Multi-mode control module

Abstract

A multi-mode control module for selectively controlling flow of one or more fluids through a thermal management system is disclosed. The control module includes a fluid valve system in fluid communication with one or more fluid manifolds. A fluid valve system includes at least one fluid valve assembly disposed in a housing defining a plurality of flow paths. Each fluid valve assembly includes a plurality of flow control members in stacked relationship movably disposed within the housing and selectively positionable within the housing to achieve various modes of operation of the control module and thereby various modes of operation of the thermal management system.

Description

Technical Field

[0001] The present disclosure relates to thermal management systems, and more particularly to a multi-mode control module for a thermal management system. Background Art

[0002] Vehicle heat exchangers, such as radiators, have valves that control the flow of fluids, such as coolant, through the system. With increasing government-mandated fuel economy regulations, companies are increasingly seeking new technologies that will reduce parasitic losses and improve the efficiency of internal combustion engines. Furthermore, the introduction of hybrid and all-electric vehicle powertrains has introduced powertrain and thermal management complexity due to the need to control the temperature of batteries, inverter electronics, electric motors, and more. These trends have led to a demand for more intelligently controlled fluid valve systems.

[0003] Conventional valve systems include diverter balls, valve cores, etc. to enable the heat exchanger to accommodate various intake and exhaust flows. Thus, a single heat exchanger can function as a charge air cooler (CAC), an exhaust gas recirculation (EGR) cooler, and a heat recovery device. While these designs can provide adequate performance for proportional flow applications, they do have some disadvantages. For example, some conventional valve systems have a vertical inlet at the base of the diverter valve. This allows for a wider outlet to provide smooth mixing of flows between two horizontal outlets positioned 90 degrees apart radially. Using a vertical inlet, the inlet does not take up space on the outer diameter of the valve core required for the wider outlet, and the inlet can remain in a stable position because the inlet is located on the rotational axis of the valve core. However, a vertical inlet on the valve core typically requires a vertical inlet located on the port housing of the valve system. Relative to all other vehicle components mounted around the valve system, the vertical inlet on the port housing and the fluid connections to the vertical inlet take up valuable packaging space in the vehicle. Summary of the Invention

[0004] Technical issues

[0005] Therefore, it is desirable to produce a multi-mode control module for a thermal management system wherein the size, weight, and cost of the multi-mode control module are minimized while optimizing the performance and functionality of the thermal management system.

[0006] Technical Solution

[0007] In accordance with and consistent with the presently described subject matter, a new multi-mode control module for a thermal management system has been designed that minimizes its size, weight, and cost while optimizing its performance and functionality.

[0008] In one embodiment, a fluid valve assembly includes a first flow control member and a second flow control member in stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second control member.

[0009] In another embodiment, a control module includes: at least one fluid manifold; and a fluid valve system in fluid communication with the at least one fluid manifold, wherein the control module is configured to selectively control the flow of one or more fluids through the thermal management system, wherein the fluid valve system includes a plurality of fluid valve assemblies, wherein at least one of the fluid valve assemblies includes: a first flow control member; and a second flow control member in a stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second control member.

[0010] In yet another embodiment, a method of operating a fluid valve assembly includes providing a first flow control member; providing a second flow control member in a stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second control member; rotationally moving the first flow control member in a first direction to selectively position the second flow control member in a desired position; and rotationally moving the first flow control member in an opposite, second direction to selectively position the first control member in a desired position.

[0011] As an aspect of some embodiments, each of the fluid valve assemblies is configured to operate independently of the other fluid valve assemblies of the fluid valve system.

[0012] As an aspect of some embodiments, a position of at least one of the first flow control member and the second flow control member is dependent on an operating mode of the thermal management system.

[0013] As an aspect of some embodiments, one of the fluids is a refrigerant and another of the fluids is a coolant.

[0014] As an aspect of some embodiments, the first flow control member is configured to be driven by at least one of a drive element and an actuator.

[0015] As an aspect of some embodiments, the second flow control member is configured to be driven by the first flow control member.

[0016] As an aspect of some embodiments, at least one of the first flow control member and the second flow control member includes a body having at least a fluid passage formed therein.

[0017] As an aspect of some embodiments, the body of the first flow control member includes at least one driven element disposed thereon.

[0018] As an aspect of some embodiments, the body of the first flow control member includes at least one locating element extending axially outward from a surface thereof.

[0019] As an aspect of some embodiments, the body of the second flow control member includes at least one locating element extending axially outward from a surface thereof.

[0020] As an aspect of some embodiments, the at least one positioning element of the first flow control member is configured to selectively engage the at least one positioning element of the second flow control member.

[0021] Further areas of applicability will become apparent from the description provided herein.The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

[0023] Figure 1 is a side perspective view of a vehicle interface of a multi-mode control module according to an embodiment of the present disclosure, wherein the control module includes a fluid valve system in fluid communication with a pair of fluid manifolds to selectively control the flow of one or more fluids through a thermal management system;

[0024] Figure 2 yes Figure 1 a perspective view of a plurality of fluid valve assemblies of a fluid valve system of a control module;

[0025] Figure 3 yes Figure 1 a perspective view of a portion of one of the fluid valve assemblies of the fluid valve system of the control module, showing a positioning element of the fluid valve assembly;

[0026] Figure 4 yes Figure 1 a side perspective view of a vehicle interface of a control module, wherein various fluid flow paths are shown in phantom;

[0027] Figure 5 is connected to the thermal management subsystem Figure 1 a perspective view of a control module;

[0028] Figure 6 Indicates when the control module is operating in battery cooling mode (mode B) Figure 1a table of valve positions of a fluid valve assembly of a control module;

[0029] Figure 7 Indicates when the control module is operating in active cabin and battery cooling mode (Mode C) Figure 1 a table of valve positions of a fluid valve assembly of a control module;

[0030] Figure 8 Indicates when the control module is operating in cabin cooling / dehumidification / reheating and passive battery cooling mode (mode D) Figure 1 a table of valve positions of a fluid valve assembly of a control module;

[0031] Figure 9 Indicates when the control module is operating in cabin cooling and battery circulation mode (Mode N) Figure 1 a table of valve positions of a fluid valve assembly of a control module;

[0032] Figure 10 Indicates when the control module is operating in cabin and battery heating or fixed battery heating only mode (Mode H) Figure 1 a table of valve positions of a fluid valve assembly of a control module;

[0033] Figure 11 Indicates when the control module is operating in cabin heating and passive battery heating and cooling mode (Mode P) Figure 1 a table of valve positions of a fluid valve assembly of a control module;

[0034] Figure 12 is a side perspective view of a thermal management system interface of a multi-mode control module according to another embodiment of the present disclosure, wherein the control module includes a fluid valve system in fluid communication with a pair of fluid manifolds to selectively control the flow of one or more fluids through the thermal management system;

[0035] Figure 13 yes Figure 12 a perspective view of a plurality of fluid valve assemblies of a fluid valve system of a control module;

[0036] Figure 14 yes Figure 12 A side perspective view of a vehicle interface of a control module;

[0037] Figure 15 yes Figure 12 an enlarged cross-sectional view of a control module;

[0038] Figure 16 Indicates various modes throughout the thermal management system Figure 12 a table of valve positions of the fluid valve assembly, heater core valve, and low-temperature radiator bypass valve of the control module;

[0039] Figure 17 Indicates when the control module is operating in battery cooling mode (mode B) Figure 12 a table of valve positions of a fluid valve assembly of a control module;

[0040] Figure 18 Indicates when the control module is operating in active cabin and battery cooling mode (Mode C) Figure 12 a table of valve positions of a fluid valve assembly of a control module;

[0041] Figure 19 Indicates when the control module is operating in cabin cooling / dehumidification / reheating and passive battery cooling mode (mode D) Figure 12 a table of valve positions of a fluid valve assembly of a control module;

[0042] Figure 20 Indicates when the control module is operating in cabin cooling and battery circulation mode (Mode N) Figure 12 a table of valve positions of a fluid valve assembly of a control module;

[0043] Figure 21 Indicates when the control module is operating in cabin and battery heating or fixed battery heating only mode (mode H). Figure 12 a table of valve positions of a fluid valve assembly of a control module;

[0044] Figure 22 Indicates when the control module is operating in cabin heating and passive battery heating and cooling mode (Mode P) Figure 12 A table of valve positions for the fluid valve assemblies of the control modules. DETAILED DESCRIPTION

[0045] The following technical descriptions of the subject matter, manufacture and use of one or more inventions are merely exemplary in nature and are not intended to limit the scope, application or use of any particular invention claimed in this application or in such other applications that may claim priority for this application or a patent granted in accordance with this application. With respect to the disclosed method, the order of the steps presented is exemplary in nature, and therefore, the order of the steps may be different in various embodiments. As used herein, "one" and "a" indicate that there is "at least one" item in the project; where possible, there may be multiple such items. Except where otherwise expressly indicated, when describing the broadest scope of the present technology, all numerical quantities in this description should be understood to be modified by the word "about", and all geometric and spatial descriptors should be understood to be modified by the word "substantially". "About" indicates that calculation or measurement allows some slight inaccuracy of the value when applied to a numerical value (wherein, to a certain extent, the exact value of the value; approximately or reasonably close to the value; approximately). If for some reason the imprecision provided by "about" and / or "substantially" is not otherwise understood in the art with such ordinary meaning, then "about" and / or "substantially" as used herein at least indicates variations that may result from ordinary methods of measuring or using such parameters.

[0046] Unless expressly indicated otherwise, all documents cited in this detailed description, including patents, patent applications, and scientific literature, are incorporated herein by reference. In the event of any conflict or ambiguity between a document incorporated by reference and this detailed description, the detailed description shall prevail.

[0047] Although embodiments of the present technology are described and claimed herein using the open-ended term "comprising" as a synonym for a non-limiting term such as includes, contains, or having, more restrictive terms such as "consisting of" or "consisting essentially of" may alternatively be used to describe embodiments. Thus, for any given embodiment reciting a material, component, or process step, the present technology also specifically includes embodiments consisting of or consisting essentially of such material, component, or process step, and excluding additional materials, components, or processes (for consisting of such material, component, or process step) and excluding additional materials, components, or processes (for consisting essentially of such material, component, or process step) that affect the significant characteristics of the embodiment, even if such additional materials, components, or processes are not expressly recited in this application. For example, a recitation of a composition or process reciting elements A, B, and C specifically contemplates embodiments consisting of and consisting essentially of A, B, and C, and excluding element D, which may be described in the art, even if element D is not expressly recited herein as not included.

[0048] As mentioned herein, unless otherwise stated, all composition percentages are by weight of total composition. Unless otherwise stated, the disclosure of a range includes endpoints and includes all different values ​​and further divided ranges within the entire range. Therefore, for example, the scope of "from A to B" or "from about A to about B" includes A and B. The disclosure of the value and range of values ​​for a particular parameter (such as amount, weight percent, etc.) does not exclude other values ​​and ranges of values ​​that can be used herein. It is conceivable that two or more specific exemplified values ​​for a given parameter can define the endpoints of the range of values ​​that may be claimed for the parameter. For example, if parameter X is exemplified herein as having value A and also exemplified as having value Z, it is conceivable that parameter X can have a value range from about A to about Z. Similarly, it is conceivable that the disclosure of the range of two or more values ​​of a parameter (whether such ranges are nested, overlapping or different) includes all possible combinations of the range of values ​​that may be claimed using the endpoints of the disclosed ranges. For example, if parameter X is exemplified herein as having values ​​in the range of 1 to 10, or 2 to 9, or 3 to 8, it is also contemplated that parameter X can have other ranges of values, including 1 to 9, 1 to 8, 1 to 3, 1 to 2, 2 to 10, 2 to 8, 2 to 3, 3 to 10, 3 to 9, etc.

[0049] When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, the element or layer may be directly on, engaged to, connected to, or coupled to the other element or layer, or there may be intervening elements or layers. Conversely, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0050] Although the terms first, second, third, etc. can be used to describe various elements, components, regions, layers and / or sections in this article, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can only be used to distinguish one element, component, region, layer or section from another region, layer or section. Unless the context clearly indicates, terms such as "first", "second" and other numerical terms do not imply an order or sequence when used in this article. Therefore, without departing from the teachings of the example embodiments, the first element, component, region, layer or section discussed below can be referred to as a second element, component, region, layer or section.

[0051] For ease of description, spatially relative terms such as "in," "out," "below," "beneath," "down," "above," "upper," etc. may be used herein to describe the relationship of one element or feature to another element or feature as illustrated in the accompanying drawings. Spatially relative terms may be intended to encompass different orientations of the device in use or operation other than the orientation depicted in the accompanying drawings. For example, if the device in the accompanying drawings is turned over, elements described as "below" or "beneath" other elements or features will be oriented "above" the other elements or features. Thus, the example term "below" may encompass both the above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein shall be interpreted accordingly.

[0052] Figure 1 and Figure 4 FIG2 illustrates a multi-mode control module 10 according to an embodiment of the present disclosure. Figure 5 As shown in FIG, the control module 10 can be configured as a thermal management system 50 for an electric vehicle or a hybrid vehicle. It should be understood that the control module 10 can be coupled to any component and / or subsystem of the thermal management system 50 by any method and device as needed. The control module 10 can be configured to selectively control the flow of one or more fluids (e.g., coolant, refrigerant) through the thermal management system 50, such as Figure 7 、 Figure 9 、 Figure 11 、 Figure 13 、 Figure 15 and Figure 17 However, it should be understood that the control module 10 can be employed in other fluid flow control applications as desired.

[0053] The control module 10 can include a pair of fluid manifolds 12, 14 disposed on opposite sides of a fluid valve system 16. Each of the fluid manifolds 12, 14 can include one or more openings 18 formed therein. In some embodiments, the openings 18 can serve as ports to provide fluid communication between the control module 10 and various components of the thermal management system 50. It should be understood that the openings 18 can be formed at locations other than those shown in the fluid manifolds 12, 14. It should also be understood that each of the fluid manifolds 12, 14 can have any size, shape, and configuration as desired to optimize the performance and functionality of the control module 10, and thereby optimize the performance and functionality of the thermal management system 50.

[0054] In some embodiments, the fluid valve system 16 includes a valve disposed within a defined area ( Figure 4 At least one fluid valve assembly 20 in a housing 22 (depicted by dashed lines in FIG) having a plurality of fluid flow paths 24. Each of the fluid flow paths 24 can be in fluid communication with one or more of the openings 18 formed at at least one of the fluid manifolds 12, 14 of the control module 10. In one particular embodiment, the fluid valve system 16 includes a first fluid valve assembly 20a, a second fluid valve assembly 20b, and a third fluid valve assembly 20c. If desired, more or fewer fluid valve assemblies 20 can be employed in the control module 10. Figure 2 As best shown in the figures, each of the fluid valve assemblies 20a, 20b, 20c may include a first flow control member 26 and a second flow control member 28, which are movably disposed within the housing 22 and can be selectively positioned within the housing 22 to achieve various operating modes of the control module 10 and thereby optimize the performance and functionality of the thermal management system 50.

[0055] In some embodiments, the flow control members 26 and 28 can each include a body 30 and 32, respectively. Both the body 30 of the first flow control member 26 and the body 32 of the second flow control member 28 can have a generally cylindrical shape. However, it should be understood that each of the bodies 30 and 32 can have any suitable shape as needed. If necessary, each of the bodies 30 and 32 can be a unitary structure or formed by multiple parts. It should also be understood that the bodies 30 and 32 can be formed, for example, by any suitable material such as metal, non-metal (e.g., plastic), etc., or a combination thereof. As needed, the bodies 30 and 32 can be formed by a molding process, an additive process (e.g., a three-dimensional printing process), a subtractive process (e.g., a machining process), or any other molding or manufacturing process, or a combination thereof.

[0056] In some embodiments, the body 30 of one or more of the first flow control members 26 and / or the body 32 of one or more of the second flow control members 28 of at least one of the fluid valve assemblies 20 can have one or more fluid passages 38 formed in the body 30, 32 to receive a fluid flow therethrough. Each of the fluid passages 38 can include one or more fluid openings 40. If desired, additional fluid openings 40 can be formed in the body 30, 32 of the flow control members 26, 28. Each of the fluid openings 40 can function as a fluid inlet and / or a fluid outlet during operation of the fluid valve system 16. Figure 2 As best seen in FIG, the cross-sectional area of ​​each of the fluid openings 40 can vary and the cross-sectional shape of each of the fluid openings 40 can be non-circular. The cross-sectional area and shape of the fluid passage 38 and / or the fluid openings 40 facilitate proportional flow through the fluid valve system 16 and the control module 10. It should be appreciated that the shape, size, and configuration of the flow control members 26, 28 of the fluid valve system 16 result in simplified manufacturing (e.g., a molding process, a three-dimensional printing process, a machining process, or any other forming process or combination thereof, as desired) and sealing structure of the fluid valve system 16 and a compact shape, size, and configuration of the control module 10.

[0057] The housing 22 of the fluid valve system 16 may include one or more chambers formed therein to receive the fluid valve assembly 20 (e.g., Figure 21 14). In one particular embodiment, the housing 22 can include a first chamber, a second chamber, and a third chamber. It should be understood that each of the chambers can have any size and shape as desired to accommodate a corresponding one of the fluid valve assemblies 20 therein. The first flow control member 26 and the second flow control member 28 of each of the fluid valve assemblies 20 can be removably disposed within the chambers of the housing 22 such that, during certain operating modes of the control module 10 and the thermal management system 50, at least one of the fluid openings 40 of the fluid passages 38 of the flow control members 26, 28 is generally aligned with at least one fluid inlet formed in the outer wall of the housing 22, and at least one of the fluid openings 40 of the fluid passages 38 of the flow control members 26, 28 is generally aligned with at least one fluid outlet formed in the outer wall of the housing 22. The fluid inlet and fluid outlet formed in the housing 22 of the fluid valve system 16 can be in fluid communication with the openings 18 of the fluid manifolds 12, 14.

[0058] In some embodiments, the control module 10, and more particularly the housing 22 of the fluid valve system 16, may include an electronic water pump mounted directly to the fluid valve assembly 20 and operating integrally with the functionality of the fluid valve assembly 20. However, it should be understood that the electronic water pump may be located elsewhere and / or mounted on the control module 10 at various other locations.

[0059] One or more sealing elements (e.g., O-rings, gaskets, elastomeric seals, etc.) may be disposed between at least one of the flow control members 26, 28 of at least one of the fluid valve assemblies 20 and the inner surface of the housing 22 to form a substantially fluid-tight seal between the at least one of the flow control members 26, 28 and the inner surface of the housing 22 and to prevent undesirable fluid leakage around the periphery of the fluid opening 40 of the fluid passage 38. It should be understood that various other sealing methods may be employed, if desired.

[0060] Each of the flow control members 26, 28 of each of the fluid valve assemblies 20 is selectively positionable within the housing 22 of the fluid valve system 16 and configured to selectively control the flow of one or more fluids therethrough. In certain embodiments, the first flow control member 26 and the corresponding one of the second flow control members 28 of at least one of the fluid valve assemblies 20 are stacked within the chamber of the housing 22. Figure 2 In the embodiment shown in FIG, the first flow control member 26 may be in an uppermost position and the second flow control member 28 may be in a lowermost position. Figure 3 As best seen in FIG, the body 30 of the first flow control member 26 may include one or more positioning elements 44, and the body 32 of the second flow control member 28 may include one or more positioning elements 46. Each of the positioning elements 44, 46 may extend outwardly and axially along the central axis of the body 30. As depicted, the positioning elements 44 of the first flow control member 26 may extend downwardly from a surface of the body 30, and the positioning elements 46 of the second flow control member 28 may extend upwardly from a surface of the body 32 that faces the surface of the body 30, to allow the positioning elements 44 and 46 to be selectively engaged during positioning of the flow control members 26, 28.

[0061] The stacked flow control members 26, 28 are configured to rotate in unison or substantially simultaneously when the positioning element 44 of the first flow control member 26 engages the positioning element 46 of the second flow control member 28. When the positioning elements 44, 46 are disengaged, the first flow control member 26 of the fluid valve assembly 20 can operate proportionally to the second flow control member 28 of the fluid valve assembly 20. Thus, the first flow control member 26 can rotate independently while the second flow control member 28 remains stationary. In a non-limiting example, the first flow control member 26 is moved in a first rotational direction until the positioning element 44 of the first flow control member 26 engages the positioning element 46 of the second flow control member 28. Once the positioning elements 44, 46 are engaged, the flow control members 26, 28 rotate substantially simultaneously in the first rotational direction until the desired position of the second flow control member 28 is reached. In some cases, the desired position of the first flow control member 26 may not be achieved while positioning the second flow control member 28 in its desired position. Thus, the first flow control member 26 can then be moved in the opposite second rotational direction to disengage the positioning elements 44, 46 so that the desired position of the second flow control member 28 is maintained. The first flow control member 26 can then continue to be rotated in the second rotational direction until the desired position of the first flow control member 26 is reached.

[0062] Each of the flow control members 26, 28 can be selectively positioned between 0 degrees and 360 degrees around its central axis. However, in some embodiments, each of the flow control members 26, 28 can be connected to one or more drive stops during its positioning. The drive stops can be configured to prevent at least one of the flow control members 26, 28 from rotating a full 360 degrees around its central axis and / or limit the range of rotational motion of the flow control members 26, 28. As a non-limiting example, at least one of the flow control members 26, 28 can be connected to one or more drive stops during its positioning to limit the range of rotational motion and prevent over-rotation. In a preferred embodiment, each of the flow control members 26, 28 of each fluid valve assembly in the fluid valve assembly 20 can be positioned in a desired position.

[0063] At least one driven element (e.g. Figure 15In the illustrated embodiment, a driven gear, pinion, or the like, such as indicated by reference numeral 148, can be formed on the body 30 of the first flow control member 26. However, it should be understood that, if desired, the driven element can be formed on the body 32 of the second flow control member 28. The driven element can extend outwardly and axially along the central axis of the body 30. The driven element can be configured to be coupled to a drive element or actuator 49 to cause rotational movement of one or more of the flow control members 26, 28 about their central axes in a first rotational direction and an opposite second rotational direction. The drive element or actuator 49 can be powered by any electric motor capable of generating rotational motion. For example, the drive element or actuator 49 can be driven by a stepper motor or a brushless DC (BLDC) motor. It should be understood that other methods of actuating and causing rotational movement of the flow control members 26, 28 within the fluid valve system 16 can be used.

[0064] An exemplary embodiment of the thermal management system 50 may include a refrigerant circuit in heat exchange communication with a coolant circuit (e.g., a refrigerant thermal management system (RTMS)). The thermal management system 50 may include a heater core, a cooler core, a power source (e.g., a battery), one or more heat exchangers (e.g., a condenser, an evaporator, a chiller, a radiator), one or more valves (e.g., a bypass valve, a heater control valve), one or more prime movers (e.g., a coolant pump, a refrigerant pump), and / or one or more blower assemblies. It should be understood that the thermal management system itself can be modularly configured by integrating with the control module 10 described above.

[0065] It should be understood that the control module 10 and thermal management system 50 may include more or fewer components, valves, conduits, and other features and aspects than illustrated and described herein without departing from the spirit and scope of the present disclosure.

[0066] Figure 6 Indicates when the control module 10 is operating in the battery cooling mode (mode B) Figure 1 10. In a non-limiting example, the first flow control member 26, 28 of the first fluid valve assembly 20a has a valve position of 0 degrees, the first flow control member 26 of the second fluid valve assembly 20b has a valve position of 0 degrees, and the second flow control member 28 of the second fluid valve assembly 20b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20c has a valve position of 135 degrees, and the second flow control member 28 of the third fluid valve assembly 20c is a second proportional valve.

[0067] Figure 7Indicates when the control module 10 is operating in the cabin and battery active cooling mode (Mode C) Figure 1 10. A table of valve positions of the fluid valve assemblies 20a, 20b, and 20c of the control module 10 is shown. In a non-limiting example, the first flow control member 26 of the first fluid valve assembly 20a has a valve position of 45 degrees and the second flow control member 28 of the first fluid valve assembly 20a is positioned at 0 degrees, the first flow control member 26 of the second fluid valve assembly 20b has a valve position of 45 degrees and the second flow control member 28 of the second fluid valve assembly 20b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20c has a valve position of 135 degrees and the second flow control member 28 of the third fluid valve assembly 20c is a second proportional valve.

[0068] Figure 8 Indicates when the control module 10 is operating in the cabin cooling / dehumidification / reheating and passive battery cooling mode (mode D) Figure 1 10. A table of valve positions of the fluid valve assemblies 20a, 20b, and 20c of the control module 10 is shown. In a non-limiting example, the first flow control member 26 of the first fluid valve assembly 20a has a valve position of 135 degrees and the second flow control member 28 of the first fluid valve assembly 20a is positioned at 45 degrees, the first flow control member 26 of the second fluid valve assembly 20b has a valve position of 45 degrees and the second flow control member 28 of the second fluid valve assembly 20b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20c has a valve position of 90 degrees and the second flow control member 28 of the third fluid valve assembly 20c is a second proportional valve.

[0069] Figure 9 Indicates when the control module 10 is operating in the cabin cooling and battery circulation mode (mode N) Figure 1 1 . A table of valve positions of the fluid valve assemblies 20a, 20b, and 20c of the control module 10 is shown. In a non-limiting example, the first flow control member 26 of the first fluid valve assembly 20a has a valve position of 90 degrees and the second flow control member 28 of the first fluid valve assembly 20a is positioned at 0 degrees, the first flow control member 26 of the second fluid valve assembly 20b has a valve position of 135 degrees and the second flow control member 28 of the second fluid valve assembly 20b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20c has a valve position of 135 degrees and the second flow control member 28 of the third fluid valve assembly 20c is a second proportional valve.

[0070] Figure 10 Indicates when the control module 10 is operating in cabin and battery heating or fixed battery heating only mode (mode H) Figure 1FIG1 is a table of valve positions of the fluid valve assemblies 20 a, 20 b, and 20 c of the control module 10. In a non-limiting example, the first flow control member 26 of the first fluid valve assembly 20 a has a valve position of 135 degrees and the second flow control member 28 of the first fluid valve assembly 20 a is positioned at 90 degrees, the first flow control member 26 of the second fluid valve assembly 20 b has a valve position of 90 degrees and the second flow control member 28 of the second fluid valve assembly 20 b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20 c has a valve position of 45 degrees and the second flow control member 28 of the third fluid valve assembly 20 c is a second proportional valve.

[0071] Figure 11 Indicates when the control module 10 is operating in the cabin heating and passive battery heating and cooling mode (Mode P) Figure 1 1 . A table of valve positions of the fluid valve assemblies 20a, 20b, and 20c of the control module 10 is shown. In a non-limiting example, the first flow control member 26 of the first fluid valve assembly 20a has a valve position of 135 degrees and the second flow control member 28 of the first fluid valve assembly 20a is positioned at 135 degrees, the first flow control member 26 of the second fluid valve assembly 20b has a valve position of 0 degrees and the second flow control member 28 of the second fluid valve assembly 20b is a first proportional valve, and the first flow control member 26 of the third fluid valve assembly 20c has a valve position of 0 degrees and the second flow control member 28 of the third fluid valve assembly 20c is a second proportional valve.

[0072] Figures 12 to 15 A multi-mode control module 10' for a thermal management system 50' according to another embodiment of the present disclosure is illustrated. The features, aspects, and structure of the control module 10' and the thermal management system 50' are substantially similar or identical to the control module 10 and the thermal management system 50 described herein and have similar identifying marks except for the addition of a prime (') symbol. For simplicity, the control module 10' and the thermal management system 50' may be described with reference to the control module 10 and the thermal management system 50 described above.

[0073] Figure 16 is indicative of various modes throughout the thermal management system 50' Figure 12 A table of valve positions of the fluid valve assemblies 20a', 20b', 20c', the first proportional valve, and the second proportional valve of the control module 10'.

[0074] Figure 17 Indicates when the control module 10' is operating in the battery cooling mode (mode B) Figure 12FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 5 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 285 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 285 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0075] Figure 18 Indicates when the control module 10' is operating in the cabin and battery active cooling mode (Mode C) Figure 12 FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 5 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 195 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 285 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0076] Figure 19 Indicates when the control module 10' is operating in the cabin cooling / dehumidification / reheating and passive battery cooling mode (mode D) Figure 12 FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 5 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 195 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 195 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0077] Figure 20 Indicates when the control module 10' is operating in the cabin cooling and battery circulation mode (mode N) Figure 12FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 50 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 240 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 285 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0078] Figure 21 Indicates when the control module 10' is operating in cabin and battery heating or fixed battery heating only mode (mode H) Figure 12 FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 95 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 240 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 285 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0079] Figure 22 Indicates when the control module 10' is operating in the cabin heating and passive battery heating and cooling mode (Mode P) Figure 12 FIG1 is a table showing valve positions of the fluid valve assemblies 20 a ′, 20 b ′, and 20 c ′ of the control module 10 ′. In a non-limiting example, the first flow control member 26 ′ of the first fluid valve assembly 20 a ′ has a valve position of 140 degrees and the second flow control member 28 ′ of the first fluid valve assembly 20 a ′ is not applicable, the first flow control member 26 ′ of the second fluid valve assembly 20 b ′ has a valve position of 240 degrees and the second flow control member 28 ′ of the second fluid valve assembly 20 b ′ is a first proportional valve, and the first flow control member 26 ′ of the third fluid valve assembly 20 c ′ has a valve position of 240 degrees and the second flow control member 28 ′ of the third fluid valve assembly 20 c ′ is a second proportional valve.

[0080] Advantageously, the control module 10, 10' has the ability to achieve six or more operating modes using only three drive elements / actuators; independently operate six flow control members using only three drive elements / actuators; and proportionally operate one of the first flow control member and the second flow control member of at least one of the fluid valve assemblies while the remaining one of the first flow control member and the second flow control member of at least one of the fluid valve assemblies remains stationary in position.

[0081] These example embodiments are provided so that the present disclosure will be thorough and will fully convey the scope to those skilled in the art. Many specific details, such as examples of specific components, devices and methods, are set forth to provide a thorough understanding of each embodiment of the present disclosure. It will be readily understood by those skilled in the art that specific details do not need to be adopted, and the example embodiments can be implemented in many different forms, and none of them should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures and well-known technologies are not described in detail. Equivalent changes, modifications and variations can be made to some embodiments, materials, compositions and methods within the scope of the present technology with substantially similar results.

Claims

1. A fluid valve assembly, comprising: a first flow control member; as well as A second flow control member is provided in stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second control member.

2. The fluid valve assembly according to claim 1, wherein: The first flow control member is configured to be driven by at least one of a drive element and an actuator.

3. The fluid valve assembly according to claim 1, wherein: The second flow control member is configured to be driven by the first flow control member.

4. The fluid valve assembly according to claim 1, wherein: At least one of the first flow control member and the second flow control member includes a body having at least a fluid passage formed therein.

5. The fluid valve assembly according to claim 4, wherein: The body of the first flow control member includes at least one driven element disposed thereon.

6. The fluid valve assembly according to claim 4, wherein: The body of the first flow control member includes at least one locating element extending axially outward from a surface of the body.

7. The fluid valve assembly according to claim 4, wherein: The body of the second flow control member includes at least one locating element extending axially outward from a surface of the body.

8. The fluid valve assembly according to claim 7, wherein: The at least one positioning element of the first flow control member is configured to selectively engage the at least one positioning element of the second flow control member.

9. A control module comprising: at least one fluid manifold; as well as a fluid valve system in fluid communication with the at least one fluid manifold, wherein the control module is configured to selectively control the flow of one or more fluids through the thermal management system, wherein the fluid valve system includes a plurality of fluid valve assemblies, wherein at least one of the fluid valve assemblies includes: a first flow control member; and A second flow control member is provided in stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second control member.

10. The control module according to claim 9, wherein: Each of the fluid valve assemblies is configured to operate independently of the other fluid valve assemblies of the fluid valve system.

11. The control module according to claim 9, wherein: The position of at least one of the first flow control member and the second flow control member is dependent on an operating mode of the thermal management system.

12. The control module according to claim 9, wherein: One of the fluids is a refrigerant and another of the fluids is a coolant.

13. The control module according to claim 9, wherein: The first flow control member is configured to be driven by at least one of a drive element and an actuator.

14. The control module according to claim 9, wherein: The second flow control member is configured to be driven by the first flow control member.

15. The control module according to claim 9, wherein: At least one of the first flow control member and the second flow control member includes a body having at least a fluid passage formed therein.

16. The control module according to claim 15, wherein: The body of the first flow control member includes at least one driven element disposed thereon.

17. The control module according to claim 15, wherein: The body of the first flow control member includes at least one locating element extending axially outward from a surface of the body.

18. The control module according to claim 15, wherein: The body of the second flow control member includes at least one locating element extending axially outward from a surface of the body.

19. The control module according to claim 18, wherein: The at least one positioning element of the first flow control member is configured to selectively engage the at least one positioning element of the second flow control member.

20. A method of operating a fluid valve assembly, comprising: providing a first flow control member; providing a second flow control member in stacked relationship with the first flow control member, wherein the first flow control member is configured to rotate substantially simultaneously and independently with the second flow control member; Rotating the first flow control member in a first direction to selectively position the second flow control member in a desired position; and The first flow control member is rotationally moved in an opposite second direction to selectively position the first control member in a desired position.

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