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With more vehicles adopting fuel-saving engine start-stop routines and with the number of hybrid and electric vehicles on the rise, automotive A/C (air conditioning) systems are facing a challenge to maintain passenger comfort during the time when the compressor is inactive due to engine shut down. Using PCM (Phase Change Material) in the evaporator enables it to store cold when the compressor is active and release it to the cooling air stream when the compressor is not running. A unique feature of Delphi's design is that a refrigerant thermosiphon mechanism inside the evaporator drives the energy transport between the PCM and air stream. Delphi's PCM evaporator extends comfort for short duration idle stops, reduces emissions, and increases fuel economy and electric drive range. In this paper, the design aspects of a thermosiphon based PCM cold storage evaporator are described and the performance and operation of the PCM evaporator in a MAC (Mobile Air Conditioning) system discussed.

CFD analysis was performed using the FLUENT software to design the thermal system for a hybrid vehicle battery pack. The battery pack contained multiple modular battery elements, called bricks, and the inlet and outlet bus bars that electrically connected the bricks into a series string. The simulated thermal system was comprised of the vehicle cabin, seat cavity, inlet plenum, battery pack, a downstream centrifugal fan, and the vehicle trunk. The fan was modeled using a multiple reference frame approach. A full system analysis was done for airflow and thermal performance optimization to ensure the most uniform cell temperatures under all operating conditions. The mesh for the full system was about 13 million cells run on a 6-node HP cluster. A baseline design was first analyzed for fluid-thermal performance. Subsequently, multiple design iterations were run to create uniform airflow among all the individual bricks while minimizing parasitic pressure drop.