Heat management apparatus, heat management system and method of operating heat management system

Abstract

A heat management device includes a manifold defining a first manifold flow path for directing a first working fluid and a second manifold flow path for directing a second working fluid; a first heating element in thermal communication with the first manifold flow path for heating the first working fluid; a second heating element operable independently of the first heating element and in thermal communication with the second manifold flow path for heating a second working fluid; and a heat exchanger defining a first heat exchanger flow path and a second heat exchanger flow path, the first heat exchanger flow path being in fluid communication with the first manifold flow path and the second heat exchanger flow path being in fluid communication with the second manifold flow path. The first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and all benefits of U.S. Provisional Patent Application No. 63 / 562,771, filed on March 8, 2024. Technical Field

[0002] The present disclosure generally relates to thermal management devices, thermal management systems, and methods of operating thermal management systems for hybrid and electric vehicles. Background Art

[0003] Compared to traditional internal combustion engine vehicles, hybrid vehicles and electric vehicles have different thermal management requirements. In particular, neither hybrid vehicles nor electric vehicles have an "always-on" internal combustion engine that continuously supplies heat energy for thermal management purposes. In addition, the optimized performance, durability and safety of key components of hybrid vehicles and electric vehicles (such as batteries and electric motors) are dependent on operating temperature. Current thermal management systems for hybrid vehicles and electric vehicles typically utilize electric heaters to heat a working fluid (such as coolant) to assist in thermal management operations such as heating the passenger cabin and regulating battery temperature. However, these thermal management systems often lack the ability to independently control the temperature of multiple fluids or require an undesirable number of components to do so. For this reason, there remains a need for improved thermal management components and systems for hybrid vehicles and electric vehicles. Summary of the Invention

[0004] One general aspect of the present disclosure relates to a thermal management device. The thermal management device includes a manifold that defines a first manifold flow path and a second manifold flow path. The first manifold flow path is configured to guide a first working fluid. The second manifold flow path is configured to guide a second working fluid. The second manifold flow path is not in fluid communication with the first manifold flow path. The thermal management device also includes a first heating element that is operatively attached to the manifold and in thermal communication with the first manifold flow path. The first heating element is configured to generate heat in response to energization to heat the first working fluid when the first working fluid flows through the first manifold flow path. The thermal management device also includes a second heating element that is operatively attached to the manifold and in thermal communication with the second manifold flow path. The second heating element is configured to generate heat in response to energization to heat the second working fluid when the second working fluid flows through the second manifold flow path. The second heating element can operate independently of the first heating element. The thermal management device further includes a heat exchanger that is operatively attached to the manifold. The heat exchanger defines a first heat exchanger flow path and a second heat exchanger flow path, the first heat exchanger flow path being in fluid communication with the first manifold flow path, and the second heat exchanger flow path being in fluid communication with the second manifold flow path. The first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

[0005] Another general aspect of the present disclosure relates to a thermal management system. The thermal management system includes: a first fluid circuit, a second fluid circuit, and a manifold, the first fluid circuit being used to circulate a first working fluid, the second fluid circuit being used to circulate a second working fluid, and the manifold defining a first manifold flow path and a second manifold flow path. The first manifold flow path is in fluid communication with the first fluid circuit for guiding the first working fluid. The second manifold flow path is in fluid communication with the second fluid circuit for guiding the second working fluid. The second manifold flow path is not in fluid communication with the first manifold flow path. The thermal management system also includes a first heating element that is operatively attached to the manifold and in thermal communication with the first manifold flow path for heating the first working fluid as the first working fluid flows through the first manifold flow path. The thermal management system also includes a second heating element that is operatively attached to the manifold and in thermal communication with the second manifold flow path for heating the second working fluid as the second working fluid flows through the second manifold flow path. The second heating element can operate independently of the first heating element. The thermal management system also includes a heat exchanger defining a first heat exchanger flow path and a second heat exchanger flow path, the first heat exchanger flow path being interposed in fluid communication between the first manifold flow path and the first fluid circuit to facilitate flow of a first working fluid therebetween, and the second heat exchanger flow path being interposed in fluid communication between the second manifold flow path and the second fluid circuit to facilitate flow of a second working fluid therebetween. The first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

[0006] Another general aspect of the present disclosure relates to a method of operating a thermal management system, the thermal management system comprising: a manifold defining a first manifold flow path and a second manifold flow path, the first manifold flow path being configured to direct a first working fluid and the second manifold flow path being configured to direct a second working fluid; a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path to heat the first working fluid as the first working fluid flows through the first manifold flow path; a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path to heat the second working fluid as the second working fluid flows through the second manifold flow path; and a heat exchanger operatively attached to the manifold and defining a first heat exchanger flow path and a second heat exchanger flow path, the first heat exchanger flow path being in fluid communication with the first manifold flow path and the second heat exchanger flow path being in fluid communication with the second manifold flow path, wherein the first heat exchanger flow path and the second heat exchanger flow path are arranged to be in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid. The method includes circulating a first working fluid in one of a first direction and a second direction opposite the first direction through a first manifold flow path and a first heat exchanger flow path. The method also includes circulating a second working fluid in one of a third direction and a fourth direction opposite the third direction through a second manifold flow path and a second heat exchanger flow path. The method also includes operating the thermal management system in a first operating mode in response to the first working fluid circulating in the first direction and the second working fluid circulating in the third direction, and operating the thermal management system in a second operating mode in response to the first working fluid circulating in the second direction and the second working fluid circulating in the fourth direction. Operating the thermal management system in the first operating mode includes operating a first heating element to heat the first working fluid, directing the first working fluid heated by the first heating element from the first manifold flow path through the first heat exchanger flow path, directing the second working fluid through the second heat exchanger flow path so that the first working fluid transfers heat to the second working fluid and passes through the second manifold flow path, and operating the second heating element to further heat the second working fluid. The steps of operating the thermal management system in the second operating mode include: operating the second heating element to heat the second working fluid, directing the second working fluid heated by the second heating element from the second manifold flow path through the second heat exchanger flow path, directing the first working fluid through the first heat exchanger flow path so that the second working fluid transfers heat to the first working fluid and through the second manifold flow path, and operating the first heating element to further heat the first working fluid.

[0007] Advantageously, based on the direction of flow of the first working fluid and / or the second working fluid, the activation of the first heating element and / or the second heating element, and the heat transfer achieved between the first working fluid and the second working fluid by the heat exchanger, the thermal management device / system according to the present disclosure functions to selectively prioritize heating one of the first working fluid and the second working fluid over the other of the first working fluid and the second working fluid. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Other advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.

[0009] Figure 1 is a top perspective view of one example of a thermal management device according to the present disclosure.

[0010] Figure 2 yes Figure 1 A partial schematic exploded view of a thermal management device.

[0011] Figure 3 is a top perspective view of another example of a thermal management device according to the present disclosure.

[0012] Figure 4 yes Figure 3 A partial schematic exploded view of a thermal management device.

[0013] Figure 5 is a top perspective view of yet another example of a thermal management device according to the present disclosure.

[0014] Figure 6 yes Figure 5 A top perspective view of the manifold of the thermal management device.

[0015] Figure 7 yes Figure 6 Cross-sectional view of the manifold.

[0016] Figure 8 yes Figure 5 A partial schematic exploded view of a thermal management device.

[0017] Figure 9 is a schematic diagram of a thermal management system according to the present disclosure operating in a first operating mode.

[0018] Figure 10 It is operated in the second operating mode Figure 9 Schematic diagram of the thermal management system.

[0019] Figure 11 is a schematic diagram of one embodiment of a thermal management system according to the present disclosure operating in a first operating mode.

[0020] Figure 12 It is operated in the second operating mode Figure 11 Schematic diagram of the thermal management system.

[0021] Figure 13 is a flow chart illustrating a method of operating a thermal management system according to the present disclosure.

[0022] Figure 14 is a flow chart illustrating steps for operating a thermal management system in a first operating mode.

[0023] Figure 15 is a flow chart illustrating steps for operating the thermal management system in the second operating mode. DETAILED DESCRIPTION

[0024] Referring to the drawings, wherein like numerals refer to like parts throughout the several views, Figure 1-8 Various examples of thermal management devices 50 according to the present disclosure are generally shown.

[0025] exist Figure 1-8 In each of the examples, the thermal management device 50 includes a manifold 54. The manifold 54 defines a first manifold flow path 58 configured to direct the first working fluid WF1 and a second manifold flow path 62 configured to direct the second working fluid WF2.

[0026] The first manifold flow path 58 may extend between a first port 58A and a second port 58B, such that the first manifold flow path 58 is configured to direct the first working fluid WF1 between the first port 58A and the second port 58B. It should be appreciated that, in this context, the phrase "between the first port 58A and the second port 58B" is not directionally limiting. For example, the first working fluid WF1 may flow from the first port 58A to the second port 58B, or from the second port 58B to the first port 58A. The second manifold flow path 62 may extend between a third port 62A and a fourth port 62B, such that the second manifold flow path 62 is configured to direct the second working fluid WF2 between the third port 62A and the fourth port 62B. Similar to the above, it should be appreciated that, in this context, the phrase "between the third port 62A and the fourth port 62B" is not directionally limiting. For example, the second working fluid WF2 may flow from the third port 62A to the fourth port 62B, or from the fourth port 62B to the third port 62A. It should also be appreciated that the second manifold flow path 62 is not in fluid communication with the first manifold flow path 58 .

[0027] The composition of the first working fluid WF1 and the second working fluid WF2 is not particularly limited for the purposes of this disclosure. In some examples, the first working fluid WF1 and the second working fluid WF2 are the same composition, but in other examples, the first working fluid WF1 and the second working fluid WF2 are different compositions. The first working fluid WF1 and / or the second working fluid WF2 can be a cooling fluid suitable for vehicle applications, such as water, ethylene glycol, propylene glycol, etc. The first working fluid WF1 and / or the second working fluid WF2 can also be a refrigerant suitable for vehicle applications, such as 1,1,1,2-tetrafluoroethane (also known as R-134a), 2,3,3,3-tetrafluoropropylene (also known as R1234yf), etc.

[0028] The construction of the manifold 54 is not particularly limited for the purposes of this disclosure. From a material perspective, the manifold 54 can be made of any suitable material that is compatible with the first working fluid WF1 and the second working fluid WF2 and their operating temperatures. For example, the manifold 54 can be made of metal / metal alloy (such as steel, aluminum, etc.) or plastic / composite material. Similarly, the shape of the manifold 54 is not particularly limited for the purposes of this disclosure. Any shape / size suitable for defining the first manifold flow path 58 and the second manifold flow path 62 is contemplated. In some examples, the first manifold flow path 58 and the second manifold flow path 62 may have the same shape / size, but in other constructions, the first manifold flow path 58 and the second manifold flow path 62 may have different shapes / sizes. Example constructions of the manifold 54 are described in further detail below.

[0029] Continue to refer Figure 1-8 The thermal management device 50 further includes a first heating element 66 and a second heating element 70. The first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58. Thus, the first heating element 66 is configured to generate heat in response to being energized when the first working fluid WF1 flows through the first manifold flow path 58 of the manifold 54, thereby heating the first working fluid WF1. The second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62. Thus, the second heating element 70 is configured to generate heat in response to being energized when the second working fluid WF2 flows through the second manifold flow path 62 of the manifold 54, thereby heating the second working fluid WF2.

[0030] The first heating element 66 and the second heating element 70 are independently operable. In other words, the first heating element 66 can be activated without activating the second heating element 70, the second heating element 70 can be activated without activating the first heating element 66, or the first and second heating elements 66, 70 can be activated simultaneously, etc. The independent operability of the first and second heating elements 66, 70 permits the thermal management device 50 to independently adjust the temperatures of the first and second working fluids WF1, WF2.

[0031] The first heating element 66 and the second heating element 70 are typically electrical heating elements, such as resistive heaters. The first heating element 66 and / or the second heating element 70 may be a tube / sheath resistive heating element, a coil resistive heating element, a screen printed resistive heating element, a thermally sprayed resistive heating element, a positive temperature coefficient (PTC) heating element, etc., and combinations thereof. The first heating element 66 and / or the second heating element 70 may operate at high voltages, such as voltages typically associated with electric vehicle battery architectures (e.g., 400 volts, 800 volts, etc.). The arrangement of the first heating element 66 and the second heating element 70 relative to the first manifold flow path 58 and the second manifold flow path 62, respectively, is not necessarily limited for the purposes of this disclosure. In certain configurations, the first heating element 66 and / or the second heating element 70 are arranged within the first manifold flow path 58 and the second manifold flow path 62, respectively. In other examples, the first heating element 66 and / or the second heating element 70 are disposed on the manifold 54 (e.g., on a surface of the manifold 54), but are still in thermal communication with the first manifold flow path 58 and the second manifold flow path 62, respectively. Other configurations and arrangements of the first heating element 66 and the second heating element 70 are contemplated.

[0032] The thermal management device 50 may further include a control module 74 that communicates with the first heating element 66 and the second heating element 70 to activate the first heating element 66 and the second heating element 70 to heat the first working fluid WF1 and the second working fluid WF2, respectively. Figure 1-8 In the configurations shown, the control module 74 is coupled to the manifold 54 or integrated within the manifold 54. In these examples, the control module 74 includes a plurality of connection ports for power / connectivity purposes (e.g., to connect the control module 74 to a wiring harness of a vehicle or system-level controller 144, described below). However, it is contemplated that in other examples, the hardware for energizing the first heating element 66 and the second heating element 70 may be located remotely from the thermal management device 50 (e.g., within a separate electrical module of the vehicle).

[0033] Still refer to Figure 1-8The thermal management device 50 also includes a heat exchanger 78 operatively attached to the manifold 54. The heat exchanger 78 defines a first heat exchanger flow path 82 and a second heat exchanger flow path 86. The first heat exchanger flow path 82 is in fluid communication with the first manifold flow path 58 (e.g., via at least one of the first port 58A and the second port 58B), such that the first heat exchanger flow path 82 is configured to direct the first working fluid WF1 therethrough. The second heat exchanger flow path 86 is in fluid communication with the second manifold flow path 62 (e.g., via at least one of the third port 62A and the fourth port 62B), such that the second heat exchanger flow path 86 is configured to direct the second working fluid WF2 therethrough. As described in further detail below, the first manifold flow path 58 and the first heat exchanger flow path 82 are configured to direct the first working fluid WF1 in a first direction D1 and a second direction D2 opposite to the first direction D1, and the second manifold flow path 62 and the second heat exchanger flow path 86 are configured to direct the second working fluid WF2 in a third direction D3 and a fourth direction D4 opposite to the third direction D3.

[0034] The first heat exchanger flow path 82 and the second heat exchanger flow path 86 are arranged in thermal communication to facilitate heat transfer between the first working fluid WF1 and the second working fluid WF2. By facilitating heat transfer between the first working fluid WF1 and the second working fluid WF2, the heat exchanger 78 provides additional operational flexibility and advantages when using the thermal management device 50 according to the present disclosure, as described in further detail below. More specifically, based on the direction of flow of the first working fluid WF1 and / or the second working fluid WF2, the activation of the first heating element 66 and / or the second heating element 70, and the heat transfer achieved between the first working fluid WF1 and the second working fluid WF2 by the heat exchanger 78, the thermal management device 50 functions to selectively prioritize heating one of the first working fluid WF1 and the second working fluid WF2 over the other.

[0035] In an example where heating the second working fluid WF2 takes precedence over the first working fluid WF1, in response to the first working fluid WF1 flowing in the first direction D1 and the second working fluid WF2 flowing in the third direction D3, the first heating element 66 can be energized to heat the first working fluid WF1, and the first working fluid WF1 heated by the first heating element 66 flows from the first manifold flow path 58 through the first heat exchanger flow path 82, and the second working fluid WF2 flows through the second heat exchanger flow path 86, so that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the second manifold flow path 62, so that the second heating element 70 further heats the second working fluid WF2. In an example where heating the first working fluid WF1 takes precedence over the second working fluid WF2, in response to the first working fluid WF1 flowing in the second direction D2 and the second working fluid WF2 flowing in the fourth direction D4, the second heating element 70 heats the second working fluid WF2, and the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 through the second heat exchanger flow path 86, and the first working fluid WF1 flows through the first heat exchanger flow path 82, so that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the first manifold flow path 58, so that the first heating element 66 further heats the first working fluid WF1.

[0036] The configuration of the heat exchanger 78 is not necessarily limited for the purposes of this disclosure. Figure 1-8 In the example shown, the heat exchanger 78 is a plate heat exchanger in which the first working fluid WF1 and the second working fluid WF2 exchange heat by flowing between plates arranged parallel to each other adjacent to each other (not shown in detail). However, it is also contemplated that the heat exchanger 78 may be other forms of heat exchangers, such as a tube heat exchanger, a spiral heat exchanger, etc. In addition, the direction of flow of the first working fluid WF1 and the second working fluid WF2 through the heat exchanger 78 is not necessarily limited for the purposes of this disclosure. In other words, the first working fluid WF1 and the second working fluid WF2 may flow through the heat exchanger 78 in the same direction (i.e., concurrent flow), or the first working fluid WF1 and the second working fluid WF2 may flow through the heat exchanger 78 in opposite directions (i.e., countercurrent flow).

[0037] refer to Figure 1-4 In certain examples, the manifold 54 is defined by a pair of stamped metal sheets that are coupled to each other to define a first manifold flow path 58 and a second manifold flow path 62. Figure 1-4In the examples shown, the manifold 54 is made of aluminum sheets that are brazed together and have corresponding stamped grooves that cooperate to define the first manifold flow path 58 and the second manifold flow path 62. In these examples, the first heating element 66 and the second heating element 70 are coupled to the outer surface of the manifold 54 to heat the first working fluid WF1 and the second working fluid WF2, respectively. Figure 1-4 In the example of FIG. 5 , a heat exchanger 78 is attached to one side of the manifold 54 and a control module 74 is coupled to the other side of the manifold 54 to activate the first heating element 66 and the second heating element 70 to heat the first working fluid WF1 and the second working fluid WF2, respectively. Figure 5-8 The example of FIG. 5 shows the manifold 54, the first and second heating elements 66 and 70, and the control module 74 integrated into one assembly (eg, Figure 6-8 ), where the heat exchanger 78 is coupled to two of the ports of the manifold 54 .

[0038] refer to Figure 9 and Figure 10 The present disclosure also relates to a thermal management system 100 (for example, for a hybrid vehicle or an electric vehicle), which includes the thermal management device 50 described above. The thermal management system 100 includes a first fluid circuit 104 and a second fluid circuit 108. The first fluid circuit 104 is configured to circulate a first working fluid WF1 and a second fluid circuit 108 is configured to circulate a second working fluid WF2. The first fluid circuit 104 is configured to be connected to one or more components of the vehicle (in the embodiment of FIG. Figure 9 and Figure 10 112) for thermal management of such component(s) 112 by the first working fluid WF1. Similarly, the second fluid circuit 108 is configured to be in fluid communication with one or more components of the vehicle (in Figure 9 and Figure 10104 ) are in fluid communication with the first and second fluid circuits 108 (schematically illustrated by dashed box 116 in the figure), for thermal management of such component(s) 116 by the second working fluid WF2. Exemplary component(s) 112, 116 include, but are not limited to, a vehicle battery, an electric motor, an inverter, power electronics, a compressor, an ambient air heat exchanger, and a cabin heat exchanger. It should be appreciated that more than one component 112, 116 may be arranged in fluid communication with the first fluid circuit 104 and the second fluid circuit 108, respectively. Using the first fluid circuit 104 as an example, multiple components 112 may be arranged in series, with the first working fluid WF1 flowing between the components 112 via the first fluid circuit 104; however, in other examples, the first fluid circuit 104 may be bifurcated, such that multiple components 112 are arranged in parallel, with the first working fluid WF1 flowing between the components 112 via the first fluid circuit 104. Of course, the same arrangement described with respect to the first fluid circuit 104 may be applicable to the second fluid circuit 108. In certain examples, the first working fluid WF1 is a coolant (as described above) and the first fluid circuit 104 is in communication with the vehicle's powertrain components (e.g., a battery, an electric motor, an inverter, etc.), and the second working fluid WF2 is a refrigerant (as described above) and the second fluid circuit 108 is in communication with the vehicle's HVAC components (e.g., a compressor, a passenger compartment heat exchanger, etc.). Other configurations of the first and second fluid circuits 104, 108 are contemplated.

[0039] Both the first fluid circuit 104 and the second fluid circuit 108 are configured such that the first working fluid WF1 and the second working fluid WF2 are configured to flow in two directions, respectively. Figure 9 , the first fluid circuit 104 is configured to circulate the first working fluid WF1 in a first direction D1 (schematically depicted by arrow 120 ), and with reference to Figure 10 , the first fluid circuit 104 is also configured to circulate the first working fluid WF1 in a second direction D2 (schematically depicted by arrow 124) opposite to the first direction D1. Figure 9 , the second fluid circuit 108 is configured to circulate the second working fluid WF2 in a third direction D3 (schematically depicted by arrow 128), and with reference to Figure 10 , the second fluid circuit 108 is also configured to circulate the second working fluid WF2 in a fourth direction D4 (schematically depicted by arrow 132) that is opposite to the third direction D3. As will be appreciated from the subsequent description, configuring both the first working fluid WF1 and the second working fluid WF2 to flow in two directions provides additional flexibility in transferring heat within the thermal management system 100.

[0040] A variety of configurations are contemplated for circulating the first working fluid WF1 about the first fluid circuit 104 in both the first direction D1 and the second direction D2, and for circulating the second working fluid WF2 about the second fluid circuit 108 in both the third direction D3 and the fourth direction D4. In one non-limiting example, the thermal management system 100 includes: a first pump 136 in fluid communication with the first fluid circuit 104 and configured to circulate the first working fluid WF1 about the first fluid circuit 104 in the first direction D1 and the second direction D2; and a second pump 140 in fluid communication with the second fluid circuit 108 and configured to circulate the second working fluid WF2 about the second fluid circuit 108 in the third direction D3 and the fourth direction D4. The first pump 136 and the second pump 140 may be embodied as separate components, coupled to the first fluid circuit 104 and the second fluid circuit 108, respectively. In other examples, for example, Figure 9 and Figure 10 As schematically illustrated in FIG, the first pump 136 and the second pump 140 are integrated within the component(s) 112, 116. The first pump 136 and / or the second pump 140 can be implemented as bidirectional pumps to achieve bidirectional flow of the first working fluid WF1 and the second working fluid WF2 around the first fluid circuit 104 and the second fluid circuit 108, respectively. Other configurations can be implemented through an actuable valve arrangement or other suitable components to achieve bidirectional flow of the first working fluid WF1 and the second working fluid WF2 around the first fluid circuit 104 and the second fluid circuit 108, respectively.

[0041] As in Figure 9 and Figure 10 As schematically illustrated in FIG, the first manifold flow path 58 of the manifold 54 is in fluid communication with the first fluid circuit 104 for directing the first working fluid WF1. In one configuration, at least one of the first port 58A and the second port 58B of the first manifold flow path 58 is in fluid communication with the first fluid circuit 104 such that the first manifold flow path 58 directs the first working fluid WF1 between the first port 58A and the second port 58B, although other configurations are also contemplated. As also shown in FIG. Figure 9 and Figure 10 As schematically illustrated in FIG, the second manifold flow path 62 of the manifold 54 is in fluid communication with the second fluid circuit 108 to direct the second working fluid WF2. In one configuration, at least one of the third port 62A and the fourth port 62B is in fluid communication with the second fluid circuit 108 such that the second manifold flow path 62 directs the second working fluid WF2 between the third port 62A and the fourth port 62B, although other configurations are also contemplated. As described above and in Figure 9 and Figure 10As schematically illustrated in FIG, a first heating element 66 is operatively attached to the manifold 54 and in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as the first working fluid WF1 flows through the first manifold flow path 58, and a second heating element 70 is operatively attached to the manifold 54 and in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as the second working fluid WF2 flows through the second manifold flow path 62.

[0042] like Figure 9 and Figure 10 As schematically illustrated in FIG, the first heat exchanger flow path 82 of the heat exchanger 78 is interposed in fluid communication between the first manifold flow path 58 of the manifold 54 and the first fluid circuit 108 to facilitate flow of the first working fluid WF1 therebetween. In one configuration, the first heat exchanger flow path 82 extends between a first opening 82A and a second opening 82B such that the first heat exchanger flow path 82 directs the first working fluid WF1 between the first opening 82A and the second opening 82B. Here, the first opening 82A is in fluid communication with the other of the first port 58A and the second port 58B of the manifold 54, and the second opening 82B is in fluid communication with the first fluid circuit 108, but other configurations are also contemplated. Continuing with reference to FIG. Figure 9 and Figure 10 , the second heat exchanger flow path 86 is in fluid communication between the second manifold flow path 62 of the manifold 54 and the second fluid circuit 108 to facilitate the flow of the second working fluid WF2 therebetween. In one configuration, the second heat exchanger flow path 86 extends between the third opening 86A and the fourth opening 86B, such that the second heat exchanger flow path 86 directs the second working fluid WF2 between the third opening 86A and the fourth opening 86B. Here, the third opening 86A is in fluid communication with the other of the third port 62A and the fourth port 62B of the manifold 54, and the fourth opening 86B is in fluid communication with the second fluid circuit 108, but other configurations are also contemplated. As described above and in Figure 9 and Figure 10 As schematically illustrated in FIG, a first heat exchanger flow path 82 and a second heat exchanger flow path 86 are arranged in thermal communication to facilitate heat transfer between the first working fluid WF1 and the second working fluid WF2.

[0043] Continue to refer Figure 9 and Figure 10The thermal management system 100 further includes a controller 144. The controller 144 is in communication with the first heating element 66 to selectively activate the first heating element 66 to heat the first working fluid WF1 within the first manifold flow path 58, and is in communication with the second heating element 70 to selectively activate the second heating element 70 to heat the second working fluid WF2 within the second manifold flow path 62. The controller 144 is configured to operate the thermal management system 100 between a plurality of modes, including but not limited to a first operating mode (in which the first operating mode is selected). Figure 9 and described below) and a second mode of operation (in Figure 10 In some examples, such as in Figure 9 and Figure 10 As schematically illustrated in FIG, the controller 144 is also in communication with the first fluid circuit 104 to control the direction of the first working fluid WF1 (e.g., via the first pump 136), and / or in communication with the second fluid circuit 108 to control the direction of the second working fluid WF2 (e.g., via the second pump 140). However, it should be appreciated that in other configurations, the direction of the first working fluid WF1 and / or the direction of the second working fluid WF2 may be controlled by other systems of the vehicle, and the controller 144 of the thermal management system 100 may select an operating mode of the thermal management system 100 in response to the direction of the first working fluid WF1 and / or the direction of the second working fluid WF2. In other words, in some examples, the controller 144 does not control the direction of the first working fluid WF1 and / or the direction of the second working fluid WF2, but instead operates the thermal management system 100 based on the direction of the first working fluid WF1 and / or the direction of the second working fluid WF2.

[0044] refer to Figure 9 , when the controller 144 operates the thermal management system 100 in the first operating mode, the controller 144 operates the first heating element 66 to heat the first working fluid WF1, while the first pump 136 circulates the first working fluid WF1 in the first direction D1, so that the first working fluid WF1 heated by the first heating element 66 flows from the first manifold flow path 58 of the manifold 54 through the first heat exchanger flow path 82 of the heat exchanger 78 and reaches the first fluid circuit 104. In some configurations, such as Figure 9 As schematically illustrated in FIG, the controller 144 operates the first pump 136 to circulate the first working fluid WF1 in the first direction D1 such that the first working fluid WF1 heated by the first heating element 66 flows from the first manifold flow path 58 of the manifold 54, through the first opening 82A of the heat exchanger 78, through the first heat exchanger flow path 82, to the second opening 82B, and through the second opening 82B to the first fluid circuit 104, although other configurations are also contemplated.

[0045] Meanwhile, continue to refer to Figure 9 When the controller 144 operates the thermal management system 100 in the first operating mode, the controller 144 operates the second pump 140 to circulate the second working fluid WF2 in the third direction D3, so that the second working fluid WF2 flows from the second fluid circuit 108 through the second heat exchanger flow path 86 of the heat exchanger 78, so that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the second manifold flow path 62 of the manifold 54, so that the second heating element 70 further heats the second working fluid WF2. In some configurations, such as Figure 9 As schematically illustrated in FIG, the controller 144 operates the second pump 140 to circulate the second working fluid WF2 in the third direction D3, such that the second working fluid WF2 flows from the fourth opening 86B of the heat exchanger 78 and passes through the second heat exchanger flow path 86, such that the first working fluid WF1 transfers heat to the second working fluid WF2 and passes through the third opening 86A to the second manifold flow path 62 of the manifold 54, such that the second heating element 70 further heats the second working fluid WF2, but other configurations are also contemplated.

[0046] In any case, with the controller 144 operating the thermal management system 100 in the first operating mode, the first heating element 66 heats the first working fluid WF1, which then flows through the heat exchanger 78 and heats the second working fluid WF2, which is then subsequently further heated by the second heating element 70. Thus, in effect, the second working fluid WF2 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70.

[0047] refer to Figure 10 In the case where the controller 144 operates the thermal management system 100 in the second operating mode, the controller 144 operates the second heating element 70 to heat the second working fluid WF2, while the second pump 140 circulates the second working fluid WF2 in the fourth direction D4, so that the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 of the manifold 54 through the second heat exchanger flow path 86 of the heat exchanger 78 and reaches the second fluid circuit 108. In some configurations, such as in Figure 10As schematically illustrated in FIG, the controller 144 operates the second pump 14 to circulate the second working fluid WF2 in the fourth direction D4 such that the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 of the manifold 54, through the third opening 86A of the heat exchanger 78, through the second heat exchanger flow path 86, to the fourth opening 86B, and through the fourth opening 86B to the second fluid circuit 108, although other configurations are also contemplated.

[0048] Meanwhile, continue to refer to Figure 10 In the case where the controller 144 operates the thermal management system 100 in the second operating mode, the controller 144 operates the first pump 136 to circulate the first working fluid WF1 in the second direction D2, so that the first working fluid WF1 flows from the first fluid circuit 104 through the first heat exchanger flow path 82 of the heat exchanger 78, so that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the second manifold flow path 62 of the manifold 54, so that the first heating element 66 further heats the first working fluid WF1. In some configurations, such as in Figure 10 As schematically illustrated in FIG, the controller 144 operates the first pump 136 to circulate the first working fluid WF1 in the second direction D2, so that the first working fluid WF1 flows from the second opening 82B of the heat exchanger 78 and passes through the first heat exchanger flow path 82, so that the second working fluid WF2 transfers heat to the first working fluid WF1, and passes through the first opening 82A to reach the first manifold flow path 58 of the manifold 54, so that the first heating element 66 further heats the first working fluid WF1.

[0049] In any case, where the controller 144 operates the thermal management system 100 in the second operating mode, as opposed to the first operating mode described above, the second heating element 70 heats the second working fluid WF2, which then flows through the heat exchanger 78 to heat the first working fluid WF1, which is then further heated by the first heating element 66. Thus, in effect, the first working fluid WF1 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70.

[0050] It should be appreciated upon considering this disclosure that the thermal management device 50 disclosed herein has particular operational advantages when employed in a thermal management system 100 for a hybrid or electric vehicle. Specifically, by including a first heating element 66 and a second heating element 70 that are operable independently of one another, and by adjacently arranging a heat exchanger 78 for exchanging heat between the first working fluid WF1 and the second working fluid WF2, various advantages are achieved, including increased operational flexibility, reduced packaging footprint, and the like. It should also be appreciated that additional operating modes of the thermal management system 100 are contemplated. More specifically, any operating direction of the circulation of the first working fluid WF1 around the first fluid circuit 104, any operating direction of the circulation of the second working fluid WF2 around the second fluid circuit 108, and any activation of the first and / or second heating elements are contemplated.

[0051] Figure 11 and Figure 12 An illustrative example of one embodiment of a thermal management system 100 is provided. The thermal management system 100 operates in a first mode of operation (in Figure 11 shown in ) and in the second operating mode (in Figure 12 (shown in) operation. Figure 11 and Figure 12 In both, the component(s) 112 in fluid communication with the first fluid circuit 104 include at least the vehicle battery 148, and the component(s) 116 in fluid communication with the second fluid circuit include a compressor 152, a vehicle cabin heat exchanger 156, and an expansion valve 160, which are arranged in series with respect to each other. Of course, it should be appreciated that other components 116 may be in communication with the first fluid circuit 104.

[0052] First reference Figure 11 , controller 144 (in Figure 11 ) can be configured to operate the thermal management system 100 in a first operating mode in response to a scenario in which the vehicle passenger compartment heat exchanger 156 has a high heat demand. Here, there are at least three potential heat sources for the vehicle passenger compartment heat exchanger 156 - namely, the first heating element 66, the second heating element 70, and the compressor 152. Therefore, as described above in Figure 9, the controller 144 may be configured to operate the thermal management system 100 in the first operating mode such that the first heating element 66 heats the first working fluid WF1, which then flows through the heat exchanger 78 to heat the second working fluid WF2, which is then subsequently further heated by the second heating element 70 and, ultimately, provided to the passenger compartment heat exchanger 156. Again, in effect, the second working fluid WF2 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70, thereby allowing more heat to be provided to the passenger compartment heat exchanger 156 than would be possible without utilizing higher capacity heating elements for the first fluid circuit 104 and the second fluid circuit 108.

[0053] Next reference Figure 12 , controller 144 (in Figure 12 148 has a high thermal demand (e.g., where the vehicle battery is pre-configured to receive a fast charge). Here, there are at least three potential heat sources for the vehicle battery 148 - namely, the first heating element 66, the second heating element 70, and the compressor 152. Thus, similar to the above description of Figure 10 , the controller 144 may be configured to operate the thermal management system 100 in the second operating mode such that the second heating element 70 heats the second working fluid WF2, which then flows through the heat exchanger 78 to heat the first working fluid WF1, which is then further heated by the first heating element 66 and, ultimately, provided to the vehicle battery 148. Again, in effect, the first working fluid WF1 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70, thereby allowing more heat to be provided to the vehicle battery 148 than would be possible without utilizing higher capacity heating elements for the first and second fluid circuits.

[0054] The present disclosure also relates to a method 200 of operating a thermal management system 100. Figure 13The method 200 generally includes step 202 of circulating a first working fluid WF1 in one of a first direction D1 and a second direction D2 opposite to the first direction D1 through the first manifold flow path 58 and the first heat exchanger flow path 82. The method 200 also includes step 204 of circulating a second working fluid WF2 in one of a third direction D3 and a fourth direction D4 opposite to the third direction D3 through the second manifold flow path 62 and the second heat exchanger flow path 86. The method 200 also includes step 206 of operating the thermal management system 100 in a first operating mode in response to the first working fluid WF1 circulating in the first direction D1 and the second working fluid WF2 circulating in the third direction D3; and step 208 of operating the thermal management system 100 in a second operating mode in response to the first working fluid WF1 circulating in the second direction D2 and the second working fluid WF2 circulating in the fourth direction D4.

[0055] refer to Figure 14 , step 206 of operating the thermal management system 100 in the first operating mode includes: sub-step 206a: operating the first heating element 66 to heat the first working fluid WF1; sub-step 206b: directing the first working fluid WF1 heated by the first heating element 66 from the first manifold flow path 58 through the first heat exchanger flow path 82; sub-step 206c: directing the second working fluid WF2 through the second heat exchanger flow path 86 such that the first working fluid WF1 transfers heat to the second working fluid WF2 and through the second manifold flow path 62; and sub-step 206d: operating the second heating element 70 to further heat the second working fluid WF2. Here, according to step 206 of the method 200, operation of the thermal management system 100 in the first operating mode prioritizes heating of the second working fluid WF2 over the first working fluid WF1.

[0056] refer to Figure 15 , step 208 of operating the thermal management system 100 in the second operating mode includes: sub-step 208a: operating the second heating element 70 to heat the second working fluid WF2; sub-step 208b: directing the second working fluid WF2 heated by the second heating element 70 from the second manifold flow path 62 through the second heat exchanger flow path 86; sub-step 208c: directing the first working fluid WF1 through the first heat exchanger flow path 82 so that the second working fluid WF2 transfers heat to the first working fluid WF1 and through the second manifold flow path 62, and operating the first heating element 66 to further heat the first working fluid WF1. Here, according to step 208 of method 200, operation of the thermal management system 100 in the second operating mode prioritizes heating of the first working fluid WF1 over the second working fluid WF2.

[0057] It should also be appreciated that the method 200 can include operating the thermal management system 100 in additional operating modes. More specifically, any operating direction of the circulation of the first working fluid WF1 around the first fluid circuit 104, any operating direction of the circulation of the second working fluid WF2 around the second fluid circuit 108, and any activation of the first heating element and / or the second heating element are contemplated.

[0058] The present invention has been described in an illustrative manner, and it will be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. In light of the above teachings, many modifications and variations of the present invention are possible, and the present invention may be practiced in ways other than those specifically described.

Claims

1. A heat management device, comprising: Manifold, which defines: a first manifold flow path configured to direct a first working fluid, and a second manifold flow path configured to channel a second working fluid, wherein the second manifold flow path is not in fluid communication with the first manifold flow path; a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path, wherein the first heating element is configured to generate heat in response to an activation to heat the first working fluid as the first working fluid flows through the first manifold flow path; a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path, wherein the second heating element is configured to generate heat in response to an energization to heat the second working fluid as the second working fluid flows through the second manifold flow path, and wherein the second heating element is operable independently of the first heating element; and a heat exchanger operatively attached to the manifold and defining: a first heat exchanger flow path in fluid communication with the first manifold flow path, and A second heat exchanger flow path is in fluid communication with the second manifold flow path, wherein the first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

2. The heat management device according to claim 1, in, The first manifold flow path and the first heat exchanger flow path are configured to: direct the first working fluid in a first direction and a second direction opposite to the first direction; and The second manifold flow path and the second heat exchanger flow path are configured to guide the second working fluid in a third direction and a fourth direction opposite to the third direction.

3. The heat management device according to claim 2, wherein: In response to the first working fluid flowing in the first direction and the second working fluid flowing in the third direction, the first heating element heats the first working fluid, and the first working fluid heated by the first heating element flows from the first manifold flow path through the first heat exchanger flow path, and the second working fluid flows through the second heat exchanger flow path, so that the first working fluid transfers heat to the second working fluid, and through the second manifold flow path, so that the second heating element further heats the second working fluid.

4. The heat management device according to claim 2, wherein: In response to the first working fluid flowing in the second direction and the second working fluid flowing in the fourth direction, the second heating element heats the second working fluid, and the second working fluid heated by the second heating element flows from the second manifold flow path through the second heat exchanger flow path, and the first working fluid flows through the first heat exchanger flow path, so that the second working fluid transfers heat to the first working fluid and through the first manifold flow path, so that the first heating element further heats the first working fluid.

5. The thermal management device of claim 1 , further comprising a control module in communication with the first heating element and the second heating element and configured to energize the first heating element to heat the first working fluid and energize the second heating element to heat the second working fluid.

6. The heat management device according to claim 1, wherein: The manifold includes a pair of stamped metal plates coupled to each other to define the first manifold flow path and the second manifold flow path.

7. The heat management device according to claim 6, wherein: The pair of stamped metal plates include aluminum and are brazed together.

8. The heat management device according to claim 1, wherein: The first heating element and the second heating element are coupled to an outer surface of the manifold.

9. The heat management device according to claim 1, wherein: The first heating element is disposed in the first manifold flow path, and the second heating element is disposed in the second manifold flow path.

10. A heat management system comprising: a first fluid circuit for circulating a first working fluid; a second fluid circuit for circulating a second working fluid; Manifold, which defines: a first manifold flow path in fluid communication with the first fluid circuit for directing the first working fluid, and a second manifold flow path in fluid communication with the second fluid circuit for directing the second working fluid, wherein the second manifold flow path is not in fluid communication with the first manifold flow path; a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path for heating the first working fluid as it flows through the first manifold flow path; a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path for heating the second working fluid as it flows through the second manifold flow path, wherein the second heating element is operable independently of the first heating element; and Heat exchangers, which define: a first heat exchanger flow path in fluid communication between the first manifold flow path and the first fluid circuit to facilitate flow of the first working fluid therebetween, and a second heat exchanger flow path in fluid communication between the second manifold flow path and the second fluid circuit to facilitate flow of the second working fluid therebetween, wherein the first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

11. The thermal management system of claim 10, further comprising: a first pump in fluid communication with the first fluid circuit and configured to circulate the first working fluid around the first fluid circuit in a first direction and in a second direction opposite the first direction; a second pump in fluid communication with the second fluid circuit and configured to circulate the second working fluid around the second fluid circuit in a third direction and in a fourth direction opposite the third direction; as well as A controller is in communication with the first pump, the second pump, the first heating element, and the second heating element, wherein the controller is configured to operate the thermal management system between a plurality of operating modes.

12. The thermal management system according to claim 11, wherein: The plurality of operating modes includes a first operating mode, wherein the controller: operating the first heating element to heat the first working fluid, operating the first pump to circulate the first working fluid in the first direction so that the first working fluid heated by the first heating element flows from the first manifold flow path, through the first heat exchanger flow path, and to the first fluid circuit, operating the second pump to circulate the second working fluid in the third direction so that the second working fluid flows from the second fluid circuit through the second heat exchanger flow path so that the first working fluid transfers heat to the second working fluid and through the second manifold flow path, and The second heating element is operated to further heat the second working fluid.

13. The thermal management system according to claim 11, wherein: The plurality of operating modes includes a second operating mode, wherein the controller: operating the second heating element to heat the second working fluid, operating the second pump to circulate the second working fluid in the fourth direction so that the second working fluid heated by the second heating element flows from the second manifold flow path through the second heat exchanger flow path and reaches the second fluid circuit, operating the first pump to circulate the first working fluid in the second direction such that the first working fluid flows from the first fluid circuit through the first heat exchanger flow path such that the second working fluid transfers heat to the first working fluid and through the second manifold flow path, and The first heating element is operated to further heat the first working fluid.

14. The heat management system according to claim 10, in, the first manifold flow path extending between a first port and a second port, wherein one of the first port and the second port is in fluid communication with the first fluid circuit such that the first manifold flow path directs the first working fluid between the first port and the second port; and wherein the first heat exchanger flow path extends between a first opening and a second opening, wherein the first opening is in fluid communication with the other of the first port and the second port, and the second opening is in fluid communication with the first fluid circuit, such that the first heat exchanger flow path directs the first working fluid between the first opening and the second opening.

15. The heat management system according to claim 10, in, the second manifold flow path extending between a third port and a fourth port, wherein one of the third port and the fourth port is in fluid communication with the second fluid circuit such that the second manifold flow path directs the second working fluid between the third port and the fourth port; and wherein the second heat exchanger flow path extends between a third opening and a fourth opening, wherein the third opening is in fluid communication with the other of the third port and the fourth port, and the fourth opening is in fluid communication with the second fluid circuit, such that the second heat exchanger flow path directs the second working fluid between the third opening and the fourth opening.

16. A method of operating a thermal management system, the thermal management system comprising: a manifold defining a first manifold flow path configured to direct a first working fluid and a second manifold flow path configured to direct a second working fluid; a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path to heat the first working fluid as it flows through the first manifold flow path; a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path to heat the second working fluid as it flows through the second manifold flow path; and a heat exchanger operatively attached to the manifold and defining a first heat exchanger flow path and a second heat exchanger flow path, the first heat exchanger flow path being in fluid communication with the first manifold flow path and the second heat exchanger flow path being in fluid communication with the second manifold flow path, wherein the first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid, the method comprising: circulating the first working fluid through the first manifold flow path and the first heat exchanger flow path in one of a first direction and a second direction opposite the first direction; circulating the second working fluid through the second manifold flow path and the second heat exchanger flow path in one of a third direction and a fourth direction opposite the third direction; operating the thermal management system in a first operating mode in response to the first working fluid circulating in the first direction and the second working fluid circulating in the third direction; operating the thermal management system in a second operating mode in response to the first working fluid circulating in the second direction and the second working fluid circulating in the fourth direction; The step of operating the thermal management system in the first operating mode includes: operating the first heating element to heat the first working fluid; directing the first working fluid heated by the first heating element from the first manifold flow path through the first heat exchanger flow path; directing the second working fluid through the second heat exchanger flow path such that the first working fluid transfers heat to the second working fluid and through the second manifold flow path; and operating the second heating element to further heat the second working fluid; and The step of operating the thermal management system in the second operating mode includes: operating the second heating element to heat the second working fluid; directing the second working fluid heated by the second heating element from the second manifold flow path through the second heat exchanger flow path; directing the first working fluid through the first heat exchanger flow path such that the second working fluid transfers heat to the first working fluid and through the second manifold flow path; and The first heating element is operated to further heat the first working fluid.

17. The method of operating a thermal management system according to claim 16, wherein: The thermal management system also includes a first pump, and the step of circulating the first working fluid through the first manifold flow path and the first heat exchanger flow path in one of a first direction and a second direction opposite to the first direction includes operating the first pump to circulate the first working fluid in one of the first direction and the second direction.

18. The method of operating a thermal management system according to claim 16, wherein: The thermal management system further includes a second pump, and circulating the second working fluid through the second manifold flow path and the second heat exchanger flow path in one of a third direction and a fourth direction opposite the third direction further includes operating the second pump to circulate the second working fluid in one of the third direction and the fourth direction.

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