/or 103 , or simply flow through the central heat exchanger following a pathway 203 / 204 . It will be appreciated that a fan, or fans, may be mounted at one or both air outlets 201 / 202 .
- louvers 301 - 304 and 401 - 402 maximizes airflow control through heat exchangers 101 - 103
- the invention may utilize a different number of control louvers, depending primarily upon the constraints and requirements placed on the thermal management system by the vehicle's design.
- system 500 shown in FIG. 5 only includes outboard louvers 303 and 304 and system 600 shown in FIG. 6 only includes inboard louvers 301 and 302 .
- FIGS. 7-12 illustrate a variety of airflow paths through preferred system 300 , the designated flow path depending upon the relative positions of louvers 301 - 304 .
- louvers 301 - 304 are completely closed.
- the air flowing in direction 109 which is due to the forward movement of the vehicle, bypasses heat exchangers 101 - 103 altogether and instead follows pathways 701 / 702 .
- louvers 303 and 304 positioned in front of heat exchangers 102 and 103 , respectively, are open while louvers 301 and 302 are closed. This arrangement causes the incoming air to follow pathways 801 and 802 through heat exchangers 102 and 103 , respectively, while bypassing heat exchanger 101 .
- louvers 301 and 302 which control the flow of air through the left and right sides of heat exchanger 101 are in an open position while louvers 303 and 304 are closed. Due to the ducting, the air flowing through heat exchanger 101 must also pass through heat exchangers 102 and 103 following airflow paths 901 and 902 . Since the air flowing through heat exchangers 102 and 103 must first pass through heat exchanger 101 , typically the air flowing through heat exchangers 102 / 103 will be at a higher temperature than the ambient temperature unless coolant is by-passing this heat exchanger and not adding heat to the airstream. In FIG. 10 , all louvers 301 - 304 are in an open position. As a result, air will flow through all three heat exchangers, i.e., following pathways 1001 and 1002 through center heat exchanger 101 and following pathways 1003 and 1004 through side-mounted heat exchangers 102 and 103 .
- louvers are completely independent from one another. This allows fine tuning of the thermal management system depending upon the requirements of the vehicle subsystems to which the various heat exchangers are coupled.
- the arrangement shown in FIG. 11 illustrates this flexibility. Specifically, on the left side of the vehicle, louver 301 is in the open position while louver 303 is in the closed position. As a result, most of the air flowing against the left side of the vehicle will follow pathway 1101 and pass first through heat exchanger 101 , and then through heat exchanger 102 .
- louver 302 On the right side of the vehicle, louver 302 is in the closed position and louver 304 is in the open position, thus causing most of the air flowing against the right side of the vehicle to pass directly through heat exchanger 103 following pathway 1103 rather than first going through heat exchanger 101 .
- the louvers may be positioned in a range of positions from fully open to fully closed, thus allowing fine modulation of the airflow.
- the thermal management system may be fine-tuned to insure efficient use of the heat exchangers, i.e., achieving the airflow required for cooling while minimizing hydraulic and aerodynamic losses.
- FIG. 12 This aspect of the invention is illustrated in FIG. 12 , based on preferred system 300 .
- louver 302 on the right side of the vehicle is fully closed and louver 304 is fully opened, thus causing the air flowing against the right side of the vehicle to pass directly through heat exchanger 103 following pathway 1201 .
- louver 301 On the left side of the vehicle, louver 301 is opened to a very small degree, thus allowing only a small portion of air to follow path 1203 through both heat exchanger 101 and heat exchanger 102 . Additionally, on this side of the vehicle louver 303 is opened to the maximum extent possible, causing most of the air on this side of the vehicle to follow path 1205 and pass through heat exchanger 102 without first passing through heat exchanger 101 .
- louvers 301 and 302 have each been replaced by two sets of louvers each, i.e., 1301 A/ 1301 B and 1302 A/ 1302 B, respectively.
- Louvers 303 and 304 have each been replaced by three sets of louvers each, i.e., 1303 A/ 1303 B/ 1303 B and 1304 A/ 1304 B/ 1304 C, respectively.
- louvers 1301 A In the illustrated configuration, one of the louvers that controls the airflow through the left side of heat exchanger 101 , louver 1301 A, is closed while the other louver in this set, louver 1301 B, is open. Both louvers 1302 A and 1302 B that control airflow through the right side of heat exchanger 101 are closed in this figure.
- louvers 1303 B and 1303 C In front of heat exchanger 102 , louvers 1303 B and 1303 C are shown open, while louver 1303 A is closed.
- two sets of louvers, i.e., louvers 1304 A and 1304 C are closed while the middle set of louvers, 1304 B, is open. It will be appreciated that each air duct opening may use less than the illustrated number of louver sets, or more than the illustrated number of louver sets.
- FIGS. 14-16 illustrate a preferred embodiment of the invention, this embodiment utilizing three heat exchangers as shown in FIGS. 1-13 .
- FIG. 14 provides a front, perspective view of assembly 1400 ;
- FIG. 15 provides a rear, perspective view of assembly 1400 ;
- FIG. 16 provides a view from above assembly 1400 .
- the central heat exchanger 1401 is a radiator, and the left-side and right side heat exchangers, 1402 and 1403 respectively, are condensers. It will be appreciated that due to the fans, louvers and ducting, heat exchangers 1402 and 1403 are not clearly visible. Situated behind heat exchangers 1402 and 1403 are fans 1405 and 1406 , respectively.
- Louvers 1407 and 1408 positioned in front of heat exchangers 1402 and 1403 , respectively, are clearly shown in FIG. 14 .
- louvers 1407 and 1408 are horizontal louvers as preferred, rather than the vertical louvers shown in FIGS. 3-13 .
- Louvers 1409 and 1410 control the airflow through the left and right sides, respectively, of central heat exchanger 1401 .
- louvers 1409 and 1410 are located within the air ducts as previously described relative to FIGS. 3-13 , they are not clearly visible in FIGS. 14-16 .
- Also visible in FIGS. 14-16 are the left and right air ducts 1411 and 1412 , respectively.
- FIG. 17 provides a high-level view of the primary vehicle subsystems involved in a thermal management system designed in accordance with a preferred embodiment of the invention. It will be appreciated that a vehicle can utilize other system configurations while still retaining the functionality of the present invention. Additionally, it should be understood that FIG. 17 only illustrates portions of a thermal management system and such a system may include other subsystems, depending upon the type of vehicle, power train design and configuration, battery pack composition, etc.
- a thermal management control system 1701 At the heart of system 1700 is a thermal management control system 1701 .
- System 1701 may be integrated within another vehicle control system or configured as a stand-alone control system.
- control system 1701 includes a control processor as well as memory for storing a preset set of control instructions.
- Coupled to controller 1701 are a plurality of temperature sensors 1703 that monitor the temperature of the various vehicle components in general, and the vehicle components that are coupled to the vehicle cooling systems in particular.
- Exemplary components that may be monitored include the battery or batteries, motor, drive electronics, transmission, and coolant.
- Ambient temperature is preferably monitored as well.
- the charging system temperature may also be monitored. The monitored temperatures at these various locations are used by control system 1701 to determine the operation of the various thermal management subsystems.
- controller 1701 In addition to preferably regulating the flow of coolant within the coolant loop(s) utilizing any of a variety of regulators 1705 (e.g., circulation pump operation or flow rate, flow valves, etc.), controller 1701 preferably controls fan operation (e.g., fans 305 / 306 , 1405 / 1406 , etc.). Controller 1701 also controls operation of the louvers (e.g., louvers 301 - 304 , 401 - 402 , 1301 A-C, 1302 A-C, 1303 A-C, 1304 A-C, 1407 - 1410 , etc.). Preferably louver control is provided by electro-mechanical actuators although other means may be used (e.g., hydraulic actuators). Preferably control system 1701 is designed to operate automatically based on programming implemented by the system's processor. Alternately, system 1700 may be manually controlled, or controlled via a combination of manual and automated control.
- fan operation e.g., fans 305 / 306
Abstract
Description
- This application claims benefit of the filing date of U.S. Provisional Patent Application Ser. No. 61/429,825, filed 5 Jan. 2011, the disclosure of which is incorporated herein by reference for any and all purposes.
- The present invention relates generally to vehicles and, more particularly, to an automotive radiator and condenser airflow system.
- Vehicle cooling systems vary widely in complexity, depending primarily upon the thermal requirements of the various vehicle systems employed in the vehicle in question. In general, these cooling systems utilize heat exchangers of one form or another to transfer the heat generated by the vehicle subsystems to the surrounding ambient environment. Such heat transfer may either be performed directly, for example in the case of a simple radiator coupled to a vehicle engine, or indirectly, for example in the case of a thermal management system utilizing multiple heat transfer circuits to transfer the heat through multiple stages in order to sufficiently lower the temperature of the component in question.
- In general, vehicle heat exchangers are designed to exchange heat between two different fluids, or two similar fluids that are at different temperatures, thereby helping to maintain the various vehicle systems and components within a safe and effective operating range of temperatures. One of the fluids is typically composed of a refrigerant or water, the water often mixed with ethylene glycol or propylene glycol or a similar liquid that provides anti-freeze protection at low temperatures. In many vehicle heat exchangers such as condensers and radiators, the second fluid is air which is forced to flow through the heat exchanger, either as a result of vehicle movement or through the use of a fan.
- Within the automotive industry there are several types of air heat exchangers, the design of each being based on their intended application. Exemplary heat exchangers include:
- A powertrain radiator in which a coolant-to-air heat exchanger is used to remove heat from an internal combustion engine or electric motor.
- A condenser in which a refrigerant-to-air heat exchanger is used to remove heat for cabin air conditioning systems or other systems (e.g., battery packs and power electronics) that employ refrigerant as the cooling fluid.
- A transmission oil cooler in which an oil-to-air heat exchanger is used to remove heat from the transmission via the transmission fluid.
- A steering pump oil cooler in which an oil-to-air heat exchanger is used to remove heat from the steering system via the steering fluid.
- A charge air cooler in which an air-to-air heat exchanger is used to remove heat from turbocharged (compressed) air used in the engine intake system.
- For a given set of fluid temperatures, the performance of a fluid-to-fluid heat exchanger depends primarily on the surface area of the heat exchanger and the volume flow rate of the two fluids through the heat exchanger. Flow rate is commonly determined as the fluid velocity through the heat exchanger multiplied by the frontal area of the heat exchanger. Larger heat exchanger surface areas and mass flow rates result in greater heat transfer from the inner fluid to the outer fluid. An increase in these same variables, however, also results in an increase in the hydraulic losses, or pressure drop losses, which are manifested in increased aerodynamic drag (i.e., vehicle motive power), pump power, and fan power. Additionally, in a fluid-to-fluid heat exchanger, the transfer of heat between the two fluids increases as the temperature difference between the two fluids increases.
- In a conventional vehicle utilizing multiple heat exchangers, regardless of whether the vehicle utilizes a combustion engine, an electric motor, or a combination of both (i.e., a hybrid), the individual heat exchangers are typically positioned one in front of the other, followed by a fan, this configuration referred to as a “stack”. In such a stacking arrangement, commonly the heat exchanger with the lowest outlet air temperature is located upstream, followed by higher temperature heat exchangers downstream. An example of such a configuration is a condenser followed directly by an engine radiator, followed by one or more fans. While this arrangement is more common with vehicles utilizing a combustion engine, hybrid vehicles may also use a stack of heat exchangers in order to provide cooling for the battery pack, power electronics and the motor. A principal drawback of the practice of stacking heat exchangers is an increase in hydraulic losses (i.e., fan power, aerodynamic drag) that result regardless of whether each heat exchanger in the stack is in active use. Additionally, since the temperature of the air entering the inner heat exchanger(s) will be the temperature of the air exiting the upstream heat exchanger which is typically higher than the ambient temperature, the efficiency and overall performance of the inner heat exchanger(s) is compromised. As a consequence, it is common practice to increase the surface area or thickness of the downstream heat exchangers to compensate for this decrease in expected performance which, in turn, adds weight and cost to the affected heat exchangers.
- While a variety of different techniques and system configurations have been used to control the temperatures of the various subsystems and components in a vehicle, they are often inefficient, which in turn affects vehicle performance. Accordingly, what is needed is a thermal management system that maximizes heat transfer while minimizing the hydraulic power consumed in the process. The present invention provides such a thermal management system.
- A vehicle thermal management system is provided that is comprised of at least first and second heat exchangers configured in a non-stacked arrangement, wherein the first heat exchanger is coupled to a first vehicle cooling subsystem and the second heat exchanger is coupled to a second vehicle cooling subsystem; a first air inlet, wherein air flowing through the first air inlet flows directly into the first heat exchanger without first passing through the second heat exchanger; a second air inlet, wherein air flowing through the second air inlet flows directly into the second heat exchanger without first passing through the first heat exchanger; and a first set of adjustable louvers that controls air flowing directly through the first air inlet into the first heat exchanger. The system may further comprise a second set of adjustable louvers that controls air flowing directly through the second air inlet into the second heat exchanger. The second set of adjustable louvers may be located between the second heat exchanger's airflow entrance surface and the ambient environment. The first and second sets of adjustable louvers may each have a first, fully opened position and a second, fully closed position. The first and second sets of adjustable louvers may each be adjustable over a range of positions between fully opened and fully closed. The first and second sets of adjustable louvers may each be comprised of two or more groups of adjustable louvers that are independently operable from one another.
- In one aspect of the invention, an air duct couples at least a portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger. If there is a single set of adjustable louvers, they may be (i) positioned within the air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger, or (ii) positioned between the second heat exchanger's airflow entrance surface and the ambient environment. If the system includes a second set of adjustable louvers, preferably the first set of adjustable louvers is positioned within the air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger and the second set of adjustable louvers is located between the second heat exchanger's airflow entrance surface and the ambient environment, for example adjacent to the second heat exchanger's airflow entrance surface. A fan may be positioned adjacent to the airflow exit surface of the second heat exchanger.
- In another aspect of the invention, the system further comprises a second set of adjustable louvers that controls air flowing directly through the second air inlet into the second heat exchanger; a third heat exchanger configured in a non-stacked arrangement with the first and second heat exchangers, wherein the third heat exchanger is coupled to a third vehicle cooling subsystem; a third air inlet, wherein air flowing through the third air inlet flows directly into the third heat exchanger without first passing through either the first or second heat exchangers; and a third set of adjustable louvers that controls air flowing directly through the third air inlet into the third heat exchanger that does not first pass through either the first or second heat exchangers. The first, second and third sets of adjustable louvers may each have a first, fully opened position and a second, fully closed position. The first, second and third sets of adjustable louvers may each be adjustable over a range of positions between fully opened and fully closed. The first, second and third sets of adjustable louvers may each be comprised of two or more groups of adjustable louvers that are independently operable from one another. The first, second and third vehicle cooling subsystems may be selected from battery cooling subsystems, refrigeration subsystems, passenger cabin HVAC subsystems, power electronics cooling subsystems, motor cooling subsystems, transmission cooling subsystems, and charging system cooling subsystems. The second and third vehicle cooling subsystems may be the same cooling subsystem. The system may further comprise a first air duct that couples at least a first portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger, and a second air duct that couples at least a second portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the third heat exchanger. The first set of adjustable louvers may be comprised of at least a first group and a second group of adjustable louvers, where the first group of adjustable louvers is positioned within the first air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the second heat exchanger, and where the second group of adjustable louvers is positioned within the second air duct and between the airflow exit surface of the first heat exchanger and the airflow entrance surface of the third heat exchanger. The second set of adjustable louvers may be located between the airflow entrance surface of the second heat exchanger and the ambient environment, for example adjacent to the airflow entrance surface of the second heat exchanger, and the third set of adjustable louvers may be located between the airflow entrance surface of the third heat exchanger and the ambient environment, for example adjacent to the airflow entrance surface of the third heat exchanger. The system may further comprise a first fan adjacent to the airflow exit surface of the second heat exchanger and a second fan adjacent to the airflow exit surface of the third heat exchanger.
- In another aspect of the invention, the system further comprises a third heat exchanger configured in a non-stacked arrangement with the first and second heat exchangers, wherein the third heat exchanger is coupled to a third vehicle cooling subsystem; a third air inlet, wherein air flowing through the third air inlet flows directly into the third heat exchanger without first passing through either the first or second heat exchangers; a first air duct that couples at least a first portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the second heat exchanger; a second air duct that couples at least a second portion of the airflow exit surface of the first heat exchanger to an airflow entrance surface of the third heat exchanger; a second set of adjustable louvers that controls air flowing directly through the third air inlet into the third heat exchanger that does not first pass through either the first or second heat exchangers, and wherein the first set of adjustable louvers controls air flowing directly through the second air inlet into the second heat exchanger that does not first pass through either the first or third heat exchangers.
- A further understanding of the nature and advantages of the present invention may be realized by reference to the remaining portions of the specification and the drawings.
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FIG. 1 provides a simplified view of a vehicle thermal management system in accordance with the invention; -
FIG. 2 illustrates the vehicle thermal management system shown inFIG. 1 , modified to allow air to pass unimpeded through the central heat exchanger; -
FIG. 3 illustrates a preferred embodiment of the invention based on the thermal management system shown inFIG. 1 ; -
FIG. 4 illustrates a preferred embodiment of the invention based on the thermal management system shown inFIG. 2 ; -
FIG. 5 illustrates an alternate embodiment utilizing only a portion of the louvers shown inFIG. 3 ; -
FIG. 6 illustrates another alternate embodiment utilizing only a portion of the louvers shown inFIG. 3 ; -
FIG. 7 provides a first airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 8 provides a second airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 9 provides a third airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 10 provides a fourth airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 11 provides a fifth airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 12 provides a sixth airflow pattern for a given arrangement of the louvers shown in the thermal management system ofFIG. 3 ; -
FIG. 13 illustrates an alternate embodiment of the thermal management system shown inFIG. 3 ; -
FIG. 14 provides a front, perspective view of a preferred embodiment of the thermal management system of the invention; -
FIG. 15 provides a rear, perspective view of the thermal management system shown inFIG. 14 ; -
FIG. 16 provides a top view of the thermal management system shown inFIGS. 14 and 15 ; and -
FIG. 17 provides a high-level view of the primary vehicle subsystems involved in a thermal management system designed in accordance with a preferred embodiment of the invention. - In the following text, the terms “battery”, “cell”, and “battery cell” may be used interchangeably and may refer to any of a variety of different cell types, chemistries and configurations including, but not limited to, lithium ion (e.g., lithium iron phosphate, lithium cobalt oxide, other lithium metal oxides, etc.), lithium ion polymer, nickel metal hydride, nickel cadmium, nickel hydrogen, nickel zinc, silver zinc, or other battery type/configuration. The term “battery pack” as used herein refers to multiple individual batteries contained within a single piece or multi-piece housing, the individual batteries electrically interconnected to achieve the desired voltage and capacity for a particular application. The term “electric vehicle” as used herein refers to either an all-electric vehicle, also referred to as an EV, plug-in hybrid vehicles, also referred to as a PHEV, or a hybrid vehicle (HEV), a hybrid vehicle utilizing multiple propulsion sources one of which is an electric drive system. It should be understood that identical element symbols used on multiple figures refer to the same component, or components of equal functionality. Additionally, the accompanying figures are only meant to illustrate, not limit, the scope of the invention and should not be considered to be to scale.
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FIG. 1 provides a simplified view of a vehicle thermal management system in accordance with the invention.System 100 includes three heat exchangers 101-103; more specifically,central heat exchanger 101 and a pair ofheat exchangers 102/103 that are mounted on either side ofcentral heat exchanger 101. Heat exchangers 101-103 are thermally coupled to one or more vehicle cooling subsystems (e.g., battery cooling subsystem, refrigeration subsystem, passenger cabin HVAC subsystem, power electronics cooling subsystem, motor and/or transmission cooling subsystem, charging system cooling subsystem, etc.). While the use of three heat exchangers is preferred, it should be understood that the invention described herein is equally applicable to thermal management systems utilizing only a pair of side-by-side exchangers, e.g.,heat exchangers heat exchangers System 100 is designed to provide symmetry about centralvehicular axis 105. Note that in this configuration, forward vehicle motion is shown byarrow 107, resulting in airflow through the heat exchangers indirection 109. -
Thermal management system 100, as with other embodiments of the invention, includes a number of air ducts that control the flow of air through, or around, the heat exchangers. In the illustrated system,rear ducting 111A prevents air from flowing unimpeded throughheat exchanger 101. Rather, the air that flows through the left side ofheat exchanger 101 and exits rearheat exchanger surface 112 is forced to flow throughheat exchanger 102, followingpath 113. Similarly,rear ducting 111B forces air flowing through the right side ofheat exchanger 101 and exiting rearheat exchanger surface 112 to pass throughheat exchanger 103, followingpath 115. Note that in this and other preferred embodiments, ductingsection 117 prevents air from flowing through the left side ofheat exchanger 101 without also passing throughheat exchanger 102. Similarly, ductingsection 119 prevents air from flowing through the right side ofheat exchanger 101 without also passing throughheat exchanger 103. Alternate embodiments eliminateducting sections 117/119, thus allowing air to flow throughcentral heat exchanger 101 and then exit the system without also passing through one of the side-mountedheat exchangers 102/103. Note that adjustable louvers may be positioned at ductingsections 117/119, thus allowing control over whether the air flowing through thecentral heat exchanger 101 passes through a side-mounted heat exchanger. - The forward portions of the air ducting include a pair of
air inlets heat exchangers entrance 124 to thecentral heat exchanger 101 forms a third air inlet that provides a pathway for air to flow directly intoheat exchanger 101.Air duct inlet 121 provides anairflow path 125 that bypassesheat exchanger 101 as shown. Similarly,air duct inlet 123 allows air to flow directly throughheat exchanger 103 without passing throughcentral heat exchanger 101, followingpath 127. -
Thermal management system 200, shown inFIG. 2 , illustrates a minor modification of the air ducts ofsystem 100. In the illustrated system, at least a portion ofrear ducting 111A/111B is modified to includeair exhaust ports Outlets heat exchanger 101 to flow out of the back ofheat exchanger 101 without also passing through one or bothheat exchangers 102 and 103 (e.g.,pathways 203/204). Depending upon the size ofoutlets heat exchanger 101, air may or may not followpathways FIG. 1 . As withsystem 100, air passing throughinlets 121/123 will flow directly through the side heat exchangers without first passing throughcentral heat exchanger 101. -
FIG. 3 illustrates a preferred embodiment of the invention based onthermal management system 100.System 300 includes four sets of louvers 301-304 that provide means for controlling the flow of air through heat exchangers 101-103. In addition to providing independent control of the flow of air through the side heat exchangers versus the central heat exchanger, preferably louvers 301-304 are completely independent from one another, thereby providing even finer thermal management control. Preferablysystem 300 includes at least one fan, and more preferably at least twofans 305/306, to augment airflow by drawing air through the heat exchangers or, in some embodiments, blowing air through the heat exchangers. -
FIG. 4 illustrates a preferred embodiment of the invention based onthermal management system 200. In this embodiment, the system not only includes louvers 301-304, but also louvers 401 and 402 as shown.Louvers central heat exchanger 101 also passes through a side-mounted heat exchanger, i.e.,heat exchanger 102 and/or 103, or simply flow through the central heat exchanger following apathway 203/204. It will be appreciated that a fan, or fans, may be mounted at one or bothair outlets 201/202. - While the use of multiple louvers 301-304 and 401-402 maximizes airflow control through heat exchangers 101-103, it should be understood that the invention may utilize a different number of control louvers, depending primarily upon the constraints and requirements placed on the thermal management system by the vehicle's design. For example,
system 500 shown inFIG. 5 only includesoutboard louvers system 600 shown inFIG. 6 only includesinboard louvers -
FIGS. 7-12 illustrate a variety of airflow paths throughpreferred system 300, the designated flow path depending upon the relative positions of louvers 301-304. InFIG. 7 , louvers 301-304 are completely closed. As a result, the air flowing indirection 109, which is due to the forward movement of the vehicle, bypasses heat exchangers 101-103 altogether and instead followspathways 701/702. InFIG. 8 ,louvers heat exchangers louvers pathways heat exchangers heat exchanger 101. InFIG. 9 ,louvers heat exchanger 101 are in an open position whilelouvers heat exchanger 101 must also pass throughheat exchangers airflow paths heat exchangers heat exchanger 101, typically the air flowing throughheat exchangers 102/103 will be at a higher temperature than the ambient temperature unless coolant is by-passing this heat exchanger and not adding heat to the airstream. InFIG. 10 , all louvers 301-304 are in an open position. As a result, air will flow through all three heat exchangers, i.e., followingpathways center heat exchanger 101 and followingpathways heat exchangers - As previously noted, in the preferred embodiment of the invention the louvers are completely independent from one another. This allows fine tuning of the thermal management system depending upon the requirements of the vehicle subsystems to which the various heat exchangers are coupled. The arrangement shown in
FIG. 11 illustrates this flexibility. Specifically, on the left side of the vehicle,louver 301 is in the open position whilelouver 303 is in the closed position. As a result, most of the air flowing against the left side of the vehicle will followpathway 1101 and pass first throughheat exchanger 101, and then throughheat exchanger 102. On the right side of the vehicle,louver 302 is in the closed position andlouver 304 is in the open position, thus causing most of the air flowing against the right side of the vehicle to pass directly throughheat exchanger 103 followingpathway 1103 rather than first going throughheat exchanger 101. - In at least one preferred embodiment of the invention, the louvers may be positioned in a range of positions from fully open to fully closed, thus allowing fine modulation of the airflow. As a result of allowing a range of louver positions, the thermal management system may be fine-tuned to insure efficient use of the heat exchangers, i.e., achieving the airflow required for cooling while minimizing hydraulic and aerodynamic losses. This aspect of the invention is illustrated in
FIG. 12 , based onpreferred system 300. In this figure,louver 302 on the right side of the vehicle is fully closed andlouver 304 is fully opened, thus causing the air flowing against the right side of the vehicle to pass directly throughheat exchanger 103 followingpathway 1201. On the left side of the vehicle,louver 301 is opened to a very small degree, thus allowing only a small portion of air to followpath 1203 through bothheat exchanger 101 andheat exchanger 102. Additionally, on this side of thevehicle louver 303 is opened to the maximum extent possible, causing most of the air on this side of the vehicle tofollow path 1205 and pass throughheat exchanger 102 without first passing throughheat exchanger 101. - In an alternate embodiment, fine adjustment of the air flowing through the louvers is achieved by utilizing two or more sets of louvers for each opening where fine control is desired. Preferably each set of louvers is only capable of two positions: fully open or fully closed, thus simplifying louver operation. In an exemplary configuration shown in
FIG. 13 and based onsystem 300,louvers Louvers heat exchanger 101, louver 1301A, is closed while the other louver in this set, louver 1301B, is open. Both louvers 1302A and 1302B that control airflow through the right side ofheat exchanger 101 are closed in this figure. In front ofheat exchanger 102, louvers 1303B and 1303C are shown open, while louver 1303A is closed. In front ofheat exchanger 103, two sets of louvers, i.e., louvers 1304A and 1304C are closed while the middle set of louvers, 1304B, is open. It will be appreciated that each air duct opening may use less than the illustrated number of louver sets, or more than the illustrated number of louver sets. -
FIGS. 14-16 illustrate a preferred embodiment of the invention, this embodiment utilizing three heat exchangers as shown inFIGS. 1-13 .FIG. 14 provides a front, perspective view ofassembly 1400;FIG. 15 provides a rear, perspective view ofassembly 1400; andFIG. 16 provides a view from aboveassembly 1400. Inpreferred system 1400, the central heat exchanger 1401 is a radiator, and the left-side and right side heat exchangers, 1402 and 1403 respectively, are condensers. It will be appreciated that due to the fans, louvers and ducting,heat exchangers heat exchangers fans heat exchangers FIG. 14 . Note that louvers 1407 and 1408 are horizontal louvers as preferred, rather than the vertical louvers shown inFIGS. 3-13 .Louvers louvers FIGS. 3-13 , they are not clearly visible inFIGS. 14-16 . Also visible inFIGS. 14-16 are the left andright air ducts -
FIG. 17 provides a high-level view of the primary vehicle subsystems involved in a thermal management system designed in accordance with a preferred embodiment of the invention. It will be appreciated that a vehicle can utilize other system configurations while still retaining the functionality of the present invention. Additionally, it should be understood thatFIG. 17 only illustrates portions of a thermal management system and such a system may include other subsystems, depending upon the type of vehicle, power train design and configuration, battery pack composition, etc. - At the heart of
system 1700 is a thermalmanagement control system 1701.System 1701 may be integrated within another vehicle control system or configured as a stand-alone control system. Typically controlsystem 1701 includes a control processor as well as memory for storing a preset set of control instructions. Coupled tocontroller 1701 are a plurality oftemperature sensors 1703 that monitor the temperature of the various vehicle components in general, and the vehicle components that are coupled to the vehicle cooling systems in particular. Exemplary components that may be monitored include the battery or batteries, motor, drive electronics, transmission, and coolant. Ambient temperature is preferably monitored as well. Depending upon the configuration of the vehicle, the charging system temperature may also be monitored. The monitored temperatures at these various locations are used bycontrol system 1701 to determine the operation of the various thermal management subsystems. In addition to preferably regulating the flow of coolant within the coolant loop(s) utilizing any of a variety of regulators 1705 (e.g., circulation pump operation or flow rate, flow valves, etc.),controller 1701 preferably controls fan operation (e.g.,fans 305/306, 1405/1406, etc.).Controller 1701 also controls operation of the louvers (e.g., louvers 301-304, 401-402, 1301A-C, 1302A-C, 1303A-C, 1304A-C, 1407-1410, etc.). Preferably louver control is provided by electro-mechanical actuators although other means may be used (e.g., hydraulic actuators). Preferably controlsystem 1701 is designed to operate automatically based on programming implemented by the system's processor. Alternately,system 1700 may be manually controlled, or controlled via a combination of manual and automated control. - As will be understood by those familiar with the art, the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Accordingly, the disclosures and descriptions herein are intended to be illustrative, but not limiting, of the scope of the invention.
Claims (24)
Priority Applications (2)
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US13/150,553 US20120168125A1 (en) | 2011-01-05 | 2011-06-01 | Multi-Function Automotive Radiator and Condenser Airflow System |
US13/468,836 US9250020B2 (en) | 2011-01-05 | 2012-05-10 | Active louver system for controlled airflow in a multi-function automotive radiator and condenser system |
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US13/150,553 US20120168125A1 (en) | 2011-01-05 | 2011-06-01 | Multi-Function Automotive Radiator and Condenser Airflow System |
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US20210268895A1 (en) * | 2020-03-02 | 2021-09-02 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Cooling air opening, and motor vehicle front end having a cooling air opening |
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