# US 2014/0193683 A1 · Battery Pack Base Plate Heat Exchanger > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0193683 A1 - Document ID: US20140193683A1 - Status: Published application - Kind: A1 - Application number: 13/736,217 - Filed: 2013-01-08 - Published: 2014-07-10 - Earliest claimed: 2013-01-08 - Assignees: Tesla Motors, Inc. - Applicants: Tesla Motors, Inc. - Inventors: Joseph Mardall; Paul Yeomans - Web page: https://patentgrep.com/patent/US20140193683A1 ## CPC - H01M 10/6562: with free flow by convection only - B60K 1/04: of the electric storage means for propulsion - B60L 50/64: Constructional details of batteries specially adapted for electric vehicles - H01M 10/625: Vehicles - H01M 10/6556: Solid parts with flow channel passages or pipes for heat exchange (closed pipes H01M10/6552) - H01M 10/658: by thermal insulation or shielding - H01M 50/213: adapted for cells having curved cross-section, e.g. round or elliptic (H01M50/209, H01M50/216 take precedence) - H01M 50/249: specially adapted for aircraft or vehicles, e.g. cars or trains (constructional details of batteries specially adapted for electric vehicles B60L50/64) - B60K 11/02: with liquid cooling - B60K 11/04: Arrangement or mounting of radiators, radiator shutters, or radiator blinds - B60K 2001/005: {the electric storage means} - B60K 2001/0438: {Arrangement under the floor} - Y02E 60/10: Energy storage using batteries - Y02T 10/70: Energy storage systems for electromobility, e.g. batteries - H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY - B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES - B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION ## Abstract A heat exchanger integrated into an electric vehicle's battery pack enclosure is provided, where the heat exchanger conduits are mechanically and thermally coupled to the inside surface of the enclosure base plate and where the battery pack enclosure is mounted such that ambient air flows over the outside surface of the enclosure base plate during vehicle motion. A thermal management system is coupled to, and controls operation of, the integrated battery pack heat exchanger such that in a first operational mode the heat exchanger is thermally coupled to the batteries within the battery pack, and in a second operational mode the heat exchanger is thermally decoupled from the batteries within the battery pack. ## Claims ### Claim 1 An integrated battery pack heat exchanger system, comprising: a battery pack enclosure mounted under an electric vehicle, wherein said battery pack enclosure comprises an enclosure top panel, an enclosure base plate, and a plurality of enclosure side members, wherein said battery pack enclosure is configured to hold a plurality of batteries, wherein said battery pack enclosure is mounted between a passenger cabin floor panel and a driving surface, wherein an outside surface of said enclosure base plate is exposed to an ambient environment outside of said vehicle, and wherein ambient air flows past said outside surface of said enclosure base plate during motion of said electric vehicle; a plurality of heat exchanger conduits mechanically and thermally coupled to an inside surface of said enclosure base plate; and a thermal management system coupled to said integrated battery pack heat exchanger system and controlling operation of said integrated battery pack heat exchanger system, wherein said plurality of heat exchanger conduits are thermally coupled to said plurality of batteries within said battery pack enclosure when said thermal management system configures said integrated battery pack heat exchanger system into a first operational mode, and wherein said plurality of heat exchanger conduits are thermally decoupled from said plurality of batteries within said battery pack enclosure when said thermal management system configures said integrated battery pack heat exchanger system into a second operational mode. ### Claim 2 (depends on 1) The integrated battery pack heat exchanger system of claim 1, wherein said plurality of heat exchanger conduits are thermally coupled to at least one of a vehicle traction motor, a transmission, a battery charging system, and a power electronics module when said thermal management system configures said integrated battery pack heat exchanger system into either said first operational mode or said second operational mode. ### Claim 3 (depends on 2) The integrated battery pack heat exchanger system of claim 2, further comprising a heat exchanger bypass valve, wherein said heat exchanger bypass valve in a first position thermally couples said plurality of heat exchanger conduits to at least one of said vehicle traction motor, said transmission, said battery charging system, and said power electronics module when said integrated battery pack heat exchanger system is in either said first operational mode or said second operational mode, and wherein said heat exchanger bypass valve in a second position circumvents said plurality of heat exchanger conduits and decouples said plurality of heat exchanger conduits from said vehicle traction motor, said transmission, said battery charging system, and said power electronics module when said integrated battery pack heat exchanger system is in either said first operational mode or said second operational mode. ### Claim 4 (depends on 1) The integrated battery pack heat exchanger system of claim 1, further comprising a layer of a thermally insulating material interposed between said plurality of batteries and said plurality of heat exchanger conduits, wherein said layer of said thermally insulating material thermally isolates said plurality of batteries from said plurality of heat exchanger conduits. ### Claim 5 (depends on 4) The integrated battery pack heat exchanger system of claim 4, wherein said layer of thermally insulating material has a thermal conductivity of less than 1.0 W/m-K. ### Claim 6 (depends on 1) The integrated battery pack heat exchanger system of claim 1, wherein said plurality of heat exchanger conduits are mechanically and thermally coupled to said inside surface of said enclosure base plate using a coupling technique selected from the group consisting of brazing, soldering, welding and bonding. ### Claim 7 (depends on 1) The integrated battery pack heat exchanger system of claim 1, wherein said plurality of heat exchanger conduits are integrated within said enclosure base plate. ### Claim 8 (depends on 1) The integrated battery pack heat exchanger system of claim 1, wherein said outside surface of said enclosure base plate further comprises a plurality of thermally conductive fins that enhance withdrawal of thermal energy from said integrated battery pack heat exchanger system. ### Claim 9 (depends on 1) The integrated battery pack heat exchanger system of claim 1, further comprising a blower fan, wherein said blower fan directs air over said outside surface of said enclosure base plate. ### Claim 10 (depends on 9) The integrated battery pack heat exchanger system of claim 9, wherein said blower fan is mounted within said electric vehicle, and wherein an air duct directs air flow from said blower fan over said outside surface of said enclosure base plate. ### Claim 11 (depends on 9) The integrated battery pack heat exchanger system of claim 9, further comprising at least one slot integrated into said outside surface of said enclosure base plate. ### Claim 12 (depends on 1) The integrated battery pack heat exchanger system of claim 1, further comprising a blower fan and at least one closed channel integrated into said outside surface of said enclosure base plate, wherein said blower fan directs air through said at least one closed channel integrated into said outside surface of said enclosure base plate. ### Claim 13 (depends on 1) The integrated battery pack heat exchanger system of claim 1, further comprising: a first coolant loop thermally coupled to said plurality of batteries, said first coolant loop comprising a first circulation pump for circulating a coolant within said first coolant loop; a second coolant loop thermally coupled to said plurality of heat exchanger conduits and to at least one of a vehicle traction motor, a transmission, a battery charging system, and a power electronics module, said second coolant loop comprising a second circulation pump for circulating said coolant within said second coolant loop; a dual mode valve system coupled to said thermal management system, wherein in said first operational mode said dual mode valve system is configured in a first mode and wherein in said second operational mode said dual mode valve system is configured in a second mode, wherein when said dual mode valve system is configured in said first mode said first coolant loop is serially coupled to said second coolant loop, and wherein when said dual mode valve system is configured in said second mode said first coolant loop operates in parallel with and separate from said second coolant loop. ### Claim 14 (depends on 13) The integrated battery pack heat exchanger system of claim 13, further comprising a heat exchanger bypass valve integrated into said second coolant loop, wherein said heat exchanger bypass valve controls flow of said coolant through said plurality of heat exchanger conduits. ### Claim 15 (depends on 13) The integrated battery pack heat exchanger system of claim 13, wherein said dual mode valve system is comprised of a four-way valve, wherein said four-way valve configured in said first mode couples a first portion of said first coolant loop to a second portion of said second coolant loop and couples a first portion of said second coolant loop to a second portion of said first coolant loop, and wherein said four-way valve configured in said second mode couples said first portion of said first coolant loop to said second portion of said first coolant loop and couples said first portion of said second coolant loop to said second portion of said second coolant loop. ### Claim 16 (depends on 13) The integrated battery pack heat exchanger system of claim 13, wherein said dual mode valve system is comprised of a first three-way valve and a second three-way valve, wherein when said dual mode valve system is configured in said first mode said first three-way valve couples a first portion of said first coolant loop to a second portion of said second coolant loop and said second three-way valve couples a first portion of said second coolant loop to a second portion of said first coolant loop, and wherein when said dual mode valve system is configured in said second first mode said first three-way valve couples said first portion of said first coolant loop to said second portion of said first coolant loop and said second three-way valve couples said first portion of said second coolant loop to said second portion of said second coolant loop. ### Claim 17 (depends on 13) The integrated battery pack heat exchanger system of claim 13, further comprising a refrigeration subsystem thermally coupleable to said first coolant loop via a refrigeration subsystem heat exchanger. ### Claim 18 (depends on 17) The integrated battery pack heat exchanger system of claim 17, wherein said refrigeration subsystem further comprises a refrigerant, a compressor, a condenser and a thermostatic expansion valve. ### Claim 19 (depends on 17) The integrated battery pack heat exchanger system of claim 17, further comprising a cabin heating, ventilation and cooling (HVAC) subsystem thermally coupleable to said refrigeration subsystem via said refrigeration subsystem heat exchanger. ### Claim 20 (depends on 13) The integrated battery pack heat exchanger system of claim 13, further comprising a heater thermally coupled to said first coolant loop.