High pressure pump and heater assembly

Abstract

A pump and heater assembly (32; 132, 132; 232) may include an electric motor (52; 152-2, 152-2; 252-2), a pump (50; 150, 150; 250), an electric heater module (56; 156, 156; 260), a control module (54; 154, 154; 254) and a flow path (F). The electric heater module may include a housing (156-1; 260-1), a plurality of heater elements (561 to 56n; 156-2; 156-2; 256-2) and a plurality of heat exchange elements (156-3; 256-3) each has a primary heat transfer surface (156-3P; 256-3P) and a protruding secondary heat transfer surface (156-3S; 256-3S) in the housing. The flow path passes from the inlet (I) through the pump, then through the electric heater module, and then through the outlet (O). The flow path further passes through a first manifold (M1) and a second manifold (M2) fluidly connected to a plurality of fluidly parallel portions (F1 to Fn) of the flow path, at least one of the plurality of fluidly parallel portions passing along each of the heat exchange elements.

Description

Technical Field

[0001] The present invention generally relates to high pressure electric fluid pump and heater assemblies, as well as components and related methods thereof. Background Art

[0002] The advent of zero emission vehicles (ZEVs), such as battery electric vehicles and fuel cell electric vehicles (the latter are considered ZEVs because fuel cells have no smog-related or greenhouse gas tailpipe emissions), has opened up the need to provide pre-conditioning for other on-board components, such as energy storage devices, electronics, etc., and to provide a heat source for heating the cabin of such vehicles. Pre-conditioning assists in the thermal management of on-board components, such as batteries, etc., to help them operate at more optimal temperatures. Climate controlled heating as part of a heating, ventilation, and air conditioning (HVAC) system helps provide a comfortable on-board working environment for the operator and any passengers in the cab and / or sleeper unit, as well as cargo space (including in trailers, etc.) when ambient temperatures are low, such as during the winter months, etc.

[0003] Vehicles and equipment powered by internal combustion engines are often heated by using the engine's waste heat to provide a heat source for air conditioning of the cabin, etc. However, when the internal combustion engine is eliminated in a ZEV, etc., the engine heat source no longer exists, and a new source must be used to provide heat for climate control and / or preconditioning. Summary of the invention

[0004] In one aspect, a disclosed embodiment of a pump and heater assembly (suitable for high voltage operation, such as at 450V DC or greater) may include an electric motor, a pump operably connected to the electric motor, an electric heater module fluidly connected to the pump, a control module, and a flow path. The electric heater module may include: a housing; a plurality of heater elements, each of the plurality of heater elements being configured to generate heat; and a plurality of heat exchange elements, each of the plurality of heat exchange elements having a primary heat transfer surface and a secondary heat transfer surface protruding from the corresponding primary heat transfer surface. At least one of the heat exchange elements may be disposed adjacent to each of the heater elements within the housing. The control module is electrically connected to the electric motor and the heater elements. The flow path may fluidly pass from an inlet through the pump, then through the electric heater module, and then through an outlet. The flow path may also pass through a first manifold and a second manifold, the first manifold and the second manifold being fluidly connected to a plurality of fluid parallel portions of the flow path, and at least one of the plurality of fluid parallel portions may pass along each of the heat exchange elements to allow heat transfer between the heat exchange elements.

[0005] In some embodiments, the pump and heater assembly may optionally be part of a vehicle, the vehicle further comprising an on-board high voltage power source electrically connected to the pump and heater assembly, a liquid to air heat exchanger, and a fluid circuit fluidly connecting the heat exchanger to the pump and heater assembly.

[0006] In another aspect, embodiments of the disclosed method of electrically heating and pumping a fluid may include providing high voltage electrical power to a motor and a plurality of heater elements using a shared control module, operating the motor to drive a pump (the motor, heater elements, and pump may all be part of a pump and heater assembly configured as an integrated unit having a flow path therethrough), pressurizing a coolant fluid using the pump, distributing the pressurized coolant fluid to a plurality of heat exchange elements using a manifold, each of the plurality of heat exchange elements being positioned adjacent to at least one of the heater elements, generating thermal energy using the heater elements, conductively transferring the generated heat to the pressurized coolant fluid through the plurality of heat exchange elements, collecting the heated pressurized coolant fluid in an additional manifold, and moving the heated pressurized coolant fluid through an outlet port to exit the pump and heater assembly.

[0007] In yet another aspect, an embodiment of the disclosed method of manufacturing a high-voltage electric pump and heater assembly may include manufacturing a first pump and heater assembly and a second pump and heater assembly. Manufacturing the first pump and heater assembly may include providing a first pump module, connecting a first electric motor to the first pump module, connecting a first control module to the first electric motor, determining a maximum expected heat demand for a first application, determining a sufficient number of resistive heater elements capable of meeting the maximum expected heat demand for the first application, and connecting a sufficient number of resistive heater elements to the first control module to be able to meet the maximum expected heat demand for the first application. Manufacturing the second pump and heater assembly may include providing a second pump module having a configuration substantially the same as the first pump module, connecting a second electric motor to the second pump module, wherein the second electric motor has a configuration substantially the same as the first electric motor, connecting a second control module to the second electric motor, wherein the second control module has a configuration substantially the same as the first control module, determining a maximum expected heat demand for a second application, determining a sufficient number of resistive heater elements capable of meeting the maximum expected heat demand for the second application, wherein the sufficient number for the first application and the second application is different, and connecting a sufficient number of additional resistive heater elements to the second control module to be able to meet the maximum expected heat demand for the second application.

[0008] In yet another aspect, an integrated pump and heater assembly includes an electric motor, a pump, an electric heater module, a control module, and a flow path, wherein the pump is operably connected to the electric motor, the electric heater module is fluidly connected to the pump, and the flow path passes from an inlet through the pump, then through the electric heater module, and then through an outlet. The electric heater module may include a housing, a plurality of heater elements, and a plurality of heat exchange elements, each of the plurality of heater elements being configured to generate heat from electrical power. At least one of the heat exchange elements may be disposed adjacent to each of the heater elements within the housing. The control module may be electrically connected to the electric motor and the heater elements. The flow path may also pass along each heat exchange element to allow heat transfer with the fluid in the flow path.

[0009] This summary is provided by way of example only and not limitation. Other aspects of the invention will be appreciated in view of the entirety of this disclosure, including the text, claims, and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 are schematic electrical and hydraulic diagrams of an embodiment of a system with separate pump and heater devices connected by electrical cables, fluid hoses, and associated electrical and fluid connectors.

[0011] Figure 2 are schematic electrical and hydraulic diagrams of an embodiment of a system with a combined pump and heater assembly.

[0012] Figure 3 is a schematic block diagram of an embodiment of a zero emission vehicle (ZEV) having a pump and heater assembly.

[0013] Figure 4 is a schematic diagram of an embodiment of a pump and heater assembly.

[0014] Figure 5A and Figure 5B is a cross-sectional view of an embodiment of a pump and heater assembly, wherein arrows indicate Figure 5B The fluid flow annotated in , and Figure 5C yes Figure 5A An enlarged cross-sectional view of a portion of.

[0015] Fig. 6A yes Figure 5A-5C Rear perspective view of the pump and heater assembly showing the control module cover omitted to reveal the internal structure.

[0016] Figure 6B It is along Fig. 6A A cross-sectional view of the pump and heater assembly taken along line 6B-6B.

[0017] Figure 7 yes FIG. 5A to FIG. 6BA cross-sectional perspective view of a portion of the heater section of a pump and heater assembly.

[0018] Fig. 8A and Figure 8B is a cross-sectional view of another embodiment of a pump and heater assembly, wherein arrows indicate Figure 8B Fluid flow annotated in .

[0019] Fig. 9A yes Fig. 8A and Figure 8B Rear view of a portion of the combined motor and heater module of the pump and heater assembly.

[0020] Fig. 9B yes Fig. 9A An enlarged perspective view of a portion of the combined motor and heater module is shown in FIG.

[0021] Fig.10 is shown separately FIG. 8A to FIG. 9B A perspective view of the heater group of the pump and heater assembly.

[0022] Although the above-identified drawings set forth one or more embodiments of the present invention, other embodiments are also contemplated, as noted in the discussion. In all cases, the present disclosure presents the present invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments may be devised by those skilled in the art that fall within the scope and spirit of the principles of the present invention. The drawings may not be drawn to scale, and applications and embodiments of the present invention may include features, steps, and / or components not specifically shown in the drawings. DETAILED DESCRIPTION

[0023] It is desirable to provide an on-board electric heater that can warm a coolant fluid that can be pumped through a climate control heat exchanger that provides heat to a cabin, berth, cargo hold, etc. For example, the heat load can be about 10-70kW, depending on the need and application. Due to the relatively high heat load requirements, it is desirable to use high voltage power from at least one on-board battery or fuel cell to power the heater. The voltage of such an on-board power supply for a traction motor in a zero emission vehicle (ZEV) can range, for example, from about 400V direct current (DC) to 1200V DC, or 450V DC to 850V DC as another example. The on-board power supply can have a nominal operating voltage, but can have an operating voltage that varies across actual operating conditions, such as a temporarily reduced operating voltage during a near-depleted condition when the on-board power supply is composed of one or more batteries that are nearly fully discharged. There can be a minimum operating voltage (such as about 400V DC or greater) to account for such variations in operating voltage. The design can be modular so that essentially any desired number of discrete heater elements can be used together for a particular application (e.g., to provide a desired total heating capacity) while still allowing the assembly to be provided as an integrated unit. In some embodiments, the discrete heater elements can be resistive elements, or in other embodiments can have different configurations to operate on different bases.

[0024] It is also necessary to pump the coolant fluid through the system and other components for heating or cooling purposes. These pumps will also benefit from operating with power from the on-board high-voltage power supply. The amount of electricity that the cable can conduct is proportional to the amount of current that the cable can carry. Because electrical power is a function of current multiplied by voltage, an increase in voltage causes a similar drop in current. In addition, the amount of current that the cable can carry is related to the cross-sectional area of ​​the wire, which depends on the square of the diameter (for cables with a generally circular cross-sectional shape). Therefore, the cable size can be reduced exponentially as the voltage increases. Considering weight and packaging, this is very important. In vehicle applications, it is important to provide relatively low mass and relatively compact designs for on-board components and systems. However, high-voltage connectors suitable for use in vehicles are expensive and require great care in installation and application. Further, extending high-voltage wires to multiple devices is expensive and complicated. It is desirable to minimize the number of wires and connections. In addition, it is desirable to allow wiring that is relatively easy to manufacture and assemble by avoiding complex and / or inaccessible wire paths. The disclosed embodiments of the present invention provide a pump and heater assembly that will reduce or eliminate the need for separate wiring and connections to both the pump and the heater, and / or provide relatively easy wiring during manufacturing and assembly. In addition, embodiments of the present invention are intended to reduce the number of fluid coolant connections and / or hoses. Figure 1 and Figure 2 The schematic shows how the components in the combination (see Figure 2 ) to eliminate separate pump and heater units (see Figure 1 ) required cables, fluid hoses and various associated connectors. For example, even in Figure 2 There may be internal fluid and electrical connections in the combined assembly that may not require the types of cables, hoses, etc. required outside the housing and may be integrated with internal components, or lighter weight and / or less expensive cables and connectors may be used inside the protective housing of the combined assembly.

[0025] In general, embodiments of pump and heater assemblies according to the present invention include a pump element driven by an electric motor (e.g., a permanent magnet brushless DC motor or a synchronous DC motor), one or more housings, and one or more heating elements, one or more heating elements being operatively positioned in, along, or near a flow path of a component passing through a pumped fluid referred to as a coolant. For example, a control electronics and an electrical connector module may be further provided, or such components may be alternatively integrated into a motor. In some embodiments, a common control module may be provided, which is suitable for driving both the motor and the heater element of the pump. The pump element may be a bladed or finned rotor driven by torque from the shaft of the motor. Another component of the housing or assembly may guide the coolant around the motor (e.g., from a pump located at one end of the assembly through at least a path adjacent to the motor toward the opposite end of the assembly). One or more heater elements may be located in different parts of the assembly, such as at the end of the assembly opposite to the pump, such as by being attached to the end of the motor opposite to the pump or otherwise supported on the end of the motor opposite to the pump. The coolant flow is guided through the heater element to the outlet or outlet of the component flow path. The heater element can be a resistive heater device, respectively. When an electric current passes through a given heater element, its resistance causes the heater element to warm up. The heat is transferred to the flowing coolant moved by the pump, thereby heating the coolant. In this sense, the term coolant should be understood to allow cooling or heating, as will be fully understood by those of ordinary skill in the art. In addition, a heat exchanger or heat exchange element can be disposed adjacent to any or all of the heater elements to facilitate the transfer of heat energy to the coolant. Controlling the amount of current delivered to the heater element allows the coolant temperature leaving the pump and heater assembly to be controlled. The assembly can have a modular construction, thereby allowing the desired number of discrete heater elements (and any associated heat exchangers or heat exchange elements) to be provided to provide heating capabilities suitable for the desired application, while still allowing both fluid connections and electrical connections for the pump and heater assembly to be relatively easy to carry out. Furthermore, the configuration of the assembly and the arrangement of components within the assembly can facilitate the formation of electrical connections between internal electrical components and external electrical components (e.g., motors, heater elements, control modules, external power sources, and / or external controllers), and the formation of fluid connections between internal electrical components and external components associated with a coolant circuit including a flow path through the assembly, and such electrical and fluid connections can be relatively easily achieved through or with the assembly, and without significant conflicts between closely adjacent electrical and fluid connections or paths.

[0026] It should be understood that the present disclosure is provided by way of example only and not limitation and that numerous embodiments and implementations are contemplated as would be appreciated by one of ordinary skill in the art upon reviewing the entirety of the present disclosure, including the text and drawings.

[0027] This application is based upon and claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 374,333, filed on September 1, 2022, the contents of which are incorporated herein by reference in their entirety.

[0028] Figure 3 is a schematic block diagram of an embodiment of a zero emission vehicle (ZEV) 30 having a pump and heater assembly 32. Figure 3 As shown, the pump and heater assembly 32 can receive high voltage electrical power (e.g., 400-1200V DC) from an onboard power source 34 (e.g., one or more batteries or fuel cells), which can also optionally supply power to other onboard devices, such as a traction motor 36, etc. A controller 38 communicates with the pump and heater assembly, such as via a controller area network (CAN) communication protocol, as is well known in automotive applications. In various embodiments, the controller 38 can be an overall vehicle controller, such as a central onboard computer that also controls components such as the traction motor 36, or can be a separate controller dedicated to heating and / or cooling related functions. The controller 38 can generate and / or relay a heating request signal to the pump and heater assembly 32, for example, based on operator commands, sensor measurements, and associated control determinations and schemes. Fluid loop C may circulate a coolant fluid through the ZEV 30 to provide thermal management to a conditioned space 40 (e.g., a cabin or berth or cargo hold of the ZEV, including a trailer cargo hold) and / or thermally sensitive onboard components 42 (e.g., onboard electronics, batteries, etc.). The coolant fluid may be, for example, a liquid such as water, water plus antifreeze, or other suitable fluid. One or more heat exchangers (H / X) 44 may optionally be disposed along fluid loop C, and may optionally include a blower, air handler, etc., where liquid-to-air or air-to-liquid heat transfer is involved. Although not described herein, the coolant fluid may be circulated through the ZEV 30 to provide thermal management to a conditioned space 40 (e.g., a cabin or berth of the ZEV or a cargo hold, including a trailer cargo hold) and / or thermally sensitive onboard components 42 (e.g., onboard electronics, batteries, etc.). The coolant fluid may be, for example, a liquid such as water, water plus antifreeze, or other suitable fluid. One or more heat exchangers (H / X) 44 may optionally be disposed along fluid loop C, and may optionally include a blower, air handler, etc., where liquid-to-air or air-to-liquid heat transfer is involved. Figure 3 , but additional heating, ventilation and air conditioning (HVAC) components may optionally be provided along fluid circuit C. For example, the same fluid circuit C may be connected to the pump and heater assembly 32 to provide heat and to an air conditioner or refrigeration unit (not shown) to remove heat and provide cooling. In yet further embodiments, fluid circuit C may be a dedicated fluid circuit for the pump and heater assembly 32, the dedicated fluid circuit optionally being used in conjunction with an additional fluidically isolated supplemental fluid circuit (not shown). It should be noted that Figure 3is a highly simplified schematic diagram, and various alternative configurations are possible, and various additional devices not specifically shown may be included in further embodiments. For example, there may be additional electrical and / or fluid connections between components, sensors, valves, etc. of the ZEV 30. Furthermore, in further embodiments, there may be multiple pump and heater assemblies 32, multiple power sources 34, and / or multiple traction motors 36 onboard the ZEV 30. Furthermore, as Figure 3 In the embodiment shown, the traction motor 36 is spaced apart and distinct from the pump and heater assembly 32, and those components are merely carried on board and are typically powered, although in further embodiments, waste heat from the traction motor 36 may be diverse to the fluid circuit C, wherein the pump and heater assembly 32 provides heat output when other waste heat is not available or sufficient.

[0029] Figure 4 FIG. 3 is a schematic diagram of an embodiment of a pump and heater assembly 32. Figure 4 As shown, the assembly 32 includes a pump 50, a motor 52, a control module 54, and one or more electric heater elements 561 to 56 n .

[0030] As shown, the control module 54 receives an electrical input E to the components (eg, from the power source 34 ), supplies electrical power to the motor 52 and the electrically powered heater elements 56 1 to 56 2 . n (collectively referred to as heater module 56 ) provides combined control and power distribution, and further coordinates external communication (communication) signals S (eg, communicates with external controller 38 via CAN communication protocol).

[0031] The pump 50 is mechanically driven by torque output from an output shaft 58, which is part of the motor 52 or is otherwise operably connected to the motor 52, such that the motor 52 can rotate the output shaft 58 to drive or operate the pump 50. A pump element of the pump 50 can be directly or indirectly connected to the output shaft 58 to receive torque transmitted from the motor 52. In various embodiments, the pump 50 can be an impeller-driven centrifugal pump, a scroll pump, a piston pump, or other suitable type of pump.

[0032] A flow path F forming part of a fluid circuit C traversing the pump and heater assembly 32 may pass through the inlet I to the pump 50 and then through at least the motor 52 to the heater elements 561 to 562. nFluid circuit C may have one or more flow path segments that are arranged adjacent and in close proximity to motor 52 (and optionally also control module 54) so ​​that thermal energy may be transferred therebetween. Waste heat from motor 52 (and / or from control module 54) may be transferred to the passing coolant fluid, thereby allowing cooling of the motor 52 and / or the electronics of control module 54. The coolant fluid may then pass through or through heater elements 561 to 562. n , and absorbs the n The design of the pump and heater assembly 32 is modular so that as few as one heater element 56-1 may be used or multiple heater elements 561 to 56 n , depending on how many heater elements 561 to 56 are used n To obtain the required heat (e.g., to meet the maximum expected heating demand or otherwise meet the desired heating capacity) and to meet the fluid power pressure requirements. For example, in some embodiments, the assembly 32 can meet a heat load of approximately 10-40 kW. In some embodiments, a single pump 50 can be used in the assembly 32 regardless of the number of heater elements 561 to 56 n The heated coolant fluid may then exit the outlet O of the pump and heater assembly 32 to be delivered to a desired location via the fluid circuit C.

[0033] Although not in Figure 3 or Figure 4 As specifically shown in FIG. 1 , sensors may be used to monitor coolant fluid temperature, flow rate, pressure, and / or other desired parameters, and such sensors may communicate with control module 54, either directly or via another controller or device (e.g., indirectly via controller 38 of ZEV 30 using communication signals S sent between controller 38 and control module 54). These sensors may be located at substantially any desired location along fluid circuit C.

[0034] In addition, despite the Figure 4 Although not explicitly shown in FIG. 1 , the pump and heater assembly 32 may include a housing. Furthermore, in some embodiments, the entire assembly 32 may be provided as an integrated unit.

[0035] Although Figure 4 The heater elements 561 to 562 are shown as having fluid series connections. n 1 to 56 , although other arrangements are possible in further embodiments. For example, in alternative embodiments, the flow path F may connect the various heater elements 561 to 56 in a fluidic parallel or hybrid parallel / series multi-pass arrangement. n More generally, Figure 3and Figure 4 The configuration and arrangement of the components of ZEV 30 and pump and heater assembly 21 are shown by way of example only and not limitation.

[0036] FIG. 5A to FIG. 7 One embodiment of the pump and heater assembly 132 and its components is illustrated. Figure 5A and Figure 5B is a cross-sectional view, Figure 5C is an enlarged cross-sectional view of the selected part. Fig. 6A is a rear perspective view showing a portion of the components omitted to reveal a specific interior space, Figure 6B is along Fig. 6A A cross-sectional view taken along line 6B-6B of Figure 7 It is a cross-sectional perspective view of a part of the heater section.

[0037] like Figure 5A As shown, the pump and heater assembly 132 provides an integrated unit that includes a pump module (or segment) 150 at one end, a motor module (or segment) 152 at or near a mid-portion, a control module (or segment) 154 (e.g., at or near an end opposite the pump module 150), and a heater module (or segment) 156 (e.g., in a mid-portion between the motor module 152 and the control module 154). Figure 5B Further shown is a flow path F through the pump and heater assembly 132, with arrows added for illustration purposes (it should be noted, however, that the flow path F is three-dimensionally larger than the flow path F). Figure 5B is slightly more complicated than what is explicitly indicated by the arrows in ).

[0038] The pump module 150 includes a pump housing 150-1 and a rotor 150-2. The pump housing 150-1 defines an inlet I, which in the illustrated embodiment is an opening oriented generally axially at the center of the pump housing 150-1 and the assembly 132. The inlet I may include a protruding collar, a boss, or other coupling structure suitable for connecting a hose, a conduit, or other passage of the fluid circuit C to the pump and heater assembly 132 to allow the coolant fluid to enter the pump and heater assembly 132. Although a single inlet I is shown in the illustrated embodiment, multiple separate inlet structures and / or inlet manifolds may be used in other embodiments. In the illustrated embodiment, the rotor 150-2 is a radial impeller as part of a centrifugal pump configuration of the pump module 150, although other configurations are possible. The pump housing 150-1 and the rotor 150-2 together define a section of the flow path F. In the illustrated embodiment, the pump housing 150-1 is configured as a volute or a housing volute passage 150-1V. Pump volutes are well known so that no further explanation is required.

[0039] During operation, coolant fluid entering inlet I passes to rotor 150-2, which pressurizes the coolant fluid and moves the coolant fluid along flow path F. In the illustrated embodiment, as shown in FIG. Figure 5B As shown, the rotor 150 - 2 and housing 150 - 1 of the pump module 150 move the pressurized coolant fluid generally outward (eg, along a curved volute path) and toward the motor module 152 .

[0040] like Figure 5C , the illustrated embodiment of the rotor 150-2 has a closed or covered configuration and includes fins or blades 150-2A, a rear wall 150-2B, and a front wall (or cover) 150-2C. In some embodiments, a sealing element positioned adjacent to the rotor 150-2 may be spring-biased to an operating position. One or more stepped protrusions 150-2X extend from the front wall 150-C of the rotor 150-2 toward the pump housing 150-1 at a position where the front wall 150-2C is bent. A corresponding set of stepped recesses 150-1X is provided in the pump housing 150-1, and a set of stepped recesses 150-1X receives at least a portion of the stepped protrusions 150-2X. The stepped protrusions 150-2X and the stepped recesses 150-1X together define a labyrinthine path between the pump housing 150-1 and the front wall 150-2C of the rotor 150-2, which helps limit recirculation of the coolant fluid in an area along or defining a desired flow path F through the fins 150-2A between the rear wall 150-2B and the front wall 150-2C. In other words, the pump module 150 is intended to pressurize a coolant fluid that is intended to move along the flow path F and through the coolant circuit C without lingering in the pump module 150, and the labyrinth defined by the stepped protrusions 150-2X and the stepped recesses 150-1X helps limit unproductive recirculation, which otherwise can cause portions of the coolant fluid to inefficiently remain in the pump module 150 during operation rather than moving through and past the pump module 150.

[0041] The motor module 152 can generate a force to drive or operate the pump module 150, such as a torque that rotates the rotor 150-2 via the shaft 158. The motor module 152 can be positioned adjacent to the pump module 150. In the illustrated embodiment, as shown in FIG. Figure 5A and Figure 5B As shown, the motor module 152 is positioned axially adjacent to the pump module 150. In the illustrated embodiment, the motor module 152 includes a motor housing 152-1, a motor 152-2, and a plate 152-3 (which may be used to cover the mass reduction cavity).

[0042] The motor housing 152-1 can partially or completely surround the motor 152-2 and can be connected to the pump housing 150-1. In the illustrated embodiment, the motor housing 152-1 has a central cavity and fins (or lugs) 152-1F, in which the motor 152-2 (or at least a portion thereof) can be positioned, and the fins (or lugs) 152-1F are located at the outer area. In the illustrated embodiment, the motor housing 152-1 has a quasi-cylindrical shape, although other shapes are possible in alternative embodiments. At least one flow channel 152-1C passes through the motor housing 152-1, and the motor housing 152-1 forms a section of the flow path F through the pump and heater assembly 132. In the illustrated embodiment, the flow channel 152-1C is located radially outside the associated central cavity of the motor 152-2 and the motor housing 152-1, and axially passes through the entire length of the motor housing 152-1. Furthermore, in the illustrated embodiment, flow passage 152-1C is generally linear and axially arranged, although other configurations are possible in alternative embodiments. Flow passage 152-1C may be fluidly connected in series to volute passage 150-1V and may receive pressurized coolant fluid exiting pump module 150. In alternative embodiments, flow passage 152-1C may be provided by one or more hoses, which may optionally be connected by one or more valves.

[0043] The motor 152-2 includes a rotor 152-2R and a stator 152-2S. The motor 152-2 can be, for example, a permanent magnet brushless DC motor (or a synchronous DC motor), wherein the permanent magnet is carried by the rotor 152-2R, and can optionally have a three-phase configuration. The rotor 152-2R is directly or indirectly connected to the shaft 158, which in turn is directly or indirectly connected to the rotor 150-2 of the pump module 150, so that the torque generated by the motor 152-2 can be transmitted to the rotor 150-2 to operate the pump module 150 to pressurize the coolant fluid. In some embodiments, at least one end of the rotor 152-2R (e.g., an end adjacent to the pump module 150) can be supported by the motor housing 152-1 via a suitable bearing at the bearing guide 152-1B, and the opposite end of the rotor 152-2R can be supported on the heater module 156 via an additional bearing.

[0044] During operation, waste heat from motor 152-2 can be removed along flow path F through flow channel 152-1C (see Figure 5B) coolant fluid absorption. In the illustrated embodiment, flow path F is from motor 152-2 outward through flow channel 152-1C upstream of heater module 156 (and the heater element contained therein, as will be explained further). The gaps between fins 152-1F help reduce the mass of motor housing 152-1 and the mass of the entire pump and heater assembly 132 (see Fig. 6A ), and can potentially further provide some thermal isolation and insulating space between the flow channel 152-1C and any external objects present nearby.

[0045] The control module 154 may include a cover (or housing) 154-1, a circuit 154-2, and one or more electrical connectors 154-3H, 154-3L. In the illustrated embodiment, the control module 154 is located at or near the end of the pump and heater assembly 132 opposite the pump module 150, although other arrangements of the control module 154 are possible in alternative embodiments. The circuit 154-2 may include one or more circuit boards and may provide motor control functionality for operating the motor 152-2 of the motor module 152 and heater control functionality for operating the heater module 156. For example, in an embodiment in which the motor 152-2 has a brushless DC configuration, the motor control functionality of the circuit 154-2 may be provided using a switching transistor (such as an integrated gate bipolar transistor (IGBT) or a silicon carbide (SiC) metal oxide semiconductor field effect transistor (MOSFET), etc.). In the illustrated embodiment, one of the connectors is a high voltage electrical connector 154-3H, and the other is a low voltage electrical connector 154-3L. The high voltage electrical connector 154-3H may, for example, provide a high voltage power input (e.g., in various embodiments, at about 400-1200V DC or about 850-1200V DC or about 850-900V DC) to the circuit 154-2 to power the heater module 156 and / or the motor 152-2, and optionally also provide a high voltage interlock loop (HVIL) signal line. The low voltage electrical connector 154-3L may, for example, provide communication signals (such as when connected to an external communication network (e.g., a CAN bus of the ZEV 30)) and / or a low voltage power input (such as for powering a low voltage portion of the circuit 154-2 used for communication), etc. The circuit 154-2 may include or be supplemented by an electromagnetic interference (EMI) filter circuit that is similar or identical to the circuit disclosed in, for example, PCT International Patent Application No. PCT / US2023 / 64617.

[0046] The heater module 156 of the illustrated embodiment includes a heater housing 156-1, one or more heater elements 156-2 (e.g., three as shown) and corresponding heat exchange elements 156-3, a base 156-4, a first manifold M1, and a second manifold M2. The heater module 156 can be positioned adjacent to the motor module 152 and operably connected between the motor module 152 and the control module 154.

[0047] In some embodiments, the heater housing 156-1 can be axially operatively connected between the motor housing 152-1 and the cover 154-1. In the illustrated embodiment, the heater housing 156-1 includes a thermal breaker 156-1T and further defines an outlet O. The first manifold M1 can be fluidly connected to the flow channel 152-1C in the flow path F, wherein the second manifold M2 is located downstream of the first manifold M1 in the flow path F, and the outlet O is located downstream of the second manifold M2 in the flow path F. In the illustrated embodiment, the inward protrusion 156-1P of the heater housing 156-1 defines the boundary of the first manifold M1, and the boundary of the first manifold M1 provides a fluid barrier between the first manifold M1 and the outlet O to provide a desired configuration of the flow path F, as further explained below. Other components such as the base 156-4 can further define the boundary of the first manifold M1. In the illustrated embodiment, the first manifold M1 and the second manifold M2 are located at discrete angular positions or circumferential positions having a semi-annular internal volume, and can be positioned opposite each other or diametrically opposite each other at a radially outward portion of the heater module 156. In other embodiments, such as when there are a greater number of heater elements 156-2, one or more additional manifolds may be utilized. The outlet O may allow the coolant fluid passing along the flow path F to leave the pump and heater assembly 132 and pass to other parts of the fluid circuit C. The heat breaker 156-1T may include at least one channel or cavity located between the flow path F and the exterior of the heater module 156, such as a curved channel near the outer periphery of the heater housing 156-1 as shown in the illustrated embodiment, which provides a thermal insulation gap. The heat breaker 156-1T may be filled with air alone or alternatively another thermal insulation material. In some embodiments, the heat breaker 156-1T may extend over most of the axial length of the heater housing 156-1. In the illustrated embodiment, the thermal break 156-1T is open to the interior volume of the control module cover 154-1. The thermal break 156-1T can help promote efficiency by keeping heat within the assembly 132 and also potentially prevent the outer surface of the heater module 156 from getting too hot. In some embodiments, additional thermal insulation material can optionally be placed along or around the outer surface of the heater housing 156-1.

[0048] A component stack is provided at least partially within the interior cavity of the heater housing 156-1, which establishes a non-linear section of the flow path F that is functionally close to the heater element 156-2 and the corresponding heat exchange element 156-3 while still allowing electrical connections (e.g., wiring) to exist without interfering with the flow path F and optionally providing mechanical support for the motor 152-2. The stacked arrangement of the heater elements 156-2 and the corresponding heat exchange elements 156-3 allows for a modular configuration within the heater module 156, so that the total number of heater elements 156-2 (and optionally also the number of corresponding heat exchange elements 156-3) can be changed as needed for a specific application in order to adjust operating parameters (such as thermal capacity, etc.) and meet fluid dynamic pressure requirements. For example, in other embodiments, a greater or lesser number of heater elements 156-2 may be included to provide greater or lesser heating capabilities. In embodiments where fewer heater elements 156-2 are used, the heat exchange element 156-3 may be present so long as the heat exchange element lacks a corresponding heater element 156-2, or alternatively, the heat exchange element 156-3 may be omitted and the heater housing 150-1 and / or other components of the heater module 156 are modified to accommodate a modified segment of the flow path F through the heater module 156. However, modifications to the configuration of the heater module 156 may involve little or no modification to the other modules of the pump and heater assembly 132, such that the same configuration of the pump module 150, motor module 152, and / or control module 154 may be used with a range of different configurations of the heater module 156. This modular configuration means that the basic design of the pump and heater assembly 132 and certain common core subcomponents may be used for a relatively wide variety of applications having different operating requirements for thermal capacity, etc., by making changes to only a limited number of subcomponents (such as only selected components of a single module, etc.).

[0049] As shown in the illustrated embodiment, the base 156-4 is located near the motor module 152 and provides a bearing guide 156-4B. In different embodiments, the base 156-4 can be configured as a single monolithic piece or an assembly of multiple discrete components. One end of the rotor 152-2R of the motor 152-2 can be rotatably supported on the bearing guide 156-4B by a suitable bearing (i.e., an additional bearing). This arrangement allows a more axially compact arrangement of the pump and heater assembly 132. For example, in some embodiments, the motor housing 152-1 directly supports one end of the rotor 152-2R via the bearing guide 152-1B, while the opposite end of the rotor 152-2R is supported by the bearing guide 156-4B, which is part of a component that can be separated from the motor housing 152-1, so that the structural support function is shared between different modules of the assembly 132. Although in further embodiments, the rotor 152 - 2R may be supported solely by or within the motor module 152 , such that the motor module 152 and the heater module 156 are more mechanically distinct than in the illustrated embodiment.

[0050] As shown in the illustrated embodiment, the heater elements 156-2 are generally planar, annular resistive heating elements that generate heat when an electric current is applied to them. For example, in some embodiments, the resistive heating elements may be ceramic heating elements of a known type. Figure 7 A portion of the heater module 156 is shown separately, with certain components omitted to better illustrate two of the heater elements 156-2 and the corresponding heat exchange element 156-3 in a stacked relationship. For a given one of the heater elements 156-2 in the illustrated embodiment, there is a front heat exchange element 156-3F and a rear heat exchange element 156-3R, with the corresponding heater element 156-2 sandwiched between the front heat exchange element and the rear heat exchange element to form a heater group 156H. The front heat exchange element 156-3F and the rear heat exchange element 156-3R can provide at least a liquid-tight seal around the corresponding heater element 156-2 to isolate and separate the corresponding heater element 156-2 from the flow path F and the coolant fluid. The front heat exchange element 156-3F and the rear heat exchange element 156-3R can be made of a metal material that is a relatively good thermal conductor, such as aluminum, etc. In alternative embodiments, the front heat exchange element 156-3F and the rear heat exchange element 156-3R may be combined into a single integral piece or may consist of two or more pieces connected together. During operation, heat may be conducted from both sides (or optionally only one side) of each heater element 156-2 through the front heat exchange element 156-3F and the rear heat exchange element 156-3R to the coolant fluid present in the adjacent portion of the flow path F.

[0051] In addition, channel 156W is provided by heater module 156, which is at least partially formed by corresponding channel openings through each of heater element 156-2, heat exchange element 156-3 and heater housing 156-1. In the illustrated embodiment, channel 156W is configured as a central, substantially linear, axially extending opening. Electrical connections such as using wires, cables, etc. can pass through channel 156W, which is separated from flow path F by at least a liquid-tight seal. For example, portions of heat exchange element 156-3 and heater housing 156-1 can form the boundaries of channel 156W and produce a fluid barrier. One or more sealing elements (such as O-ring seals, diaphragms, isolation tubes, etc.) can also be provided to properly fluidly isolate channel 156W from flow path F and coolant fluid (e.g., provide at least a liquid-tight seal between them). It can be electrically connected to heater element 156-2 in channel 156W or through channel 156W. Channel 156W can further provide a mass reduction function. The passage 156W may contain air or may optionally have a thermally insulating material inserted inside. In the illustrated embodiment, the lug 156-2T extends radially inward from each of the heater elements 156-2, and the terminal 156-5 (e.g., a screw clamp terminal, a ring terminal, etc.) electrically connects the wire 156-6 to the heater element 156-2 at the lug 156-2T. The wire 156-6 is further electrically connected to the circuit 154-2 of the control module 154. In some embodiments, timing can be used to rotationally position the lug 156-2T of each heater element 156-2 at different offset or staggered angular positions, and in addition, the terminals 156-5 can be arranged and / or rotated separately so that electrical connection (e.g., via the wire 156-6) can be achieved without interfering with each other. In this way, the passage 156W can provide a relatively easy passage so that the heater element 156-2 is electrically connected to the heater element after being stacked in the heater housing 156-1. For example, in some embodiments, electrical connections or other actions may be made in passage 156W using line of sight access (either before installing cover 154-1 of control module 154 or after removing the cover). In addition, because pump and heater assembly 132 may be used in vehicle applications where vibration and other forces may act on electrical connections, relatively robust electrical connections may be made in passage 156W (e.g., using screw terminals), which may be facilitated by having line of sight access during the manufacturing process.

[0052] like Figure 6B and Figure 7As shown, for example, the front heat exchange element 156-3F and the rear heat exchange element 156-3R can have a primary heat transfer surface 156-3P and a secondary heat transfer surface 156-3S. The primary heat transfer surface 156-3P can generally be a planar base surface. The secondary heat transfer surface 156-3S can be a fin, a column, etc. extending from the primary heat transfer surface 156-3P. The secondary heat transfer surface 156-3S can be staggered, such as in a repeating quincunx pattern. For example, in Figure 7 In the illustrated embodiment shown in the greatest detail, the secondary heat transfer surfaces 156-3S are configured as fins, each fin having an elongated generally rectangular perimeter, the fins being arranged to extend in a flow direction along the flow path F in staggered rows. In addition, the fins forming the secondary heat transfer surfaces 156-3S may each have a width that is less than the flow gap between fins of adjacent rows (e.g., slightly less than half the flow gap). In addition, the height (e.g., the general axial dimension) of the secondary heat transfer surfaces 156-3S may be such that a small gap exists between the secondary heat transfer surfaces 156-3S of the heat exchange elements 156-3 of adjacent groups 156H that face each other. For example, where the heights of all the secondary heat transfer surfaces 156-3S are equal or approximately equal, the secondary heat transfer surfaces 156-3S may have a height that is slightly less than half the spacing distance between the primary heat transfer surfaces 156-3P of adjacent groups 156H that face each other. Further, in some embodiments, the arrangement of the secondary heat transfer surfaces 156-3S facing the front heat exchange elements 156-3F and the rear heat exchange elements 156-3R of adjacent groups 156H can have the same pattern, so that the fins, pins, etc. are generally aligned with each other when the groups 156H are stacked together. However, the illustrated arrangement is disclosed only by way of example and not limitation. In other embodiments, other configurations and steps of the front heat exchange elements 156-3F and the rear heat exchange elements 156-3R and the primary heat transfer surfaces 156-3P and the secondary heat transfer surfaces 156-3S are possible, and in alternative embodiments, the secondary heat transfer surfaces 156-3S can even be omitted entirely.

[0053] During operation, heat energy is transferred from the heater element 156-2 to the heat exchange element 156-3 and then conducted through the material of the heat exchange element 156-3, which contacts the adjacent portions F1 to F2 present in the flow path F. n The coolant fluid in the heat exchange element 156-3 passes through the primary heat transfer surface 156-3P and the secondary heat transfer surface 156-3S. The secondary heat transfer surface 156-3S allows more surface area of ​​the heat exchange element 156-3 to be in contact with the coolant fluid. Thermal energy (i.e., heat) can thereby be transferred from the heat exchange element 156-3 to the portions F1 to F2 of the flow path F by conduction. n The coolant fluid in the

[0054] Steering Figure 5B As can be seen, in the illustrated embodiment, the flow path F enters the heater module 156 generally axially at the first manifold M1, which then distributes the coolant fluid parallel to two different generally radial portions of the flow path F (one portion F1 between the bottom 156-4 and the front heat exchange element 156-3F of the forward-most heater group 156H and another portion F2 between the rear heat exchange element 156-3R of the forward-most heater group 156H and the front heat exchange element 156-3F of the adjacent (middle) heater group 156H). As the coolant fluid passes along the groups 156H and / or between the groups 156H upon exiting the first manifold M1, the coolant fluid flows around the passage 156W in a generally annular path and then enters the second manifold M2. The coolant fluid may then flow generally axially within the second manifold M2, which then distributes the coolant fluid parallel to two additional generally radial portions of the flow path F, one portion F3 between the rear heat exchange element 156-3R of the middle heater group 156H and the front heat exchange element 156-3F of the rearmost heater group 156H, and another portion F4 between the rear heat exchange element 156-3R of the rear heater group 156H and the rear wall of the heater housing 156-1. As the coolant fluid passes along and / or between the groups 156H upon exiting the second manifold M2, the coolant fluid flows around the passage 156W in a generally annular path and then exits the heater module 156 (and the pump and heater assembly 132) in a generally radial direction through the outlet O, as shown. A collection manifold may optionally be disposed adjacent the outlet O to help collect coolant fluid from multiple paths for delivery to the outlet O. Thus, as shown in FIG. Figure 5B As shown, in some embodiments, the flow path F through the heater module 156 can have a hybrid parallel / series multi-pass arrangement, such as having multiple fluid parallel paths along the heater element 156-2, etc., which are arranged to flow in series with each other in a 2×2 or dual-pass arrangement. The groups 156H allow coolant fluid to flow between them without the need to manufacture any separate tubes, plates, etc. for fluid flow. The illustrated arrangement is shown only by way of example and not limitation, and other arrangements are possible in other embodiments, such as in embodiments with a smaller or larger number of heater elements 156-2, different directions of the outlet O (e.g., axial arrangement).

[0055] The housing of the pump and heater assembly 132 may be defined by a pump housing 150 - 1 , a motor housing 152 - 1 , a cover 154 - 1 , and / or a heater housing 156 - 1 .

[0056] FIG. 8A to FIG. 10 Another embodiment of a pump and heater assembly 232 is shown in FIG. Fig. 8A and Figure 8B is a cross-sectional view of the entire pump and heater assembly 232, and Fig. 9A , Fig. 9B and Fig.10 Portions or components thereof are shown. The pump and heater assembly 232 may be an integrated unit including a pump module 250, a control module 254, and a combined motor and heater module 260 (which may constitute a combination of a motor module and a heater module). Because many components of the assembly 232 are the same or similar to those of the assembly 132, and often operate in a similar manner, like reference numerals increased by one hundred are used.

[0057] The pump module 250 includes a pump housing 250-1 and a rotor 250-2 that together define a portion of the flow path F. The pump housing 150-1 defines an inlet I, which in the illustrated embodiment is a generally axially oriented opening located at the center of the pump housing 250-1 and the assembly 232, and the pump housing 150-1 may optionally include a thermal breaker 250-1T. The pump housing 250-1 has a profile with a rectangular end and a cylindrical rear in the illustrated embodiment, and the pump housing 250-1 lacks a volute, but the pump housing 250-1 can be configured in other ways similar to the pump module 150 discussed previously, and the pump housing 250-1 can function in a similar manner. In the illustrated embodiment, the rotor 250-2 is a radial impeller as part of the centrifugal pump configuration of the pump module 250, although in alternative embodiments, other configurations are also possible. The illustrated embodiment of the rotor 250-2 has a closed or covered configuration and includes fins or blades, a rear wall, and a front wall or cover. One or more stepped protrusions 250-2X extend from the front wall of the rotor 250-2 toward the pump housing 250-1 at the location where the front wall bends, and a corresponding set of stepped recesses 250-1X are provided in the pump housing 250-1, which receive at least a portion of the stepped protrusions 250-2X. The protrusions 150-2X and recesses 250-1X can help limit undesirable recirculation of coolant fluid within the pump module 250. During operation, coolant fluid entering the inlet I passes to the rotor 250-2, which pressurizes the coolant fluid and moves the coolant fluid along the flow path F. In the illustrated embodiment, as shown in FIG. Figure 8B As shown, the rotor 250 - 2 and housing 250 - 1 of the pump module 250 move the pressurized coolant fluid generally outward and toward the combined motor and heater module 260 .

[0058] The control module 254 may include a removable cover 254-1C, a thermal breaker 254-1T, and an opening 254W. H , 254W M254-3H, 254-3L. In the illustrated embodiment, the control module 254 is located at or near the end of the pump and heater assembly 232 opposite the pump module 250 and has a profile having a rectangular end portion and a cylindrical front portion adjacent to the combined motor and heater module 260, although other arrangements and configurations are possible in alternative embodiments. For example, in a further embodiment, the control module 254 may alternatively be positioned adjacent to the pump module 250, and in yet a further embodiment, the control module 254 may be divided into any desired number of separate sub-modules dedicated to controlling the pump module 250 and the combined motor and heater module 260. The housing 254-1 may include a bearing guide 254-1B and may further define an outlet O. The circuit 254-2 may include one or more circuit boards and may be capable of providing motor control and heater control functions to operate the combined motor and heater module 260 (such as via an opening 254W). H and 254W M The control module 154 may include a plurality of circuits 254-3A and 254-3B, and the plurality of circuits 254-3B may include a plurality of circuits 254-3A and 254-3B, and the plurality of circuits 254-3A may include a plurality of circuits 254-3B and a plurality of circuits 254-3C. The control module 154 may include a plurality of circuits 254-3A and 254-3B, and the plurality of circuits 254-3B may include a plurality of circuits 254-3C and a plurality of circuits 254-3A. The control module 154 may include a plurality of circuits 254-3A and 254-3B, and the plurality of circuits 254-3B ...

[0059] The combined motor and heater module 260 combines the functionality of the motor module 152 and the heater module 156, but uses a combined housing 260-1 and a different heater configuration and a different flow path arrangement than the assembly 132. In the illustrated embodiment, as shown in FIG. Fig. 8A and Figure 8B As shown, the combined motor and heater module 260 is axially positioned adjacent to and between the pump module 250 and the control module 254. As explained further below, in the illustrated embodiment, the combined motor and heater module 260 includes a combined housing 260-1, a motor 252-2, and one or more heater groups 256H.

[0060] The combined housing 260-1 can be configured as a single integral piece (as shown) or as an assembly of multiple discrete pieces. In some embodiments, the combined housing 260-1 includes a bearing guide 260-1B, one or more heater cavities 260-1H, one or more mass reduction cavities 260-1M, and a heat breaker 260-1T. In the illustrated embodiment, the combined housing 260-1 has a cylindrical profile. The bearing guide 260-1B can be arranged at or near the center or middle of the combined housing 260-1, at the cavity for the motor 252-2. The heat breaker 260-1T may include at least one channel or cavity between the flow path F and the outside of the combined pump and heater module 260, such as a curved channel near the outer periphery of the combined housing 260-1 as shown in the illustrated embodiment, which provides a thermal insulation gap. In some embodiments, the heat breaker 254-1T of the control module housing 254-1 can be aligned with the heat breaker 260-1T near the outside of the pump and heater assembly 232, and the heat breaker 250-1T of the pump housing 250-1 can be open to the heat breaker 260-1T of the combined housing 260-1. The heat breakers 254-1T, 260-1T can be filled with air or another thermal insulation material separately. In some embodiments, the heat breaker 260-1T can extend over most of the axial length of the combined housing 260-1, while the heat breaker 254-1T can extend axially only over a relatively short distance (e.g., only near the manifold). The heat breakers 250-1T, 254-1T, 260-1T can help promote efficiency by keeping heat in the assembly 232 and also prevent the outer surface of the pump and heater assembly 232 from becoming too hot. In some embodiments, additional thermal insulation can be optionally placed along or around the outer surface of the pump and heater assembly 232. Mass reduction chamber 260-1M (see Fig. 8A and Fig. 9A ) can help reduce the mass of the combined housing 260-1. The number and arrangement of the mass reduction cavities 260-1M can vary depending on the number of heater groups 256H. For example, while the heater group mass reduction cavities 260-1M are shown as axial cavities interspersed with the heater groups 256H in a circumferential pattern in the illustrated embodiment, in alternative embodiments, the mass reduction cavities 260-1M can be arranged in a different direction (e.g., radially) or position, or can take the form of gaps more like between the fins 152-1F.

[0061] The motor 252-2 includes a rotor 252-2R and a stator 252-2S, and is capable of generating a driving force (such as a torque that rotates the rotor 250-2 via the shaft 258, etc.) to drive or operate the pump module 250. The motor 252-2 can be, for example, a permanent magnet brushless DC motor similar or identical to the motor 152-2. The rotor 252-2R is directly or indirectly connected to the shaft 258, which in turn is directly or indirectly connected to the rotor 250-2 of the pump module 250, so that the torque generated by the motor 252-2 can be transmitted to the rotor 250-2 to operate the pump module 250 to pressurize the coolant fluid. At least one end of the rotor 252-2R (for example, the end adjacent to the pump module 250) can be supported by a bearing guide 260-1B of the combined housing 260-1 via a suitable bearing, and in some embodiments, the opposite end of the rotor 252-2R can be supported on the bearing guide 254-1B of the control module housing 254-1 via an additional bearing, so that the combined housing 260-1 directly supports one end of the rotor 252-2R via the bearing guide 260-1B, while the opposite end of the rotor 252-2R is supported by the bearing guide 254-1B, which is part of a component that can be spaced apart from the combined housing 260-1, thereby sharing structural support functions between different modules of the assembly 232 to help provide a more compact overall package. During operation, waste heat from the motor 252-2 can potentially be absorbed by the coolant fluid passing along the flow path F, which, in the illustrated embodiment, includes one or more segments passing outward from a portion of the motor 252-2 proximate the stator 252-2S (see FIG. Figure 8B ). Alternatively or additionally, an insulating air gap or insulating material may optionally be positioned between at least a portion of the motor 252-2 and one or more of the heater groups 256H.

[0062] The array of heater cavities 260-1H and corresponding heater groups 256H establishes a segment or segments of the flow path F through which the heater groups 256H pass in functional proximity, while still allowing electrical connections (e.g., wiring) to exist without interfering with the flow path F. The fluidly parallel arrangement of the heater cavities 260-1H and corresponding heater groups 256H allows for modular configuration within the combined motor and heater module 260, such that the total number of heater groups 256H can be varied as desired for a particular application in order to adjust operating parameters (like thermal capacity) and meet fluid dynamic pressure requirements, wherein the corresponding number of discrete parallel segments F1 to F2 of the flow path F are arranged in parallel. n In the illustrated embodiment, five heater groups 256H are provided (these heater groups 256H are circumferentially alternating with the five mass reduction chambers 260-1M; see Fig. 9A) and corresponding generally axial flow path portions F1 to F5 (although in Figure 8B Only portions F1, F2 are labeled in FIG. 1 ). However, a greater or lesser number of heater groups 256H may be included in further embodiments to provide greater or lesser thermal capacity. In embodiments utilizing fewer heater elements 156-2, a heater cavity 260-1H may be present, provided that the heater cavity 260-1H lacks a corresponding heater group 256H, or alternatively, one or more of the heater cavities 260-1H may be omitted (and optionally replaced with a mass reduction cavity 260-1M), and the combined housing 260-1 and / or other components of the combined motor and heater module 260 are modified to accommodate modified portions of the flow path F through the combined motor and heater module 260. However, modifications to the configuration of the combined motor and heater module 260 may include little or no modification to other modules of the pump and heater assembly 232, such that the same configuration of the pump module 250 and / or control module 254 may be used with a range of different configurations of the combined motor and heater module 260. This modular configuration means that the basic design of the pump and heater assembly 232 and certain common core subcomponents can be used for a relatively wide variety of applications having different operating requirements for thermal capacity, etc. by changing only a limited number of subcomponents (such as only selected components of a single module, etc.).

[0063] like FIG. 9A to FIG. 10As shown, each heater group 256H may include a resistive heater element 256-2 and a corresponding heat exchange element 256-3. In the illustrated embodiment, each heater element 256-2 may have an elongated configuration (such as the shape of an elongated cylinder or rod, etc.) or other non-planar shape. The heat exchange element 256-3 may be configured as a sleeve having a central cavity 256-3C that may be closed or sealed at one end and open at the opposite end, and a primary heat transfer surface 256-3P and a secondary heat transfer surface 256-3S. In some embodiments, the primary heat transfer surface 256-3P may be a generally cylindrical surface, and the secondary heat transfer surface 256-3S may be a plurality of fins, pins, or the like that protrude outwardly from the primary heat transfer surface 256-3P. In the illustrated embodiment, the secondary heat transfer surface 256-3S is a plurality of circumferentially spaced elongated fins that project radially outward (e.g., in a starburst pattern) with gaps therebetween and extend axially over a majority or majority of the primary heat transfer surface 256-3P at a generally mid-portion thereof. Further, in the illustrated embodiment, portions 256-3P1, 256-3P2 of the primary heat transfer surface 256-3P (which may be located at opposite ends of the heat exchange element 256-3) are free of the secondary heat transfer surface 256-3S. Each heater group 256H may be at least partially inserted within one of the heater cavities 260-1H. In the illustrated embodiment, each heater group 256H further extends into cavities 250-1H, 254-1H in the pump housing 250-1 and the control module housing 254-1, respectively, at opposite ends, and a seal can be provided between the heater group 256H and the cavities 250-1H, 254-1H at opposite ends of the heat exchange element 256-3. The opening 254WH can be aligned with the cavity 254-1H. The protruding secondary heat transfer surface 256-3S of the heat exchange element 256-3 can abut against the interior of the corresponding heater cavity 260-1H to support the heat exchange element 256-3, and in turn support the corresponding heater element 256-2. An electrical connection to the heater element 256-2 can be formed at the open end of the corresponding heat exchange element 256-3, wherein an electrical connection 256-6 (e.g., a wire) between the heater element 256-2 and the circuit 254-2 is routed through one or more openings 254W H .

[0064] Steering Figure 8B , Figure 8B Arrows are included to help illustrate fluid flow (although it should be noted that fluid flow in three dimensions is much smaller than in Figure 8B2 (slightly more complex as indicated by the arrows in FIG. 2 ), it can be seen that in the illustrated embodiment, the flow path F enters the pump and heater assembly 232 at an inlet I, which may be axially arranged, and then turns radially outward in the pump module 250 and reaches the first manifold M1. The flow path F may then flow from the manifold M1 along a flow path portion F1 to F n Axially passing through the heater cavity 260-1H and passing along the corresponding heater group 256H via multiple fluid parallel paths, wherein the first manifold M1 distributes the coolant fluid between the heater cavity 260-1H and the corresponding heater group 256H. The first manifold M1 can be at least partially defined by the pump housing 250-1, the combined housing 260-1 and / or the heat exchange element 256-3. In the illustrated embodiment, a portion 256-3P1 of the primary heat transfer surface 256-3P faces the first manifold M1 in a radial direction, such as where a portion of the portion 256-3P1 faces the outlet portion of the rotor 250-2, without any other structure radially therebetween. When the coolant fluid passes through the heater cavity 260-1H and along the group 256H, the coolant fluid is generally positioned outward (e.g., radially outward) and is in contact with the motor 252-2 and the opening 254W. M Isolation. The coolant fluid (now heated) exiting the heater cavity 260-1H flows into and enters the second manifold M2, which may be located on a side of the combined motor and heater module 260 axially opposite to the first manifold M1. The second manifold M2 may be at least partially defined by the combined housing 260-1, the control module housing 254-1, and / or the heat exchange element 256-3. In the illustrated embodiment, the first manifold M1 and the second manifold M1 are located at axially opposite ends of the heater cavity 260-1H, separated by a portion of the combined housing 260-1. In addition, in the illustrated embodiment, a portion 256-3P2 of the primary heat transfer surface 256-3P faces the second manifold M2 in a radial direction. In the illustrated embodiment, the coolant fluid in the second manifold M2 may flow generally (but not exclusively) circumferentially from the separate heater cavity 260-1H to an outlet O, which may be timed to be circumferentially or angularly offset from the heater cavity 260-1H. In the illustrated embodiment, the control module housing 254 - 1 may support the bearing guide 254 - 1B and may include an opening 254W. M A portion of occupies a central region that promotes circumferential flow in the second manifold M2. The coolant fluid may exit the pump and heater assembly 232 through an outlet O at a location spaced apart, for example, from the center or middle of the assembly 232 in a generally axial direction. Thus, as Figure 8BAs shown, in some embodiments, the flow path F through the combined motor and heater module 260 can have a generally parallel flow arrangement, such as having a plurality of discrete fluid parallel paths along the heat exchange elements 256-3 and the corresponding heater elements 256-2, which fluidly connect the first manifold M1 with the second manifold M2. The elongated configuration of the heater group 256H allows the coolant fluid to flow along them, defined by the walls of the heater cavity 260-1H, which can be cast, drilled, milled or otherwise formed in the combined housing 260-1 without the need to manufacture any separate tubes, plates, etc. for fluid flow. However, it should be noted that the illustrated arrangement is shown only by way of example and not limitation, and other arrangements are possible in other embodiments (such as in embodiments having a smaller or greater number of heater groups 256H, etc.). During operation, heat can be conducted from each heater element 256-2 through the corresponding heat exchange element 256-3 to adjacent portions F1 to F present in the flow path F. n The coolant fluid in the

[0065] The enclosure of the pump and heater assembly 232 may be defined by the pump housing 250 - 1 , the control module housing 254 - 1 (and cover 254 - 1C), and / or the combination housing 260 - 1 .

[0066] In yet further embodiments, the different heater elements and associated heat exchangers in the heater section may have different configurations, for example, such as the mix and match configurations disclosed with respect to the different embodiments discussed above, etc. Furthermore, the resistive heater elements discussed above may be used in conjunction with non-electric heater elements or heat exchangers to further heat the coolant fluid, as desired for a particular embodiment.

[0067] For any embodiment of the pump and heater assembly 32, 132, and / or 232, the heat output of the entire unit can be controlled in a variable manner. Such variable heat output can be controlled by the control module 54, 154, or 254. For example, the pump and heater assembly 32, 132, or 232 can adjust the heater modules 56, 156, 260 and associated heater elements 561 to 562 based on a heating demand that can be established based on sensor data, the availability of heat from other sources (e.g., the availability of waste heat from a traction motor, etc., which can be used to handle the total heat demand), and / or a heating request signal from an external controller 38. n , 156-2, or 256-2 to a desired set point between 0%-100% of the (maximum) available heat output. In one embodiment, all heater elements 561 to 56 n, 156-2 or 256-2 may be controlled together, that is, all together in the same manner at the same power level. In alternative embodiments, the heater elements 561 to 562 may be controlled differently. n , 156 - 2 or 256 - 2, some or all of them, for example, to lessen the power supply to the heater elements 56 1 to 56 n , 156-2, or 256-2, or completely shut down the heater elements 561 to 56 n , 156-2 or 256-2, while powering the heater elements 561 to 565 at a relatively high level. n In this alternative embodiment, the total heat output of the pump and heater assembly 32, 132, or 232 at any given time is determined by the heater elements 561 to 562. n , 156-2 or 256-2. In addition, the variable heat output control can be continuously variable, generally at any possible level between 0%-100% of the available heat output, or alternatively at a given number of discrete heat output levels, such as at discrete high heat output levels, medium heat output levels, and low heat output levels.

[0068] The method of manufacturing and using the embodiment of the pump and heater assembly according to the present invention will be clear to those of ordinary skill in the art from the whole of the present disclosure (including the drawings). In addition, many advantages and benefits associated with the disclosed invention will be appreciated. For example, the embodiments disclosed in the present invention provide a high-voltage electric pump and heater assembly that is highly modular in construction to allow flexibility in heating capacity while still allowing the use of the same or highly similar core components. A relatively compact and relatively low-quality overall package is also provided in the disclosed embodiments. In addition, electrical connectors (such as wired connectors, etc.) can be relatively easily manufactured without interference between the wiring of wires and fluid lines that must be isolated to prevent short circuits and / or leaks. In some embodiments, the manufacture and assembly of the pump and heater assembly can be completed modularly, thereby allowing different heater modules (including different combinations of motors and heater modules) to be used with similar or identical core components, and the assembly can involve the overall axial stacking of the modules, which makes the assembly relatively easy, such as making it relatively easy to complete the internal electrical connections and / or fluid connections within or between the modules. Furthermore, a relatively strong and rigid structure and connections may be provided to accommodate the sometimes extreme conditions that the pump and heater assembly may experience when used in a vehicle application.

[0069] Discussion of Possible Implementations

[0070] A pump and heater assembly may include an electric motor, a pump operably connected to the electric motor, an electric heater module fluidly connected to the pump, a control module, and a flow path, the electric heater module including a housing, a plurality of heater elements each configured to generate heat by electrical resistance, and a plurality of heat exchange elements each having a primary heat transfer surface and a secondary heat transfer surface protruding from the corresponding primary heat transfer surface, such that at least one of the heat exchange elements is provided within the housing adjacent to each of the heater elements, the control module being electrically connected to the electric motor and the heater elements, the flow path fluidly passing from an inlet through the pump, then through the electric heater module, and then through an outlet, the flow path further passing through a first manifold and a second manifold, the first manifold and the second manifold being fluidly connected to a plurality of fluid parallel portions of the flow path, wherein at least one of the plurality of fluid parallel portions passes along each of the heat exchange elements to allow heat transfer therebetween (and to the fluid present in the flow path).

[0071] The pump and heater assembly of the preceding paragraph may optionally (additionally and / or alternatively) include any one or more of the following features, configurations and / or additional components:

[0072] The electric motor and heater element may each be configured to operate at approximately 450V DC (nominal) or higher;

[0073] The electric motor may be configured as a permanent magnet brushless DC motor;

[0074] The pump may include a radial impeller operatively connected to the motor via a shaft;

[0075] The radial impeller may include a rear wall, a front wall, and a plurality of blades between the rear wall and the front wall;

[0076] The front wall may include a plurality of stepped protrusions extending at least partially into a corresponding plurality of stepped recesses in a pump housing positioned adjacent the radial flow impeller;

[0077] The heater element may be configured as a panel arranged in a stacked relationship with a heat exchange element such that the heat exchange element isolates the heater element from the flow path (fluidically or at least in a liquid-tight manner);

[0078] The primary heat transfer surface of each of the heater elements may be generally planar, and the secondary heat transfer surfaces may be configured as fins projecting from the corresponding primary heat transfer surface in a staggered pattern;

[0079] The fins of opposing ones of the heat exchange elements may be aligned with each other, separated by gaps;

[0080] The heater module may further include a passageway formed at least in part by a passageway opening through each of the heater elements, each of the heat exchange elements, and the housing, the electrical connections between the heater elements and the control module being able to extend through the passageway, and the passageway being able to be isolated (fluidically or at least in a liquid-tight manner) from the flow path;

[0081] The heater elements may each have an annular configuration with at least one radially inwardly facing tab protruding into the channel, and the heater elements may be arranged such that corresponding tabs are rotated to different angular positions;

[0082] A further plurality of fluidly parallel portions of the flow path may be fluidly connected to the second manifold downstream of the second manifold such that the flow path has a multi-pass arrangement through the electric heater module;

[0083] The first manifold and the second manifold may be positioned radially opposite each other at a radially outward portion of the electric heater module;

[0084] The heater elements may be configured as rods, the heat exchange elements may each be configured as sleeves having a central cavity, and each of the heater elements may be at least partially positioned within the central cavity of a corresponding one of the heat exchange elements;

[0085] The secondary heat transfer surface may be configured as a plurality of circumferentially spaced elongated fins projecting radially outward;

[0086] The housing may have a plurality of heater cavities, and one of the heater elements and one of the heat exchange elements may each be at least partially positioned with one of the heater cavities;

[0087] The housing may include a thermal disconnect between the flow path and an exterior of the heater module; and / or

[0088] The motor may include a rotor and a stator, and opposite ends of the rotor may be rotatably supported via bearing guides of different, separable structures (eg, modular, separable structures).

[0089] A vehicle may include: the above-mentioned pump and heater assembly (with or without any of the above-mentioned optional features or configurations); an on-board high-voltage power supply, which is electrically connected to the pump and heater assembly; a liquid to air heat exchanger; and a fluid circuit, which fluidly connects the heat exchanger and the pump and heater assembly.

[0090] A method for electrically heating and pumping a fluid may include: providing high voltage electrical power to a motor and a plurality of heater elements using a shared control module; operating the motor to drive a pump, wherein the motor, heater elements, and pump are all part of a pump and heater assembly, and the pump and heater assembly are configured as an integrated unit having a flow path therethrough; pressurizing a coolant fluid using the pump; distributing the pressurized coolant fluid to a plurality of heat exchange elements using a manifold, wherein each of the plurality of heat exchange elements is positioned adjacent to at least one of the heater elements; generating thermal energy using the heater elements; conductively transferring the generated heat to the pressurized coolant fluid through the plurality of heat exchange elements; collecting the heated, pressurized coolant fluid in an additional manifold; and moving the heated, pressurized coolant fluid through an outlet port to exit the pump and heater assembly.

[0091] Additionally and / or alternatively, the method of the preceding paragraph may optionally include any one or more of the following features, configurations and / or additional steps:

[0092] The pressurized coolant fluid in the flow path may be passed outwardly from the motor;

[0093] Pressurized coolant fluid may be passed through the motor upstream of the heater element in the flow path;

[0094] Carrying the pump and heater assembly on board the vehicle such that the high voltage electrical power provided to the motor and the plurality of heater elements is provided by one or more power sources carried on board the vehicle; and / or

[0095] The heated, pressurized coolant fluid is delivered from the pump and heater assembly via a fluid circuit to at least one heat exchanger and then back to the pump and heater assembly.

[0096] A method of manufacturing a high voltage electric pump and heater assembly may include: manufacturing the first pump and heater assembly by providing a first pump module, connecting a first electric motor to the first pump module, connecting a first control module to the first electric motor, determining a maximum expected heat demand for a first application, determining a sufficient number of resistive heater elements to meet the maximum expected heat demand for the first application, and connecting the sufficient number of resistive heater elements to the first control module to be able to meet the maximum expected heat demand for the first application; and manufacturing a second pump and heater assembly by providing a second pump module having substantially the same configuration as the first pump module, connecting a second electric motor to the second pump module, wherein the second electric motor has substantially the same configuration as the first electric motor, connecting a second control module to the second electric motor, wherein the second control module has substantially the same configuration as the first control module, thereby determining a maximum expected heat demand for a second application, determining a sufficient number of resistive heater elements to be able to meet the maximum expected heat demand for the second application, wherein the sufficient number for the first application and the second application is different, and connecting a sufficient number of additional resistive heater elements to the second control module to be able to meet the maximum expected heat demand for the second application.

[0097] The method of the preceding paragraph may optionally additionally and / or alternatively include any one or more of the following features, configurations and / or additional steps:

[0098] Connecting a sufficient number of the resistive heater elements to the first control module may include electrically connecting the wires through a shared channel, and the shared channel may provide line-of-sight access to the resistive heater elements.

[0099] An integrated pump and heater assembly may include: an electric motor, a pump operably connected to the electric motor, an electric heater module fluidly connected to the pump, a control module, and a flow path, the electric heater module including a housing, a plurality of heater elements, and a plurality of heat exchange elements, each of the plurality of heater elements being configured to generate heat from a power source, wherein at least one of the plurality of heat exchange elements is provided within the housing adjacent to each of the heater elements, the control module being electrically connected to the electric motor and the heater elements, and the flow path flowing from an inlet through the pump, then through the electric heater module, and then through the outlet, wherein the flow path flows along each of the heat exchange elements to allow heat transfer with the fluid in the flow path.

[0100] Overview

[0101] Any relative terms or terms of degree used herein, such as "substantially," "essentially," "substantially," "approximately," and the like, should be interpreted in accordance with and subject to any applicable definitions or limitations expressly set forth herein. In all cases, any relative terms or terms of degree used herein should be interpreted as broadly encompassing any relevant disclosed embodiments as well as such ranges or variations as would be understood by one of ordinary skill in the art in view of the entirety of the present disclosure, such as encompassing ordinary manufacturing tolerance variations, accidental alignment variations, transient alignment or shape variations caused by thermal, rotational, or vibratory operating conditions, transient signal or power fluctuations, and the like. In addition, any relative terms or terms of degree used herein should be interpreted as encompassing ranges that expressly include the specified qualities, characteristics, parameters, or values, without variations, as if no qualifying relative terms or terms of degree were utilized in a given disclosure or narrative.

[0102] The word "comprise" or variations such as "comprises" or "comprising" are used herein in an open-ended manner and should be interpreted as referring to the inclusion of the stated elements, features, or steps, or groups of elements, features, or steps, but not to the exclusion of any other elements, features, or steps, or groups of elements, features, or steps. Unless further expressly limited, the use of the word "comprise" or variations thereof does not individually exclude additional, unmentioned elements, steps, or groups of elements or steps. In addition, unless otherwise expressly limited, the words "a" and "an" as used herein refer to one or more and do not limit the identified elements, features, steps, etc. to one and only one. However, the use of the words "a" and "an" herein should be interpreted in accordance with any applicable further limitations expressly stated in the context of any specific example of use, and is subject to any applicable further limitations, without generally extending such context-specific limitations to all other uses.

[0103] Although the present invention has been described with reference to preferred embodiments, those skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the present invention. Figure 4 , Figures 5A to 7 B and Figures 8A to 10Embodiments of pump and heater assemblies are illustrated separately. In general, those skilled in the art will appreciate that the components, configurations, and functionality described with respect to one embodiment may be generally used with another disclosed embodiment unless otherwise expressly indicated relative thereto. In addition, some embodiments may include the same or similar pump, motor, and control module components, but may have different configurations of heater sections, for example, with a spiral or helical flow path along or between heater elements. In addition, in other embodiments, the manifold (when used) may be formed or defined entirely by one or more heat exchange elements, external housing components, dedicated manifold structures, and the like.

Claims

1. A pump and heater assembly comprising: Electric motor; a pump operatively connected to the electric motor; an electric heater module fluidly connected to the pump, the electric heater module comprising: case; a plurality of heater elements, each of the plurality of heater elements being configured to generate heat through electrical resistance; and a plurality of heat exchange elements, each of the plurality of heat exchange elements having a primary heat transfer surface and a secondary heat transfer surface projecting from the respective primary heat transfer surface, wherein at least one of the heat exchange elements is disposed within the housing adjacent each of the heater elements; a control module, wherein the control module is electrically connected to the electric motor and the heater element; and a flow path from an inlet through the pump, then through the electric heater module, and then through an outlet, wherein the flow path further passes through a first manifold and a second manifold, the first manifold and the second manifold being fluidly connected to a plurality of fluid parallel sections of the flow path, and wherein at least one of the plurality of fluid parallel sections passes along each of the heat exchange elements to allow heat transfer between the heat exchange elements.

2. The pump and heater assembly of claim 1, wherein: The electric motor and the heater element are each configured to operate at approximately 450V DC or greater.

3. The pump and heater assembly of claim 1, wherein: The electric motor is configured as a permanent magnet brushless DC motor.

4. The pump and heater assembly of claim 1, wherein: The pump includes a radial impeller operatively connected to the motor via a shaft.

5. A pump and heater assembly according to claim 4, wherein: The radial impeller includes a rear wall, a front wall, and a plurality of blades therebetween, wherein the front wall includes a plurality of stepped protrusions extending at least partially into a corresponding plurality of stepped recesses in a pump housing positioned adjacent the radial impeller.

6. The pump and heater assembly of claim 1, wherein: The heater element is configured as a panel arranged in a stacked relationship with the heat exchange element, wherein the heat exchange element isolates the heater element from the flow path.

7. A pump and heater assembly according to claim 6, wherein: The primary heat transfer surface of each of the heater elements is substantially planar, and wherein the secondary heat transfer surfaces are configured as fins protruding from the corresponding primary heat transfer surface in a staggered pattern.

8. A pump and heater assembly according to claim 7, wherein: The fins of opposing ones of the heat exchanging elements are aligned with each other, separated by gaps.

9. The pump and heater assembly of claim 6, wherein: The heater module further includes a channel formed at least in part by a channel opening through each of the heater elements, each of the heat exchange elements, and the housing, and wherein an electrical connection between the heater elements and the control module extends through the channel, and wherein the channel is isolated from the flow path.

10. A pump and heater assembly according to claim 9, wherein: The heater elements each have an annular configuration with at least one radially inwardly facing tab protruding into the channel, wherein the heater elements are arranged to rotate respective ones of the tabs to different angular positions.

11. The pump and heater assembly of claim 6, wherein: Another plurality of fluidly parallel portions of the flow path are fluidly connected to the second manifold downstream of the second manifold such that the flow path has a multi-pass arrangement through the electric heater module.

12. A pump and heater assembly according to claim 11, wherein: The first manifold and the second manifold are positioned radially opposite each other at a radially outward portion of the electric heater module.

13. The pump and heater assembly of claim 1, wherein: The heater elements are configured as rods, wherein the heat exchange elements are respectively configured as sleeves having a central cavity, and wherein each of the heater elements is at least partially positioned within the central cavity of a corresponding one of the heat exchange elements.

14. A pump and heater assembly according to claim 13, wherein: The secondary heat transfer surface is configured as a plurality of circumferentially spaced elongated fins projecting radially outwardly.

15. The pump and heater assembly of claim 13, wherein: The housing has a plurality of heater cavities, wherein one of the heater elements and one of the heat exchange elements are each at least partially positioned with one of the heater cavities.

16. The pump and heater assembly of claim 1, wherein: The housing includes a heat disconnect between the flow path and an exterior of the heater module.

17. The pump and heater assembly of claim 1, wherein: The motor includes a rotor and a stator, wherein opposite ends of the rotor are rotatably supported via bearing guides having different structures that can be spaced apart.

18. A vehicle comprising: The pump and heater assembly of claim 1; an on-board high voltage power supply electrically connected to the pump and heater assembly; Liquid-to-air heat exchangers; and A fluid circuit fluidly connects the heat exchanger and the pump and heater assembly.

19. A method of electrically heating and pumping a fluid, the method comprising: using a shared control module to provide high voltage electrical power to the motor and to the plurality of heater elements; operating the motor to drive a pump, wherein the motor, the heater element, and the pump are all part of a pump and heater assembly, the pump and heater assembly being configured as an integrated unit having a flow path therethrough; pressurizing the coolant fluid using the pump; distributing the pressurized coolant fluid to a plurality of heat exchange elements using a manifold, wherein each of the plurality of heat exchange elements is positioned adjacent to at least one of the heater elements; generating heat energy using the heater element; conductively transferring the generated heat to the pressurized coolant fluid through the plurality of heat exchange elements; collecting heated, pressurized coolant fluid in an additional manifold; and The heated, pressurized coolant fluid is moved through an outlet aperture to exit the pump and heater assembly.

20. The method according to claim 19, wherein: The pressurized coolant fluid in the flow path passes outwardly through the motor.

21. The method according to claim 19, wherein: The pressurized coolant fluid passes through the motor in the flow path upstream of the heater element.

22. The method of claim 19, further comprising: carrying the pump and heater assembly on a vehicle, wherein the high voltage electrical power provided to the motor and the plurality of heater elements is provided by one or more power sources carried on the vehicle; and The heated, pressurized coolant fluid is delivered from the pump and heater assembly via a fluid circuit to at least one heat exchanger and then back to the pump and heater assembly.

23. A method of manufacturing a high voltage electric pump and heater assembly, the method comprising: The first pump and heater assembly is manufactured by the following steps: providing a first pump module; connecting a first electric motor to the first pump module; connecting a first control module to the first electric motor; determining a maximum expected heat demand for a first application; determining a sufficient number of resistive heater elements to meet the maximum expected heat demand of the first application; as well as connecting a sufficient number of resistive heater elements to the first control module to be capable of satisfying a maximum expected heat demand of a first application; and The second pump and heater assembly is manufactured by the following steps: providing a second pump module, wherein the second pump module has substantially the same configuration as the first pump module; connecting a second electric motor to the second pump module, wherein the second electric motor has substantially the same configuration as the first electric motor; connecting the second control module to the second electric motor, wherein the second control module has substantially the same configuration as the first control module; determining a maximum expected heat demand of a second application; determining a sufficient number of resistive heater elements to meet the maximum expected heat demand of the second application, wherein the sufficient number is different for the first application and the second application; and A sufficient number of additional resistive heater elements are connected to the second control module to be able to meet a maximum expected heat demand of the second application.

24. The method according to claim 23, wherein: The step of connecting the sufficient number of resistive heater elements to the first control module includes electrically connecting wires through a shared channel, wherein the shared channel provides line-of-sight access to the resistive heater elements.

25. An integrated pump and heater assembly comprising: Electric motor; a pump operatively connected to the electric motor; an electric heater module fluidly connected to the pump, the electric heater module comprising: case; a plurality of heater elements, each of the plurality of heater elements being configured to generate heat from electrical power; and a plurality of heat exchange elements, wherein at least one of the heat exchange elements is disposed within the housing adjacent to each of the heater elements; a control module electrically connected to the electric motor and the heater element; and A flow path from the inlet through the pump, then through the electric heater module, and then through the outlet, wherein the flow path further passes along each of the heat exchange elements to allow heat transfer with the fluid in the flow path.

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