Hydraulic architecture including heating and cooling for motorized vehicles

Abstract

A system includes a coolant system and a refrigerant system. The coolant system is in fluid communication with the power electronics, the battery pack, and the cabin. The refrigerant system interacts only with the coolant from the coolant system, and wherein all cabin heat exchanges and all refrigerant heat exchanges are carried out by the coolant.

Description

Technical Field

[0001] The present disclosure relates to a hydraulic architecture for a thermal management system for an electrified vehicle, and more particularly to a hydraulic architecture in which all heat exchange between vehicle components, the vehicle cabin, and ambient air occurs through a coolant. Background Art

[0002] Electrified vehicles include a high voltage traction battery pack that powers the electric motor and other electrical loads of the electrified vehicle. Managing heat transfer between different groups of components in an electrified vehicle is challenging without significantly increasing the number of heat exchangers and / or multiple valve systems. Summary of the invention

[0003] A system according to an exemplary aspect of the present disclosure includes, inter alia: a coolant system that is in fluid communication with power electronics, a battery pack, and a cabin; and a refrigerant system that interfaces only with coolant from the coolant system, and wherein all cabin heat exchanges and all refrigerant heat exchanges are performed through the coolant.

[0004] In another non-limiting embodiment of the foregoing system, the system includes a valve associated with a first configuration or a second configuration, and wherein: in the first configuration, the valve is fluidly connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryocooler and a second cryocooler, at least one water-cooled condenser and a low-temperature radiator; and in the second configuration, the valve is fluidly connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryocooler, a second cryocooler and a third cryocooler, at least a first water-cooled condenser and a second water-cooled condenser and a low-temperature radiator.

[0005] In a further non-limiting embodiment of any of the foregoing systems, the valve comprises a only valve used in the first configuration and the second configuration.

[0006] In a further non-limiting embodiment of any of the foregoing systems, the valve operates in a plurality of different valve states, and the system includes a controller that controls the valve based on input from a plurality of sensors to manage heat transfer for the plurality of different valve states.

[0007] In a further non-limiting embodiment of any of the foregoing systems, one of the plurality of different valve states includes a DC fast charging mode when there is no request for heating or cooling of the cabin, and wherein: when in the first configuration, the first cryogenic cooler and the second cryogenic cooler are used to cool the battery pack via the refrigerant system, and when in the second configuration, the first cryogenic cooler, the second cryogenic cooler, and the third cryogenic cooler are used to cool the battery pack via the refrigerant system.

[0008] In another non-limiting embodiment of any of the foregoing systems, one of the plurality of different valve states includes a cabin cooling and a battery cooling mode, and wherein: when in the first configuration, one of the first cryogenic freezer and the second cryogenic freezer is used to cool the battery pack and the other of the first cryogenic freezer and the second cryogenic freezer is used to cool the cabin via the cooler core; and when in the second configuration, two of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer are used to cool the cabin via the cooler core, and the remaining of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer is used to cool the battery pack.

[0009] In another non-limiting embodiment of any of the foregoing systems, one of the plurality of different valve states includes cabin cooling and battery cooling modes, and wherein: when in the first configuration, one of the first cryogenic freezer and the second cryogenic freezer is used to cool the battery pack and the other of the first cryogenic freezer and the second cryogenic freezer is used to cool the cabin via the cooler core; and when in the second configuration, two of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer are used to cool the battery pack and the remaining of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer cools the cabin via the cooler core.

[0010] In a further non-limiting embodiment of any of the foregoing systems, one of the plurality of different valve states includes cabin cooling and battery recirculation modes, and wherein: when in the first configuration, the first cryogenic cooler and the second cryogenic cooler are used to cool the cabin via the cooler core; and when in the second configuration, the first cryogenic cooler, the second cryogenic cooler, and the third cryogenic cooler are used to cool the cabin via the cooler core.

[0011] In another non-limiting embodiment of any of the foregoing systems, one of the multiple different valve states includes active cabin cooling and passive battery cooling modes, and wherein: when in the first configuration, the low-temperature radiator is used to cool the battery pack and the power electronic devices, one of the first deep freezer and the second deep freezer is used to cool the power electronic devices and the battery pack, and the other of the first deep freezer and the second deep freezer is used to cool the cabin; and when in the second configuration, the low-temperature radiator is used to cool the battery pack and the power electronic devices, two of the first deep freezer, the second deep freezer and the third deep freezer are used to cool the cabin via the cooler core, and the remaining of the first deep freezer, the second deep freezer and the third deep freezer is used to cool the power electronic devices and the battery pack.

[0012] In a further non-limiting embodiment of any of the foregoing systems, one of the plurality of different valve states includes dehumidification and battery heating / cooling or cabin heating and battery cooling, and wherein:

[0013] When in the first configuration,

[0014] The low temperature radiator is used to cool the battery and power electronic devices.

[0015] One of the first cryocooler and the second cryocooler is used to cool the power electronic device and the battery,

[0016] heat from the power electronics, the battery, and the low temperature radiator is transferred from at least one of the first cryocooler and the second cryocooler to the water-cooled condenser through the refrigerant system to warm the cabin when needed,

[0017] dehumidifying the vehicle cabin by cooling by one of the first cryocooler and the second cryocooler when necessary, and

[0018] compensating for cabin cooling via heat from the water-cooled condenser while using the heater core when needed; and

[0019] When in the second configuration,

[0020] The low temperature radiator is used to cool the battery and power electronic devices.

[0021] One of the first cryocooler and the second cryocooler is used to cool the power electronic device and the battery,

[0022] heat from the power electronics, the battery, and the low temperature radiator is transferred from at least one of the first cryocooler and the second cryocooler to the water-cooled condenser through the refrigerant system to warm the cabin when needed,

[0023] dehumidifying the vehicle cabin by cooling by two of the first cryocooler, the second cryocooler, and the third cryocooler when necessary, and

[0024] The heater core is simultaneously used to compensate for cabin cooling via heat from the water-cooled condenser when needed.

[0025] In another non-limiting embodiment of any of the foregoing systems, one of the multiple different valve states includes at least a battery heating and cabin heating mode when predetermined conditions are met, and wherein: when in the first configuration, heat is transferred directly from the PTC heater to the battery, or heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronics is transferred to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then transferred to the heater core and the battery; and when in the second configuration, heat is transferred directly from the PTC heater, or heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronics is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then transferred to the heater core and the battery.

[0026] In another non-limiting embodiment of any of the foregoing systems, one of the multiple different valve states includes a cabin and battery heating mode, and wherein: when in the first configuration, heat from the power electronic circuit directly heats the battery, and heat recovered from the ambient air through the low-temperature radiator and power electronic device waste heat is transferred to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then transferred to the heater core; and when in the second configuration, heat from the power electronic circuit directly heats the battery, and heat recovered from the ambient air through the low-temperature radiator and power electronic device waste heat is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler, and the third cryogenic cooler, and then transferred to the heater core.

[0027] In a further non-limiting embodiment of any of the foregoing systems, the system includes a plurality of pumps, the plurality of pumps including at least a first pump positioned immediately downstream of the battery, a second pump positioned immediately downstream of the heater core, a third pump positioned immediately downstream of the low-temperature radiator, and a fourth pump positioned immediately downstream of the cooler core.

[0028] A method according to another exemplary aspect of the present disclosure includes, inter alia: providing a coolant system, which is fluidly connected to power electronics, a battery pack, and a vehicle cabin; providing a refrigeration system, which interacts only with coolant from the coolant system; performing all vehicle cabin heat exchanges through the coolant; and performing all refrigerant heat exchanges through the coolant.

[0029] In another non-limiting embodiment of the foregoing method, the method includes associating the valve with a first configuration or a second configuration, and the method further includes: in the first configuration, the valve is connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryocooler and a second cryocooler, at least one water-cooled condenser and a low-temperature radiator fluid; and in the second configuration, the valve is connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryocooler, a second cryocooler and a third cryocooler, at least a first water-cooled condenser and a second water-cooled condenser and a low-temperature radiator fluid.

[0030] In a further non-limiting embodiment of any of the foregoing methods, the valve comprises a only valve used in both the first configuration and the second configuration.

[0031] In a further non-limiting embodiment of any of the foregoing methods, the method includes positioning at least a first pump immediately downstream of a battery, a second pump immediately downstream of the heater core, a third pump immediately downstream of the low-temperature radiator, and a fourth pump immediately downstream of the cooler core.

[0032] In a further non-limiting embodiment of any of the foregoing methods, the valve operates in a plurality of different valve states, and the method includes controlling the valve based on input from a plurality of sensors to manage heat transfer for the plurality of different valve states.

[0033] In another non-limiting embodiment of any of the foregoing methods, one of the multiple different valve states includes at least a battery heating and cabin heating mode when predetermined conditions are met, and the method includes: when in the first configuration, transferring heat directly from the PTC heater to the battery, or transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of power electronics to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then to the heater core and the battery; and when in the second configuration, transferring heat directly from the PTC heater to the battery, or transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of power electronics to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then to the heater core and the battery.

[0034] In another non-limiting embodiment of any of the foregoing methods, one of the multiple different valve states includes a cabin and battery heating mode, and the method includes: when in the first configuration, using heat from the power electronic circuit to directly heat the battery, and transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronic device to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then to the heater core; and when in the second configuration, using heat from the power electronic circuit to directly heat the battery, and transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronic device to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then to the heater core.

[0035] The embodiments, examples and alternatives of the preceding paragraphs, claims or the following description and drawings (including any of their various aspects or corresponding individual features) may be adopted independently or in any combination. Features described in conjunction with one embodiment apply to all embodiments, unless such features are incompatible.

[0036] The various features and advantages of the present disclosure will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 is a schematic diagram of a vehicle including a thermal management system according to the present disclosure.

[0038] Figure 2 is a schematic diagram showing indirect refrigerant heat to ambient in the case of distributing coolant only.

[0039] Figure 3 is a schematic diagram of a valve for use with a first configuration of a thermal management system.

[0040] Figure 4 is a schematic diagram of a valve for use with a second configuration of a thermal management system.

[0041] Figure 5-1 is a first portion of a chart detailing a plurality of operating modes and valve states for a first configuration and a second configuration. Figure 5-2 yes Figure 5-1 The rest of the chart.

[0042] Fig. 6A is an example of a valve state for the first configuration.

[0043] Figure 6B The second configuration Fig. 6A Example of valve status.

[0044] Fig. 7A is an example of another valve state for the first configuration.

[0045] Figure 7B The second configuration Fig. 7A Example of valve status.

[0046] Fig. 8A is an example of another valve state for the first configuration.

[0047] Figure 8B The second configuration Fig. 8A Example of valve status.

[0048] Fig.9A is an example of another valve state for the first configuration.

[0049] Fig. 9B The second configuration Fig.9A Example of valve status.

[0050] Fig. 10A is an example of another valve state for the first configuration.

[0051] Fig. 10B The second configuration Fig. 10A Example of valve status.

[0052] Fig.11A is an example of another valve state for the first configuration.

[0053] Fig. 11B The second configuration Fig.11A Example of valve status.

[0054] Fig. 12Ais an example of another valve state for the first configuration.

[0055] Fig. 12B The second configuration Fig. 12A Example of valve status.

[0056] Fig.13A is an example of another valve state for the first configuration.

[0057] Fig. 13B The second configuration Fig.13A Example of valve status.

[0058] Fig.14A is an example of another valve state for the first configuration. Fig. 14B The second configuration Fig.14A Example of valve status. DETAILED DESCRIPTION

[0059] The present disclosure details a hydraulic architecture for a thermal management system for an electrified vehicle, and more particularly relates to a hydraulic architecture in which all heat exchange is performed through a coolant.

[0060] Figure 1 An electrified vehicle 10 is schematically shown. The vehicle 10 may include a hybrid electric vehicle (HEV), a plug-in hybrid electric vehicle (PHEV), a battery electric vehicle (BEV), etc. In one example, the battery pack 12 is located under the floor of the vehicle; however, the battery pack 12 may be at other locations within the vehicle. In one example, the battery pack 12 is a high-voltage traction battery including a plurality of battery arrays (i.e., a battery assembly or group of battery cells) that is capable of outputting power to the electrical loads of the electric vehicle 10 to propel the wheels as needed and to operate the vehicle operating system.

[0061] In one example, the cabin cooler core 14 and the heater core 16 are located in a vehicle HVAC module 18. The vehicle 10 may also have a second cooler core and heater core located in the rear of the cabin 20 as a secondary climate control system. In one example, the power electronics 22 are located under the hood 24 of the vehicle. The power electronics 22 include components such as a charger, DC / DC converter, ISC, drive motor, water-cooled transmission cooler, onboard generator, PTC heater, etc. In one example, a refrigeration system 26 is also located under the hood 24. In one disclosed example, the system 26 includes a single tank refrigerant system 28 ( Figure 3 ) or double tank refrigerant system 30( Figure 4). In one example, the single tank refrigerant system 28 includes an electric compressor, two cryocoolers (refrigerant to coolant heat exchangers) that absorb heat from the coolant into the refrigerant, a water-cooled condenser (refrigerant to coolant heat exchanger) that rejects heat from the refrigerant to the coolant, and various refrigerant valves and temperature / pressure sensors. In one example, the dual tank refrigerant system 30 includes the same components as the single tank refrigerant system 28, but may include only one cryocooler and one WCC, and may have unique capacities and efficiencies from the single tank refrigerant system 28. These will be discussed in more detail below. In one example, the vehicle 10 additionally includes cooling system major components such as pumps, valves, low temperature radiators (LTRs) with or without bypass valves, temperature sensors, low temperature radiators, radiator fans, hoses, etc.

[0062] Figure 2 An example of a thermal management system 32 is shown, which includes a coolant system 34 and a refrigerant system 36 that interact with the power electronics 22, the battery 12, the cabin 20, and a coolant-based LTR 38 that is exhausted and drawn from the environment 40. In one disclosed configuration, the refrigerant system 36 interacts only with a coolant (e.g., ethylene glycol) so that all cabin heat exchange is through the coolant and all refrigerant heat exchange is through the coolant. This allows each system to transfer heat to wherever it is needed. It also allows a heat pump to absorb heat from the atmosphere to warm up the cabin 20 and / or the battery 12.

[0063] The present disclosure provides various hydraulic modes to support vehicle functions using a compact refrigerant system (RTMS) where heat is transferred to and from the system only via coolant. In one example, the BEV cooling architecture and hydraulic modes utilize coolant as the working medium to transfer heat to and from components for power electronics 22, battery 12, and cabin 20 heating and cooling through one or more valves.

[0064] BEV architectures typically employ complex refrigerants and complex coolant systems to transfer heat to and from electrified components and to and from the cabin 20. To reduce the number of components, increase efficiency, and improve heat transfer functionality within the vehicle 10, the present disclosure provides a unique hydraulic architecture. The subject system reduces the components, complexity, expense, and mass of the refrigerant system. The subject thermal management system performs all required heat exchange between the electrified components and the cabin, transferring heat to and from a simplified refrigerant system as needed. In one example, the system uses an indirect coolant heat exchanger to the refrigerant system, and direct heat exchangers with vehicle components, the cabin, and the environment.

[0065] In one disclosed example, the system has a series of initial modes required for heat transfer between components and subsystems. The system can then switch between the various modes to achieve the desired heating / cooling functions as needed. Benefits of the system include a significantly simplified refrigerant system that is filled just before final vehicle assembly, thus reducing cycle time, rework, and tooling requirements at the final assembly plant. Additional benefits include reduced part count, modularity across vehicles, and better facilitation of the vehicle's thermal response under various conditions.

[0066] In one example, the disclosed architecture allows the use of one refrigerant system or two refrigerant systems working together (e.g., a single tank refrigerant system 28 or a dual tank refrigerant system 30) to increase the functional capacity of the thermal system. The refrigerant system can be selected based on the efficiency and load of the two refrigerant tanks to independently transfer heat to each other or to various systems / components. Each refrigerant tank can receive a different heat load. The mode disclosed herein describes how the hydraulic system can utilize each refrigerant tank efficiency based on its heat load. In a vehicle with a single refrigerant tank system 28, the same valves as in a dual tank refrigerant system 30 can be used, which allows commonality of hardware and functionality.

[0067] As discussed above, the coolant serves as the sole heat transfer mechanism across vehicle components. In electrified vehicles, heat captured from various components is utilized within the refrigerant system to take advantage of the coefficient of performance (COP) of the refrigerant system, thereby reducing heat generation requirements from components with lower COPs, thereby improving vehicle range.

[0068] Figure 3 An example of a single tank refrigerant system 28 is shown. In this example, the system includes valves including a valve body V associated with a first cryocooler 1a and a second cryocooler 1b, a heater core 42, a PTC heater 44, power electronics 22, a water cooled condenser (WCC) 46, and a cooler core 48. The valve body V of the system is also associated with one or more pumps 50 having associated motors 52. Figure 3 In the example shown, there are four pumps 50a to 50d and a motor 52. The valve body V of the system is also associated with a battery charging port 54 as well as a low temperature radiator 56 and a bypass. Figure 4 An example of a dual tank refrigerant system 30 is shown. This example includes the same components as the single tank refrigerant system 28, but additionally includes an additional cryocooler 2a associated with a valve body V and a second WCC 58.

[0069] In one example, the power electronics 22 has a maximum inlet temperature of 70 degrees Celsius for most components (such as chargers, DC / DC converters, ISCs, oil coolers, etc.). In one example, the battery pack 12 has a maximum inlet temperature of 40 degrees Celsius to 50 degrees Celsius and includes batteries and other electrified components that may require cooling, such as, for example, AV computers. In one example, the WCC 46, 58 includes a heat exchanger that transfers heat to and from the refrigerant system 36 and the coolant. In one example, the deep freezer 1a, 1b, 2a includes a heat exchanger that transfers heat to and from the refrigerant system 36 and the coolant. In one example, the LTR 56 includes a heat exchanger that transfers heat to and from the coolant and ambient air 40. In one example, the cooler core 48 includes a heat exchanger that absorbs heat from the cabin 20 and transfers it to the coolant. In one example, the heater core 42 includes a heat exchanger that rejects heat.

[0070] The valve body V is subjected to a plurality of different states of use. In one example, these valve states include at least:

[0071] State A: Filling, degassing

[0072] State B: DCFC - Direct Current Fast Charging - (all deep coolers are used for batteries)

[0073] State C: Independent cabin and battery cooling

[0074] State Q: Cabin and battery cooling (RTMS-swap)

[0075] State N: AC rapid cooling (all deep coolers are used in the cabin)

[0076] State D: Cabin cooling, battery passive cooling

[0077] State E: Dehumidification / heat recovery from PE and batteries

[0078] State H: Stationary battery heating

[0079] State P: Independent cabin and battery heating.

[0080] The mode definition determines the components and systems required to transfer heat over various vehicle drive cycles at various ambient temperatures.

[0081] In one example, the thermal management system 32 has three main "clients", including the battery 12, the power electronics 22, and the cabin 20. These clients experience various states, including, for example, a fill / maintenance state, a hot state, a cold state, and a wet state. The system is also subject to various environmental conditions, such as hot, cold, and mild, for example. FIG. 5 is a table showing various architectures for each configuration for different modes, states, and environmental conditions. The table shows all of the above modes and defines the ambient temperature at which the components transfer heat.

[0082] In one example, the valves of the thermal management system 32 include unique valves used in each system 28 , 30 such that a single valve body V can accomplish different operating functions for each valve state.

[0083] Valve V is controlled by system controller C( Figure 3 to Figure 4 ) control to control the flow through the plurality of ports, as will be described below. The controller C receives data from various sensors S, which may include, for example, temperature sensors, speed sensors, flow sensors, etc. The system controller C analyzes the sensor data and controls the valve V in response to various vehicle operating conditions, as will be explained below.

[0084] The controller C may include a processor, a memory, and one or more input and / or output (I / O) device interfaces communicatively coupled via a local interface (including, for example, one or more buses and / or other wired or wireless connections). The controller C may be a hardware device for executing software, and may be a custom or commercially available processor, a central processing unit, an auxiliary processor in a plurality of processors associated with a computing device, or any device generally used to execute software instructions. The software in the memory may include one or more separate programs, each of which includes an ordered list of executable instructions for implementing logical functions. The controller C may be configured to execute software stored in the memory to communicate data to and from the memory, and generally control the operation of the computing device according to the software. The software in the memory is read in whole or in part by the processor, may be buffered within the processor, and then executed.

[0085] FIG. 6A to FIG. 6B An example of valve state A is shown. This state includes a mode for cooling system filling at an assembly plant and for a coolant filling service procedure. This mode can also be used as a limp home mode for the vehicle, allowing cooling of both the power electronics 22 and the battery 12 via the low temperature radiator.

[0086] As in Fig. 6AAs shown in the single tank refrigerant system 28 of FIG. 1 , the power electronics (PE) 22 has an inlet from a pump 50d and an outlet to port P3, which is connected to port P18 and feeds into the cryocooler 1b. The cryocooler 1b has an outlet into port P19, which is connected to port P14 and enters the battery 12 and the charging port 54. The outlet of the battery 12 is fed into and passes through the pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to the LTR 56 via port P2. The LTR 56 discharges to the environment 40. The WCC 46 is in a flow-only condition (no heat), and the outlet from the WCC 46 enters port P7 and is connected to port P9, which feeds the PTC 44 and the heater core 42. The outlet from the heater core 42 enters port E and is sent into and passes through the pump 50c via ports PF and P10. Port P10 is connected to port P2, which then directs the flow to the LTR 56 and out to the environment 40. Cooler core 48 has an outlet to port PG, which is connected to pump 50a via port PH. The output from pump 50a is directed into port P13, which is connected to port P20 to enter cryocooler 1a. The outlet from cryocooler 1a enters port P21 and is connected to LTR 56 via port P2, and LTR 56 exhausts to the environment. Therefore, in this mode: heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and battery 12; heat from LTR 56 goes to the environment; WCC 46 is flow-only (no heat); and cryocoolers 1a, 1b are both flow-only (no heat).

[0087] As in Figure 6BAs shown in the dual tank refrigerant system 30 of FIG. 5 , PE 22 has an inlet from pump 50d, an outlet to port P3, which is connected to port P18 and feeds into cryocooler 2a. Cryocooler 2a has an outlet into port P19, which is connected to port P14 and enters battery 12 / charging port 54. The outlet of battery 12 is fed into and through pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to LTR 56 via port P2. LTR 56 discharges to ambient 40. WCC 46, 58 are in a flow-only condition (no heat), and the outlets from WCC 46, 58 enter port P7 and are connected to port P9, which feeds PTC 44 and heater core 42. The outlet from heater core 42 enters port E and is sent into and through pump 50 via ports PF and P10. Port P10 is connected to port P2, which then directs flow to LTR 56 and out to the environment 40. The cooler core 48 has an outlet to port PG, which is connected to pump 50a via port PH. The output from pump 50a is directed into port P13, which is connected to port P20 to enter cryocoolers 1a, 1b. The outlet from cryocoolers 1a, 1b enters port P21 and connects to LTR 56 via port P2, and LTR 56 exhausts to the environment. Therefore, in this mode: heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and battery 12; heat from LTR 56 goes to the environment; WCC 46, 58 are flow-only (no heat); and cryocoolers 1a, 1b, 2a are all flow-only (no heat).

[0088] FIG. 7A to FIG. 7B An example of valve state B is shown. This state includes a mode for battery DC fast charging when there is no heating or cooling request for the cabin 20. This mode allows two cryocoolers 1a, 1b for a single tank system 28 and three cryocoolers 1a, 1b, 2a for a dual tank system 30 to cool the battery 12 via the refrigerant system. Valve state B is suitable for ambient conditions that are considered hot, such as 30 degrees Celsius +.

[0089] like Fig. 7AAs shown in the single tank refrigerant system 28 of FIG. 4 , the outlet from the battery 12 / charging port 54 is fed via ports PC, PD, P15 and passes through the pump 50b, respectively. Port P15 is connected to port P20, which feeds the cryocooler 1a, and the outlet from the cryocooler 1a is connected to port P21, which feeds port P14. Port P14 feeds the battery 12 / charging port 54. The outlet from the WCC 46 is connected to port P7, which is connected to port P2, which feeds the LTR 56. The outlet from the LTR 56 is connected to port P1, which enters and passes through the pump 50d via ports PA and PB. Port PB is connected to port P8, which feeds the WCC 46. The PE 22 has an inlet from the pump 50d, and the outlet from the PE 22 is connected to port P3, which is connected to port P2, which feeds the LTR 56. There is zero flow through the heater core / PTC 42, 44, and zero flow through the cooler core 48. Thus, in this mode (DCFC without cabin cooling): heat from the PE 22 goes to the LTR 56; the LTR 56 takes heat from the PE 22 and the WCC 46; heat from the LTR 56 goes to the ambient 40; heat from the WCC 46 goes to the LTR 56; and the cryocoolers 1a, 1b take heat from the battery 12.

[0090] like Figure 7BAs shown in the dual tank refrigerant system 30 of FIG. 3 , the outlet from the battery 12 / charging port 54 is fed into and through the pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to port P20, which feeds the cryocoolers 1a, 1b, and the outlets from the cryocoolers 1a, 1b are connected to port P21, which feeds port P14. Port P14 feeds the battery 12 / charging port 54. The outlets from the WCC 46, 58 are connected to port P7, which is connected to port P2, which feeds the LTR 56. The outlet from the LTR 56 is connected to port P1, which enters and passes through the pump 50d via ports PA and PB. Port PB is connected to port P8, which feeds the WCC 46, 58. PE 22 has an inlet from the pump 50d, and the outlet from PE 22 is connected to port P3, which is connected to port P2, which feeds the LTR 56. There is zero flow through the heater core / PTC 42, 44, and zero flow through the cooler core 48. Thus, in this mode (DCFC without cabin cooling): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46, 58; heat from LTR 56 goes to ambient 40; heat from WCC 46, 58 goes to LTR 56; and cryocoolers 1a, 1b, 2a take heat from battery 12.

[0091] FIG. 8A to FIG. 8B An example of valve state C is shown. This state includes a mode for cabin and battery cooling. For a dual tank system 30, this mode allows the use of two deep coolers to cool the cabin 20, and allows the use of one deep cooler to cool the battery 12. Valve state C is suitable for ambient conditions that are considered hot, such as 30 degrees Celsius +.

[0092] like Fig. 8AAs shown in the single tank refrigerant system 28 of FIG. 4 , the outlet from the battery 12 / charging port 54 is fed via ports PC, PD, P15 and through pump 50b, respectively. Port P15 is connected to port P18, which feeds into cryocooler 1b, which is connected to port P19, which feeds back into the battery inlet port P14. The outlet of PE 22 is connected to port P3, which feeds into LTR 56 via port P2. The outlet from LTR 56 is connected to port P1, which feeds into port PA and PB and through pump 50d. Port PB is connected to port P8, which feeds into WCC 46. The outlet from WCC 46 is connected to port P7, which feeds into LTR 56 via port P2. The outlet from the cooler core 48 is connected to port PG, which feeds into port PH and P13 and through pump 50a. Port P13 feeds into port P20 which serves as the inlet to cryocooler 1a. The outlet from cryocooler 1a is connected to port P21 which is connected to port P12 which feeds back into cooler core 48. The inlet of PE22 is associated with pump 50d. There is no flow through heater core 42 / PTC 44. Thus, in this mode (cabin and battery cooling): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46; heat from LTR 56 goes to ambient 40; heat from WCC 46 goes to LTR 56; cryocooler 1a takes heat from cooler core 48; and cryocooler 1b takes heat from battery 12.

[0093] like Figure 8BAs shown in the dual tank refrigerant system 30 of FIG. 3 , the outlet from the battery 12 / charging port 54 is fed via ports PC, PD, P15 and through pump 50b, respectively. Port P15 is connected to port P18, which feeds into the cryocooler 2a, which is connected to port P19, which feeds back into the battery inlet port P14. The outlet of PE 22 is connected to port P3, which feeds into LTR 56 via port P2. The outlet from LTR 56 is connected to port P1, which feeds into port PA and PB and through pump 50d. Port PB is connected to port P8, which feeds into WCC 46, 58. The outlet from WCC 46, 58 is connected to port P7, which feeds into LTR 56 via port P2. The outlet from the cooler core 48 is connected to port PG, which feeds into port PH and P13 and through pump 50a. Port P13 feeds into port P20 which serves as the inlet to cryocoolers 1a, 1b. The outlets from cryocoolers 1a, 1b are connected to port P21 which is connected to port P12 which feeds back into cooler core 48. The inlet to PE 22 is associated with pump 50d. There is no flow through heater core 42 / PTC 44. Thus, in this mode (cabin and battery cooling): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46; heat from LTR 56 goes to ambient 40; heat from WCC 46, 58 goes to LTR 56; cryocooler 2a takes heat from cooler core 48; and cryocoolers 1a, 1b take heat from battery 12.

[0094] FIG. 9A to FIG. 9B An example of valve state N is shown. This state includes a mode where all cryocoolers are used to cool the cabin 20. For a single tank system 28, two cryocoolers are used to cool the cabin 20. For a dual tank system 30, three cryocoolers are used to cool the cabin 20. Valve state N is suitable for ambient conditions that are considered hot, such as 30 degrees Celsius+.

[0095] like Fig.9AAs shown in the single tank refrigerant system 28 of FIG. 4 , the outlet from the chiller core 48 is connected to port PG, which feeds into and passes through pump 50a via ports PH and P13. Port P13 feeds into ports P18 and P20, which feed into chillers 1a and 1b. The outlets from chillers 1a and 1b are fed into ports P21 and P19, respectively, which are combined and connected to port P12, which serves as an inlet into the chiller core 48. The inlet of PE 22 is associated with pump 50d. The outlet of PE 22 is connected to port P3, which feeds into LTR 56 via port P2. The outlet from LTR 56 is connected to port P1, which feeds into and passes through pump 50d via ports PA and PB. Port PB is connected to port P8, which feeds into WCC 46. The outlet from WCC46 is connected to port P7, which feeds into LTR 56 via port P2. The outlet from battery 12 / charging port 54 is fed via ports PC, PD, P15 respectively and through pump 50b. Port P15 is connected to port P14, which feeds back into battery 12 / charging port 54. There is no flow through heater core 42 / PTC 44. There is a recirculating flow via battery 12 / charging port 54. Therefore, in this mode (AC fast cool down, recirculating battery): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46; heat from LTR 56 goes to ambient; heat from WCC 46 goes to LTR 56; cryocooler 1a takes heat from cooler core 48; and cryocooler 1b takes heat from cooler core 48.

[0096] like Fig. 9BAs shown in the dual tank refrigerant system 30, the outlet from the chiller core 48 is connected to port PG, which feeds into and through pump 50a via ports PH and P13. Port P13 feeds port P18, which feeds cryocooler 2a. Port 13 is also connected to port P20, which feeds chillers 1a and 1b. The outlet from cryocooler 2a feeds port P19, which is connected to port P12, which serves as an inlet into the chiller core 48. The outlets from chillers 1a and 1b feed port P21, which is combined with the feed from cryocooler 2a and connected to port P12, which serves as an inlet into the chiller core 48. The inlet of PE 22 is associated with pump 50d. The outlet of PE 22 is connected to port P3, which feeds LTR 56 via port P2. The outlet from LTR 56 is connected to port P1 which feeds into pump 50d via ports PA and PB. Port PB is connected to port P8 which feeds into WCC 46. The outlet from WCC 46 is connected to port P7 which feeds into LTR 56 via port P2. The outlet from battery 12 / charging port 54 is fed into pump 50b via ports PC, PD, P15 respectively. Port P15 is connected to port P14 which feeds back into battery 12 / charging port 54. There is no flow through heater core 42 / PTC 44. There is recirculation flow through battery 12 / charging port 54. Thus, in this mode (AC fast cool down, battery recirculation): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46; heat from LTR 56 goes to ambient; heat from WCC 46, 58 goes to LTR 56; and cryocoolers 1a, 1b, 2a take heat from cooler core 48.

[0097] FIG. 10A to FIG. 10B An example of valve state Q is shown. This state includes the same operating mode as mode C of the single tank system 28. For a dual tank system 30, this mode allows the use of two cryocoolers for battery cooling and one cryocooler for cooling the cabin 20. Valve state Q is suitable for ambient conditions that are considered hot, such as 30 degrees Celsius+.

[0098] like Fig. 10AAs shown in the single tank refrigerant system 28 of FIG. 4 , the outlet from the battery 12 / charging port 54 is fed via ports PC, PD, P15 and through pump 50b, respectively. Port P15 is connected to port P20, which feeds into the cryocooler 1a, which is connected to port P21, which feeds back into the battery inlet port P14. The inlet of PE 22 is associated with pump 50d. The outlet of PE22 is connected to port P3, which feeds into LTR 56 via port P2. The outlet from LTR 56 is connected to port P1, which feeds into and through pump 50d via ports PA and PB. Port PB is connected to port P8, which feeds into WCC 46. The outlet from WCC 46 is connected to port P7, which feeds into LTR 56 via port P2. The outlet from the cooler core 48 is connected to port PG, which feeds into and through pump 50a via ports PH and P13. Port P13 feeds into port P18, which serves as the inlet to cryocooler lb. The outlet from cryocooler lb connects to port P19, which connects to port P12, which feeds back into cooler core 48. There is no flow through heater core 42 / PTC 44. Thus, in this mode (cabin and battery cooling): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC 46; heat from LTR 56 goes to ambient 40; heat from WCC 46 goes to LTR 56; cryocooler 1a takes heat from battery 12; and cryocooler 1b takes heat from cooler core 48.

[0099] like Fig. 10BAs shown in the dual tank refrigerant system 30 of FIG. 3 , the outlet from the battery 12 / charging port 54 is fed into and through the pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to port P20, which feeds into the cryocoolers 1a, 1b, and the outlets from the cryocoolers 1a and 1b are connected to port P21, which feeds back into the battery inlet port P14. The inlet of PE 22 is associated with pump 50d. The outlet of PE 22 is connected to port P3, which feeds into LTR 56 via port P2. The outlet from LTR 56 is connected to port P1, which feeds into and through pump 50d via ports PA and PB. Port PB is connected to port P8, which feeds into WCC 46, 58. The outlets from WCC 46, 58 are connected to port P7, which feeds into LTR 56 via port P2. The outlet from the cooler core 48 is connected to port PG, which feeds via ports PH and P13 and passes through pump 50a. Port P13 feeds port P18, which serves as the inlet to the deep cooler 2a. The outlet from the deep cooler 2a is connected to port P19, which is connected to port P12, which feeds back to the cooler core 48. There is no flow through the heater core 42 / PTC 44. Therefore, in this mode (cabin and battery cooling): heat from PE 22 goes to LTR 56; LTR 56 takes heat from PE 22 and WCC46; heat from LTR 56 goes to ambient 40; heat from WCC 46, 58 goes to LTR 56; deep coolers 1a, 1b take heat from battery 12; and deep cooler 2a takes heat from cooler core 48.

[0100] FIG. 11A to FIG. 11B An example of a valve state D for active cabin cooling and passive battery cooling is shown. This state includes a mode in which the LTR 56 is used to cool the battery 12 and the power electronics 22. A cryocooler may also be used to cool the power electronics 22 and the battery 12. The cabin 20 may be cooled with a single cryocooler on a single tank system 28 or two cryocoolers on a dual tank system 30. Valve state D is suitable for ambient conditions that are considered mild, such as 15 to 30 degrees Celsius.

[0101] As in Fig.11AAs shown in the single tank refrigerant system 28 of FIG. 4 , the inlet of PE 22 is associated with pump 50 d, and the outlet of PE 22 feeds port P3, which is connected to port P18, which feeds cryocooler 1 b. The output from cryocooler 1 b feeds port P19, which is connected to inlet port P14 of battery 12 / charging port 54. The outlet from battery 12 / charging port 54 feeds into pump 50 b via ports PC, PD, and P15, respectively. Port P15 is connected to port P2, which feeds LTR 56. The outlet port P1 from LTR 56 is connected to port P1, which is fed into pump 50 d via ports PA and PB. Port PB is connected to port P8, which feeds WCC 46. The outlet from WCC 46 feeds port P7, which is connected to port P2 to feed LTR 56. The outlet from cooler core 48 feeds port PG, which feeds via ports PH and P13 and passes through pump 50a. Port P13 is connected to port P20, which feeds deep cooler 1a. The outlet from deep cooler 1a feeds port P21, which is connected to port P12, which feeds cooler core 48. There is no flow through heater core 42 / PTC44. Therefore, in this mode (active cabin cooling and passive battery cooling): heat from PE goes to LTR 56; LTR 56 takes heat from PE 22, battery 12 and WCC 46; heat from LTR 56 goes to ambient; heat from WCC 46 goes to LTR 56; deep cooler 1a takes heat from cooler core 48; and deep cooler 1b is flow-only or takes heat from battery 12.

[0102] As in Fig. 11BAs shown in the dual tank refrigerant system 30 of FIG. 3 , the inlet of PE 22 is associated with pump 50 d, and the outlet of PE 22 feeds port P3, which is connected to port P18, which feeds cryocooler 2 a. The output from cryocooler 2 a feeds port P19, which is connected to inlet port P14 of battery 12 / charging port 54. The outlet from battery 12 / charging port 54 feeds into pump 50 b via ports PC, PD, and P15, respectively. Port P15 is connected to port P2, which feeds LTR 56. LTR 56 is connected to port P1, which is fed into pump 50 d via ports PA and PB. Port PB is connected to port P8, which feeds WCC 46, 58. The outlet from WCC 46, 58 feeds port P7, which is connected to port P2 to feed LTR 56. The outlet from the cooler core 48 feeds port PG, which feeds via ports PH and P13 and passes through pump 50a. Port P13 is connected to port P20, which feeds deep coolers 1a, 1b. The outlet from deep coolers 1a, 1b feeds port P21, which is connected to port P12, which feeds cooler core 48. There is no flow through heater core 42 / PTC 44. Therefore, in this mode (active cabin cooling and passive battery cooling): heat from PE goes to LTR 56; LTR 56 takes heat from PE22, battery 12 and WCC 46; heat from LTR 56 goes to ambient; heat from WCC 46, 58 goes to LTR 56; deep coolers 1a, 1b take heat from cooler core 48; and deep cooler 2a is flow-only or takes heat from battery 12.

[0103] FIG. 12A to FIG. 12B An example of valve state E is shown. This state includes multiple modes. In one or more modes, the LTR 56 is used to cool the battery 12 and the power electronics 22. In one mode, the cryocooler can also be used to cool the power electronics 22 and the battery 12. Heat from the power electronics 22, the battery 12, and the LTR 56 can then be transferred from the cryocooler to the WCC via the refrigerant system to warm the cabin 20. The cabin 20 can be dehumidified by cooling with a single cryocooler on a single tank system 28 or two cryocoolers on a dual tank system 30. To compensate for cabin cooling, the cabin heater core 42 can be used simultaneously via heat from the WCC. Valve state E is applicable to two different sets of ambient conditions: (1) ambient conditions that are considered mild / humid, such as 0 to 20 degrees Celsius; or (2) ambient conditions that are cold, such as below 20 degrees Celsius.

[0104] As in Fig. 12AAs shown in the single tank refrigerant system 28 of FIG. 1 , the inlet of PE 22 is associated with pump 50d, and the outlet of PE 22 feeds port P3, which is connected to port P18, which feeds cryocooler 1b. The output from cryocooler 1b feeds port P19, which is connected to inlet port P14 of battery 12 / charging port 54. The outlet from battery 12 / charging port 54 feeds into pump 50b via ports PC, PD, and P15, respectively. Port P15 is connected to port P2, which feeds LTR 56. LTR 56 is connected to port P1, which is fed into pump 50d via port PA. Pump 50d then feeds the inlet of PE 22. The outlet from WCC 46 feeds into port P7, which is connected to port P9 to feed heater core 42 / PTC 44. The outlet of the cooler core 42 / PTC 44 feeds into port PE, which is fed via ports PF and P10 and passes through pump 50c. Port P10 is connected to port P8, which feeds into WCC 46. The outlet from the cooler core 48 feeds into port PG, which is fed via ports PH and P13 and passes through pump 50a. Port P13 is connected to port P20, which feeds into cryocooler 1a. The outlet from cryocooler 1a feeds into port P21, which is connected to port P12, which feeds into the cooler core 48.

[0105] In this valve state E, in one example, there are three different possible configurations for a single tank configuration. In the first configuration, there is dehumidification and battery cooling, so in this mode: heat from the PE goes to the LTR 56; the LTR 56 takes heat from the PE 22 and the battery 12; heat from the LTR 56 goes to the ambient; heat from the WCC 46 goes to the heater core 42; the cryocooler 1a takes heat from the cooler core 48; and the cryocooler 1b is flow-only or takes heat from the battery 12.

[0106] In the second configuration, there is dehumidification and battery heating using PE waste heat, so in this mode: heat from PE goes to battery 12; LTR 56 is in the "off" state (LTR bypass); heat from WCC 46 goes to heater core 42; cryocooler 1a takes heat from cooler core 48; and cryocooler 1b is flow only (no heat).

[0107] In the third configuration, there is cabin heating and battery cooling / energy recovery, so in this mode: heat from PE goes to battery 12 and deep cooler; LTR 56 is in the "off" state (LTR bypass); heat from WCC 46 goes to heater core 42; deep cooler 1a is flow only (no heat); and deep cooler 1b takes heat from battery 12.

[0108] As in Fig. 12B As shown in the dual tank refrigerant system 30 of FIG. 3 , the inlet of PE 22 is associated with pump 50 d, and the outlet of PE 22 feeds port P3, which is connected to port P18, which feeds cryocooler 2 a. The output from cryocooler 2 a feeds port P19, which is connected to inlet port P14 of battery 12 / charging port 54. The outlet from battery 12 / charging port 54 feeds into pump 50 b via ports PC, PD, and P15, respectively. Port P15 is connected to port P2, which feeds LTR 56. LTR 56 is connected to port P1, which is fed into pump 50 d via port PA. Pump 50 d then feeds the inlet of PE 22. The outlets from WCC 46, 58 feed into port P7, which is connected to port P9 to feed heater core 42 / PTC 44. The outlet of the cooler core 42 / PTC 44 feeds into port PE, which feeds into port PF and P10 and passes through pump 50c. Port P10 is connected to port P8, which feeds into WCC 46, 58. The outlet from the cooler core 48 feeds into port PG, which feeds into port PH and P13 and passes through pump 50a. Port P13 is connected to port P20, which feeds into cryocoolers 1a, 1b. The outlet from cryocoolers 1a, 1b feeds into port P21, which is connected to port P12, which feeds into the cooler core 48.

[0109] In this valve state E, in one example, there are three different possible configurations for a dual tank configuration. In the first configuration, there is dehumidification and battery cooling, so in this mode: heat from the PE goes to the LTR 56; the LTR 56 takes heat from the PE 22 and the battery 12; heat from the LTR 56 goes to the ambient; heat from the WCC 46, 58 goes to the heater core 42; cryocooler 1a takes heat from the cooler core 48; cryocooler 1b takes heat from the cooler core 48; and cryocooler 2a is flow-only or takes heat from the battery 12.

[0110] In the second configuration, there is dehumidification and battery heating using PE waste heat, so in this mode: heat from PE goes to battery 12; LTR 56 is in the "off" state (LTR bypass); heat from WCC 46, 58 goes to heater core 42; cryocoolers 1a, 1b take heat from cooler core 48; and cryocooler 2a is flowing (no heat).

[0111] In the third configuration, there is cabin heating and battery cooling / energy recovery, so in this mode: heat from PE goes to battery 12 and deep cooler; LTR 56 is in the "off" state (LTR bypass); heat from WCC 46, 58 goes to heater core 42; deep coolers 1a, 1b are flow-only (no heat); and deep cooler 2a takes heat from battery 12.

[0112] FIG. 13A to FIG. 13B An example of valve state H is shown. This state includes a mode for heating the battery 12 and possibly the cabin 20 if conditions are met. Heat can come directly from the PTC heater 44, or heat recovered from the ambient air 40 through the LTR 56 and power electronics waste heat can be transferred to the WCC 46 (single tank system 28) or two water-cooled condensers 46, 58 (dual tank system 30) through two cryocoolers in a single tank system 28 or three cryocoolers in a dual tank system 30, to the heater core 42 and battery 12. Heat from the heater core 42 can be limited from entering the cabin 20 by using the HVAC blower motor and blend door (not shown). Valve state H is suitable for ambient conditions that are considered cold, such as below 20 degrees Celsius.

[0113] like Fig.13AAs shown in the single tank refrigerant system 28 of FIG. 5 , ambient air 40 drawn from the LTR 56 is fed into port P1, which is fed into port PA and passes through pump 50d. The flow leaves pump 50d and enters the inlet of PE 22. The outlet from PE 22 is fed into port P3, which is connected to port P18, which is fed into cryocooler 1b. Cryocooler 1b is fed into port P19, which is connected to port P2, which serves as the inlet of LTR 56. Port P3 of PE 22 is also connected to port P20, which is fed into cryocooler 1a. Cryocooler 1a is fed into port P21, which is connected to port P2, which serves as the inlet of LTR 56. The outlet from the battery 12 / charging port 54 is fed into pump 50b via ports PC, PD, and P15, respectively. Port P15 is connected to port P8, which serves as the inlet of WCC 46. The outlet of WCC 46 feeds port P7, which is connected to port P9, which serves as the inlet to heater core 42 / PTC 44. The outlet from cooler core 42 / PTC 44 feeds port PE, which is fed via ports PF and P10 and passes through pump 50c. Port P10 is connected to port P14, which serves as the inlet to battery 12. There is no flow through cooler core 48. Therefore, in this mode (cabin and battery heating via heat pump): heat from PE22 goes to deep coolers 1a, 1b, and LTR 56; LTR 56 takes heat from the environment; heat from LTR 56 goes to PE22 and deep coolers 1a, 1b; heat from WCC 46 goes to heater core 42 and battery 12; and deep coolers 1a, 1b take heat from LTR56 and PE 22.

[0114] like Fig. 13BAs shown in the dual tank refrigerant system 30 of FIG. 5 , ambient air 40 drawn from LTR 56 is fed into port P1, which is fed into and passes through pump 50d via port PA. The flow leaves pump 50d and enters the inlet of PE 22. The outlet from PE 22 is fed into port P3, which is connected to port P18, which is fed into cryocooler 2a. Cryocooler 2a is fed into port P19, which is connected to port P2, which serves as the inlet of LTR 56. Port P3 of PE 22 is also connected to port P20, which is fed into cryocoolers 1a, 1b. Cryocoolers 1a, 1b are fed into port P21, which is connected to port P2, which serves as the inlet of LTR 56. The outlet from battery 12 / charging port 54 is fed into and passes through pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to port P8, which serves as the inlet to WCC 46, 58. The outlet of WCC 46, 58 feeds port P7, which is connected to port P9, which serves as the inlet to heater core 42 / PTC 44. The outlet from cooler core 42 / PTC 44 feeds port PE, which feeds via ports PF and P10 and passes through pump 50c. Port P10 is connected to port P14, which serves as the inlet to battery 12. There is no flow through cooler core 48. Thus, in this mode (cabin and battery heating via heat pump): heat from PE 22 goes to deep coolers 1a, 1b and LTR 56; LTR 56 takes heat from the environment; heat from LTR 56 goes to PE 22 and deep coolers 1a, 1b; heat from WCC 46, 58 goes to heater core 42 and battery 12; and deep coolers 1a, 1b, 2a take heat from LTR 56 and PE 22.

[0115] FIG. 14A to FIG. 14B An example of valve state P is shown. This state includes modes for heating the battery 12 and heating the cabin 20. Heat from the power electronics can be used directly to heat the battery 12. The cryocooler uses heat from the environment through the LTR 56 to warm the cabin. Heat recovered from the ambient air 40 through the LTR 56 can be transferred to the WCC (single tank system 28) or two water-cooled condensers (dual tank system 30) to the heater core 42 through two cryocoolers in a single tank system 28 or three cryocoolers in a dual tank system 30. Valve state P is applicable to ambient conditions that are considered cold, such as below 20 degrees Celsius.

[0116] like Fig.14AAs shown in the single tank refrigerant system 28 of FIG. 5 , the outlet from the battery 12 / charging port 54 is fed into and through the pump 50b via ports PC, PD, P15, respectively. Port P15 is connected to port PA, which serves as the inlet of 50d. Pump 50d feeds the inlet of PE 22, which feeds port P3, which is connected to port P14, which serves as the inlet of the battery 12. Ambient air 40 is drawn through LTR 56 and fed into pump 50a via port PH. The flow leaves pump 50a via port P13, which is connected to ports P18 and P20. These ports P18, P20 feed cryocoolers 1b and 1a, respectively, and the outputs from these cryocoolers 1b, 1a are fed into ports P19 and P21, respectively, which are connected to port P2, which serves as the inlet of LTR 56. The outlet from the WCC feeds port P7, which is connected to port P9, which serves as the inlet into the PTC 44 and then into the heater core 42. The outlet from the heater core 42 feeds port PE and then feeds into and through pump 50c via ports PF and P10. Port P10 is connected to port P8, which serves as the inlet to the WCC 46. There is no flow through the cooler core 48. Therefore, in this mode (cabin heating via heat pump, battery heating using PE waste heat or electric drive torque losses): heat from PE 22 goes to battery 12; LTR 56 takes heat from the environment; heat from LTR 56 goes to deep coolers 1a, 1b; heat from WCC 46 goes to heater core 42; and deep coolers 1a, 1b take heat from LTR 56.

[0117] like Fig. 14BAs shown in the dual tank refrigerant system 30, the outlet from the battery 12 / charging port 54 is fed into and through the pump 50b via ports PC, PD, P15 respectively. Port P15 is connected to port PA, which serves as the inlet of 50d. Pump 50d feeds the inlet of PE 22, which feeds port P3, which is connected to port P14, which serves as the inlet of the battery 12. Ambient air 40 is drawn through LTR 56 and fed into pump 50a via port PH. The flow leaves pump 50a via port P13 connected to ports P18 and P20. Port P18 feeds cryocooler 2A. Port P20 feeds cryocoolers 1a, 1b. The outputs from these cryocoolers are fed into ports P19 and P21, which are connected to port P2, which serves as the inlet of LTR 56. The outlet from the WCC 46, 58 feeds port P7, which is connected to port P9, which serves as the inlet into the PTC 44 and then into the heater core 42. The outlet from the heater core 42 feeds port PE and then feeds into and through pump 50c via ports PF and P10. Port P10 is connected to port P8, which serves as the inlet to the WCC 46. There is no flow through the cooler core 48. Therefore, in this mode (cabin heating via heat pump, battery heating using PE waste heat or electric drive torque loss): heat from PE 22 goes to battery 12; LTR 56 takes heat from the environment; heat from LTR 56 goes to deep coolers 1a, 1b; heat from WCC 46, 58 goes to heater core 42; and deep coolers 1a, 1b, 2a take heat from LTR 56.

[0118] Although different non-limiting embodiments are shown as having specific components or steps, the embodiments of the present disclosure are not limited to these specific combinations. Some components or features from any one of the non-limiting embodiments may be used in combination with features or components from any one of the other non-limiting embodiments.

[0119] It should be understood that like reference numerals designate corresponding or similar elements throughout the several drawings.It should be understood that although particular component arrangements are disclosed and shown in these exemplary embodiments, other arrangements may benefit from the teachings of the present disclosure.

[0120] The above description should be interpreted as illustrative and not in any limiting sense. It will be appreciated by those skilled in the art that certain modifications may occur within the scope of the present disclosure. For these reasons, the attached claims should be studied to determine the true scope and content of the present disclosure.

[0121] According to the present invention, a system is provided, which has: a coolant system, which is connected to the power electronic device, the battery pack and the vehicle cabin fluid; and a refrigerant system, which interacts only with the coolant from the coolant system, and wherein all vehicle cabin heat exchange and all refrigerant heat exchange are performed through the coolant.

[0122] According to an embodiment, the present invention is also characterized by a valve associated with a first configuration or a second configuration, and wherein: in the first configuration, the valve is fluidly connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryogenic freezer and a second cryogenic freezer, at least one water-cooled condenser and a low-temperature radiator; and in the second configuration, the valve is fluidly connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryogenic freezer, a second cryogenic freezer and a third cryogenic freezer, at least a first water-cooled condenser and a second water-cooled condenser and a low-temperature radiator.

[0123] According to an embodiment, the valve comprises the only valve used in both the first configuration and the second configuration.

[0124] According to an embodiment, the valve operates in a plurality of different valve states, and the system includes a controller that controls the valve based on input from a plurality of sensors to manage heat transfer for the plurality of different valve states.

[0125] According to an embodiment, one of the plurality of different valve states includes a DC fast charging mode when there is no request for heating or cooling of the vehicle cabin, and wherein: when in the first configuration, the first cryogenic cooler and the second cryogenic cooler are used to cool the battery pack via the refrigerant system, and when in the second configuration, the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler are used to cool the battery pack via the refrigerant system.

[0126] According to an embodiment, one of the multiple different valve states includes cabin cooling and battery cooling modes, and wherein: when in the first configuration, one of the first cryogenic freezer and the second cryogenic freezer is used to cool the battery pack and the other of the first cryogenic freezer and the second cryogenic freezer is used to cool the cabin via the cooler core; and when in the second configuration, two of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer are used to cool the cabin via the cooler core, and the remaining cryogenic freezer of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer is used to cool the battery pack.

[0127] According to an embodiment, one of the multiple different valve states includes cabin cooling and battery cooling modes, and wherein: when in the first configuration, one of the first cryogenic freezer and the second cryogenic freezer is used to cool the battery pack and the other of the first cryogenic freezer and the second cryogenic freezer is used to cool the cabin via the cooler core; and when in the second configuration, two of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer are used to cool the battery pack, and the remaining cryogenic freezer of the first cryogenic freezer, the second cryogenic freezer and the third cryogenic freezer cools the cabin via the cooler core.

[0128] According to an embodiment, one of the multiple different valve states includes cabin cooling and battery recirculation modes, and wherein: when in the first configuration, the first cryogenic cooler and the second cryogenic cooler are used to cool the cabin via the cooler core; and when in the second configuration, the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler are used to cool the cabin via the cooler core.

[0129] According to an embodiment, one of the multiple different valve states includes active cabin cooling and passive battery cooling modes, and wherein: when in the first configuration, the low-temperature radiator is used to cool the battery pack and the power electronic devices, one of the first deep freezer and the second deep freezer is used to cool the power electronic devices and the battery pack, and the other of the first deep freezer and the second deep freezer is used to cool the cabin; and when in the second configuration, the low-temperature radiator is used to cool the battery pack and the power electronic devices, two of the first deep freezer, the second deep freezer and the third deep freezer are used to cool the cabin via the cooler core, and the remaining deep freezer of the first deep freezer, the second deep freezer and the third deep freezer is used to cool the power electronic devices and the battery pack.

[0130] According to an embodiment, one of the plurality of different valve states includes dehumidification and battery heating / cooling or cabin heating and battery cooling, and wherein: when in the first configuration, the low-temperature radiator is used to cool the battery and the power electronics, one of the first deep freezer and the second deep freezer is used to cool the power electronics and the battery, heat from the power electronics, the battery and the low-temperature radiator is transferred from at least one of the first deep freezer and the second deep freezer to the water-cooled condenser through the refrigerant system to warm the cabin when necessary, dehumidify the cabin by cooling it by one of the first deep freezer and the second deep freezer when necessary, and simultaneously cool the cabin via the heat from the water-cooled condenser when necessary The heater core is used to compensate for cabin cooling; and when in the second configuration, the low-temperature radiator is used to cool the battery and the power electronics, one of the first deep freezer and the second deep freezer is used to cool the power electronics and the battery, and heat from the power electronics, the battery and the low-temperature radiator is transferred from at least one of the first deep freezer and the second deep freezer to the water-cooled condenser through the refrigerant system to warm the cabin when necessary, dehumidify the cabin when necessary by cooling by two of the first deep freezer, the second deep freezer and the third deep freezer, and the heater core is used simultaneously to compensate for cabin cooling via heat from the water-cooled condenser when necessary.

[0131] According to an embodiment, one of the multiple different valve states includes at least a battery heating and a cabin heating mode when predetermined conditions are met, and wherein: when in the first configuration, heat is transferred directly from the PTC heater to the battery, or heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronics is transferred to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then transferred to the heater core and the battery; and when in the second configuration, heat is transferred directly from the PTC heater, or heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronics is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then transferred to the heater core and the battery.

[0132] According to an embodiment, one of the multiple different valve states includes a cabin and battery heating mode, and wherein: when in the first configuration, heat from the power electronic circuit directly heats the battery, and heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronic device is transferred to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then transferred to the heater core; and when in the second configuration, heat from the power electronic circuit directly heats the battery, and heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronic device is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then transferred to the heater core.

[0133] According to an embodiment, the present invention is also characterized by multiple pumps, which include at least a first pump positioned immediately downstream of the battery, a second pump positioned immediately downstream of the heater core, a third pump positioned immediately downstream of the low-temperature radiator, and a fourth pump positioned immediately downstream of the cooler core.

[0134] According to the present invention, a method: providing a coolant system, the coolant system is in fluid communication with power electronics, a battery pack and a vehicle cabin; providing a refrigeration system, the refrigeration system interacting only with coolant from the coolant system; performing all vehicle cabin heat exchanges through the coolant; and performing all refrigerant heat exchanges through the coolant.

[0135] In one aspect of the present invention, the method includes associating a valve with a first configuration or a second configuration, and the method also includes: in the first configuration, the valve is connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryogenic freezer and a second cryogenic freezer, at least one water-cooled condenser and a low-temperature radiator fluid; and in the second configuration, the valve is connected to the battery pack, the power electronic device, the cooler core, the heater core, at least a first cryogenic freezer, a second cryogenic freezer and a third cryogenic freezer, at least a first water-cooled condenser and a second water-cooled condenser and a low-temperature radiator fluid.

[0136] In one aspect of the invention, the valve comprises a sole valve used in both the first configuration and the second configuration.

[0137] In one aspect of the invention, the method includes positioning at least a first pump immediately downstream of a battery, a second pump immediately downstream of the heater core, a third pump immediately downstream of the low-temperature radiator, and a fourth pump immediately downstream of the cooler core.

[0138] In one aspect of the invention, the valve operates in a plurality of different valve states, and the method includes controlling the valve based on input from a plurality of sensors to manage heat transfer for the plurality of different valve states.

[0139] In one aspect of the present invention, one of the multiple different valve states includes at least a battery heating and cabin heating mode when predetermined conditions are met, and the method includes: when in the first configuration, transferring heat directly from the PTC heater to the battery, or transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of power electronic devices to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then to the heater core and the battery; and when in the second configuration, transferring heat directly from the PTC heater to the battery, or transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of power electronic devices to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then to the heater core and the battery.

[0140] In another non-limiting embodiment of any of the foregoing methods, one of the multiple different valve states includes a cabin and battery heating mode, and the method includes: when in the first configuration, using heat from the power electronic circuit to directly heat the battery, and transferring heat recovered from the ambient air through the low radiator and waste heat of the power electronic device to the at least one water-cooled condenser through the first cryogenic cooler and the second cryogenic cooler, and then to the heater core; and when in the second configuration, using heat from the power electronic circuit to directly heat the battery, and transferring heat recovered from the ambient air through the low-temperature radiator and waste heat of the power electronic device to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler and the third cryogenic cooler, and then to the heater core.

Claims

1. A system comprising: a coolant system in fluid communication with the power electronics, the battery pack, and the vehicle cabin; as well as A refrigerant system that interacts only with coolant from the coolant system and in which all cabin heat exchange and all refrigerant heat exchange occurs through the coolant.

2. The system of claim 1 , comprising a valve associated with the first configuration or the second configuration, and wherein: In the first configuration, the valve is in fluid communication with the battery pack, the power electronics, a cooler core, a heater core, at least a first cryocooler and a second cryocooler, at least one water-cooled condenser, and a low temperature radiator; and In the second configuration, the valve is in fluid communication with the battery pack, the power electronics, a cooler core, a heater core, at least first, second and third cryocoolers, at least first and second water-cooled condensers, and a low temperature radiator.

3. The system of claim 2, wherein the valve comprises a unique valve used in both the first configuration and the second configuration.

4. The system of claim 2, wherein the valve operates in a plurality of different valve states, and the system includes a controller that controls the valve based on input from a plurality of sensors to manage heat transfer for the plurality of different valve states.

5. The system of claim 4, wherein one of the plurality of different valve states comprises a DC fast charge mode when there is no request for heating or cooling of the cabin, and wherein: When in the first configuration, the first cryocooler and the second cryocooler are used to cool the battery pack via the refrigerant system, and When in the second configuration, the first cryocooler, the second cryocooler, and the third cryocooler are used to cool the battery pack via the refrigerant system.

6. The system of claim 4, wherein one of the plurality of different valve states includes a cabin cooling and a battery cooling mode, and wherein: When in the first configuration, one of the first cryocooler and the second cryocooler is used to cool the battery pack and the other of the first cryocooler and the second cryocooler is used to cool the vehicle cabin via the cooler core; and When in the second configuration, two of the first, second and third cryocoolers are used to cool the vehicle cabin via the cooler core, and the remaining of the first, second and third cryocoolers are used to cool the battery pack.

7. The system of claim 4, wherein one of the plurality of different valve states includes a cabin cooling and a battery cooling mode, and wherein: When in the first configuration, one of the first cryocooler and the second cryocooler is used to cool the battery pack and the other of the first cryocooler and the second cryocooler is used to cool the vehicle cabin via the cooler core; and When in the second configuration, two of the first, second and third cryogenic coolers are used to cool the battery pack, and the remaining of the first, second and third cryogenic coolers cools the vehicle cabin via the cooler core.

8. The system of claim 4, wherein one of the plurality of different valve states includes a cabin cooling and battery recirculation mode, and wherein: When in the first configuration, the first and second cryocoolers are used to cool the vehicle cabin via the cooler core; and When in the second configuration, the first cryocooler, the second cryocooler, and the third cryocooler are used to cool the vehicle cabin via the cooler core.

9. The system of claim 4, wherein one of the plurality of different valve states includes a cabin active cooling and a battery passive cooling mode, and wherein: When in the first configuration, the low temperature radiator is used to cool the battery pack and the power electronic device, one of the first cryocooler and the second cryocooler is used to cool the power electronic device and the battery pack, and the other of the first cryocooler and the second cryocooler is used to cool the vehicle cabin; and When in the second configuration, the low-temperature radiator is used to cool the battery pack and the power electronic device, two of the first deep freezer, the second deep freezer and the third deep freezer are used to cool the vehicle compartment via the cooler core, and the remaining of the first deep freezer, the second deep freezer and the third deep freezer is used to cool the power electronic device and the battery pack.

10. The system of claim 4, wherein one of the plurality of different valve states includes dehumidification and battery heating / cooling or cabin heating and battery cooling, and wherein: When in the first configuration, The low temperature radiator is used to cool the battery and power electronic devices. One of the first cryocooler and the second cryocooler is used to cool the power electronic device and the battery, heat from the power electronics, the battery, and the low temperature radiator is transferred from at least one of the first cryocooler and the second cryocooler to the water-cooled condenser through the refrigerant system to warm the cabin when needed, dehumidifying the vehicle cabin by cooling by one of the first cryocooler and the second cryocooler when necessary, and compensating for cabin cooling via heat from the water-cooled condenser while using the heater core when needed; and When in the second configuration, The low-temperature radiator is used to cool the battery and the power electronic device. One of the first cryocooler and the second cryocooler is used to cool the power electronic device and the battery, heat from the power electronics, the battery, and the low temperature radiator is transferred from at least one of the first cryocooler and the second cryocooler to the water-cooled condenser through the refrigerant system to warm the cabin when needed, dehumidifying the vehicle cabin by cooling by two of the first cryocooler, the second cryocooler, and the third cryocooler when necessary, and The heater core is simultaneously used to compensate for cabin cooling via heat from the water-cooled condenser when needed.

11. The system of claim 4, wherein one of the plurality of different valve states includes at least a battery heating mode and a cabin heating mode when a predetermined condition is satisfied, and wherein: When in the first configuration, heat is transferred directly from the PTC heater to the battery, or heat recovered from ambient air via the low temperature radiator and power electronics waste heat is transferred to the at least one water-cooled condenser via the first cryocooler and the second cryocooler, and then to the heater core and the battery; and When in the second configuration, heat is transferred directly from the PTC heater, or heat recovered from ambient air through the low-temperature radiator and power electronics waste heat is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryogenic cooler, the second cryogenic cooler, and the third cryogenic cooler, and then to the heater core and the battery.

12. The system of claim 4, wherein one of the plurality of different valve states includes a cabin and battery heating mode, and wherein: When in the first configuration, heat from the power electronics circuit directly heats the battery, and heat recovered from ambient air via the low temperature radiator and power electronics waste heat is transferred to the at least one water-cooled condenser via the first cryocooler and the second cryocooler and then to the heater core; and When in the second configuration, heat from the power electronic circuit directly heats the battery, and heat recovered from ambient air through the low-temperature radiator and power electronic device waste heat is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryocooler, the second cryocooler, and the third cryocooler, and then transferred to the heater core.

13. The system of claim 2, comprising a plurality of pumps, the plurality of pumps including at least a first pump positioned immediately downstream of the battery, a second pump positioned immediately downstream of the heater core, a third pump positioned immediately downstream of the low temperature radiator, and a fourth pump positioned immediately downstream of the cooler core.

14. A method comprising: providing a coolant system in fluid communication with the power electronics, the battery pack, and the vehicle cabin; providing a refrigeration system that interacts only with coolant from the coolant system; All cabin heat exchange is performed via the coolant; as well as All refrigerant heat exchange is performed through the coolant.

15. The method of claim 14, comprising associating the valve with the first configuration or the second configuration, and further comprising: In the first configuration, placing the valve in fluid communication with the battery pack, the power electronics, a cooler core, a heater core, at least a first cryocooler and a second cryocooler, at least one water-cooled condenser, and a low-temperature radiator; In the second configuration, the valve is in fluid communication with the battery pack, the power electronics, the cooler core, the heater core, at least the first, second and third cryocoolers, at least the first and second water-cooled condensers, and a low temperature radiator; and optionally: positioning at least a first pump immediately downstream of a battery, a second pump immediately downstream of the heater core, a third pump immediately downstream of the low temperature radiator, and a fourth pump immediately downstream of the cooler core; wherein the valve operates in a plurality of different valve states, and the method includes controlling the valve based on inputs from a plurality of sensors to manage heat transfer for the plurality of different valve states; wherein one of the plurality of different valve states includes at least a battery heating mode and a cabin heating mode when a predetermined condition is satisfied, and wherein: When in the first configuration, heat is transferred directly from the PTC heater to the battery, or heat recovered from ambient air via the low temperature radiator and power electronics waste heat is transferred via the first cryocooler and the second cryocooler to the at least one water-cooled condenser and then to the heater core and the battery; and When in the second configuration, heat is transferred directly from the PTC heater to the battery, or heat recovered from ambient air through the low-temperature radiator and power electronics waste heat is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryocooler, the second cryocooler, and the third cryocooler, and then to the heater core and the battery; or One of the plurality of different valve states includes a cabin and battery heating mode, and the method includes: When in the first configuration, the battery is heated directly using heat from the power electronics circuit, and heat recovered from ambient air via the low temperature radiator and power electronics waste heat is transferred to the at least one water-cooled condenser via the first cryocooler and the second cryocooler and then to the heater core; and When in the second configuration, the battery is directly heated using heat from the power electronic circuit, and heat recovered from ambient air through the low-temperature radiator and power electronic device waste heat is transferred to the first water-cooled condenser and the second water-cooled condenser through the first cryocooler, the second cryocooler, and the third cryocooler, and then to the heater core.

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