Fluid distribution system and fluid distribution system for vehicle reconfigurable thermal management

Abstract

The utility model relates to a fluid distribution system. In one example, a fluid distribution system includes a fluid manifold including a plurality of portions having a plurality of inlets and outlets, and a pilot assembly including a plurality of manifold portions, a plurality of selectively coupleable fluid chambers, and a plurality of electromagnetic pilot valve assemblies. The plurality of electromagnetic pilot valve assemblies control fluid flow through the plurality of selectable coupling fluid chambers by controlling differential pressure across the plurality of main diaphragms. The utility model further relates to a fluid distribution system for the reconfigurable thermal management of the vehicle.

Description

Technical Field

[0001] Embodiments of the subject matter disclosed herein relate to thermal management and, more particularly, to a multi-valve integrated fluid distribution system for reconfigurable vehicle thermal management. Background Art

[0002] Automotive thermal management systems utilize fluids to transfer heat from one system to another. In many automotive systems, actuated valves are used to control pressure or fluid flow. Common direct solenoid flow valves are simple to operate and utilize a continuous DC current in a solenoid coil to allow or block fluid flow. Hydraulic flow valves are controlled by pilot pressure provided by a solenoid pilot valve assembly and are sometimes used to replace direct solenoid flow valves to reduce power consumption and valve size. Regardless of the type of valve, each valve in the system contains an electromagnet, which results in increased manufacturing cost and packaging weight.

[0003] In order to meet the required drive cycle and environmental conditions, the fluid flow within the vehicle needs to be reconfigured to divert cold, warm and hot fluids to components within the vehicle, such as the battery system. Current electric vehicle thermal management systems typically use multiple individual valves to complete fluid redirection throughout the vehicle. The valves of this distribution system occupy a large amount of packaging space. These valves are typically actuated by solenoid valves, which can be directly or indirectly actuated as described above, and therefore include coils (such as copper coils), which leads to high manufacturing and production costs and increases the weight and size of the package. Utility Model Content

[0004] The inventors of this article have recognized the above problems and proposed a fluid distribution system for reconfigurable thermal management of electric vehicles. The disclosed fluid distribution system includes a fluid manifold having multiple sections arranged in multiple layers, and a pilot assembly, the pilot assembly including multiple manifold sections and multiple solenoid pilot valve assemblies, which control the position / state of multiple main diaphragms through pressure differential changes. Each solenoid pilot valve assembly includes multiple solenoid valves arranged side by side and multiple pilot diaphragms arranged side by side and vertically below the multiple solenoid valves.

[0005] A control board located directly above the one or more solenoid valves can selectively provide current to each of the multiple solenoid valves to energize and / or de-energize each of the multiple solenoid valves. The multiple solenoid valves control the position / state of the multiple pilot diaphragms, and one or more of the multiple main diaphragms can be opened and / or closed when the multiple solenoid valves drive one of the pilot valve assemblies to open and / or close. Opening the main diaphragms in this manner allows fluid to flow through the orifices, thereby achieving fluid communication between the selectively coupled fluid chambers in the independent parts of the fluid manifold. Similarly, after closing the main diaphragms, fluid cannot flow through the orifices, thereby selectively disconnecting the connection between the fluid chambers. Each part of the manifold includes one or more external fluid connections and one or more internal fluid connections that allow fluid to flow into and out of the manifold. The first part of the manifold is an inlet manifold, which includes or is otherwise connected to a plurality of inlet ports. The second part of the manifold is an outlet manifold, which includes or is otherwise connected to a plurality of outlet ports.

[0006] The multi-valve, multi-port design provides a compact integrated assembly that enables the distribution and recovery of fluids between multiple vehicle components. The fluid distribution system disclosed herein also includes an integrated pump, wherein the involute of the pump is integrated into a portion of the manifold. In this way, the weight of the pump can be reduced because the involute is manufactured together with the manifold.

[0007] Since actuating one of the multiple solenoid pilot valve assemblies can control actuation of more than one main diaphragm, a single solenoid valve can control flow through / to more than one fluid chamber. This can reduce the number of solenoid valves required to reconfigure fluid flow. Reducing the number of solenoid coils, and thus the number of coils (such as copper coils) in the entire system, can reduce the weight and size of the package.

[0008] It should be understood that the above brief description is intended to introduce in a simplified form the concepts that are further described in the detailed description. It is not intended to identify key or essential features of the claimed subject matter, the scope of which is solely determined by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] According to the accompanying drawings, those skilled in the art can easily see the above and other advantages of the present disclosure from the following detailed description:

[0010] Figure 1 An example of an at least partially electrified vehicle is shown.

[0011] Figure 2A A perspective view of an example fluid distribution system is shown.

[0012] Figure 2BA top view of a fluid distribution system is shown.

[0013] Figure 2C The fluid distribution system is shown from the bottom up.

[0014] Figure 2D A front view of the fluid distribution system is shown.

[0015] Figure 2E A rear view of the fluid distribution system is shown.

[0016] Figure 2F A first side view of a fluid distribution system is shown.

[0017] Figure 2G A second side view of the fluid distribution system is shown.

[0018] Figure 3A A cross-sectional view of a portion of a fluid distribution system is shown.

[0019] Figure 3B A cross-sectional view of another portion of the fluid distribution system is shown.

[0020] Figure 4A An example of a fluid distribution system manifold assembly is shown.

[0021] Figure 4B Another example of a fluid distribution system manifold assembly is shown.

[0022] Figure 5A A cross-sectional view of the fluid distribution system is shown with the manifold assembly removed.

[0023] Figure 5B Another cross-sectional view of the fluid distribution system is shown with the manifold assembly removed.

[0024] Figure 5C Another cross-sectional view of the fluid distribution system is shown with the manifold assembly in place.

[0025] Figure 5D Another cross-sectional view of the fluid distribution system is shown.

[0026] Figure 5E A perspective view of the manifold assembly cavity is shown.

[0027] Figure 6 A perspective view of the manifold assembly is shown.

[0028] Figure 7 The housing of a fluid distribution system pilot assembly is shown.

[0029] Figure 8 A cross-sectional perspective view of a fluid distribution system is shown. DETAILED DESCRIPTION

[0030] The following description relates to a multi-valve, multi-port integrated fluid distribution system for reconfigurable thermal management of a vehicle, such as an electric vehicle. The fluid distribution system includes a manifold having first and second manifold portions and a pilot assembly including a manifold subassembly. The manifold subassembly includes a plurality of portions arranged in two separate layers, the manifold layers having selectively couplable fluid chambers arranged on / in the separate layers. The fluid chambers arranged in the separate layers can be selectively coupled via an electromagnetically actuated pilot valve assembly and a main diaphragm in the manifold subassembly to direct fluid to a plurality of components of the vehicle through outlet ports. Figure 1 An example of a vehicle is depicted in schematic form. Figure 2A-2G An external view of the fluid distribution system is shown. Figure 3A-3B A cross-sectional view of a fluid distribution system is shown, including the housing, cover, inlet / outlet, and manifold assembly. Figure 4A-4B The manifold subassembly and the components therein are shown. Figures 5A-5E , the internal components of the fluid distribution system are shown in a cross-sectional view with the manifold assembly removed for ease of viewing. Figure 6 A perspective view of the manifold assembly is shown. The pilot assembly housing is shown in Figure 7 The pressure sensor ports and connected circuit board are shown in Figure 8 This is described in the cross-sectional view of the fluid distribution system in FIG.

[0031] Now watch Figure 1 , an example of a vehicle 105 is shown. In some examples, the vehicle 105 can be a hybrid vehicle with multiple torque sources available to one or more wheels 155. In other examples, the vehicle 105 can be an all-electric vehicle that is powered entirely by an energy storage device such as a battery assembly (referred to herein as battery 158). In the example shown, the vehicle 105 includes an electric machine 152, which can be an electric motor or a motor / generator. The electric machine 152 receives electrical energy from the battery 158 and converts it into rotational energy, such as torque, at the transmission 156. The torque is delivered to the wheels 155. For example, during braking operations, the electric machine 152 can also operate as a generator to provide power to charge the battery 158.

[0032] Although the electric machine 152 is shown to provide rotational energy to the wheels 155 near the front end 100 of the vehicle 105 (e.g., the front wheels of the vehicle) through the transmission 156, it is understood that the transmission 156 can also be arranged at the rear wheels of the vehicle 105 (e.g., the wheels 155 near the rear end 102 of the vehicle) and transmit energy from the electric machine 152 to the rear wheels. In addition, in other examples, the front wheels and the rear wheels can be connected to separate transmissions, such as when the vehicle 105 is configured as all-wheel drive.

[0033] In some examples, the vehicle 105 may further include a thermal management system 168. The thermal management system 168 may communicate with the battery 158 to provide a variable temperature fluid to change the temperature of the battery 158. The thermal management system 168 may further communicate with the electric machine 152 and other components not shown. The thermal management system 168 may be configured to control external and internal temperature conditions and adjust the optimal temperature of the battery 158, the electric machine 152, etc. In some examples, the thermal management system 168 includes a fluid distribution system for re-distributing the variable temperature fluid to the components of the vehicle 105.

[0034] The battery assembly (e.g., battery 158) can be a single battery or can include multiple batteries or modules electrically connected to each other. The number of multiple batteries can determine the capacity of battery 158. Battery 158 can be configured to have a high power-to-weight ratio, high specific energy, and high energy density to provide power for a long time. The types of batteries that can be used in vehicle 105 include lithium-ion batteries, lithium polymer batteries, lead-acid batteries, nickel-cadmium batteries, and nickel-metal hydride batteries, among others. Battery 158 can be a rechargeable battery, such as a battery composed of lithium-ion batteries. When configured as a rechargeable battery, battery 158 can be charged by regenerative braking operation or an external power source. The performance and life of the battery may depend on the load applied (and therefore also on the charge and discharge rate) and the operating conditions (such as temperature). Battery 158 can operate effectively at a range of discharge rates (e.g., C / 8-2C), a target operating temperature range (typically 20°C to 45°C), and a relatively uniform temperature (e.g., temperature uniformity is less than 5°C).

[0035] The temperature and / or pressure within the battery 158 may rise to a level where the battery 158 cannot continue to operate, or may cause degradation of the battery 158. The thermal management system 168 and the fluid distribution system therein may regulate and / or maintain the temperature within the battery 158 and other components discussed herein to reduce battery 158 degradation and extend its useful life.

[0036] Now watch Figure 2A-2G , an external view of an example of a fluid dispensing system 200 is shown. Figure 2A A perspective view of a fluid dispensing system 200 is specifically depicted, Figure 2B A top view of a fluid distribution system 200 is specifically depicted. Figure 2C A bottom view of the fluid distribution system 200 is specifically depicted, Figure 2D A front view of a fluid distribution system 200 is specifically depicted, Figure 2E A top view of the fluid distribution system 200 is particularly depicted. Figure 2D A front view of a fluid distribution system 200 is specifically described. Figure 2E A rear view of the fluid dispensing system 200 is specifically described. Figure 2FA first side view of a fluid dispensing system 200 is specifically depicted, Figure 2G A second side view of the fluid dispensing system 200 is depicted in detail. Figure 2A-2G as well as Figure 3A-8 An axis system is provided for reference in . In one example, the Y axis can be a vertical axis (e.g., parallel to the gravity axis), the X axis can be a lateral axis (e.g., a horizontal axis), and / or the Z axis can be a longitudinal axis. However, in other examples, these axes may have other directions.

[0037] The fluid dispensing system 200 may be Figure 1 A portion of the thermal management system 168 of the vehicle 105. The fluid distribution system 200 may include a fluid manifold 230 including a first portion 222 and a second portion 224, a pilot assembly 202, and a pump 214. The first portion 222 may be located closer to an upper end 290 of the fluid distribution system 200 than the second portion 224. When assembling the fluid distribution system 200, the first and second portions 222, 224 may be connected together. When assembled, the upper end 290 of the second portion 224 may be connected to the lower end 296 of the first portion 222. The plurality of inlet ports 208 and the plurality of outlet ports 210 may be part of or otherwise connected to the first portion 222 and the second portion 224. In some embodiments, each of the plurality of inlet ports 208 may be coupled to the first portion 222, and each of the plurality of outlet ports 210 may be coupled to the second portion 224. In these embodiments, the first portion 222 may be an inlet manifold and the second portion 224 may be an outlet manifold. However, other inlet port and outlet port configurations are also contemplated. The pilot assembly 202 can be integrated into the fluid manifold 230. In one example, integration into the fluid manifold 230 can include mounting within and coupling to a setback region of a fluid manifold 230 mold, as will be further explained.

[0038] A plurality of inlet ports 208 and a plurality of outlet ports 210 may be disposed at and / or extend from a front portion 298 of the fluid distribution system 200. The "front portion" of the fluid distribution system 200 is used illustratively herein and does not refer to the orientation of the fluid distribution system 200 when positioned within a vehicle. In some examples, the first portion 222 may include three inlets and the second portion 224 may include three outlets. Each of the plurality of inlet ports 208 and the plurality of outlet ports 210 may be in fluid communication with a chamber of the pilot assembly 202. The pump inlet 221 may be in fluid communication with the pump 214 so that the pump 214 receives fluid from the pump inlet 221. In addition, each of the inlet port 208 and the outlet port 210 may be in fluid communication with one or more components of the vehicle, such as a heating, ventilation, and air conditioning (HVAC) system, an energy storage system (ESS), and the like. In some examples, a vehicle component may receive fluid from the fluid distribution system 200 through one of the outlet ports and deliver fluid to the fluid distribution system 200 through one of the inlet ports.

[0039] Both the first portion 222 and the second portion 224 may include one or more external fluid connections and one or more internal fluid connections. In this way, fluid from other components in the vehicle may flow into and / or out of the fluid distribution system 200 through the internal fluid passages of the fluid distribution system 200. In this way, the fluid manifold 230 may combine multiple ports and multiple solenoid valves into a single unit to distribute fluid throughout the vehicle. In some examples, the fluid distribution system 200 may be paired with a second fluid distribution system to create a fluid management system.

[0040] The pump 214 can pressurize fluid entering the fluid distribution system 200 and / or output from the fluid distribution system 200 through the plurality of inlet ports 208 and the plurality of outlet ports 210. The pump 214 includes a pump outlet port 220. The flow direction and which of the plurality of inlets 208 and the plurality of outlets 210 to use can be determined based on the needs of different vehicle systems, taking into account priority factors. For example, some systems may have higher priority heating / cooling needs than other systems. Which valve is opened and / or closed at a given time is determined by an intelligent control system in the vehicle, which can drive a given solenoid valve based on input parameters received from temperature, pressure and / or other sensors located at different locations and associated with different systems within the vehicle. The pump 214 can be an electronically commutated centrifugal pump or other type of electric or non-electric (such as mechanical or other) fluid pump to provide power to multiple components of the vehicle 105 (such as Figure 1 The pump 214 may be connected to a power source (such as the battery 158 of the vehicle 105).

[0041] The pump 214 can be disposed on the first side 292 of the fluid manifold 230, opposite the second side 294. The fluid manifold 230, for example, the first or second portions 222, 224, can be integrated or otherwise coupled with the pump 214. As an example, the first portion 222 of the fluid manifold 230 can be formed as a mold including an involute of the pump 214, thereby integrating the pump 214 into the fluid distribution system 200, such as Figure 2C Integrating the pump 214 into the fluid distribution system 200 can reduce the weight of the pump 214 because parts of the pump 214 can be manufactured together with the fluid manifold 230.

[0042] The pilot assembly 202 may include a cover 204 and a pilot assembly housing 206, and a manifold subassembly mounted within the pilot assembly housing 206 and the cover 204 when the pilot assembly housing 206 and the cover 204 are coupled together. Each component of the pilot assembly 202 may be manufactured separately and then assembled and tested as a unit prior to connection with the first and second portions 222, 224 of the fluid manifold 230. In this way, errors in manufacturing or assembly may be identified prior to assembly of the fluid dispensing system 200, thereby reducing downstream effects in the production process.

[0043] When assembled, the upper end 290 of the first portion 222 can be connected to the lower end 296 of the pilot assembly housing 206, and the upper end 290 of the pilot assembly housing 206 can be connected to the lower end 296 of the cover 204. The cover 204 can include a connector 212 for connecting the fluid manifold 230 to another component within the vehicle. In some examples, the connector 212 can be a connector that connects the control board (e.g., Figure 4A The control board 418 mentioned in the figure is connected to the electrical interface of the vehicle electrical system to provide current to the control board. The connector 212 can be set at the front 298 of the cover plate 204.

[0044] The first portion 222, the second portion 224, the pilot assembly housing 206 and the cover 204 may include planar joint surfaces. Thus, welding work for connecting the second portion 224 to the first portion 222, the first portion 222 to the pilot assembly housing 206, and the pilot assembly housing 206 to the cover 204 is simplified, thereby reducing manufacturing time.

[0045] A cross-sectional view of the fluid manifold 230 of the fluid distribution system 200 is shown in FIG. Figure 3A and 3BAs shown. In some examples, the involute 320 of the pump 214 can be integrated as part of the first portion 222 mold, as previously described, which can reduce the weight of the pump 214. The pilot assembly 202 can accommodate a manifold subassembly 302. The manifold subassembly 302 can be connected to the pilot assembly housing 206 via pins 304, thereby reducing the movement of the manifold subassembly 302 within the pilot assembly housing 206, which can reduce damage to the manifold subassembly 302. After the cover plate 204 is connected to the pilot assembly housing 206, it can further protect the manifold subassembly 302 from degradation.

[0046] The manifold subassembly 302 may include a plurality of solenoid pilot valve assemblies 310. Pilot solenoid valves may provide higher flow capacity, reliability, and lower power consumption than direct-acting solenoid valves. As will be described in more detail below, each of the plurality of solenoid pilot valve assemblies 310 may include a solenoid coil and a pilot diaphragm. In addition, the plurality of solenoid pilot valve assemblies 310 may be mounted in a common assembly. In one example, the common assembly may be a unit housing (e.g., a pilot assembly 202) that at least partially surrounds each of the plurality of solenoid-driven pilot valve assemblies 310. Each solenoid-driven pilot valve assembly 310 may be mounted directly to an assembly of the fluid manifold 230, thereby integrating the plurality of solenoid valves into the fluid distribution system 200. Since each solenoid pilot valve assembly is integrated (e.g., fixedly coupled) with the manifold subassembly 302, only one control board ( Figure 3A-3B 21) and electrical interfaces (e.g., connector 212), which can reduce the size and weight of the overall package and improve versatility in various vehicle applications.

[0047] like Figure 3B As shown, the pilot assembly housing 206 may include a recessed area 330 and a plurality of protrusions 332. Each of the plurality of protrusions 332 may couple the manifold assembly 302 to the pilot assembly housing 206, maintaining contact and position of the manifold assembly 302. Each of the plurality of protrusions 332 may include a central hole 334 into which a corresponding protrusion or fastener of the manifold subassembly 302 may be inserted to couple the manifold subassembly 302 to the pilot assembly housing 206. Similarly, the cover 204 may include a raised area 340 that may accommodate the upper end 290 of the manifold subassembly 302 when the fluid manifold 230 is assembled. Thus, the first width 342 of the raised area 340 may be greater than the second width 344 of the manifold assembly 302.

[0048] Now watch Figure 4A and 4B, the manifold subassembly 302 is shown. In some examples, the manifold assembly 302 includes an upper portion 404 of the pilot manifold 402, a lower portion 406 of the pilot manifold 402, a first plurality of fasteners 408, a plurality of solenoid valves 412, a second plurality of fasteners 414, a pressure plate 416, a control plate 418, and a plurality of pilot diaphragms (not shown). The upper portion 404 and the lower portion 406 are separated by a first coupling plane 430. Figure 4A The manifold subassembly 302 is depicted with the control board 418 positioned above the plurality of solenoid valves 412. Figure 4B The manifold subassembly 302 is depicted without the control plate 418 .

[0049] The control board 418 may include one or more tool holes 420 (e.g., mounting holes) that align with one or more protrusions 410 of the upper portion 404 of the pilot manifold 402. The one or more protrusions 410 may protrude axially upward (e.g., in a positive vertical direction) away from the upper portion 404. The one or more protrusions 410 may pass through the one or more tool holes 420 to maintain the lateral and longitudinal position of the control board 418 when it is assembled to the upper portion of the plurality of solenoid valves 412. Maintaining the position of the control board 418 during assembly can reduce damage to the control board 418 caused by positioning errors and / or contact with other components. As described below, the control board 418 can be removably connected to the plurality of solenoid valves 412 via a pin connector.

[0050] In some examples, each of the plurality of solenoid valves 412 can include a solenoid coil (not shown) that can be energized or de-energized based on an electrical current provided by the control board 418. The plurality of solenoid valves 412 can be arranged side by side so that each of the plurality of solenoid valves 412 is laterally adjacent to at least one other solenoid valve. The plurality of solenoid valves 412 can be located directly on top of the pressure plate 416, thereby maintaining a stable position of the pressure plate 416. The upper portion 404 of the pilot manifold 402 can include a raised area 432 that is positioned so that the pressure plate 416 is in direct face-to-face contact therewith. The plurality of solenoid valves 412 can also maintain pressure between the pressure plate 416 and components directly below (e.g., the raised area 432 of the upper portion 404), thereby reducing the number of fasteners required in the fluid distribution system 200 to maintain the position of components therein. The lower portion 406 can include a recessed area 434 that is used to place the plurality of main diaphragms ( Figure 4A-4B 406 ).

[0051] The first plurality of fasteners 408 may secure the upper portion 404 of the pilot manifold 402 and the lower portion 406 of the pilot manifold 402 together. The second plurality of fasteners 414 may couple the plurality of solenoid valves 412 to the upper portion 404 to maintain a stable position of the plurality of solenoid valves 412. A pressure plate 416 may be located between the plurality of solenoid valves 412 and the upper portion 404. The upper and lower portions 404, 406 of the pilot manifold 402 may be configured as irregular shapes including a plurality of circular side protrusions 440 with central holes (not shown). Each of the first plurality of fasteners 408 may extend through a pair of corresponding central holes of the plurality of circular side protrusions 440, including one central hole of the circular side protrusion of the upper portion 404 and one central hole of the circular side protrusion of the lower portion 406. The circular side protrusions of the upper portion 404 and the circular side protrusions of the lower portion 406 may be coupled on a first coupling plane 430. Furthermore, in certain examples, each fastener 408 in first plurality of fasteners 408 may correspond to one of plurality of protrusions 332 with central aperture 334 , such that each fastener 408 in plurality of fasteners 408 serves as a fastening point between pilot manifold 402 and pilot assembly housing 206 .

[0052] In some examples, the control board 418 may include a plurality of sensors located within the control board 418, and each of the plurality of sensors is located directly above one of the plurality of solenoid valves 412 when the control board 418 is located on top of the plurality of solenoid valves 412. The sensors may sense the ratchet position of each of the plurality of solenoid valves 412. In some examples, the sensors may be Hall effect sensors. The plurality of sensors may detect position errors of the solenoid valves during operation, thereby reducing the possibility of fluid flowing to the wrong vehicle components.

[0053] like Figures 5A-5E As shown, the fluid dispensing system 200 further includes a plurality of pilot diaphragms 502 and a plurality of main diaphragms 504 . Figure 5A A plurality of pilot diaphragms 502 are specifically depicted, while the pilot manifold 402 has been removed for ease of viewing; Figure 5B A plurality of main diaphragms 504 are depicted in detail, with the pilot manifold 402 removed for ease of viewing. Figure 5C Specifically depicted is a situation where a plurality of main diaphragms 504 are in place in the pilot manifold 402 . Figure 5D A cross section of the pilot manifold 402 is depicted in detail, showing a plurality of pilot diaphragms 502 and a differential pressure chamber. Figure 5E Specifically shows the pressure difference chamber ( Figure 5EThe pilot diaphragm 502 and the main diaphragm 504 together constitute a plurality of electromagnetically driven pilot valve assemblies. The pilot diaphragm 502 and the main diaphragm 504 can be formed as materials of a single injection mold (e.g., a single injection mold), respectively, which can reduce the manufacturing time and installation time during the assembly of the fluid distribution system 200.

[0054] The pilot diaphragms 502 can be arranged side by side, similar to multiple solenoid valves 412 in a single injection mold. Each pilot diaphragm 502 can be directly below one of the multiple solenoid valves 412 and can communicate with multiple solenoid valves 412 to form an electromagnetically driven pilot valve assembly 310. For example, when the solenoid valve is energized by an electric current through the control board 418, the pilot diaphragm is opened (for example, the pilot diaphragm is pulled up or pushed down) to allow the pressure differential across one or more main diaphragms to change. Each electromagnetic pilot valve assembly 310 includes a solenoid coil and a pilot diaphragm. For example, as Figure 4B As shown, the fluid distribution system 200 including four electromagnetic pilot valve assemblies 310 may include four electromagnets and four pilot diaphragms. However, the number of electromagnetic pilot valve assemblies 310 in the fluid distribution system 200 may not be equal to the number of main diaphragms 504. For example, the fluid distribution system including four electromagnetic pilot valve assemblies may include six main diaphragms 504, such as Figure 5B shown.

[0055] Each of the plurality of main diaphragms 504 can include a valve spring 505, and when the valve spring 505 contracts or expands under pressure, the state of one of the plurality of main diaphragms 504 changes from open to closed or from closed to open to prohibit or allow fluid flow through the orifice, thereby selectively coupling or decoupling the fluid chambers. Regardless of the number of solenoid-actuated pilot valve assemblies 310 and / or the number of main diaphragms 504, the plurality of inlet ports 208 and the plurality of outlet ports 210 can be integrated into the fluid manifold 230 (e.g., formed as part of the first and second portion 222, 224 mold, or otherwise fixedly connected to the fluid manifold 230). In this way, the number of valves and / or main diaphragms can be increased or decreased to suit the application without changing the location of the ports.

[0056] The pilot diaphragm 502 may be located directly below and in direct contact with the pressure plate 416, which holds the pilot diaphragm 502 in place. The pilot diaphragm 502 may further be located directly above the upper portion 404 ( Figure 5A-5BThe pressure plate 416 can maintain the position of the pilot diaphragm 502 between the upper portion 404 and the pressure plate 416. The close contact between the pilot diaphragm 502 and the plurality of solenoid valves 412 can enable a single printed circuit board (PCB) (e.g., control board 418) to control each of the plurality of solenoid-driven pilot valve assemblies.

[0057] The plurality of main diaphragms 504 may be positioned around the plurality of orifices 506. Each of the plurality of orifices 506 may be in fluid communication with one or more of the plurality of selectively couplable fluid chambers 510. The plurality of selectively couplable fluid chambers 510 may be arranged in layers, for example, some of the plurality of selectively couplable fluid chambers 510 are included in the first portion 222, while others of the plurality of selectively couplable fluid chambers 510 are included in the second portion 224, and the layers of the selectively couplable fluid chambers 510 are arranged at opposite ends of the second coupling plane 540. The fluid chambers arranged in different layers may be in fluid communication, for example, a first fluid chamber arranged above the second coupling plane 540 may be in fluid communication with a second fluid chamber arranged below the second coupling plane 540.

[0058] The first portion 222 may include a plurality of walls 530 that separate the plurality of rooms 532 from each other. Each of the plurality of rooms may house one or more of the plurality of selectable coupling fluid chambers 510 of the first portion 222. For example, a first pair of selectable coupling fluid chambers 510 (including a first fluid chamber disposed above the coupling plane 540 and a second fluid chamber disposed below the coupling plane 540) may be housed in a first pair of rooms 532, the first fluid chamber being housed in the first room and the second fluid chamber being housed in the second room. Each pair of fluid chambers may be housed in a different pair of rooms. In some examples, each of the plurality of selectable coupling fluid chambers 510 and / or the plurality of rooms 532 may be in fluid communication with an inlet or outlet of the first or second portion 222, 224, so that a fluid may be output from or received into the fluid chamber or room through the outlet or inlet, respectively.

[0059] The plurality of main diaphragms 504 can be operated pneumatically or hydraulically to enable or disable fluid flow through the plurality of orifices 506, the main diaphragms 504 acting as on / off control valves. As previously described, the plurality of main diaphragms 504 open and / or close according to the pressure differential controlled by the solenoid pilot valve assembly 310. Actuation (e.g., opening and / or closing) of one of the solenoid pilot valve assemblies 310 can result in the opening and / or closing of one or more main diaphragms 504. A single pilot diaphragm can be in fluid communication with a pressure differential chamber 511 that communicates with the plurality of main diaphragms through a cavity 550. As Figure 5EAs shown, each cavity 550 may include one or more ports 552, each port being in fluid communication with a main diaphragm. In this way, a pilot diaphragm can open or close one or more main diaphragms. In some examples, the cavity 550 may include only one port 552 that is in fluid communication with the main diaphragm. The pilot diaphragm in fluid communication with a cavity that includes only one port can change the pressure differential to open or close a single main diaphragm. In some examples, an increase in the pressure differential across the plurality of main diaphragms 504 can cause the main diaphragms 504 to open, allowing fluid to pass through the plurality of holes 506. Pressure acting on or removed from one of the diaphragms can cause the diaphragms to open or close to enable or inhibit flow. Which of the plurality of main diaphragms 504 is opened can control which of the plurality of inlet ports and outlet ports delivers and / or receives fluid.

[0060] In order to reconfigure the distribution of variable temperature (e.g., cold, warm, hot) fluids, the pilot assembly 202 can use multiple electromagnetically driven pilot valve assemblies 310 to control the pressure differential across multiple main diaphragms 504 to open and close them. As previously described, multiple solenoid valves 412 can be energized or de-energized, resulting in a change in the position of one or more pilot diaphragms 502. Changes in the position of the pilot diaphragms can cause changes in the pressure differential across one or more main diaphragms 504, thereby opening or closing one or more of the multiple orifices 506. Opening and / or closing one or more of the multiple orifices 506 can selectively couple and / or decouple groups of fluid chambers. Selectively opening and closing each main diaphragm 504 can cause fluid to flow between the inlet and outlet of various vehicle systems through the fluid distribution system 200. For example, under normal conditions, pressure from the pump 214 can maintain the open position of the pilot diaphragm 502, thereby causing the main diaphragm 504 to close, thereby not allowing flow between the inlet and outlet ports through the fluid chamber. When heat, pressure, or other parameters (such as heat, pressure, or other parameters detected by the sensor (such as Figure 2A-2G When the fluid is about to flow to and / or out of one or more vehicle systems flowing through the fluid distribution system 200, one or more solenoid valves will be activated. When activated, the corresponding pilot diaphragm will close, and the closing of the corresponding pilot diaphragm will cause the opening of the corresponding main diaphragm. When the corresponding main diaphragm is in the open position, the fluid is allowed to flow between the inlet and outlet of the one or more vehicle systems. The pressure differential of the pilot assembly 202 for opening and / or closing the main diaphragm 504 can come from the fluid of the multiple inlet ports 208 of the first portion 222 of the fluid manifold 230 and the pump inlet port 221.

[0061] Since actuation of one of the solenoid-driven pilot valve assemblies 310 may affect more than one of the plurality of main diaphragms 504, the number of solenoid valves required may be reduced, thereby reducing the overall weight of the package (e.g., by reducing the amount of copper or other suitable metal required to manufacture the solenoid valves). In addition, a multi-valve arrangement (in which a plurality of fluid chambers are arranged in layers and in fluid communication with a plurality of inlet and outlet ports arranged in layers) may reduce the overall package size, thereby increasing compactness and versatility in mounting options.

[0062] As previously mentioned, in some examples, multiple diaphragms in the plurality of main diaphragms 504 can be controlled by one of the solenoid-driven pilot valve assemblies 310. In this way, the number of solenoid valves required to reconfigure the fluid distribution can be further reduced, thereby further reducing the weight of the entire system.

[0063] Figure 6 The manifold subassembly 302 is shown. Each of the plurality of solenoid valves 412 may include a pin connector 602, such that each of the plurality of solenoid valves 412 includes a pin connector for connecting to the control board 418. In this way, one control board 418 may be used to control a plurality of solenoid valves 412. The pin connector 602 may extend axially upward (e.g., in a positive direction of a vertical axis) from the plurality of solenoid valves 412. When the control board 418 is positioned to be in direct face-to-face common contact with the plurality of solenoid valves 412, the pin connector 602 may be directly connected to the control board 418 so as to adhere the control board 418 to the plurality of solenoid valves 412 and electrically couple the control board 418 with the plurality of solenoid valves 412 to allow current to be transmitted from the control board 418 to the plurality of solenoid valves 412. In addition, the side-by-side configuration of the plurality of solenoid valves 412 may reduce the size of the control board 418. The pin connector 602 may reduce the soldering requirements between the control board 418 and the plurality of solenoid valves 412 , thereby reducing system weight (eg, by reducing the amount of tin, lead, and / or other metals used for soldering).

[0064] Figure 7 The pilot assembly housing 206 is shown removed from the manifold subassembly 302 and the cover 204. In some examples, the pilot assembly housing 206 can include a plurality of particulate filters 702. The plurality of particulate filters 702 can be positioned within the pilot assembly housing 206 so as to align with the connection points of the manifold subassembly 302. The plurality of particulate filters 702 can be configured to prevent debris from entering the pilot assembly housing 206 and / or the plurality of fluid chambers 510, which can reduce damage or clogging of small passages by debris. In addition, the plurality of particulate filters 702 can reduce leakage and inaccurate control of pilot diaphragm fluid flow due to contamination by preventing debris from entering the pilot assembly housing 206.

[0065] The pilot assembly housing 206 may further include a plurality of pressure ports 704. As described below, the plurality of pressure ports 704 may allow a plurality of pressure sensors (not shown) to monitor the pressure in various fluid chambers and / or cavities. In some examples, each of the plurality of pressure ports 704 may be fed from a pressure sensor located in one of the plurality of chambers 532, so that the pressure in each of the plurality of chambers 532 may be monitored separately.

[0066] Figure 8 A cross-sectional view of the fluid distribution system 200 in an assembled state is shown. The pilot assembly 202 may further accommodate a circuit board 804. A plurality of pressure ports 704 leading from the first and second portions 222, 224 may lead to a common location adjacent to a plurality of solenoid valves 412. The plurality of pressure ports 704 may enable a plurality of pressure sensors (not shown) included in the pilot assembly 202 (e.g., included in the circuit board 804 and / or the control board 418) to sense pressure to determine performance and detect any errors in valve status. The circuit board 804 may process data provided by the plurality of pressure sensors to determine whether the state of one or more solenoid valves needs to be changed. The circuit board 804 may also include sensors that provide data to the vehicle intelligent control system, thereby enabling the intelligent control system to detect the state of the solenoid valve and predict fault conditions. In this way, the fluid distribution system 200 may self-detect performance or actuation errors based on sensor data obtained by the circuit board 804 and the plurality of pressure ports 704 and pressure sensors.

[0067] In some examples, the fluid dispensing system 200 may include a fluid reservoir, bottle, or can that is connected to the pilot assembly or otherwise integrated into the system. The fluid reservoir, bottle, or can may be accessed to pull fluid into the system and / or pump 214. In other examples, the fluid reservoir, bottle, or can may be located external to the fluid dispensing system 200 and accessed through the plurality of inlet ports 208 and / or the pump inlet port 221.

[0068] A technical effect of the fluid distribution system described herein is to provide a compact integrated fluid distribution assembly that integrates multiple valves and multiple ports into a single unit. The fluid distribution system includes multiple pilot-actuated solenoid valves that reduce the number of solenoid valves required to reconfigure fluid distribution throughout the vehicle while maintaining the number of inlets and outlets. The multi-section and multi-layer design allows for the directed flow of fluid between multiple sets of fluid chambers that are arranged in different layers of the manifold through a single signal and solenoid valve. The reduction in the number of solenoid valves, as well as the integration of a portion of the pump (such as the involute of the pump) into the fluid manifold, reduces the weight and size of the package. The reduction in weight and size of the kit improves the overall versatility and usability of the system on a variety of vehicle platforms, including those with limited space.

[0069] In another statement, a method for a fluid distribution system for reconfigurable thermal management of a vehicle includes: receiving a fluid into a first portion of a fluid manifold through a plurality of inlets; opening and / or closing one or more solenoid pilot valve assemblies in response to energization and / or de-energization of one or more solenoid valves through a control panel, thereby controlling the pressure differential across a plurality of main diaphragms, opening one or more main diaphragms in response to changes in pressure differential resulting from the opening of one or more solenoid pilot valve assemblies, selectively connecting one or more pairs of fluid chambers in response to the opening of the one or more main diaphragms, and outputting the fluid to one or more components of the vehicle through one or more outlets in fluid communication with the one or more fluid chambers.

[0070] Figure 1-8 An example configuration of relative positioning of various components is shown. If the elements shown in the figure are in direct contact or directly coupled to each other, then at least in one example, these elements can be referred to as direct contact or direct coupling, respectively. Similarly, at least in one example, the elements shown as adjacent or adjacent to each other can be adjacent or adjacent to each other, respectively. For example, elements that are in face-to-face contact with each other can be referred to as face-to-face contact elements. Another example is that, at least in one example, the elements are placed separately from each other, with only space in the middle and no other elements, which can be referred to as being placed separately from each other. For example, relative to each other, the elements displayed above / below each other, relative to both sides of each other, or relative to the left / right side of each other can be referred to as such elements. In addition, as shown in the figure, in at least one example, the topmost element or element point can be referred to as the "top" of the element, and the bottommost element or element point can be referred to as the "bottom" of the element. The top / bottom, upper / lower, upper / lower used in this article can be relative to the vertical axis in the figure to describe the positioning of each element in the figure relative to each other. Therefore, in one example, the element displayed above other elements is vertically positioned above other elements. For another example, the shapes of elements depicted in the figures may be referred to as having these shapes (e.g., circular, straight, flat, curved, rounded, chamfered, beveled, or the like). Also, in at least one example, elements shown intersecting one another may be referred to as intersecting elements or intersecting one another. Also, in one example, elements that appear within another element or appear outside another element may also be referred to as intersecting elements.

[0071] The present disclosure also provides support for a fluid distribution system, the system comprising: a fluid manifold having a plurality of ports for fluid communication with a plurality of selectively couplable fluid chambers; a pilot assembly, the pilot assembly comprising a plurality of electromagnetically actuated pilot valve assemblies for controlling fluid flow between the plurality of selectively couplable fluid chambers, wherein: a plurality of selectively couplable fluid chambers are arranged in a first portion and a second portion of the fluid manifold, the first portion and the second portion are separated by a coupling plane, the fluid chambers in fluid communication are arranged at opposite ends of the coupling plane, a plurality of electromagnetic pilot valve assemblies are installed in a common assembly and directly installed on the fluid manifold, and one or more of the plurality of electromagnetic pilot valve assemblies control fluid flow through at least one selectively couplable fluid chamber. In a first example of the system, the plurality of electromagnetic pilot valve assemblies include a plurality of electromagnetic valves and a plurality of pilot diaphragms. In a second example of the system, the first example is optionally included: a plurality of pilot diaphragms are arranged side by side and formed into an injection mold, a plurality of electromagnetic valves are arranged side by side, and each of the plurality of pilot diaphragms is in communication with one of the plurality of electromagnetic valves. In a third example of the system, optionally including one or both of the first and second examples, the pilot assembly further includes a plurality of main diaphragms formed as a single injection mold, wherein each of the plurality of electromagnetically actuated pilot valve assemblies controls the pressure differential across one or more of the plurality of main diaphragms. In a fourth example of the system, optionally including one or more or each of the first to third examples, under the control of the plurality of electromagnetic pilot valve assemblies, the plurality of main diaphragms control the flow of fluid between fluid chambers arranged in different parts by opening and / or closing a plurality of orifices. In a fifth example of the system, optionally including one or more or each of the first to fourth examples, the pilot assembly further includes a housing including a plurality of particle filters disposed between a fluid manifold and a plurality of selectively coupled fluid chambers. In a sixth example of the system, optionally including one or more or each of the first to fifth examples, driving one of the plurality of electromagnetically actuated pilot valve assemblies can change the pressure differential across more than one of the plurality of main diaphragms. In a seventh example of the system, optionally including one or more or each of the first to sixth examples, the plurality of ports include a plurality of inlet ports and a plurality of outlet ports, the plurality of inlet ports are connected to a first portion of the fluid manifold, and the plurality of outlet ports are connected to a second portion of the fluid manifold. In an eighth example of the system, optionally including one or more or each of the first to seventh examples, the system further includes: an integrated pump and a pump inlet port coupled to the integrated pump. In a ninth example of the system, optionally including one or more or each of the first to eighth examples, each of the plurality of solenoid valves is electronically coupled to a control board via a pin connector, and the control board provides current to energize each of the plurality of solenoid valves.

[0072] The present disclosure also provides support for a fluid distribution system for reconfigurable thermal management of a vehicle, the system comprising a fluid manifold, including a first portion and a second portion, the first portion comprising a plurality of inlet ports in fluid communication with a plurality of fluid chambers, the second portion comprising a plurality of outlet ports in fluid communication with the plurality of fluid chambers; a pilot assembly, comprising a manifold subassembly, the manifold subassembly comprising an upper portion and a lower portion, and a pump in fluid communication with the plurality of fluid chambers, wherein the plurality of outlet ports selectively direct the fluid flow to a plurality of components of the vehicle in which the fluid distribution system is located. In a first example of the system, a plurality of fluid chambers are arranged in the first and second portions of the fluid manifold, and when a plurality of orifices are opened, the fluid chambers of the first portion and the fluid chambers of the second portion selectively communicate with each other through the plurality of orifices. In a second example of the system (optionally including the first example), the plurality of orifices are opened and / or closed according to a pressure difference across a plurality of main diaphragms. In a third example of the system, which may optionally include one or both of the first and second examples, the pressure difference across the plurality of main diaphragms is controlled by a plurality of electromagnetically driven pilot valve assemblies. In a fourth example of the system, optionally including one or more or each of the first to third examples, the pump includes a pump inlet port in fluid communication with one or more components of the vehicle. In a fifth example of the system, optionally including one or more or each of the first to fourth examples, the involute of the pump is formed with a mold of the first portion of the fluid manifold.

[0073] The present disclosure also provides support for a pilot assembly of a fluid distribution system, the assembly comprising: a pilot manifold having a plurality of manifold sections, the pilot manifold coupled to a fluid manifold, a plurality of selectively couplable fluid chambers arranged in the sections of the fluid manifold, a plurality of main diaphragms arranged to allow flow between the selectively couplable fluid chambers, and a plurality of solenoid valves in fluid communication with the plurality of main diaphragms, wherein the pilot assembly is integrated into the fluid manifold of the fluid distribution system. In a first example of the system, the plurality of solenoid valves are pilot-operated solenoid valves configured to control a pressure differential across the plurality of main diaphragms to open and / or close a plurality of orifices in fluid communication with the plurality of main diaphragms. In a second example of the system (optionally including the first example), opening one of the plurality of orifices selectively couples the fluid chambers in the independent sections of the fluid manifold together. In a third example of the system, which optionally includes one or both of the first and second examples, the system further comprises: a control board that provides current to energize the plurality of solenoid valves, wherein the control board is electrically coupled to the plurality of solenoid valves and an electrical interface integrated into the fluid manifold.

[0074] The following claims particularly point out certain combinations and subcombinations regarded as novel and non-obvious. The claims may refer to "an" element or a "first" element or the equivalent. The claims should be understood to include one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amendment of the present claims or by presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are also deemed to be included in the subject matter of the present disclosure.

Claims

1. A fluid distribution system, characterized in that: include a fluid manifold having a plurality of ports in fluid communication with a plurality of selectively couplable fluid chambers; A pilot assembly, the pilot assembly comprising a plurality of electromagnetically driven pilot valve assemblies, controlling the fluid flow between the plurality of selectively coupled fluid chambers, wherein The plurality of selectively coupleable fluid chambers are respectively arranged in a first portion and a second portion of the fluid manifold, the first portion and the second portion being separated by a coupling plane; Fluid chambers communicating with each other are arranged at opposite ends of the coupling plane; The plurality of solenoid-actuated pilot valve assemblies are mounted in a common assembly and mounted directly on the fluid manifold; as well as One or more of the plurality of solenoid-actuated pilot valve assemblies controls flow through at least one selectively coupleable fluid chamber.

2. The fluid distribution system according to claim 1, characterized in that: The plurality of electromagnetically driven pilot valve assemblies include a plurality of solenoid valves and a plurality of pilot diaphragms.

3. The fluid distribution system according to claim 2, characterized in that: The plurality of pilot diaphragms are arranged side by side to form an injection mold; The plurality of solenoid valves are arranged side by side; and Each of the plurality of pilot diaphragms is in communication with one of the plurality of solenoid valves.

4. The fluid distribution system according to claim 1, characterized in that: The pilot assembly further includes a plurality of main diaphragms formed as a single injection mold, wherein each of the plurality of solenoid-actuated pilot valve assemblies controls a pressure differential across one or more of the plurality of main diaphragms.

5. The fluid distribution system according to claim 4, characterized in that: The plurality of main diaphragms are controlled by the plurality of electromagnetically driven pilot valve assemblies to control fluid flow between the partitioned fluid chambers by opening and / or closing a plurality of orifices.

6. The fluid distribution system according to claim 1, characterized in that: The pilot assembly further includes a housing including a plurality of particulate filters positioned between the fluid manifold and the plurality of selectively coupleable fluid chambers.

7. The fluid distribution system according to claim 4, characterized in that: Actuating one of the plurality of solenoid-actuated pilot valve assemblies may change a pressure differential across one or more of the plurality of main diaphragms.

8. The fluid dispensing system according to claim 1, characterized in that: The plurality of ports includes a plurality of inlet ports connected to a first portion of the fluid manifold and a plurality of outlet ports connected to a second portion of the fluid manifold.

9. The fluid distribution system according to claim 1, characterized in that: Also included is an integrated pump and a pump inlet connected to the integrated pump.

10. The fluid dispensing system according to claim 2, characterized in that: Each of the plurality of solenoid valves is electronically connected to a control board via a pin connector, and the control board provides current to energize each of the plurality of solenoid valves.

11. A fluid distribution system for reconfigurable thermal management of a vehicle, characterized in that: include: a fluid manifold comprising a first portion including a plurality of inlet ports in fluid communication with a plurality of fluid chambers and a second portion including a plurality of outlet ports in fluid communication with the plurality of fluid chambers; a pilot assembly, the pilot assembly comprising a manifold subassembly, the manifold subassembly comprising an upper portion and a lower portion; and A pump is in fluid communication with the plurality of fluid chambers; wherein the plurality of outlet ports selectively direct fluid flow to a plurality of components of a vehicle to which the fluid distribution system is installed.

12. The fluid dispensing system according to claim 11, characterized in that The plurality of fluid chambers are disposed in the first and second portions of the fluid manifold, and the fluid chambers of the first portion and the fluid chambers of the second portion are in selective fluid communication through the plurality of ports when the plurality of ports are open.

13. The fluid dispensing system according to claim 12, characterized in that: The plurality of orifices opens and / or closes according to a pressure differential across the plurality of main diaphragms.

14. The fluid dispensing system according to claim 13, characterized in that: The pressure differential across the plurality of main diaphragms is controlled by a plurality of solenoid pilot valve assemblies.

15. The fluid dispensing system according to claim 11, characterized in that The pump includes a pump inlet port in fluid communication with one or more components of the vehicle.

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