Valve and pump module for thermal management system

Abstract

In one aspect, a valve and pump module for controlling flow of coolant in a thermal management system for a vehicle is provided. The valve and pump module includes a valve and pump module housing, a valve member, a valve actuator, a pump impeller, and a pump drive.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 378,769, filed on October 7, 2022, the entire content of which is incorporated herein by reference if permitted. Technical field

[0003] This specification generally relates to a thermal management system for an electric vehicle and, more particularly, to a valve for directing coolant flow in an electric vehicle. Background art

[0004] It is known to provide a thermal management system for an electric vehicle in which excess heat generated by one component is used by another component in need of heating. However, some such systems are complex and involve a large number of components, such as valves and pumps, and have many seals and components as well as associated complexities and high pressure drops in assembly. Improved valves and pumps are desired. Summary of the invention

[0005] In one aspect, a valve and pump module for controlling the flow of coolant in a thermal management system for a vehicle. The valve and pump module includes a valve and pump module housing, a valve member, a valve actuator, a pump impeller, and a pump driver. The valve and pump module housing defines a valve chamber and has a plurality of valve inlet ports and valve outlet ports. The valve member is positioned within the valve chamber and has at least one through-orifice. The valve member is rotatable about a valve member axis between a first position and a second position, in which, in the first position, the at least one through-orifice fluidly connects the plurality of valve inlet ports to the valve outlet port in a first manner to provide a first flow arrangement through the coolant delivery system, and in the second position, the at least one through-orifice fluidly connects the plurality of valve inlet ports to the valve outlet port in a second manner to provide a second flow arrangement through the coolant delivery system different from the first flow arrangement. The at least one through-orifice has at least one inlet end and at least one outlet end, and the at least one through-orifice extends radially inwardly from the at least one inlet end toward the valve member axis and axially inwardly from the at least one outlet end. The valve actuator includes a valve actuator motor and a valve actuator gearing, the valve actuator gearing including a final gear positioned for rotation about the valve member axis and operatively connected to the valve member to rotate the valve member between the first position and the second position. The valve actuator is located on a first axial side of the valve member. The valve and pump module housing defines a pump chamber having a volute. The valve and pump module housing has an axially extending pump inlet port and a tangentially extending pump outlet port. The pump inlet port is coaxial with and fluidly connected to the valve outlet port. The pump impeller is positioned within the pump chamber for rotation about a pump impeller axis coaxial with the valve member axis. The pump impeller is shaped to drive coolant from the pump inlet port through the volute to the pump outlet port. The pump driver includes an axial flux motor including a stator connected to the valve and pump module housing and a rotor connected to and coaxial with the pump impeller. The rotor is rotatable by energizing the stator to drive rotation of the pump impeller.

[0006] Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] To better understand the embodiments described herein and to more clearly show how these embodiments may be implemented, reference will now be made, by way of example only, to the accompanying drawings.

[0008] Figure 1 is a schematic view of a thermal management system for an electric vehicle including a valve and pump module according to a first embodiment of the present disclosure.

[0009] Figure 2 is Figure 1 a perspective view of the valve and pump module shown in

[0010] Figure 3 is Figure 2 a cross-sectional side view of the valve and pump module shown in

[0011] Figure 4 is Figure 2 a cross-sectional perspective view of a portion of the valve and pump module shown in

[0012] Figure 5A is from Figure 2 a perspective view of the valve member of the valve and pump module shown in

[0013] Figure 5B is from Figure 2 a perspective view of the valve member of the valve and pump module shown in

[0014] Figure 6 is from Figure 2 a plan view of the valve actuator of the valve and pump module shown in

[0015] Figure 7 is from Figure 2 an enlarged cross-sectional side view of the sealing member of the valve and pump module shown in

[0016] Figure 8 is a perspective view of an alternative embodiment of the valve and pump module housing, showing three valve inlet ports circumferentially spaced 120 degrees apart.

[0017] Figure 9 is a side view of an electric vehicle incorporating a valve and a thermal management system. DETAILED DESCRIPTION

[0018] For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Additionally, numerous specific details are set forth in order to provide a thorough understanding of one or more embodiments described herein. However, one of ordinary skill in the art will understand that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the embodiments described herein. It should first be understood that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the figures and described below.

[0019] Unless the context indicates otherwise, the various terms used throughout this specification can be read and understood as follows: The "or" used throughout is inclusive, as if written "and / or"; the singular articles and pronouns used throughout include their plural forms, and the plural articles and pronouns used throughout include their singular forms; similarly, gender pronouns include their corresponding pronouns, so pronouns should not be understood as restricting anything described herein to use, implementation, execution, etc. by a single gender; "exemplary" should be understood as "illustrative" or "by way of example" and is not necessarily understood as "preferred" to other embodiments. Further definitions of terms can be listed herein; as will be understood by reading this specification, these definitions can apply to prior and subsequent instances of those terms.

[0020] Without departing from the scope of the present disclosure, modifications, additions, or omissions can be made to the systems, devices, and methods described herein. For example, components of the systems and devices can be integrated or separated. Additionally, the operations of the systems and devices disclosed herein can be performed by more, fewer, or other components, and the methods described can include more, fewer, or other steps. Further, the steps can be performed in any suitable order. As used in this document, "each" refers to each member of a group or each member of a subgroup of a group.

[0021] The indefinite article "a" is not intended to be limited to meaning "one" element of a group. Where applicable, it is intended to mean "one or more" elements of a group (i.e., unless it is clear from the context that only one element of the group is suitable).

[0022] Any reference to up, down, top, bottom, etc. is intended to refer to the orientation of a particular element during use of the claimed subject matter and not necessarily to its orientation during transportation or manufacture. For example, the upper surface of an element can still be considered the upper surface of the element even when the element is lying on its side.

[0023] Reference Figure 9, which shows an electric vehicle 10. The term "electric vehicle" is intended to include any vehicle that includes an electric motor 13 that drives one or more wheels 15 of the electric vehicle 10. The electric motor 13 may also be referred to as a traction motor 13 to distinguish it from other electric motors that may be present in the electric vehicle 10 for driving the movement of secondary elements such as seats and windows of the electric vehicle 10. The electric vehicle 10 includes a battery pack 11 for storing and releasing charge for use by the traction motor 13. For simplicity, the battery pack 11 may also be referred to as the battery 11. The battery pack 11 may incorporate a plurality of any suitable type of storage units, such as pouch cells, cylindrical cells, other types of cells, or any combination thereof. In addition to the battery pack 10, the electric vehicle 10 may also include any other suitable type of energy storage device. The electric vehicle 10 also includes a passenger compartment shown at 16. The electric vehicle 10 also includes an ECU (electronic control unit) 18 that controls the operation of various components of the electric vehicle 10. The ECU 18 may be part of a control system 19 that may include several additional controllers in addition to the ECU 18.

[0024] General description of the thermal management system

[0025] Reference Figure 1 , which shows a thermal management system 20 for the electric vehicle 10. The thermal management system 20 is used to control the temperature of a plurality of thermal loads 22 in the electric vehicle 10, the plurality of thermal loads 22 including, for example, the traction motor 13 and the battery pack 11. For the purposes of the present disclosure, the traction motor 13 as a thermal load may include both the motor itself and the attached power electronics, the power electronics including an inverter for converting the DC current from the battery pack 11 into an AC current for driving the traction motor 13.

[0026] The thermal management system 20 includes a refrigerant delivery system 24 for delivering refrigerant and a coolant delivery system 26 for delivering coolant. The refrigerant is shown by conduit 28 in Figure 1 A, and the coolant is represented by conduit 30.

[0027] The refrigerant delivery system 24 includes a chiller 32 having an expansion valve upstream thereof, a cabin evaporator 36, and a condenser 40. The chiller 32 receives the refrigerant 28 and evaporates the refrigerant 30. The chiller 32 is also positioned to receive the coolant 30 from the coolant delivery system 26 and cools the coolant 30 by the evaporation of the refrigerant 28 in the chiller 32.

[0028] Conversely, the condenser 40 is positioned to receive the coolant 30 from the coolant delivery system 26 and heats the coolant 30 by the condensation of the refrigerant 28 in the condenser 40.

[0029] The compressor shown at 41 increases the pressure of the refrigerant 28 and drives the flow of the refrigerant 28 through the refrigerant delivery system 24.

[0030] The coolant delivery system 26 also includes a cabin heater core 42 positioned to use the coolant 30 to heat the air flow leading to the passenger compartment 16 of the electric vehicle 10, a coolant heater 44 positioned to heat the coolant 30 by resistive heating, and a radiator 46 positioned to cool the coolant. The coolant heater 44 can be any suitable type of heater, such as a PTC heater, and can be positioned immediately upstream of the cabin heater core 42. The radiator can be positioned near the front of the electric vehicle 10 to receive the air flow entering the electric vehicle 10 from the front end of the electric vehicle 10.

[0031] As will be understood by those skilled in the art, the degassing tank shown at 47 can be provided where appropriate.

[0032] The thermal management system can include at least one valve and pump module 200. In Figure 1 the example embodiment shown, there are a first valve and pump module 200a and a second valve and pump module 200b.

[0033] General description of the valve and pump module

[0034] Referring to Figure 2 and Figure 3 each valve and pump module 200 includes a valve 201a and a pump 201b. In the embodiment shown, the valve and pump module 200 includes a valve and pump module housing 202 (the valve and pump module housing 202 being part of both the valve 201a and the pump 201b), and also includes a valve member 204, a valve actuator 206, a pump impeller 208, and a pump driver 210.

[0035] The valve and pump module housing 202 defines a valve chamber 212 and has a plurality of valve inlet ports 214 and valve outlet ports 216. In the example shown, the valve includes three valve inlet ports 214 shown as 214a, 214b, and 214c respectively. For each of the valve inlet ports 214, there can be an optionally provided valve inlet conduit 217, and for the valve outlet port 216, there can be an optionally provided valve outlet conduit 219. As shown, there are three valve inlet conduits 217a, 217b, and 217c sealingly mating with the three valve inlet ports 214a, 214b, and 214c respectively and a valve outlet conduit 219 sealingly mating with the valve outlet port 216.

[0036] The valve member 204 controls the flow of coolant through the valve 201a and thus through the valve to the pump module 200. The valve member 204 is positioned within the valve chamber 212 and has at least one through-orifice 218. The at least one through-orifice 218 has at least one inlet end 220 and at least one outlet end 222 and may optionally extend radially inwardly from the at least one inlet end 220 towards the valve member axis Av and axially inwardly from the at least one outlet end 222.

[0037] The valve member 204 is capable of rotating about the valve member axis Av between a first position ( Figure 5A ) and a second position ( Figure 5B ), in the first position, the at least one through-orifice 218 fluidly connects the plurality of valve inlet ports 214 to the valve outlet port 216 in a first manner to provide a first flow arrangement through the coolant delivery system 26, in the second position, the at least one through-orifice 218 fluidly connects the plurality of valve inlet ports 214 to the valve outlet port 216 in a second manner to provide a second flow arrangement through the coolant delivery system 26 that is different from the first flow arrangement. Figure 5A and Figure 5B Examples are shown in Figure 5A . In Figure 5B , the valve member 204 connects the valve inlet port 214c to the valve outlet port 216. In Figure 5A and Figure 5B , the valve inlet conduits 217a, 217b and 217c are shown only in transparent outline for illustrative purposes and so as not to obscure the valve member 204 itself. The first and second positions as shown for the valve member 204 can completely cut off the flow from one of the valve inlet ports 214 and open the flow from the other of the valve inlet ports 214. However, in some embodiments, both the first and second positions for the valve member 204 can allow some flow from a particular valve inlet port 214 to the valve outlet port 216, but can vary the allowed flow rate. These two examples of the first and second positions constitute fluidly connecting the plurality of valve inlet ports 214 to the valve outlet port 216 in a second manner to provide a second flow arrangement through the coolant delivery system 26 that is different from the first flow arrangement.

[0038] The valve member 204 can have any suitable shape. For example, the valve member 204 can have a generally spherical outer surface 223.

[0039] The valve actuator 206 includes a valve actuator motor 224 and a valve actuator gearing 226, which includes a final gear 226a positioned for rotation about a valve member axis Av and operatively connected to the valve member 204 to rotate the valve member 204 between a first position and a second position. As can be seen in Figure 3 the valve actuator 206 is located on a first axial side of the valve member 204.

[0040] The valve actuator gearing 226 also includes an initial gear 226b, which may be a worm 233. The worm 233 includes threads 235 shaped to prevent backdriving, so as to allow the valve actuator motor 224 to hold the valve member 204 in one of the first position and the second position when the valve actuator motor 224 is de-energized.

[0041] The valve and pump module housing 202 also defines a pump chamber 230 having a volute 232. The valve and pump module housing 202 has an axially extending pump inlet port 234 and a tangentially extending pump outlet port 236. The pump inlet port 234 is coaxial with and fluidly connected to the valve outlet port 236.

[0042] The pump impeller 208 is positioned in the pump chamber 230 for rotation about a pump impeller axis Ap coaxial with the valve member axis Av. The pump impeller 208 is shaped to drive coolant from the pump inlet port 234 through the volute to the pump outlet port 236. The pump impeller 208 may have any suitable shape for driving the coolant 30 in this manner.

[0043] The pump driver 210 may have any suitable structure for operating to drive the pump impeller 208. In the example shown, the pump driver 210 includes an axial flux motor 238, which includes a stator 240 connected to the valve and pump module housing 202 and a rotor 242 connected to and coaxial with the pump impeller 208. As is known in the art of motors, the rotor 242 is capable of being rotated by energizing the stator 240 so as to drive the rotation of the pump impeller 208 and thus the operation of the pump impeller 208. In the embodiment shown, there are two rotors 242, each of the two rotors being connected to and coaxial with the pump impeller 208. Thus, it can be said that the pump driver 210 includes at least one stator 240 and at least one rotor 242.

[0044] At least one stator 240 and at least one rotor 242 can be PCBs, which provides a reduced axial length for the pump driver 210 compared to some actuators of the prior art. Optionally, at least one stator 240 and at least one rotor 242 are positioned within the pump chamber 230 and are thus exposed to the coolant 30.

[0045] The pump impeller 208 and the pump driver 210 are positioned on a second axial side of the valve member 204.

[0046] The valve and pump module housing 202 in the illustrated embodiment includes a single continuous valve-to-pump member 202a that defines at least a portion of the valve chamber 212, the valve inlet port 214, the valve outlet port 216, at least a portion of the pump chamber 230, the pump inlet port 234, and the pump outlet port 236.

[0047] By providing the valve and pump module 200, many conduits (e.g., hoses), couplings, seal members, and other components are eliminated. Additionally, the total pressure drop present in the coolant system 26 is reduced compared to prior art systems. By providing a single continuous valve-to-pump member 202a, even fewer components such as seals are required, thereby reducing the assembly time for the thermal management system 20 and increasing the reliability of the thermal management system 20.

[0048] In addition to the single continuous valve-to-pump member 202a, the valve and pump module housing 202 can also include a valve chamber cover 202b and a valve actuator housing 202c that mounts to the single continuous valve-to-pump member 202a and forms a seal against the valve chamber cover 202b to prevent leakage of coolant between the valve actuator housing 202c and the valve chamber cover 202b. The valve actuator housing 202c itself can include a plurality of housing members that fit together in a sealed manner, such as a first valve actuator housing member 202d and a second valve actuator housing member 202e. By providing a separate valve actuator housing 202c, the valve actuator 206 can be assembled before the valve actuator housing 202c is mounted to other elements of the valve and pump module 200, such as the single continuous valve-to-pump member 202a.

[0049] A plurality of pumps 48 are provided for driving the circulation of the coolant 30 in the coolant delivery system 26. In the illustrated example, there are a first pump 48a, a second pump 48b, and a third pump 48c. The first pump 48a drives coolant flow through the traction motor 13 and the chiller 32. The second pump 48b drives coolant flow through the battery pack 11. The third pump 48c drives coolant flow through the cabin heater core 42 and the coolant heater 44.

[0050] In Figures 2 to 5BIn the embodiment shown, the three valve inlet ports 214 are circumferentially spaced 90 degrees about the valve member axis Av. In Figure 8 In an alternative embodiment shown, the three valve inlet ports 214 may be circumferentially positioned 120 degrees about the valve member axis Av. Thus, the forces acting on the valve member 204 due to reasons such as coolant pressure and any seals acting against the valve member 204 will be balanced in order to reduce any net force acting on the valve member 204.

[0051] Although the valve and pump module 200 is shown as having three valve inlet ports 214 and one valve outlet port 216, the valve and pump module 200 may have any suitable number of valve inlet ports 214, i.e., a plurality of valve inlet ports 214. For example, the valve and pump module 200 may have two valve inlet ports 214 and one valve outlet port 216.

[0052] The valve and pump module 200 includes sealing means located between the valve members 200 and between each of the valve inlet ducts 217 in the valve inlet ducts 217. For each valve inlet duct 217, there is a duct outlet 250. The valve inlet duct 217 also includes an outlet surrounding surface 252 around the duct outlet 250. Figure 7 An enlarged view of the duct outlet 250 is shown. The first outlet surrounding surface 252 may be referred to as a seal support surface 252 and extends from a high region 254 and slopes towards a low region 256. The low region 256 enters the seal support surface 252 at a greater depth compared to the high region 254 and is closer to the duct outlet 250 compared to the high region 254. A seal member 258 is provided and the seal member 258 includes a seal member body 260 having a valve member engaging surface 262, the valve member engaging surface 262 being positioned to slidably engage the outer surface 223 of the valve member 204. The seal member 258 also includes legs 264. The legs 264 engage the outlet surrounding surface 252 and flex when bent by engaging the outlet surrounding surface 252.

[0053] Optionally, the seal member 258 is made of a first material at the valve member engaging surface 262, the first material having a first coefficient of friction Cf1 relative to the valve member 204, and the legs 264 are made of a second material, the second material having a second coefficient of friction Cf2 relative to the seal support surface 252. The second coefficient of friction Cf2 is higher than the first coefficient of friction Cf1, which helps to hold the seal member 258 in place on the first seal support surface 252 during movement of the valve member 204 between the first position and the second position.

[0054] Optionally, the sealing member 258 is made of PTFE at the valve member engagement surface 262. For example, the sealing member body 260 may include a PTFE layer shown at 266 that defines the valve member engagement surface 262. For the purpose of effectively sealing and providing good grip on the seal support surface 252, the legs 264 may be made of a suitable sealing material, such as for example a suitable rubber, such as EPDM.

[0055] By allowing the legs 264 to flex when bent rather than simply compress, the sealing member 258 can better accommodate tolerance stack-ups that may exist in the dimensions of the various components of the valve and the pump module 200 without resulting in an impractically low or impractically high sealing force against the seal support surface 252.

[0056] Those skilled in the art will understand that the embodiments disclosed herein may be modified or adjusted in various other ways while still remaining within the scope of the appended claims.

Claims

1. A valve and pump module for controlling the flow of coolant in a thermal management system for a vehicle, comprising: a valve and pump module housing that defines a valve chamber and has a plurality of valve inlet ports and valve outlet ports, a valve member positioned in the valve chamber and having at least one through-orifice, wherein the valve member is rotatable about a valve member axis between a first position and a second position, in the first position, the at least one through-orifice fluidly connects the plurality of valve inlet ports to the valve outlet ports in a first manner to provide a first flow arrangement through a coolant delivery system, and in the second position, the at least one through-orifice fluidly connects the plurality of valve inlet ports to the valve outlet ports in a second manner to provide a second flow arrangement through the coolant delivery system that is different from the first flow arrangement, wherein the at least one through-orifice has at least one inlet end and at least one outlet end, and the at least one through-orifice extends radially inward from the at least one inlet end toward the valve member axis and axially inward from the at least one outlet end; a valve actuator including a valve actuator motor and a valve actuator gear assembly, the valve actuator gear assembly including a final gear positioned for rotation about the valve member axis and operatively connected to the valve member to rotate the valve member between the first position and the second position, wherein the valve actuator is located on a first axial side of the valve member; wherein the valve and pump module housing defines a pump chamber having a volute, wherein the valve and pump module housing has an axially extending pump inlet port and a tangentially extending pump outlet port, wherein the pump inlet port is coaxial with and fluidly connected to the valve outlet port; a pump impeller positioned in the pump chamber for rotation about a pump impeller axis coaxial with the valve member axis, wherein the pump impeller is shaped to drive coolant from the pump inlet port through the volute to the pump outlet port; a pump driver including an axial flux motor having a stator connected to the valve and pump module housing and a rotor connected to and coaxial with the pump impeller, wherein the rotor is rotatable by energizing the stator to drive rotation of the pump impeller.

2. The valve and pump module according to claim 1, wherein, the stator and the rotor are PCBs.

3. The valve and pump module according to claim 1, wherein, the valve member has a generally spherical outer surface.

4. The valve and pump module according to claim 1, wherein, the valve and pump module housing includes a single continuous valve-to-pump member that defines at least a portion of the valve chamber, the valve inlet ports, the valve outlet ports, at least a portion of the pump chamber, the pump inlet port, and the pump outlet port.

5. The valve and pump module according to claim 1, wherein, The valve actuator includes an initial gear directly driven by the valve actuator motor, wherein the initial gear is a worm.

6. The valve and pump module according to claim 1, wherein, the worm includes threads shaped such that reverse driving is not possible, so as to allow the valve actuator motor to hold the valve member in one of the first position and the second position when the valve actuator motor is de-energized.

7. The valve and pump module according to claim 1, wherein, the plurality of valve inlet ports are three valve inlet ports circumferentially spaced 120 degrees around the valve member axis.

8. The valve and pump module according to claim 1, wherein, the valve member has an outer surface, and wherein for each valve inlet port of the plurality of valve inlet ports, the valve and pump module includes a valve inlet conduit mounted to the valve and pump module housing, wherein the valve inlet conduit has a conduit outlet and an outlet surrounding surface around the conduit outlet, wherein a first outlet surrounding surface extends from a high region and slopes towards a low region, wherein the low region enters the sealing support surface at a greater depth compared to the high region and is closer to the conduit outlet compared to the high region, a sealing member, wherein the sealing member includes a sealing member body having a valve member engaging surface positioned to slidably engage the outer surface of the valve member, wherein the sealing member further includes legs, wherein the legs engage the outlet surrounding surface and flex when bent by engaging the outlet surrounding surface.

9. The valve according to claim 8, wherein, the sealing member is made of a first material at the valve member engaging surface, the first material having a first coefficient of friction relative to the valve member, and wherein the legs are made of a second material, the second material having a second coefficient of friction relative to the outlet surrounding surface, wherein the second coefficient of friction is higher than the first coefficient of friction.

10. The valve according to claim 9, wherein, the sealing member is made of PTFE at the valve member engaging surface, and wherein the legs are made of rubber.

11. The valve according to claim 4, wherein, the valve and pump module housing includes a valve chamber cover that sealingly mates with the single continuous valve-to-pump member to seal the first end of the valve chamber, and further includes a valve actuator housing that houses the valve actuator motor and valve actuator gearing.

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