US 12,358,345 B2
Two-phase cooling system for electric vehicles
Michael J Wiland, Washington Township, MI (US); Matthew T Bartlett, Northville, MI (US); and Daniel E Hornback, Davisburg, MI (US)
Assigned to FCA US LLC, Auburn Hills, MI (US)
Filed by FCA US LLC, Auburn Hills, MI (US)
Filed on Mar. 21, 2023, as Appl. No. 18/187,140.
Prior Publication US 2024/0317022 A1, Sep. 26, 2024
Int. Cl. B60H 1/00 (2006.01); B60K 1/00 (2006.01); B60K 1/04 (2019.01); B60K 11/02 (2006.01); H05K 7/20 (2006.01)
CPC B60H 1/00914 (2013.01) [B60H 1/00278 (2013.01); B60K 1/04 (2013.01); B60K 11/02 (2013.01); H05K 7/20327 (2013.01); H05K 7/20354 (2013.01); H05K 7/20881 (2013.01); H05K 7/20936 (2013.01); B60H 2001/00307 (2013.01); B60H 2001/00928 (2013.01); B60H 2001/00949 (2013.01); B60K 2001/005 (2013.01); B60K 2001/006 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A cooling system for an electric vehicle, comprising:
a cooling system loop including a refrigerant, a compressor, and a heat exchanger, the cooling system loop including a plurality of sub-loops configured to receive the refrigerant after the refrigerant exits the heat exchanger,
wherein at least one of the plurality of sub-loops comprises:
a mass flow metering device configured to receive the refrigerant in a liquid phase from the heat exchanger;
a separator configured to receive the refrigerant in the liquid phase after passing through the mass flow metering device;
a pump configured to draw the refrigerant in the liquid phase from the separator; and
a component located downstream from the pump that is configured to be cooled by the refrigerant in the liquid phase;
wherein after exchanging heat with the component to be cooled, the refrigerant in the liquid phase at least partially undergoes a phase change to gas and a mixture of the refrigerant in each of the gas and liquid phases is returned to the separator, and the separator includes a pressure regulation valve configured to release the refrigerant in the gas phase from the separator to travel back to a suction line of the compressor,
wherein an amount of refrigerant that is permitted to travel to the at least one sub-loop from the heat exchanger is based on an amount of the refrigerant in the gas phase that is released from the separator.
 
12. An electric vehicle, comprising:
a vehicle body that defines a cabin;
a drive assembly including an electric drive motor and a power inverter device;
a battery for providing a current to the power inverter device that converts the current to one that can actuate the electric drive motor; and
a cooling system loop including a refrigerant, a compressor, and a heat exchanger, the cooling system loop including a plurality of sub-loops configured to receive the refrigerant after the refrigerant exits the heat exchanger,
wherein a first sub-loop of the plurality of sub-loops comprises includes a cabin heat exchanger in communication with each of the heat exchanger and compressor, the first sub-loop being configured to cool the cabin of the electric vehicle;
wherein a second sub-loop of the plurality of sub-loops includes:
a first mass flow metering device configured to receive the refrigerant from the heat exchanger;
a first separator configured to receive the refrigerant from the first mass flow metering device;
a first pump configured to draw the refrigerant from first separator; and
the drive assembly, which is located downstream from the pump and configured to be cooled by the refrigerant;
wherein after exchanging heat with the drive assembly, the refrigerant at least partially undergoes a phase change to gas and a mixture of the refrigerant in each of the gas and liquid phases is returned to the first separator, and the first separator includes a first pressure regulation valve configured to release the refrigerant in the gas phase from the first separator to travel back to a suction line of the compressor;
a third sub-loop of the plurality of sub-loops includes:
a second mass flow metering device configured to receive the refrigerant from the heat exchanger;
a second separator configured to receive the refrigerant from the second mass flow metering device;
a second pump configured to draw the refrigerant from second separator; and
the battery, which is located downstream from the second pump and configured to be cooled by the refrigerant;
wherein after exchanging heat with the battery, the refrigerant at least partially undergoes a phase change to gas and a mixture of the refrigerant in each of the gas and liquid phases is returned to the second separator, and the second separator includes a second pressure regulation valve configured to release the refrigerant in the gas phase from the second separator to travel back to a suction line of the compressor;
wherein an amount of refrigerant that is permitted to travel to the at least the second sub-loop and the third sub-loop from the heat exchanger is based on an amount of the refrigerant in the gas phase that is released from the first and second separators.