Thermal management system and integrated coolant controller

Abstract

The thermal management system is adapted for use in a vehicle to control heating and / or cooling of components of the vehicle. A thermal management system includes a plurality of fluid circuits and an integrated coolant controller. The integrated coolant controller is configured to control flow of coolant fluid through the different fluid circuits.

Description

[0001] Priority claim

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 454,610, filed on March 24, 2023, the disclosure of which is now expressly incorporated herein by reference. Technical Field

[0003] The present disclosure relates to thermal management systems, and more particularly to thermal management systems for controlling the flow of heating and / or cooling fluid into an electric or hybrid vehicle. Background Art

[0004] Thermal management systems for electric vehicles can be used to heat or cool various components included in an electric or hybrid vehicle. These thermal management systems can include multiple thermal fluid circuits with different valves and hoses to deliver cooling and / or heating fluids to various components. However, there is a need to reduce the power required to operate the thermal management system. Utility Model Content

[0005] The present disclosure provides a thermal management system suitable for use in a vehicle. The thermal management system includes a plurality of fluid circuits and an integrated coolant controller. The plurality of fluid circuits each include a conduit configured to guide a coolant fluid therethrough. The integrated coolant controller is configured to control the coolant fluid flowing through the different fluid circuits, thereby controlling the heating and / or cooling of components on the vehicle.

[0006] In an illustrative embodiment, an integrated coolant controller includes a coolant tank, a first pump, a multi-way valve, and a manifold. The coolant tank is formed to define a coolant reservoir configured to store a coolant fluid. The first pump is configured to pump the coolant fluid from the coolant tank through the flow of a plurality of fluid circuits. The multi-way valve is configured to control the flow of the coolant fluid through the plurality of fluid circuits. The manifold is coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate the coolant tank, the first pump, and the multi-way valve so that each of the plurality of fluid circuits flows through the manifold to eliminate piping between the coolant tank, the first pump, and the multi-way valve, and to reduce the amount of power used by the first pump to supply the coolant fluid through the different fluid circuits.

[0007] In an exemplary embodiment, a manifold includes a manifold body shaped to define a plurality of fluid chambers and a plurality of tubes, each of the plurality of tubes extending from the manifold body. Each of the plurality of tubes defines a tube channel, the tube channel being in fluid communication with a conduit included in one of the plurality of fluid chambers and one of the plurality of fluid circuits.

[0008] In an illustrative embodiment, the manifold is configured to include a plurality of temperature sensor docking portions. The plurality of temperature sensor docking portions are each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid chambers to measure the temperature of the coolant fluid.

[0009] In an exemplary embodiment, the manifold includes a tank docking portion configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes a top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with tank ports on the manifold.

[0010] In an exemplary embodiment, the coolant tank is welded to the tank interface portion of the manifold.In an illustrative embodiment, the coolant tank may be integrally formed with the manifold such that the coolant tank and the manifold are a one-piece assembly.

[0011] In an illustrative embodiment, the manifold includes a first pump interface configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits.

[0012] In an illustrative embodiment, the manifold includes a valve interface. The valve interface is configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold. Each of the valve ports is in fluid communication with one of the plurality of fluid chambers.

[0013] In an illustrative embodiment, the manifold includes a tank docking portion, a first pump docking portion, and a valve docking portion. The tank docking portion is configured to accommodate the coolant tank to mount the coolant tank on the manifold so that the coolant tank closes the top opening of the manifold and so that the inlet port and the outlet port included in the coolant tank are aligned with the tank port on the manifold. The first pump docking portion is configured to accommodate the first pump to mount the first pump on the manifold so that the inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and so that the outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits. The valve docking portion is configured to accommodate the multi-way valve to mount the multi-way valve on the manifold so that the plurality of holes included in the multi-way valve are aligned with the valve port on the manifold.

[0014] In an illustrative embodiment, the thermal management system includes a main fluid loop, a radiator fluid loop, and a battery fluid loop. The main fluid loop includes a main conduit, the main conduit being configured to guide a coolant fluid through the main conduit and being adapted to be thermally connected to a front drive and a rear drive included in the vehicle to transfer heat between the front drive and the rear drive and the coolant fluid. The radiator fluid loop includes a radiator loop conduit, the radiator loop conduit being configured to guide the coolant fluid through the radiator loop conduit and being adapted to be thermally connected to a radiator included in the vehicle to transfer heat between the radiator and the coolant fluid. The battery fluid loop includes a battery loop conduit and a heat exchanger, the battery loop conduit being configured to guide the coolant fluid through the battery loop conduit and being adapted to be thermally connected to a battery included in the vehicle to transfer heat between the battery and the coolant fluid, the heat exchanger being fluidly connected to the battery loop conduit to transfer heat between the coolant fluid and a fluid in the heat exchanger.

[0015] In an illustrative embodiment, the integrated coolant controller includes a first pump and a second pump. The first pump is configured to pump the coolant fluid from the coolant tank through the flow of the main fluid circuit. The second pump is configured to pump the coolant fluid through the flow of the battery fluid circuit. In an exemplary embodiment, the multi-way valve is configured to control the flow of the coolant fluid through the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit.

[0016] In an illustrative embodiment, a manifold is coupled to each of the coolant tank, the first and second pumps, and the multi-way valve to integrate the coolant tank, the first pump and the second pump, and the multi-way valve. The manifold integrates the components together so that the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit flow through the manifold to eliminate pipes between the coolant tank, the first pump and the second pump, and the multi-way valve, and to reduce the amount of power used by the pumps to supply coolant fluid through different fluid circuits.

[0017] Other features of the disclosure will become apparent to those skilled in the art upon consideration of the illustrative embodiments illustrating the best mode presently recognized for carrying out the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The detailed description makes particular reference to the accompanying drawings, in which:

[0019] Figure 1 is suitable for Figure 2A schematic diagram of an integrated coolant controller for use in a thermal management system shown to control heating and / or cooling of various components in a vehicle, the integrated coolant controller including a coolant tank defining a coolant reservoir, a pump configured to pump coolant fluid through the thermal management system, a multi-way valve configured to control the flow of coolant fluid to different thermal fluid circuits of the thermal management system, and a manifold coupled to each of the coolant tank, the pump, and the multi-way valve to integrate the components, thereby eliminating unnecessary piping or hoses between the coolant tank, the pump, and the multi-way valve, and reducing the amount of power used by the pump to supply coolant fluid through the system;

[0020] Figure 2 Yes Figure 1 A schematic diagram of a thermal management system of an integrated coolant controller of FIG. 1 , showing the integrated coolant controller supplying coolant fluid to the front and rear drive trains, a radiator, a cooler / heater for a battery of the vehicle, and other electronic components on the vehicle through a manifold;

[0021] Figure 3 yes Figure 1 An exploded view of an integrated coolant controller of the present invention is shown, showing that the manifold includes: a battery pump dock configured to receive the battery pump to mount the battery pump on the manifold; a drive pump dock configured to receive the drive pump to mount the drive pump on the manifold; and a valve dock configured to mount the multi-way valve on the manifold so that the manifold is included in the Figure 4 The holes in the multi-way valve are shown aligned with the valve ports on the manifold;

[0022] Figure 4 yes Figure 1 An exploded view of an integrated coolant controller is shown, showing that the manifold also includes a coolant tank docking portion configured to mount the coolant tank on the manifold so that the coolant tank closes the top opening of the manifold and includes Figure 3 The inlet and outlet ports in the coolant tank are shown aligned with the tank ports on the manifold;

[0023] Figure 5 yes Figure 1 A perspective schematic diagram of an integrated coolant controller of the embodiment of the present invention, wherein the coolant tank is removed to show that the tank port on the manifold is configured to be in fluid communication with the coolant reservoir of the coolant tank when the coolant tank is installed to the tank docking portion, and further showing that the manifold includes a manifold body and different inlet and outlet pipes, the manifold body defining the Figure 6 and Figure 7 a plurality of fluid chambers as shown in the figure, the inlet tubes and the outlet tubes extending from the manifold body and coupled to different fluid circuits of the thermal management system to direct the coolant fluid from the fluid chambers to the different fluid circuits to control the temperature of different components of the vehicle;

[0024] Figure 5A yes Figure 5 a cross-sectional view of the integrated coolant controller taken along line AA showing fluid cavities defined by an upper body section of the manifold body and showing which fluid circuits are in fluid communication with the respective fluid cavities;

[0025] Figure 5B yes Figure 5 a cross-sectional view of the integrated coolant controller taken along line BB, showing the fluid cavities defined by the lower body section of the manifold body, and showing which fluid circuits are in fluid communication with the respective fluid cavities;

[0026] Figure 6 is included in Figure 3 an exploded view of a manifold in an integrated coolant controller of the invention, showing that the manifold body of the manifold includes an upper body section and a lower body section that are separate components coupled together, and further showing that the upper body section of the manifold body is shaped to define a tank docking portion and a drive pump docking portion, and the lower body section is shaped to define a battery pump docking portion and a valve docking portion that defines a plurality of valve ports that align with housing apertures of a multi-way valve when the multi-way valve is coupled to the valve docking portion of the manifold;

[0027] Figure 7 is included in Figure 4 An exploded view of a manifold in an integrated coolant controller of the present invention showing an upper body section and a lower body section of the manifold body having side walls and a plurality of dividing walls extending between the side walls to define different fluid chambers;

[0028] Figure 8 is included in Figure 3The present invention is an exploded view of a multi-way valve in an integrated coolant controller, showing that the multi-way valve includes a valve housing, a valve flow controller, and a first sealing system and a second sealing system, wherein the first sealing system and the second sealing system are configured to seal between the valve housing and a valve rotor of the valve flow controller, the valve housing including: a valve housing body having a first valve cavity and a second valve cavity; an upper housing cover configured to be connected to the valve housing body to close the first valve cavity and the second valve cavity; and a lower valve housing cover connected to the valve housing body opposite to the upper valve housing cover to close the bottom opening of the valve housing body, thereby defining a connecting channel between the first valve cavity and the second valve cavity, the valve flow controller including: a first valve rotor (also called a main valve rotor) configured to be arranged in the first valve cavity; a second valve rotor (also called a throttle valve or a proportional valve rotor) configured to be arranged in the second valve cavity; and an actuator connected to the first valve rotor and the second valve rotor to drive the first valve rotor and the second valve rotor to rotate around the corresponding rotor axes, thereby forming a plurality of flow paths through the valve housing body of the valve housing, such as Figures 15A-15D and 16A- Fig. 16C As shown, to control flow through different fluid chambers of the manifold, thereby regulating which fluid circuits are connected in fluid communication or not connected in fluid communication;

[0029] Fig. 9 yes Figure 8 a perspective view of a multi-way valve of the type shown in FIG. 1 , wherein the upper housing cover is removed to show a main valve rotor disposed in a first valve cavity and a throttle valve rotor disposed in a second valve cavity, and further showing that the main valve rotor is formed to define a plurality of main rotor through holes, each of which extends axially through the main valve rotor to open into a hole formed in a valve housing body, and the throttle valve rotor is formed to define a second rotor through hole, each of which extends axially through the valve housing. A second valve rotor, the second valve rotor opening into a hole formed in the valve housing body;

[0030] Fig. 9A yes Fig. 9The invention discloses a sectional view of a multi-way valve, showing that a first sealing system includes a first sealing member and a first biasing assembly, wherein the first sealing member is axially located between the first valve rotor body and the first valve rotor cover to provide a seal between the first valve rotor and the valve housing body, so that when fluid flows through the first rotor through-hole into the hole in the valve housing body of the valve housing, leakage between the first valve rotor and the valve housing body is reduced, and the first biasing assembly is configured to selectively apply an axial force on the first valve rotor to push the first valve rotor toward a plurality of holes formed in the valve housing body so that when the first valve rotor is in different predetermined positions The invention further shows that the first sealing member of the first sealing system is engaged with the bottom surface of the valve housing body when the first sealing member is in one of the plurality of different predetermined positions, thereby improving the seal between the first valve rotor and the valve housing body, and further shows that the second sealing system includes a second sealing member and a second biasing assembly, the second biasing assembly having a biasing spring and a spring cover, the spring cover being configured to be assembled on the second valve rotor shaft to exert an axial force on the second valve rotor when the second valve rotor is in one of the plurality of different predetermined positions, so as to push the second valve rotor toward the plurality of holes formed in the valve housing body, thereby improving the seal between the second valve rotor and the valve housing body;

[0031] Fig. 9B yes Fig. 9A a detailed view of the main valve rotor and the first valve cover, showing a first sealing member axially located between the first valve rotor body and the first valve cover extending through one of the first rotor through-holes and engaging the valve housing to provide a seal between the main valve rotor and the valve housing body, thereby reducing leakage between the main valve rotor and the valve housing body when fluid flows through the first rotor through-hole, through the aperture in the valve housing body of the valve housing, and into the manifold;

[0032] Fig.10 is included in Figure 8 An exploded view of a main valve rotor in a valve flow controller of a multi-way valve, showing that the main valve rotor includes: a main valve rotor body extending circumferentially around a first rotor axis, a main valve rotor shaft extending axially away from the main valve rotor body along the first rotor axis, and a main valve rotor cover configured to be connected to the main valve rotor body, so that a plurality of chambers formed in the main valve rotor cover extend around adjacent through holes in the main valve rotor body, and when the valve rotor cover is connected to the main valve rotor body, adjacent through holes in fluid communication with each other are connected to each other, and further showing that the main valve rotor body has a locking plate, which engages the main valve rotor cover to block axial movement of the main valve rotor cover and the first sealing member relative to the main valve rotor body when the main valve rotor cover is in an engaged position on the main valve rotor body, as shown in FIG. Figure 8 As shown;

[0033] Fig.11 is included in Figure 8 An exploded view of a throttle valve rotor in a valve flow controller of a multi-way valve is shown, showing that the throttle valve rotor includes: a throttle valve rotor plate, extending circumferentially around a second rotor axis and formed to define a throttle valve rotor through hole; a throttle valve rotor wall, extending circumferentially around an outer edge of the throttle valve rotor plate and axially away from the throttle valve rotor plate; and a throttle valve rotor shaft, extending away from the throttle valve rotor plate in the same direction as the throttle valve rotor wall along the second rotor axis, and further showing that the second biasing assembly of the second sealing system includes a biasing spring and a spring cover, the spring cover being configured to be assembled on the throttle valve rotor shaft;

[0034] Fig.12 Is has Figure 7 a cross-sectional view of the throttle rotor of the assembled second biasing assembly showing the bias spring disposed about the throttle rotor shaft of the throttle rotor to exert an axial force on the throttle rotor to urge the throttle rotor body toward a seal secured to a valve housing body, and further showing a spring cover extending about the bias spring and coupled to the throttle rotor for rotation therewith such that the bias spring is located between the spring cover and the throttle rotor;

[0035] Fig.13 is included in Figure 8 a perspective view of a valve housing body in a valve housing of a multi-way valve, showing that the valve housing body is formed to define a plurality of holes circumferentially spaced about a first valve axis and aligned with a plurality of main rotor through holes, allowing fluid to flow therethrough when the main valve rotor is in different predetermined positions;

[0036] Fig.14 yes Figure 2 Schematic diagram of a thermal management system showing a multi-way valve controlling the flow of coolant fluid through different thermal fluid circuits by using a throttle rotor to change the flow of coolant fluid entering the multi-way valve from a drive pump and using a main valve rotor to switch connections to a radiator and a cooler and heater for a battery;

[0037] Fig.15 It is shown Fig. 9 A table of different modes of the multi-way valve and different flow paths created in each mode in the different modes AG;

[0038] Fig.15A Yes Fig.15 Schematic diagram of a thermal management system in a system cooling mode or Mode A, wherein the main valve rotor is in a main valve rotor first position;

[0039] Fig. 15B Yes Fig.15 A schematic diagram of a thermal management system in a system heating mode or Mode B is shown, wherein the main valve rotor is moved to a main valve rotor second position;

[0040] Fig. 15C Yes Fig.15 Schematic diagram of a thermal management system in a battery conditioning mode or Mode C, wherein the main valve rotor is moved to a main valve rotor third position;

[0041] Fig.15D Yes Fig.15 Schematic diagram of a thermal management system in a system cooling mode or Mode C, wherein the main valve rotor is moved to a main valve rotor fourth position;

[0042] Fig.16 is shown in any of the modes AD when the throttle valve or proportional valve rotor is in Figure 16A-16C A graph of the opening area of ​​each of the holes in the valve housing body leading to the second valve chamber when rotated between different predetermined positions shown;

[0043] Fig.16A is a top view of the multi-way valve, wherein the throttle valve rotor is in a first throttle valve rotor first position;

[0044] Fig. 16B is a top view of the multi-way valve, wherein the throttle valve rotor is in the throttle valve rotor second position;

[0045] Fig. 16C is a top view of the multi-way valve with the throttle valve rotor in a throttling configuration;

[0046] Fig.17A is a top view of the multi-way valve when the thermal management system is in mode A, showing the main valve rotor in the main valve rotor first position;

[0047] Fig. 17B is a top view of the multi-way valve when the thermal management system is in mode B, showing the main valve rotor in the second main valve rotor position;

[0048] Fig. 17C is a top view of the multi-way valve when the thermal management system is in mode C, showing the main valve rotor in the third main valve rotor position;

[0049] Fig.17D is a top view of the multi-way valve when the thermal management system is in mode D, showing the main valve rotor in the main valve rotor fourth position; and

[0050] Fig.17E is a top view of the multi-way valve when the thermal management system is in mode D, showing that the main valve rotor can be in the main valve rotor fifth position to achieve the same flow path to different circuits as when the main valve rotor is in the main valve rotor fourth position. DETAILED DESCRIPTION

[0051] exist Figure 1-Figure 5 An exemplary integrated coolant controller 30 is shown in FIG. The integrated coolant controller 30 is suitable for use in Figure 2 The illustrated thermal management system 20 is used to control heating and / or cooling of various components in the vehicle 10 .

[0052] The integrated coolant controller 30 includes a coolant tank 32, pumps 34, 36, a multi-way valve 38 and a manifold 40, such as Figure 1-Figure 9 As shown. The coolant tank 32 is formed to define a coolant reservoir 32R configured to store a coolant fluid. The pumps 34, 36 are configured to pump the coolant fluid through the different fluid circuits of the thermal management system 20 to transfer heat to / from the different components on the vehicle 10. The multi-way valve 38 is configured to control the flow of the coolant fluid to the different thermal fluid circuits of the thermal management system 20. The manifold 40 is coupled to each of the coolant tank 32, the pumps 34, 36, and the multi-way valve 38 to integrate the components 32, 34, 36, 38, thereby eliminating unnecessary pipes or hoses between the coolant tank 32, the pumps 34, 36, and the multi-way valve 38, and reducing the amount of electricity used by the pumps 34, 36 to supply the coolant fluid through the system 20.

[0053] Thermal management system 20 Figure 2 , Figure 5 , Fig.14 and Figures 15A-15D The thermal management system 20 also includes a plurality of fluid circuits 22, 24, 26, all of which flow through a manifold 40 of an integrated coolant controller 30. The integrated coolant controller 30 controls the flow of coolant fluid through the various fluid circuits 22, 24, 26.

[0054] Other thermal management systems may include multiple thermal fluid circuits with different valves and hoses to deliver coolant fluid to various components. However, there is a need to reduce the large lengths of the hoses and various connections to reduce the flow restrictions and power required to move the coolant fluid through the thermal management system.

[0055] The manifold 40 of the integrated coolant controller 30 integrates the components 32, 34, 36, 38, thereby eliminating unnecessary piping or hoses between the coolant tank 32, pumps 34, 36, and multi-way valve 38, and reducing the amount of power used by the pumps 34, 36 to supply coolant fluid through the system 20. Each of the components 32, 34, 36, 38 is mounted directly on the manifold 40 so that the inlet / outlet ports on each of the components 32, 34, 36, 38 are aligned with corresponding ports / holes on the manifold 40. This eliminates any unnecessary piping or hoses between them.

[0056] The manifold 40 includes a manifold body 42 and a plurality of tubes 44, 46, 48, 50, 52, 54, 56 extending from the manifold body 42. Figure 3-Figure 7 As shown. Manifold body 42 is shaped to form a plurality of fluid chambers 58A-58L. Each of conduits 44, 46, 48, 50, 52, 54, 56 defines a passage 44P, 46P, 48P, 50P, 52P, 54P, 56P in fluid communication with one of the fluid chambers 58A, 58B, 58C, 58DE, 58F, and 58G defined by manifold body 42 to direct coolant fluid through manifold body 42.

[0057] Once the components 32,34,36,38 are mounted to the manifold 40, the various fluid cavities 58A-58L of the manifold 40 are in fluid communication with the inlets / outlets of the components 32,34,36,38. The coolant fluid is directed to the various fluid circuits 22,24,26 through the various fluid cavities 58A-58L.

[0058] The thermal management system 20 includes a plurality of fluid circuits 22, 24, 26, such as Figure 2-Figure 4 The various fluid circuits 22, 24, 26 are adapted to direct coolant fluid to various components of the vehicle 10 to transfer heat to / from the components of the vehicle 10 to control the temperature of the components. In the illustrated embodiment, the thermal management system 20 includes a main fluid circuit 22, a radiator fluid circuit 24, and a battery fluid circuit 26, as shown. Figure 2 , Figure 5 , Fig.14 and Figures 15A-15D The various fluid circuits 22 , 24 , 26 all flow through a manifold 40 of the integrated coolant controller 30 .

[0059] In the illustrated embodiment, the thermal management system 20 includes a primary fluid circuit 22 and subsequent fluid circuits 24, 26, such as Figure 2-Figure 4 The main fluid circuit 22 includes a main circuit conduit 22C configured to guide a coolant fluid therethrough. The subsequent fluid circuits 24, 26 each include a conduit 24C, 26C configured to guide a coolant fluid therethrough.

[0060] In some embodiments, the thermal management system 20 may include only two fluid circuits. In some embodiments, the thermal management system 20 may include more than three circuits. The number of circuits may depend on the different components on the vehicle 10 and the heating / cooling requirements of those components.

[0061] One of the subsequent fluid circuits 24 (or sometimes referred to as the radiator fluid circuit 24) includes a radiator circuit conduit 24C configured to direct a coolant fluid therethrough, and the other subsequent fluid circuit 26 (or sometimes referred to as the battery fluid circuit 26) includes a battery circuit conduit 26C configured to direct a coolant fluid therethrough in the illustrated embodiment. In some embodiments, the thermal management system 20 may include more than two subsequent fluid circuits. In some embodiments, the thermal management system 20 may include fewer subsequent fluid circuits.

[0062] In the illustrated embodiment, the main loop conduit 22C is adapted to be in thermal communication with the front drive 12F and the rear drive 12R included in the vehicle 10 to transfer heat between the front drive 12F and the rear drive 12R and the coolant fluid. The radiator loop conduit 24C is adapted to be in thermal communication with the radiator 14 included in the vehicle 10 to transfer heat between the radiator 14 and the coolant fluid. The battery loop conduit 26C is adapted to be in thermal communication with the battery 16 and the heat exchanger 18 or the cooler / heater 18 included in the vehicle 10. The battery loop conduit 26C is adapted to be in thermal communication with one or more batteries 16 to transfer heat between the battery 16 and the coolant fluid. The battery loop conduit 26C is adapted to be in thermal communication with the cooler / heater 18 to transfer heat between the coolant fluid and the fluid in the cooler / heater 18.

[0063] The manifold 40 includes a manifold body 42 and a plurality of tubes 44, 46, 48, 50, 52, 54, 56, as shown in FIG. Figure 3-Figure 7 As shown. The manifold body 42 is shaped to define a plurality of fluid chambers 58A-58L. The number of tubes 44, 46, 48, 50, 52, 54, 56 may vary based on the number of fluid chambers 58A-58L defined by the manifold body 42, and vice versa. The number of tubes 44, 46, 48, 50, 52, 54, 56 may also vary based on the number of fluid circuits 22, 24, 26 of the thermal management system 20.

[0064] In an exemplary embodiment, the manifold body 42 is formed to define a first fluid chamber 58A, a second fluid chamber 58B, a third fluid chamber 58C, a fourth fluid chamber 58DE, a fifth fluid chamber 58F, a sixth fluid chamber 58G, a seventh fluid chamber 58H, an eighth fluid chamber 58I, a ninth fluid chamber 58J, a tenth fluid chamber 58K, and an eleventh fluid chamber 58L, as shown in FIG. Figure 5-Figure 7 The various fluid chambers 58A-58L are configured to direct coolant fluid therethrough.

[0065] In the illustrated embodiment, the plurality of tubes 44, 46, 48, 50, 52, 54, 56 includes a first tube 44, a second tube 46, a third tube 48, a fourth tube 50, a fifth tube 52, a sixth tube 54, and a seventh tube 56. Figure 3-Figure 7 In the illustrated embodiment, the first tube 44 is connected to the inlet of the main loop conduit 22C, the second tube 46 is connected to the outlet of the radiator loop conduit 24C, the third tube 48 is connected to the inlet of the radiator loop conduit 24C, the fourth tube 50 is connected to one of the outlets of the main loop conduit 22C, the fifth tube 52 is connected to the outlet of the battery loop conduit 26C, the sixth tube 54 is connected to the other outlet of the main loop conduit 22C, and the seventh tube 56 is connected to the inlet of the battery loop conduit 26C, as shown. Figure 7 shown.

[0066] In the illustrated embodiment, the first passage 44P of the first tube 44 is connected in fluid communication with the main loop conduit 22C, the second passage 46P of the second tube 46 is connected in fluid communication with the radiator loop conduit 24C, the third passage 48P of the third tube 48 is connected in fluid communication with the radiator loop conduit 24C, the fourth passage 50P of the fourth tube 50 is connected in fluid communication with the main loop conduit 22C, the fifth passage 52P of the fifth tube 52 is connected in fluid communication with the battery loop conduit 26C, the sixth passage 54P of the sixth tube 54 is connected in fluid communication with the main loop conduit 22C, and the seventh passage 56P of the seventh tube 56 is connected in fluid communication with the battery loop conduit 26C, as shown in FIG. Figure 5-Figure 7 shown.

[0067] In the illustrated embodiment, the first passage 44P of the first tube 44 is in fluid communication with the first fluid chamber 58A of the manifold body 42, the second passage 46P of the second tube 46 is in fluid communication with the second fluid chamber 58B of the manifold body 42, the third passage 48P of the third tube 48 is in fluid communication with the third fluid chamber 58C of the manifold body 42, the fourth passage 50P of the fourth tube 50 is in fluid communication with the eighth fluid chamber 58I of the manifold body 42, the fifth passage 52P of the fifth tube 52 is in fluid communication with the sixth fluid chamber 58G of the manifold body 42, the sixth passage 54P of the sixth tube 54 is in fluid communication with the ninth fluid chamber 58J of the manifold body 42, and the seventh passage 56P of the seventh tube 56 is in fluid communication with the tenth fluid chamber 58K of the manifold body 42, as shown in FIG. Figure 5-Figure 7 shown.

[0068] The manifold body 42 of the manifold 40 includes a tank interface 72, a first pump interface 74, a second pump interface 76 and a valve interface 78, as shown in FIG. Figure 3-Figure 7 The tank docking portion 72 is configured to receive the coolant tank 32 so as to mount the coolant tank 32 on the manifold 40. The first pump docking portion 74 is configured to receive the first pump 34 so as to mount the first pump 34 on the manifold 40. The second pump docking portion 76 is configured to receive the second pump 36 so as to mount the second pump 36 on the manifold 40. The valve docking portion 78 is configured to receive the multi-way valve 38 so as to mount the multi-way valve 38 on the manifold 40.

[0069] In some embodiments, each of the components 32, 34, 36, 38 may be welded to the respective interface 72, 74, 76, 78. In other embodiments, the components 32, 34, 36, 38 may be bolted or fastened to the respective interface 72, 74, 76, 78 of the manifold 40. In other embodiments, another attachment method may be used.

[0070] In the illustrated embodiment, the manifold body 42 also includes Figure 3 and Figure 6 The temperature sensor docking portions 69A, 69B are shown. The temperature sensor docking portions 69A, 69B are configured to receive the temperature sensor 17 to mount the temperature sensors 17A, 17B in fluid communication with the corresponding fluid chambers 58I, 58J. The temperature sensors 17A, 17B are configured to measure the temperature of the coolant fluid flowing back to the manifold 40 from the main fluid circuit 22, such as Figures 15A-15D shown.

[0071] In the illustrated embodiment, the coolant tank 32 also includes Figure 3 Temperature sensor interface 69C is shown. In some embodiments, manifold 40 may include a temperature sensor interface 69C that accommodates another temperature sensor 17C configured to measure the temperature of the coolant fluid in coolant tank 32 .

[0072] The tank docking portion 72 is configured to receive the coolant tank 32 to mount the coolant tank 32 on the manifold 40 such that the inlet port 32A and the outlet port 32B formed in the coolant tank 32 are aligned with the tank ports 45F, 45L formed in the manifold 40, as shown in FIG. Figure 4 , Figure 5 and Figure 7 The tank ports 45F, 45L lead to the corresponding fluid chambers 58F, 58L. The coolant tank 32 is coupled to the manifold 40 on the tank docking portion 72 such that the inlet port 32A formed in the coolant tank 32 is aligned with the fifth fluid chamber 58F, and the outlet port 32B formed in the coolant tank 32 is aligned with the eleventh fluid chamber 58L.

[0073] In the illustrated embodiment, the tank docking portion 72 accommodates the coolant tank 32 to mount the coolant tank 32 on the manifold 40 such that the coolant tank 32 closes the top opening of the manifold 40. In the illustrated embodiment, the coolant tank 32 is formed to include a lip 32L extending from the coolant tank 32 and shaped to mate with the upper body section 42U such that the coolant tank 32 is perfectly matched with the manifold body 42. In other embodiments, the manifold 40 is not open at the tank docking portion 72, but has an upper wall defining a portion of the tank docking portion 72.

[0074] In the illustrated embodiment, the coolant tank 32 is welded to the tank interface 72 of the manifold 40. The coolant tank 32 is welded to the tank interface 72 of the manifold 40 along the lip 32L to secure the coolant tank 32 to the manifold 40. In some embodiments, the coolant tank 32 may be integrally formed with the manifold 40 rather than welded thereto.

[0075] The first pump docking portion 74 is configured to receive the first pump 34 to mount the first pump 34 on the manifold 40 such that the inlet 35 of the first pump 34 is connected in fluid communication with the coolant reservoir 32R of the coolant tank 32, and the outlet 39 of the first pump 34 is connected in fluid communication with the main fluid circuit 22 through the first fluid cavity 58A, as shown in FIG. Figure 3-Figure 7 The first pump docking portion 74 is a molded shape that defines an accommodation space 74R into which the first pump 34 fits neatly. In the illustrated embodiment, the first pump 34 is mounted to the manifold 40 in the first pump docking portion 74 so that the inlet 35 of the first pump 34 is in fluid communication with the eleventh fluid chamber 58L, which is in fluid communication with the coolant reservoir 32R through the outlet port 32B, and the outlet 39 of the first pump 34 is in fluid communication with the first fluid chamber 58A, which is in fluid communication with the first passage 44P.

[0076] In this manner, the first pump 34 draws coolant fluid from the coolant tank 32 through the eleventh fluid chamber 58L and directs the coolant fluid into the first fluid chamber 58A and out through the first passage 44P to the main fluid circuit 22. The coolant fluid flows through the main circuit conduit 22C to transfer heat from the various components 12F, 12R, 13, 15 before flowing back to the manifold 40.

[0077] In some embodiments, the integrated coolant controller 30 includes only a single pump 34, 36. The single pump 34, 36 can be configured to pump coolant fluid through all of the fluid circuits 22, 24, 26. In the illustrated embodiment, the integrated coolant controller 30 includes two pumps 34, 36. In some embodiments, the integrated coolant controller 30 can include more than two pumps 34, 36.

[0078] The second pump docking portion 76 is configured to receive the second pump 36 to mount the second pump 36 on the manifold 40 such that the inlet 37 of the second pump 36 is connected in fluid communication with the seventh fluid chamber 58H of the manifold 40, and the outlet 41 of the second pump 36 is connected in fluid communication with the battery fluid circuit 26 through the tenth fluid chamber 58K, as shown in FIG. Figure 3-Figure 7The second pump docking portion 76 defines an accommodation space 76R into which the second pump 36 extends. In the illustrated embodiment, the second pump 36 is mounted to the manifold 40 in the second pump docking portion 76 so that the inlet 37 of the second pump 36 is in fluid communication with the seventh fluid chamber 58H, the seventh fluid chamber 58H is in fluid communication with the orifice of the multi-way valve 38, and the outlet 41 of the second pump 36 is in fluid communication with the sixth fluid chamber 58G, and the sixth fluid chamber 58G is in fluid communication with the seventh passage 56P.

[0079] In this manner, the second pump 36 draws the coolant fluid flowing from the multi-way valve 38 into the seventh fluid chamber 32H, and directs the coolant fluid to the sixth fluid chamber 58G, and flows out through the seventh passage 56P to the battery fluid loop 26. The coolant fluid flows through the battery loop conduit 26C to transfer heat between the battery 16 and the coolant fluid, and then flows back to the manifold 40.

[0080] The valve interface 78 is configured to receive the multi-way valve 38 to mount the multi-way valve 38 on the manifold 40 so that the plurality of holes 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J included in the multi-way valve 38 are aligned with the plurality of holes 43B, 43C, 43D, 43E, 43F, 43H, 43I, 43K1, 43K2 formed in the manifold 40, as shown. Figure 3 and Figure 6 The valve ports 43B, 43C, 43D, 43E, 43F, 43G, 43H, 43I, 43J lead to corresponding fluid chambers 58B, 58C, 58DE, 58F, 58G, 58H, 58I, 58J.

[0081] In the illustrated embodiment, a plurality of apertures 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J are defined by a valve housing 80 of the multi-way valve 38. In the exemplary embodiment, the valve housing 80 has a valve housing tube 80P extending therefrom and configured to fit into corresponding valve ports 43B, 43C, 43D, 43E, 43F, 43G, 43H, 43I, 43J when the multi-way valve 38 is mounted on the valve interface 78.

[0082] In an illustrative embodiment, a plurality of O-ring seals may be included to seal between the multi-way valve 38 and the valve interface 78 of the manifold 40, such as Fig. 9A Each seal may extend around one of the valve housing tubes 80P such that the corresponding seal is located between the valve housing 80 and the manifold 40 .

[0083] In the exemplary embodiment, the manifold body 42 is composed of two separate body sections 42U, 42L coupled together. The manifold body 42 has an upper body section 42U and a lower body section 42L, which is separate from and connected to the upper body section 42U. The first tube 44, the third tube 48, and the fifth tube 52 extend from the upper body section 42U of the manifold body 42, while the second tube 46, the fourth tube 50, the sixth tube 54, and the seventh tube 56 extend from the lower body section 42L of the manifold body 42. In the illustrated embodiment, the upper body section 42U of the manifold defines a tank docking portion 72 and a first pump docking portion 74, and the lower body section 42L of the manifold 40 defines a second pump docking portion 76 and a valve docking portion 78, as shown in FIG. Figure 3-Figure 7 shown.

[0084] In an exemplary embodiment, the upper body section 42U and the lower body section 42L cooperate with each other to define different fluid chambers 58A-58L. In an exemplary embodiment, the upper body section 42U is shaped to define a first fluid chamber 58A, a portion of a third fluid chamber 58C, a portion of a fifth fluid chamber 58F, a portion of a sixth fluid chamber 58G, and a portion of an eleventh fluid chamber 58L. In the illustrated embodiment, the lower body section 42L is shaped to define a second fluid chamber 58B, a portion of a third fluid chamber 58C, a fourth fluid chamber 58DE, a portion of a fifth fluid chamber 58F, a portion of a sixth fluid chamber 58G, a seventh fluid chamber 58H, an eighth fluid chamber I, a ninth fluid chamber 58J, and a tenth fluid chamber 58K.

[0085] like Figure 3-Figure 7 As shown, the upper body section 42U includes an upper wall 60, a side wall 62, a plurality of dividing walls 64 extending between the upper wall 60 and the side wall 62 to define different fluid chambers 58A, 58C, 58G, 58F, 58L therebetween, a tank interface 72, and a first pump interface 74. The number and shape of the flow divider walls 64 depend on the number of fluid chambers 58A-58L and can be adjusted according to the system.

[0086] The lower body section 42U includes a lower wall 66, a side wall 68, and a plurality of partition walls 70 extending between the lower wall 66 and the side wall 68 to define different fluid chambers 58B, 58C, 58DE, 58F, 58G, 58H, 58I, 58J, 58K therebetween, a second pump interface 76, and a valve interface 78, as shown in FIG. Figure 3-Figure 7 The number and shape of the diverter walls 70 depends on the number of fluid chambers 58A-58L and can be adjusted depending on the system.

[0087] In the illustrated embodiment, the upper body section 42U is coupled to the lower body section 42L to close the top openings to the fluid chambers 58B, 58DE, 58H, 58I, 58J, 58K. In the illustrated embodiment, the coolant tank 32 is coupled to the upper body section 42U to close the top openings to the fluid chambers 58A, 58C, 58G. In some embodiments, the upper body section 42U can be integrally formed with the lower body section 42L.

[0088] In some embodiments, the upper body section 42U can be integrally formed with the coolant tank 32, so that the upper body section 42U and the coolant tank 32 are a single-piece component. In some embodiments, the upper body section 42U, the lower body section 42L, and the coolant tank 32 can be a single-piece component. The manifold 40 can be a single-piece component made of a molded or extruded plastic material.

[0089] Multi-way valve 38 Figure 8-Figure 13 The multi-way valve 38 may be similar to U.S. Application Serial No. 63 / 454,447, Attorney Docket No. 3177-387874 / ST-554, filed on March 24, 2023, entitled “MULTI-WAY VALVE” and U.S. Application Serial No. 63 / 414,205, Attorney Docket No. 3177-373022 / ST-447, filed on October 7, 2022, entitled “MULTI-WAY VALVE”, the entire contents of which are hereby incorporated by reference herein as disclosed with respect to multi-way valves.

[0090] In the illustrated embodiment, the multi-way valve 38 includes a valve housing 80 and a valve flow controller 82, such as Figure 8-Figure 13 A valve flow controller 82 is disposed in the valve housing 80 to control the flow through the valve housing 80 .

[0091] The valve housing 80 includes a valve housing body 84 and an upper valve housing cover 85. Figure 8 and Fig. 9The valve housing body 84 is formed to define a first valve cavity 86, a second valve cavity 88, and a plurality of holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J in fluid communication with at least one of the first valve cavity 86 and the second valve cavity 88. The valve housing 84 is coupled to the valve interface 78 of the manifold 40 so that certain holes 89B, 89C, 89D, 89E, 89F, 89H, 89I, 89J are aligned with valve ports 43B, 43C, 43D, 43E, 43F, 43H, 43I, 43K1, 43K2 in the manifold 40 to connect the multi-way valve 38 in fluid communication with different valve cavities 58B, 58C, 58DE, 58F, 58H, 58I, 58K. The upper valve housing cover 85 is coupled to the valve housing body 84 to close the top openings of the first valve chamber 86 and the second valve chamber 88 .

[0092] The valve housing 84 is formed to include a plurality of housing holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J, as shown in FIG. Figure 4 , Fig.13 and Figures 17A-17D As shown. A plurality of housing holes 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J are in fluid communication with different fluid circuits 22, 24, 26. A plurality of housing holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J are in fluid communication with at least one of the first valve cavity 86 and the second valve cavity 88 of the valve housing body 84. In the illustrated embodiment, the holes 89B, 89C, 89D, 89E, 89F, 89G, 89H are in fluid communication with the first valve cavity 86, and the holes 89I, 89J are in fluid communication with the second valve cavity 88. The holes 89A1, 89A2 are in fluid communication with the first valve cavity 86 and the second valve cavity 88 through the connecting passage 89A defined by the valve housing 80.

[0093] In the illustrated embodiment, the housing bore 89B is aligned with the valve port 43B that opens into the second fluid chamber 58B. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89B is aligned with the valve port 43B.

[0094] In the illustrated embodiment, the housing bore 89C is aligned with the valve port 43C that opens into the third fluid chamber 58C. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89C is aligned with the valve port 43C.

[0095] In the illustrated embodiment, housing bore 89D is aligned with valve port 43D, and housing bore 89E is aligned with valve port 43E. Valve ports 43D, 43E both open into fourth fluid chamber 58DE. When valve housing body 84 is coupled to valve interface 78 of manifold body 42, housing bore 89D is aligned with valve port 43D, and housing bore 89E is aligned with valve port 43E.

[0096] In the illustrated embodiment, the housing bore 89F is aligned with the valve port 43F that opens into the fifth fluid chamber 58F. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89F is aligned with the valve port 43F.

[0097] In the illustrated embodiment, the housing bore 89G is aligned with the valve port 43G that opens into the sixth fluid chamber 58G. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89G is aligned with the valve port 43G.

[0098] In the illustrated embodiment, the housing bore 89H is aligned with the valve port 43H that opens into the seventh fluid chamber 58H. When the valve housing 84 is connected to the valve interface 78 of the manifold body 42, the housing bore 89H is aligned with the valve port 43H.

[0099] In the illustrated embodiment, the housing bore 89I is aligned with the valve port 43I that opens into the eighth fluid chamber 58I. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89I is aligned with the valve port 43I.

[0100] In the illustrated embodiment, the housing bore 89J is aligned with the valve port 43J that opens into the ninth fluid chamber 58J. When the valve housing 84 is coupled to the valve interface 78 of the manifold body 42, the housing bore 89J is aligned with the valve port 43J.

[0101] In the illustrated embodiment, the valve housing 80 also includes a plurality of valve housing tubes 80P, such as Figure 8 and Fig. 9 Each of the valve housing tubes 80P extends axially from the valve housing body 84. Each tube 80P defines one of the housing bores 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J. When the multi-way valve 38 is coupled to the valve interface 78, each tube 80P extends into one of the valve ports 43B-43J defined by the valve interface 78 of the manifold 40.

[0102] In the illustrated embodiment, the valve housing 80 includes a separate lower valve housing cover 87 that is coupled to the valve housing body 84 opposite to the upper valve housing cover 85 to close the bottom opening, thereby forming a connecting passage 89A between the first valve chamber 86 and the second valve chamber 88. Figure 8Coolant fluid can flow from the second valve cavity 88 through the hole 89A2, through the connecting passage 89A, and through the hole 89A1 into the first valve cavity 86. In some embodiments, the valve housing 84 defines the connecting passage 89A.

[0103] In some embodiments, the manifold 40 can cooperate with the valve housing 84 to form a connecting passage 89A between the first valve cavity 86 and the second valve cavity 88. When the multi-way valve 38 is coupled to the valve interface 78 of the manifold body 42, the manifold 40 cooperates with the valve housing body 84 to close the bottom opening to form the connecting passage 89A between the first valve cavity 86 and the second valve cavity 88.

[0104] In some embodiments, the upper valve housing cover 85 and the lower valve housing cover 87 are each laser welded to the valve housing body 84. In some embodiments, the upper valve housing cover 85 and the lower valve housing cover 87 can be secured to the valve housing body 84 using another suitable method.

[0105] The valve flow controller 82 includes a first valve rotor 90 disposed in a first valve cavity 86 (also referred to as a main rotor cavity 86) formed by the valve housing 80, a second valve rotor 92 disposed in a second valve cavity 88 (also referred to as a throttle valve rotor cavity 88) formed by the valve housing 80, and an actuator 93, as shown in FIG. Figure 8-Figure 12 As shown. The first valve rotor 90 is configured to rotate relative to the valve housing 80 about a first rotor axis 90A, and the second valve rotor 92 is configured to rotate relative to the valve housing 80 about a second rotor axis 92A. The second rotor axis 92A is parallel to the first rotor axis 90A. The actuator 93 is coupled to the first valve rotor 90 and the second valve rotor 92 to drive the first valve rotor 90 and the second valve rotor 92 to rotate about the respective rotor axes 90A, 92A.

[0106] The first valve rotor 90 and the second valve rotor 92 cooperate to define a plurality of flow paths through the valve housing 80 to change between different fluid circuits 22, 24, 26. When the first valve rotor 90 and the second valve rotor 92 rotate about respective rotor axes 90A, 92A to different set positions, the first valve rotor 90 and the second valve rotor 92 form different flow paths to control the flow of fluid through the valve housing 80 to the different fluid circuits 22, 24, 26.

[0107] The different modes AD of the thermal management system 20 are Fig.14 , Fig.15 and Figures 15A-15D The first valve rotor 90 and the second valve rotor 92 are in different predetermined positions in each of the different modes AD to form different flow paths through the valve housing 80, such as Figures 15A-15D and Figures 17A-17DAs shown, it changes the flow path through the manifold 40. The multi-way valve 38 and / or the actuator 93 may include a control unit pre-programmed with different modes AD.

[0108] In the illustrated embodiment, the actuator 93 may be coupled to the controller 15 or have its own controller. The temperature sensors 17A, 17B, 17C are coupled to the controller 15 to send temperature measurement data to the controller 15. The controller 15 uses the temperature sensor data to determine which mode the thermal management system 20 should be in, and controls the multi-way valve 38 to switch between different modes based on the temperature sensor data. The controller 15 may also use other data to control the thermal management system 20.

[0109] The first valve rotor 90 is formed to include a plurality of first rotor through holes 94A-94H, and the second valve rotor 92 is formed to include a plurality of second rotor through holes 96A-96C, such as Fig. 9 and Figures 17A-17D As shown. The first rotor through holes 94 (also referred to as main valve rotor through holes) each extend axially through the first valve rotor 90 relative to the first rotor axis 90A and are circumferentially spaced about the first rotor axis 90A. The second rotor through holes 96A-96C (also referred to as throttle valve rotor through holes) each extend axially through the second valve rotor 92 relative to the second rotor axis 92A and are circumferentially spaced about the second rotor axis 92A.

[0110] The main valve rotor 90 includes a main valve rotor body 90B, a main valve rotor shaft 90S and a main valve rotor cover 90C. Figure 9-10 As shown. The main valve rotor body 90B extends circumferentially around the first rotor axis 90A. The main valve rotor shaft 90S extends axially along the first rotor axis 90A away from the main valve rotor body 90B and is coupled to the actuator 93. In the illustrated embodiment, the valve housing body 84 defines a first stem 84A that extends axially from the bottom surface 84S of the valve housing body 84 into the main valve rotor shaft 90S to position and center the main valve rotor 90 in the first valve cavity 86. The main valve rotor cover 90C is coupled to the main valve rotor body 90B to rotate therewith.

[0111] The main valve rotor body 90B is formed to include a plurality of main rotor through-holes 94A-94H, and the main valve rotor cover 90C is formed to define a plurality of chambers 95A-95C and a plurality of cover through-holes 97A, 97B, as shown in FIG. Figure 8-Figure 10 and Figures 17A-17DWhen the main valve rotor cover 90C is coupled to the main valve rotor body 90B, the cover chambers 95A-95C each extend around adjacent through holes 94A-94H in the main valve rotor body 90B to interconnect adjacent through holes 94A-94H in fluid communication with each other. When the main valve rotor cover 90C is coupled to the main valve rotor body 90B, the cover through holes 97A, 97B each align with one of the main rotor through holes 94A-94H.

[0112] In the illustrated embodiment, the main valve rotor cover 90C has three cover chambers 95A-95C and two cover through holes 97A, 97B. In some embodiments, the number of cover chambers 95A-95C and the number of cover through holes can vary depending on the number of circuits 22, 24, 26.

[0113] The main valve rotor body 90B includes a body plate 98, an outer wall 100 and an inner wall 102. Figure 8-Figure 10 As shown. The body plate 98 extends circumferentially about the first rotor axis 90A and is shaped to define a plurality of main rotor through holes 94A-94H that extend axially therethrough. An outer wall 100 extends circumferentially about the outer edge of the body plate 98. The outer wall 100 extends axially from the outer edge of the body plate 98 in the same direction as the main valve rotor shaft 90S. An inner wall 102 extends circumferentially about the first rotor axis 90A and is axially away from the body plate 98 at a position radially inward of the outer wall 100.

[0114] The main valve rotor cover 90C includes a cover plate 104 and diverter housings 106A-106C, such as Figure 8-Figure 10 As shown. The cover plate 104 extends circumferentially around the first rotor axis 90A. Each of the splitter shells 106A-106C defines one of the cover chambers 95A-95C and is configured to extend around at least two through holes 94 in the body plate 98. Figure 8-Figure 10 As shown, the first diverter housing 106A defines a first cover chamber 95A, the second diverter housing 106B defines a second cover chamber 95B, and the third diverter housing 106C defines a third cover chamber 95C.

[0115] As the main valve rotor 90 rotates, the body plate 98 and the main valve rotor cover 90C cooperate to control flow to each of the holes 89A1, 89A2, 89B, 89D, 89E, 89F, 89G, 89H included in the housing holes 89A1, 89A2, 89B, 89D, 89E, 89F, 89G, 89H, as shown in FIG. Figures 15A-15D and Figures 17A-17DAs shown. The body plate 98 controls the flow to each hole 89A1, 89B, 89C, 89D, 89E, 89F, 89G, 89H by aligning different first rotor through holes 94A-94H with different holes 89A1, 89B, 89C, 89D, 89E, 89F, 89G, 89H at different predetermined positions. The cover chambers 95A-95C of the main valve rotor cover 90C each connect adjacent through holes 94A-94H in fluid communication so that fluid can only flow therebetween. The cover chambers 95A-95C of the diverter housing 106A-106C connect adjacent through holes 94 to each other, but prevent direct fluid communication with the first valve chamber 86.

[0116] In the illustrated embodiment, the main valve rotor cover 90C is a separate component coupled to the main valve rotor body 90B. The main valve rotor body 90B has a locking device for selectively securing the main valve rotor cover 90C to the main valve rotor body 90B in an engaged position on the main valve rotor body 90B, so that once the main valve rotor cover 90C is in the engaged position, the main valve rotor cover 90C is locked. Fig. 9 and Fig. 9A In the engaged position shown, the main valve rotor cover 90C is prevented from axial movement relative to the main valve rotor body 90B.

[0117] In an exemplary embodiment, each of the outer wall 100 and the inner wall 102 of the main valve rotor body 90B defines a locking device for selectively securing the main valve rotor cover 90C to the main valve rotor body 90B in an engaged position on the main valve rotor body 90B, such as Figure 9-10 The locking device of the main valve rotor body 90B includes a deflectable locking piece 100T on the outer wall 100 and a deflectable locking piece 102T on the inner wall 102 of the main valve rotor body 90B, as shown in FIG. Figure 9-10 When the main valve rotor cover 90C is in the engaged position on the main valve rotor body 90B, each deflectable locking tab 100T, 102T is configured to engage the main valve rotor cover 90C, thereby preventing the main valve rotor cover 90C from axially moving relative to the main valve rotor body 90B once the main valve rotor cover 90C is in the engaged position on the main valve rotor body 90B.

[0118] Each deflectable locking tab 100T, 102T includes a deflectable locking arm 100A, 102A and a protrusion 100P, 102P, such as Fig. 9A A deflectable locking arm 100A extends axially from the outer wall 100 toward the body plate 98, while a deflectable locking arm 102A extends axially from the body plate 98 at the inner wall 102. Protrusions 100P, 102P extend radially from the respective deflectable locking arms 100A, 102A toward each other.

[0119] Each protrusion 100P, 102P defines a guide ramp 100S, 102S that engages the main valve rotor cover 90C when the main valve rotor cover 90C moves to the engagement position to deflect the deflectable locking arms 100A, 102A from the normal position to the deflected position so that the main valve rotor cover 90C can move past the protrusions 100P, 102P. Once the main valve rotor cover 90C moves past the terminal ends of the protrusions 100P, 102P, the deflectable locking arms 100A, 102A move back to the normal position so that the protrusions 100P, 102P engage the upper surface 104S of the cover plate 104 to prevent axial movement of the main valve rotor cover 90C, thereby fixing the main valve rotor cover 90C to the main valve rotor body 90B.

[0120] The throttle rotor 92 includes a throttle rotor plate 92P, a throttle rotor wall 92W and a throttle rotor shaft 92S. Figure 8-Figure 9 and Figure 11-Figure 12 As shown. The throttle rotor plate 92P extends circumferentially around the second rotor axis 92A. The throttle rotor wall 92W extends circumferentially around the outer edge of the throttle rotor plate 92P. The throttle rotor wall 92W extends axially from the outer edge of the throttle rotor plate 92P. The throttle rotor shaft 92S extends away from the throttle rotor plate 92P along the second rotor axis 92A in the same direction as the throttle rotor wall 92W. In the illustrated embodiment, the valve housing 84 defines a second rod 84B that extends axially from the bottom surface 84S of the valve housing 84 into the throttle rotor shaft 92S to position and center the throttle rotor 92 in the second valve cavity 88.

[0121] like Figure 9-9A and Figure 11-Figure 12 As shown, the throttle rotor plate 92P is formed to define a plurality of throttle rotor through-holes 96A-96C. Each throttle rotor through-hole 96A-96C extends axially through the throttle rotor plate 92P and partially circumferentially around the second rotor axis 92A.

[0122] When the throttle rotor 92 rotates, the throttle rotor plate 92P controls the amount of fluid flowing through the holes 89A2, 89I, 89J included in the plurality of housing holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J. The throttle rotor plate 92P partially opens, fully opens, or closes the holes 89A2, 89I, 89J at different predetermined positions to control the flow of fluid through the holes 89A2, 89I, 89J. The throttle rotor plate 92P partially opens or closes the holes 89A2, 89I, 89J at different predetermined positions by partially or fully covering the holes 89A2, 89I, 89J. In some positions, the throttle rotor plate 92P partially covers the holes 89A2, 89I, 89J to block the flow of fluid through the holes 89A2, 89I, 89J.

[0123] In an illustrative embodiment, Figure 8-Figure 12 As shown, the multi-way valve 38 further includes a first sealing system 81 and a second sealing system 83. The first sealing system 81 is configured to seal between the valve housing 80 and one of the valve rotors 90 included in the valve flow controller 82. The second sealing system 83 is configured to seal between the valve housing 80 and the other valve rotor 92 included in the valve flow controller 82.

[0124] The first sealing system 81 (also referred to as the primary sealing system 81) includes a first biasing assembly 108 and a first sealing member 110, such as Figure 8-Figure 10 As shown. The first sealing member 110 is coupled to the first valve rotor 90 for rotation therewith. The first sealing member 110 engages with the axial facing surface 84S of the valve housing body 84. The first biasing assembly 108 is configured to selectively exert an axial force on the main valve rotor 90 to urge the main valve rotor 90 toward the plurality of holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H, 89I, 89J formed in the valve housing body 84 so that when the main valve rotor 90 is in one of the different predetermined positions, the first sealing member 110 is forced toward the valve housing body 84 and engages with the bottom surface 84S of the valve housing body 84 to improve the seal between the main valve rotor 90 and the valve housing body 84.

[0125] In the illustrated embodiment, the first sealing member 110 is a single sealing member 110. The first sealing member 110 extends into each of the through holes 94A-94H in the main valve rotor body 90B.

[0126] In some embodiments, the first sealing system 81 includes a plurality of sealing members 110. The plurality of sealing members 110 may be overmolded on the main valve rotor body 90B of the first valve rotor 90. In other embodiments, the first sealing member 110 may be another suitable seal coupled to the first valve rotor 90. In some embodiments, the first sealing member 110 may be a press-fit seal. In some embodiments, the first sealing member 110 may be an O-ring seal. In other embodiments, the first sealing member 110 may be another suitable seal.

[0127] In some embodiments, the first sealing system 81 includes a plurality of seals 110 extending around individual through holes 94A, 94D, and other seals extending around adjacent through holes 94B, 94C, 94E, 94F, 94G, 94H in the main valve rotor body 90B. In some embodiments, the first sealing system 81 may include a plurality of sealing members 110 extending around adjacent through holes 94B, 94C, 94E, 94F, 94G, 94H, forming a perimeter seal around the respective through holes 94B, 94C, 94E, 94F, 94G, 94H, which mate with the corresponding diverter housings 106A-106C when the main valve rotor cover 90C is coupled to the main valve rotor body 90B, such that the cover chambers 95A-95C are sealed separately from the first valve chamber 86.

[0128] The first biasing assembly 108 includes a cam ramp 112 formed on the axial facing surface 85s of the upper valve housing cover 85 of the valve housing 80 and a cam surface 114 formed on the main valve rotor 90. Figure 9-10 The cam surface 114 formed on the main valve rotor 90 is configured to engage with the cam slope 112 on the upper valve housing cover 85 when the main valve rotor 90 rotates to different predetermined positions around the first rotor axis 90A, so that the main valve rotor 90 is pushed toward the plurality of holes 89A1, 89A2, 89B, 89C, 89D, 89E, 89F, 89G, 89H formed in the valve housing body 84 at different predetermined positions.

[0129] In this manner, the cam ramp 112 and cam surface 114 serve to reduce the torque required to rotate the main valve rotor 90 between different predetermined positions. Other valves use a constant torque because the rotor is always loaded. The constant torque may adversely affect the life of the valve. The main valve rotor 90 includes a first biasing assembly 108 so that the main valve rotor 90 is loaded and unloaded as the main valve rotor 90 rotates between different predetermined positions.

[0130] The cam slope 112 is formed on the axial facing surface 85S of the upper valve housing cover 85, and the cam surface 114 is defined by the edge of the outer wall 100 of the main valve rotor body 90B, as shown in FIG. Figure 9-10 As shown. Each of the cam ramps 112 rises from the surface 85S at intervals of approximately 45 degrees around the first rotor axis 90A. The cam surface 114 also rises at intervals of approximately 45 degrees around the first rotor axis 90A. In some embodiments, the cam ramps 112 can be formed by the edge of the outer wall 100 of the main valve rotor body 90B, while the cam surface 114 is defined by the axial facing surface 85S of the upper valve housing cover 85.

[0131] Each cam ramp 112 is circumferentially aligned with one of the holes 89A1, 89B, 89C, 89D, 89E, 89F, 89G, 89H of the valve housing 84, while the raised portion of the cam surface 114 is aligned with the through holes 94A-94H. In this manner, the axial force F will be applied at different predetermined locations to seal around the corresponding holes. Then, when the main valve rotor 90 rotates about the first rotor axis 90A, the raised portion 114P of the cam surface 114 disengages the cam ramp 112, so that at least a portion of the axial force is removed and the torque required to rotate the main valve rotor 90 is reduced.

[0132] The cam ramp 112 is fixed to the upper valve housing cover 85. The cam surface 114 on the main valve rotor 90 abuts against the cam ramp 112 in a circular manner and when in contact with the cam surface 114, the cam surface 114 on the main valve rotor 90 is in a circular manner. Fig. 9A When the high points 114P of the cam surfaces 114 are aligned as shown, a downward axial force is applied to the main valve rotor 90. This axial force generates a contact pressure between the first seal member and the bottom surface 84S of the valve housing 84. The increased contact pressure and resulting increase in friction is only generated at predetermined positions of the different modes AJ. As the main valve rotor 90 rotates, the cam ramps 112 disengage from the high points 114P of the cam surfaces 114, thereby removing or reducing the axial force and the main valve rotor 90 is unloaded. This reduces friction and torque on the actuator during movement between sealing points.

[0133] The second sealing system 83 (also referred to as the throttle sealing system 83) includes a second biasing assembly 116 and a second sealing member 118, such as Figure 8 , Fig.9A , Fig.11 and Fig.12 The second biasing assembly 116 is configured to exert an axial force on the second valve rotor 92 to push the second valve rotor 92 toward the second sealing member 118 and the bottom surface 84S of the valve housing 84 and engage with the second sealing member 118 .

[0134] The second biasing assembly 116 includes a biasing member 120, a biasing member cover 122, and a flange 124 formed on the upper valve housing cover 85. Figure 11-13 As shown. The biasing member 120 is configured to be assembled on the throttle rotor shaft 92S. When the biasing member 120 extends around the throttle rotor shaft 92S, the biasing member cover 122 is arranged on the biasing member 120. The biasing member cover 122 is coupled to the throttle rotor 92 to rotate therewith. When the upper valve housing cover 85 is coupled to the valve housing 84, the flange 124 formed on the upper valve housing cover 85 engages with the biasing member cover 122, thereby loading the second biasing assembly 116 when the throttle rotor 92 is arranged in the second valve chamber 88.

[0135] like Fig. 9 and Fig.9A As shown, with the biasing member 120 and the biasing member cover 122 assembled on the throttle rotor 92, the throttle rotor 92 can be arranged in the second valve cavity 88. The upper valve housing cover 85 defines a flange 124 that extends axially toward the biasing member cover 122 and engages the biasing member cover 122 so that the biasing member 120 is compressed. This causes the biasing member 120 to exert an axial force on the throttle rotor 92, thereby forcing the throttle rotor 92 toward the plurality of holes 89A2, 89I, 89J formed in the valve housing body 84 to increase the seal between the throttle rotor 92 and the valve housing body 84.

[0136] In the illustrated embodiment, the second biasing assembly 116 applies a constant axial force to the throttle rotor 92. The second biasing assembly 116 constantly loads the throttle rotor 92. In other embodiments, the second biasing assembly 116 may include a cam feature similar to the main valve rotor 90 to selectively apply an axial force or reduce the force applied to the throttle rotor 92 so as to load and unload the throttle rotor 92 as the throttle rotor 92 rotates between different predetermined positions.

[0137] The biasing member cover 122 includes a ring 126 and a pair of deflectable attachment tabs 128, 130, such as Fig.11 and Fig.12 As shown. The ring 126 extends circumferentially around the second rotor axis 92A. The throttle rotor shaft 92S extends through a hole 126A formed in the ring 126 of the biasing member cover 122. Deflectable attachment tabs 128, 130 each extend axially from the ring 126. The deflectable attachment tabs 128, 130 each extend into openings 92O on opposite sides of the throttle rotor shaft 92S to couple the biasing member cover 122 to the throttle rotor 92.

[0138] In the illustrated embodiment, the biasing member 120 is axially located between the throttle rotor plate 92P and the ring 126 of the biasing member cover 122, as shown in FIG. Fig.12Deflectable attachment tabs 128, 130 extend axially from the ring 126 such that the attachment tabs 128, 130 are radially located between the biasing member 120 and the throttle rotor shaft 92S.

[0139] Each deflectable attachment tab 128, 130 includes a deflectable attachment arm 128A, 130A and a protrusion 128P, 130P. Figure 7 and Figure 8 The deflectable attachment arms 128A, 130A extend axially from the ring 126 on opposite sides of the ring 126. The protrusions 128P, 130P extend radially from the respective deflectable attachment arms 128A, 130A toward each other.

[0140] Each protrusion 128P, 130P defines a guide ramp 128S, 130S that engages the throttle rotor shaft 92S when the biasing member cover 122 moves to the engaged position to deflect the deflectable attachment arms 128A, 130A from the normal position to the deflected position so that the biasing member cover 122 can move to the engaged position on the throttle rotor shaft 92S. Once the terminal end of the protrusion 128P, 130P moves past the edge of the opening 92O in the throttle rotor shaft 92S, the deflectable attachment arms 128A, 130A move back to the normal position so that each of the protrusions 128P, 130P engages the edge of the corresponding opening 92O to prevent axial movement of the biasing member cover 122 away from the throttle rotor shaft 92S.

[0141] In the illustrated embodiment, the second sealing member 118 is a gasket disposed axially between the valve housing 84 and the second valve rotor 92, such as Figure 8 and Fig.9A In the illustrated embodiment, the second sealing member 118 extends around the apertures 89I, 89J. In some embodiments, the second sealing member 118 extends around the apertures 89A2, 89I, 89J.

[0142] In some embodiments, the second sealing member 118 can be another suitable sealing type. In some embodiments, the second sealing member 118 can be a press fit seal. In some embodiments, the second sealing member 118 can be an O-ring seal. In some embodiments, the second sealing member 118 can be a plurality of sealing members 118 arranged around each hole 89A2, 89I, 89J.

[0143] exist Fig.15 The different modes of the thermal management system 20 are shown in FIG. The first mode or mode A is Fig.15A The second mode or mode B is shown in Fig. 15B The third mode or mode C is shown in Fig. 15CThe fourth mode or mode D is shown in Fig.15D In the illustrated embodiment, the thermal management system 20 has four modes AD. In some embodiments, the thermal management system 20 may have more or less than four modes, depending on the number of loops 22, 24, 26 or the thermal requirements of the system 20.

[0144] In the illustrated embodiment, the coolant fluid refers to a heat transfer fluid configured to absorb and transfer heat between various components on the vehicle 10. The coolant fluid may be any suitable cooling / heating fluid configured to absorb / transfer heat to cool or heat various components on the various thermal fluid loops 22, 24, 26.

[0145] In Mode A or system cooling mode, the main fluid circuit 22 is connected in fluid communication with the radiator fluid circuit 24, and the battery fluid circuit 26 is isolated from the other circuits 22, 24, such as Fig.15A The main fluid circuit 22 is connected to the radiator fluid circuit 24, so that the electronic drive system 11 including the front drive 12F and the rear drive 12R and the electrical components 13, 15 is cooled by the coolant fluid, and heat is discharged by flowing the coolant fluid through the radiator 14. The battery fluid circuit 26 is isolated from the other circuits 22, 24, and the battery 16 is cooled by the coolant fluid, and heat is discharged by flowing the coolant fluid through the cooler / heater 18.

[0146] like Fig.15A As shown, the coolant fluid is drawn from the coolant tank 32 through the eleventh fluid chamber 58L and pumped into the first fluid chamber 58A by the first pump 34 connected to the main fluid circuit 22. The main circuit conduit 22C is thermally connected to the DC / DC converter and the on-board charger (OBC) 13 and the controller 15 to transfer heat between the components 13, 15. The main circuit conduit 22C can be divided into sections flowing to different components 13, 15, 12F, 12R. In the illustrated embodiment, it is divided into a first main circuit conduit section 22CF, so that the main circuit conduit 22C is thermally connected to the front drive 12F, and into a second main circuit conduit section 22CR, so that the main circuit conduit 22C is fluidly connected to the rear drive 12R, as shown. Fig.15A shown.

[0147] The first main loop conduit section 22CF directs the coolant fluid from the front drive 12F back to the manifold 40, while the second main loop conduit section 22CR directs the coolant fluid from the rear drive 12R back to the manifold 40, as shown in FIG. Fig.15AAs shown. The first main loop conduit section 22CF of the main fluid loop 22 is coupled in fluid communication with the eighth fluid chamber 58I. The second main loop conduit section 22CR of the main fluid loop 22 is coupled in fluid communication with the ninth fluid chamber 58J. In an illustrative embodiment, the front driver 12F and the rear driver 12R may be located on different sections of the main loop conduit 22C, such that the coolant fluid flowing from the front driver 12F flows to the ninth fluid chamber 58J, and the coolant fluid flowing from the rear driver 12R flows to the eighth fluid chamber 58I.

[0148] By Fig.16A The throttle rotor first position shown in Fig. 16B The throttle rotor second position shown in Fig. 16C The throttle rotor 92 controls the flow of coolant fluid from each fluid chamber 58I, 58J through the corresponding housing bore 89I, 89J. Fig.15A and Fig.17A As shown, the combined flow from each hole 89I, 89J into the second valve chamber 88 then flows out of the first throttling chamber hole 89A2, passes through the connecting passage 89A, and flows into the first valve chamber 86 through the first main chamber hole 89A1.

[0149] In the first throttle rotor position, the throttle rotor 92 connects the first throttle cavity hole 89A2 with the first main cavity hole 89A1 and the ninth hole 89I, while preventing flow through the tenth hole 89J. Fig.16A In the first position of the throttle rotor, the first through hole 96A in the throttle rotor 92 is aligned with the first throttle cavity hole 89A2, so that the first valve cavity 86 is in fluid communication with the second valve cavity 88 through the connecting passage 89A, as shown in FIG. Fig.16A In the first position of the throttle rotor, the throttle rotor 92 also aligns the second through hole 96B with the ninth hole 89I to connect the first throttle chamber hole 89A2 with the ninth hole 89I, and covers the tenth hole 89J to prevent flow through the tenth hole 89J, as shown in FIG. Fig.16A shown.

[0150] In the second throttle rotor position, the throttle rotor 92 connects the first throttle cavity hole 89A2 with the first main cavity hole 89A1 and the tenth hole 89J, while blocking the flow through the ninth hole 89I. Fig. 16B In the second position of the throttle rotor, the first through hole 96A in the throttle rotor 92 remains aligned with the first throttle cavity hole 89A2, so that the first valve cavity 86 is in fluid communication with the second valve cavity 88 through the connecting passage 89A, as shown in FIG. Fig. 16BHowever, in the second position of the throttle rotor, the throttle rotor 92 aligns the third through hole 96C with the tenth hole 89J to connect the first throttle chamber hole 89A2 with the tenth hole 89J and covers the ninth hole 89I to prevent flow through the ninth hole 89I, as shown in FIG. Fig. 16B shown.

[0151] In the throttle configuration, the first through hole 96A in the throttle rotor 92 is aligned with the first throttle cavity hole 89A2, so that the first valve cavity 86 is in fluid communication with the second valve cavity 88 through the connecting passage 89A. Fig. 16C However, in a throttling configuration, such as Fig. 16C and Figures 17A-17D As shown, the two through holes 96B, 96C are partially aligned with the ninth hole 89I and the tenth hole 89J, respectively.

[0152] The two through holes 96B, 96C are partially aligned with the ninth hole 89I and the tenth hole 89J, respectively, so that the first throttle chamber hole 89A2 is in fluid communication with the ninth hole 89I and the tenth hole 89J. In the throttle configuration, the throttle rotor 92 can rotate about the second rotor axis 92A to change or throttle the flow through the ninth hole 89I and the tenth hole 89J. The first through hole 96A partially extends circumferentially around the second rotor axis 92A so that when the throttle rotor 92 is toggled in the throttle configuration, the first through hole 96A in the throttle rotor 92 remains aligned with the first throttle chamber hole 89A2. When the throttle rotor 92 rotates, the corresponding through holes 96B, 96C change the flow through the ninth hole 89I and the tenth hole 89J. Fig.16 The switching of the throttle rotor 92 is shown. Fig.16 As shown, the area of ​​the bore or port openings 89I, 89J can be varied by rotating the throttle rotor 92.

[0153] In mode A, the main valve rotor 90 of the multi-way valve 38 is in the main valve rotor first position, such as Fig.15A and Fig.17A In the first position of the main valve rotor, the main valve rotor 90 connects the first main chamber hole 89A1 to the second hole 89B, the third hole 89C to the sixth hole 89F, the fourth hole 89D to the fifth hole 89E, and the seventh hole 89G to the eighth hole 89H, as shown in FIG. Fig.15A and Fig.17A shown.

[0154] In the first position of the main valve rotor, the rotor through hole 94G is aligned with the first main cavity hole 89A1, the rotor through hole 94H is aligned with the second hole 89B, and the third diverter housing 106C defining the third chamber 95C extends around the first main cavity hole 89A1 and the second hole 89B to connect the first main cavity hole 89A1 and the second hole 89B to fluid, as shown in FIG. Fig.17A In this way, the fluid flowing through the first main cavity hole 89A1 flows into the third cavity 95C defined by the third diverter housing 106C, and the third cavity 95C guides the fluid to flow through the second housing hole 89B, as shown in FIG. Fig.15A and Fig.17A The fluid flowing through the first main cavity hole 89A1 flows into the third chamber 95C defined by the third diverter housing 106C, and flows out through the second housing hole 89B, as shown. Fig.17A As shown by the arrow in , the fluid flows into the second fluid chamber 58B which is connected to the second housing hole 89B in fluid communication.

[0155] From the second fluid chamber 58B, the fluid flows out of the second passage 46P to the radiator fluid circuit 24. The radiator circuit conduit 24C is in thermal communication with the radiator 14 to remove heat from the coolant fluid through the radiator 14 when the thermal management system 20 is in mode A. The radiator circuit conduit 24C directs the coolant fluid back to the manifold 40 and into the third fluid chamber 58C. From the third fluid chamber 58C, the fluid flows through the third orifice 89C.

[0156] In the main valve rotor first position, the rotor through hole 94A and the cover through hole 97B are aligned with the third hole 89C, and the rotor through hole 94D and the cover through hole 97A are aligned with the sixth hole 89F to connect the third hole 89C and the sixth hole 89F in fluid communication, as shown in FIG. Fig.17A The coolant fluid flows into the first valve chamber 86 through the rotor through hole 94A and the cover through hole 97B, and flows out of the first fluid chamber 86 through the rotor through hole 94D and the cover through hole 97A, as shown in FIG. Fig.17A The coolant fluid flowing out of the first fluid chamber 86 flows through the sixth hole 89F, flows through the fifth fluid chamber 58F which is in fluid communication with the sixth hole 89F, and returns to the coolant tank 32, as shown in FIG. Fig.15A shown.

[0157] The second pump 36 directs the coolant fluid from the seventh fluid chamber 58H to the tenth fluid chamber 58K, which is in fluid communication with the battery fluid circuit 26, as shown in FIG. Fig.15A The battery loop conduit 26C is in thermal communication with the battery 16 to transfer heat from the battery 16. The battery loop conduit 26C is in thermal communication with the cooler / heater 18 to remove heat from the coolant fluid when the thermal management system is in mode A. The coolant fluid flows from the battery fluid loop 26 back to the sixth fluid chamber 58G, as shown. Fig.15A shown.

[0158] In the first position of the main valve rotor, the rotor through hole 94E is aligned with the seventh hole 89G, the rotor through hole 94F is aligned with the eighth hole 89H, and the second diverter housing 106B defining the second chamber 95B extends around the seventh hole 89G and the eighth hole 89H to connect the seventh hole 89G and the eighth hole 89H to fluid, such as Fig.17A In this way, the coolant fluid flowing into the sixth fluid chamber 58G of the manifold 40 is guided back to the outside of the manifold 40 through the seventh fluid chamber 58H, as shown in FIG. Fig.17A When the coolant flows only through the battery fluid circuit 26, the second pump 36 guides the coolant fluid from the seventh fluid chamber 58H to the tenth fluid chamber 58K, thereby forming a circuit.

[0159] In the first position of the main valve rotor, the rotor through hole 94B is aligned with the fourth hole 89D, the rotor through hole 94C is aligned with the fifth hole 89E, and the first diverter housing 106A defining the first chamber 95A extends around the fourth hole 89D and the fifth hole 89E to connect the fourth hole 89D and the fifth hole 89E into fluid communication, as shown in FIG. Fig.17A Both the fourth hole 89D and the fifth hole 89E are in fluid communication with the fourth fluid chamber 58DE, so that this section of the manifold 40 is isolated from the other fluid chambers 58A-58L.

[0160] In mode B or system heating mode, the different fluid circuits 22, 24, 26 are isolated from each other, such as Fig. 15B and Fig. 17B As shown. The main fluid circuit 22 is isolated from the other fluid circuits 24, 26, so that the electronic drive system 11 is heated, that is, the temperature of the lubricant in the front drive unit 12F and the rear drive unit 12R is increased, which will allow the battery 16 to be heated immediately under extremely cold conditions. The radiator fluid circuit 24 is isolated from the other fluid circuits 22, 26, thereby bypassing the radiator 14. The battery fluid circuit 26 is isolated from the other fluid circuits 22, 24, so that the battery 16 can be heated.

[0161] like Fig. 15B As shown, the coolant fluid is drawn from the coolant tank 32 through the eleventh fluid chamber 58L and pumped into the first fluid chamber 58A by the first pump 34 connected to the main fluid circuit 22. The main circuit conduit 22C is thermally connected to the DC / DC converter and the on-board charger (OBC) 13 and the controller 15 to transfer heat between the components 13, 15. The main circuit conduit 22C can be divided into sections that flow to different components 13, 15, 12F, 12R. In the illustrated embodiment, it is divided into a first main circuit conduit section 22CF, so that the main circuit conduit 22C is thermally connected to the front drive 12F, and is divided into a second main circuit conduit section 22CR, so that the main circuit conduit 22C is fluidly connected to the rear drive 12R, as shown. Fig. 15B shown.

[0162] The first main loop conduit section 22CF directs coolant fluid from the front drive 12F back to the manifold 40, and the second main loop conduit section 22CR directs coolant fluid from the rear drive 12R back to the manifold 40, as shown in FIG. Fig. 15B As shown, the first main circuit conduit section 22CF of the main fluid circuit 22 is coupled in fluid communication with the eighth fluid chamber 58I. The second main circuit conduit section 22CR of the main fluid circuit 22 is coupled in fluid communication with the ninth fluid chamber 58J.

[0163] By Fig.16A The throttle rotor first position shown in Fig. 16B The throttle rotor second position shown in Fig. 16C The throttle rotor 92 controls the flow of coolant fluid from each fluid chamber 58I, 58J through the corresponding housing bore 89I, 89J. Fig. 15B and Fig. 17B As shown, the combined flow from each hole 89I, 89J into the second valve chamber 88 then flows out of the first throttling chamber hole 89A2, passes through the connecting passage 89A, and flows into the first valve chamber 86 through the first main chamber hole 89A1.

[0164] In mode B, the main valve rotor 90 has moved to the main valve rotor second position, such as Fig. 15B and Fig. 17B In the second position of the main valve rotor, the main valve rotor 90 connects the first main chamber hole 89A1 to the sixth hole 89F, connects the second hole 89B to the third hole 89C, connects the fourth hole 89D to the fifth hole 89E, and connects the seventh hole 89G to the eighth hole 89H, as shown. Fig. 15B and Fig. 17B shown.

[0165] In the second position of the main valve rotor, the rotor through hole 94A and the cover through hole 97B are aligned with the sixth hole 89F, and the rotor through hole 94D and the cover through hole 97A are aligned with the first main chamber hole 89A1, thereby connecting the sixth hole 89F and the first main chamber hole 89A1 in fluid communication, as shown in FIG. Fig. 17B In this way, the fluid flowing through the first main cavity hole 89A1 flows through the rotor through hole 94D and the cover through hole 97A into the first valve cavity 86, and flows out of the first fluid cavity 86 through the rotor through hole 94A and the cover through hole 97B, as shown in FIG. Fig. 17B The coolant fluid in the first valve chamber 86 flows through the sixth hole 89F aligned with the rotor through hole 94A and the cover through hole 97B, flows through the fifth fluid chamber 58F in fluid communication with the sixth hole 89F, and returns to the coolant tank 32, as shown in FIG. Fig. 15B and Fig. 17BThe main valve rotor 90 is isolated from other fluid circuits 24, 26 by surrounding adjacent holes 89B, 89C, 89G, 89H with diverter housings 106B, 106A so that when the main valve rotor is in the position shown in FIG. Fig. 17B The main valve rotor is shown in the second position blocking flow to the other circuits 24 , 26 .

[0166] In the second main valve rotor position, the rotor through hole 94E is aligned with the second hole 89B, the rotor through hole 94F is aligned with the third hole 89C, and the second diverter housing 106B defining the second chamber 48B extends around the second hole 89B and the third hole 89C to connect the second hole 89B and the third hole 89C in fluid communication, as shown in FIG. Fig. 17B In this way, the coolant fluid flowing into the third fluid chamber 58C of the manifold 40 is guided back to the outside of the manifold 40 through the second fluid chamber 58B, as shown in FIG. Fig. 17B As shown by the arrows in , the radiator fluid circuit 24 is bypassed.

[0167] The second pump 36 directs the coolant fluid from the seventh fluid chamber 58H to the tenth fluid chamber 58K, which is in fluid communication with the battery fluid circuit 26, as shown in FIG. Fig. 15B The battery loop conduit 26C is in thermal communication with the battery 16 to transfer heat from the battery 16. The battery loop conduit 26C is in thermal communication with the cooler / heater 18 to remove heat from the coolant fluid when the thermal management system is in mode A. The coolant fluid flows from the battery fluid loop 26 back to the sixth fluid chamber 58G, as shown. Fig. 15B shown.

[0168] In the second position of the main valve rotor, the rotor through hole 94B is aligned with the seventh hole 89G, the rotor through hole 94C is aligned with the eighth hole 89H, and the first diverter housing 106A defining the first chamber 48A extends around the seventh hole 89G and the eighth hole 89H to connect the seventh hole 89G and the eighth hole 89H in fluid communication, as shown in FIG. Fig. 17B In this way, the coolant fluid flowing into the sixth fluid chamber 58G of the manifold 40 is guided back to the outside of the manifold 40 through the seventh fluid chamber 58H, as shown in FIG. Fig. 17B When the coolant flows only through the battery fluid circuit 26, the second pump 36 guides the coolant fluid from the seventh fluid chamber 58H to the tenth fluid chamber 58K, thereby forming a circuit.

[0169] In the second position of the main valve rotor, the rotor through hole 94G is aligned with the fourth hole 89D, the rotor through hole 94H is aligned with the fifth hole 89E, and the third diverter housing 106C defining the third chamber 95C extends around the fourth hole 89D and the fifth hole 89E to connect the fourth hole 89D and the fifth hole 89E in fluid communication, as shown in FIG. Fig. 17BBoth the fourth hole 89D and the fifth hole 89E are in fluid communication with the fourth fluid chamber 58DE, so that this section of the manifold 40 is isolated from the other fluid chambers 58A-58L.

[0170] In Mode C or the battery conditioning mode, the fluid circuits 22, 24, 26 are connected in fluid communication with each other so that the coolant fluid flows from the main fluid circuit 22 to the battery fluid circuit 26, from the battery fluid circuit 26 to the radiator fluid circuit 24, and then from the radiator fluid circuit 24 back to the main fluid circuit 22, as shown in FIG. Fig. 15C The coolant fluid is heated by the electronic drive system 11, and the heat recovered from the electronic drive system 11 can be routed to the battery 16. The battery fluid loop 26 utilizes the recovered heat to heat the battery 16 without the need to use the cooler / heater 18. The coolant fluid flows from the battery fluid loop 26 to the radiator fluid loop 24 before flowing back to the coolant tank 32.

[0171] Under more moderate heating conditions, the multi-way valve 38 allows waste heat to be recovered from the drive units 12F, 12R. The coolant fluid is mixed by the throttle rotor 92 and delivered to the battery fluid circuit 26 to heat the battery 16 without using the heater 18. This allows heater power to be saved.

[0172] like Fig. 15C As shown, the coolant fluid is drawn from the coolant tank 32 through the eleventh fluid chamber 58L and pumped into the first fluid chamber 58A by the first pump 34 connected to the main fluid circuit 22. The main circuit conduit 22C is thermally connected to the DC / DC converter and the on-board charger (OBC) 13 and the controller 15 to transfer heat between the components 13, 15. The main circuit conduit 22C can be divided into sections that flow to different components 13, 15, 12F, 12R. In the illustrated embodiment, it is divided into a first main circuit conduit section 22CF, so that the main circuit conduit 22C is thermally connected to the front drive 12F, and is divided into a second main circuit conduit section 22CR, so that the main circuit conduit 22C is fluidly connected to the rear drive 12R, as shown. Fig. 15B shown.

[0173] like Fig. 15C As shown, the first main loop conduit section 22CF guides the coolant fluid from the front drive 12F back to the manifold 40, and the second main loop conduit section 22CR guides the coolant fluid from the rear drive 12R back to the manifold 40. The first main loop conduit section 22CF of the main fluid circuit 22 is coupled in fluid communication with the eighth fluid chamber 58I. The second main loop conduit section 22CR of the main fluid circuit 22 is coupled in fluid communication with the ninth fluid chamber 58J.

[0174] By Fig.16AThe throttle rotor first position shown in Fig. 16B The throttle rotor second position shown in Fig. 16C The throttle rotor 92 controls the flow of coolant fluid from each fluid chamber 58I, 58J through the corresponding housing bore 89I, 89J. Fig. 15C and Fig. 17C As shown, the combined flow from each hole 89I, 89J into the second valve chamber 88 then flows out of the first throttling chamber hole 89A2, passes through the connecting passage 89A, and flows into the first valve chamber 86 through the first main chamber hole 89A1.

[0175] In mode C, the main valve rotor 90 has moved to the main valve rotor third position, such as Fig. 15C and 17C In the third position of the main valve rotor, the main valve rotor 90 connects the first main chamber hole 89A1 to the eighth hole 89H, connects the second hole 89B to the seventh hole 89G, connects the third hole 89C to the fourth hole 89D, and connects the fifth hole 89E to the sixth hole 89F, as shown. Fig. 15C and Fig. 17C shown.

[0176] In the third position of the main valve rotor, the rotor through hole 94B is aligned with the eighth hole 89H, the rotor through hole 94C is aligned with the first main chamber hole 89A1, and the first diverter housing 106A defining the first chamber 95A extends around the eighth hole 89H and the first main chamber hole 89A1 to connect the eighth hole 89H and the first main chamber hole 89A1 in fluid communication, as shown in FIG17. In this manner, the fluid flowing through the first main chamber hole 89A1 flows into the first chamber 95A defined by the first diverter housing 106A, which guides the fluid flowing through the eighth hole 89H, as shown in FIG17. Fig. 15C and Fig. 17C The fluid flowing through the first main cavity hole 89A1 flows into the first chamber 95A defined by the first diverter housing 106A, and flows out through the eighth hole 89H, as shown. Fig. 17C As shown by the arrow in . The fluid flows into the seventh fluid chamber 58H, and the seventh fluid chamber 58H is connected to the eighth housing hole 89H in fluid communication.

[0177] The second pump 36 directs the coolant fluid from the seventh fluid chamber 58H to the tenth fluid chamber 58K, which is in fluid communication with the battery fluid circuit 26, as shown in FIG. Fig. 15C The battery loop conduit 26C is in thermal communication with the battery 16 to transfer recovered heat from the electronic drive system 11 to the battery 16, thereby heating the battery 16 in mode C. The coolant fluid flows from the battery fluid loop 26 back to the sixth fluid chamber 58G, as shown in FIG. Fig. 15C shown.

[0178] In the third position of the main valve rotor, the rotor through hole 94A and the cover through hole 97B are aligned with the seventh hole 89G, and the rotor through hole 94D and the cover through hole 97A are aligned with the second hole 89B, thereby connecting the seventh hole 89G and the second hole 89B fluidly. Fig. 17C In this way, the fluid flowing through the seventh hole 89G flows into the first valve chamber 86 through the rotor through hole 94A and the cover through hole 97B, and flows out of the first fluid chamber 86 through the rotor through hole 94D and the cover through hole 97A, as shown in FIG. Fig. 17C As shown by the arrow in Fig. 15C and Fig. 17C As shown, coolant fluid in the first valve chamber 86 flows through the second aperture 89B aligned with the rotor through-hole 94D and the cover through-hole 97A, and flows through the second fluid chamber 58B in fluid communication with the radiator fluid circuit 24 .

[0179] In the third position of the main valve rotor, the rotor through hole 94E is aligned with the third hole 89C, the rotor through hole 94F is aligned with the fourth hole 89D, and the second diverter housing 106B defining the second chamber 95B extends around the third hole 89C and the fourth hole 89D to connect the third hole 89C and the fourth hole 89D in fluid communication, as shown in FIG. Fig. 17C In this manner, the coolant fluid returning from the radiator fluid circuit 24 flows into the third fluid chamber 58C, passes through the third hole 89C, and flows into the second chamber 95B defined by the diverter housing 106B, which directs the fluid to the fourth hole 89D, as shown. Fig. 17C As shown by the arrow in FIG. The fluid flowing out through the fourth hole 89D flows into the fourth fluid chamber 58DE, and the fourth fluid chamber 58DE is fluidically connected with the fifth hole 89E, so that the coolant fluid flows back to the multi-way valve 38 through the fifth hole 89E, as shown in FIG. Fig. 15C and Fig. 17C shown.

[0180] In the main valve rotor third position, the rotor through hole 94G is aligned with the fifth hole 89E, the rotor through hole 94H is aligned with the sixth hole 89F, and the third diverter housing 106C defining the third chamber 95C extends around the fifth hole 89E and the sixth hole 89F to connect the fifth hole 89E and the sixth hole 89F in fluid communication, as shown in FIG. Fig. 17C In this way, the coolant fluid flowing into the third chamber 95C defined by the third diverter housing 106C flows to the sixth hole 89F to flow back to the coolant tank 32 through the fifth fluid chamber 58F, as shown. Fig. 15C and Fig. 17C As indicated by the arrow in .

[0181] In Mode D or the system cooling mode, the fluid circuits 22, 24, 26 are connected in fluid communication with each other so that the coolant fluid flows from the main fluid circuit 22 to the radiator fluid circuit 24, from the radiator fluid circuit 24 to the battery fluid circuit 26, and then from the battery fluid circuit 26 back to the main fluid circuit 22, as shown in FIG. Fig.15D As shown. The coolant fluid is heated by the electronic drive system 11, and the heat recovered from the electronic drive system 11 is discharged through the radiator 14 to cool the coolant fluid before flowing to the battery fluid loop 26. The coolant fluid flows through the battery fluid loop 26 to cool the battery 16, thereby saving power for the cooler 18. Under more moderate cooling conditions, both the battery 16 and the drive units 12F, 12R of the electronic drive system 11 only utilize the radiator 14 to maintain thermal control, which allows for saving cooler power.

[0182] In mode D, the main valve rotor 90 has moved to the main valve rotor fourth position, as shown in FIG. Fig.15D and Fig.17D In the fourth position of the main valve rotor, the main valve rotor 90 connects the first main chamber hole 89A1 to the second hole 89B, connects the third hole 89C to the eighth hole 89H, connects the fourth hole 89D to the fifth hole 89E, and connects the sixth hole 89F to the seventh hole 89G, as shown in FIG. Fig.15D and Fig.17D shown.

[0183] like Fig.15D As shown, the coolant fluid is drawn from the coolant tank 32 through the eleventh fluid chamber 58L and pumped into the first fluid chamber 58A by the first pump 34 connected to the main fluid circuit 22. The main circuit conduit 22C is thermally connected to the DC / DC converter and the on-board charger (OBC) 13 and the controller 15 to transfer heat between the components 13, 15. The main circuit conduit 22C can be divided into sections that flow to different components 13, 15, 12F, 12R. In the illustrated embodiment, it is divided into a first main circuit conduit section 22CF, so that the main circuit conduit 22C is thermally connected to the front drive 12F, and is divided into a second main circuit conduit section 22CR, so that the main circuit conduit 22C is fluidly connected to the rear drive 12R, as shown. Fig.15D shown.

[0184] like Fig.15D As shown, the first main loop conduit section 22CF guides the coolant fluid from the front drive 12F back to the manifold 40, and the second main loop conduit section 22CR guides the coolant fluid from the rear drive 12R back to the manifold 40. The first main loop conduit section 22CF of the main fluid circuit 22 is coupled in fluid communication with the eighth fluid chamber 58I. The second main loop conduit section 22CR of the main fluid circuit 22 is in fluid communication with the ninth fluid chamber 58J.

[0185] By Fig.16A The throttle rotor first position shown in Fig. 16B The throttle rotor second position shown in Fig. 16C The throttle rotor 92 controls the flow of coolant fluid from each fluid chamber 58I, 58J through the corresponding housing bore 89I, 89J. Fig.15D and Fig.17D As shown, the combined flow from each hole 89I, 89J into the second valve chamber 88 then flows out of the first throttle valve chamber hole 89A2, passes through the connecting passage 89A, and flows into the first valve chamber 86 through the first main chamber hole 89A1.

[0186] In the fourth position of the main valve rotor, the rotor through hole 94B is aligned with the first main cavity hole 89A1, the rotor through hole 94C is aligned with the second hole 89B, and the first diverter housing 106A defining the first chamber 95A extends around the first main cavity hole 89A1 and the second hole 89B to connect the first main cavity hole 89A1 and the second hole 89B in fluid communication, as shown in Figure 17. In this way, the fluid flowing through the first main cavity hole 89A1 flows into the first chamber 95A defined by the first diverter housing 106A, which guides the fluid to flow through the second hole 89B, as shown in Figure 17. Fig.15D and Fig.17D The fluid flowing through the first main cavity hole 89A1 flows into the first chamber 95A defined by the first diverter housing 106A, and flows out through the second hole 89B, as shown. Fig.17D As shown by the arrow in , the fluid flows into the second fluid chamber 58B which is connected to the second housing hole 89B in fluid communication.

[0187] The coolant fluid flows from the second fluid chamber 58B to the radiator fluid circuit 24 and returns to the manifold 40 through the third fluid chamber 58C. Fig.15D In the fourth position of the main valve rotor, the rotor through hole 94A and the cover through hole 97B are aligned with the eighth hole 89H, while the rotor through hole 94D and the cover through hole 97A are aligned with the third hole 89C, thereby connecting the eighth hole 89H and the third hole 89C in fluid communication, as shown in FIG. Fig.17D In this way, the fluid flowing through the third hole 89C flows into the first valve chamber 86 through the rotor through hole 94D and the cover through hole 97A, and flows out of the first fluid chamber 86 through the rotor through hole 94A and the cover through hole 97B, as shown in FIG. Fig.17D As shown by the arrow in Fig.15D and Fig.17D As shown, the coolant fluid in the first valve chamber 86 flows through the eighth hole 89H aligned with the rotor through hole 94A and the cover through hole 97B, and flows through the seventh fluid chamber 58H in fluid communication with the battery fluid circuit 26.

[0188] The coolant fluid flows through the battery fluid circuit 26 and returns to the manifold 40 through the sixth fluid cavity 58G. Fig.15D As shown. The sixth fluid chamber 58G is in fluid communication with the seventh housing hole 89G, so that the fluid flowing through the sixth fluid chamber 58G flows through the seventh housing hole 89G of the multi-way valve 38. In the fourth position of the main valve rotor, the rotor through hole 94G is aligned with the sixth hole 89F, the rotor through hole 94H is aligned with the seventh hole 89G, and the third diverter housing 106C defining the third chamber 95C extends around the sixth hole 89F and the seventh hole 89G to connect the sixth hole 89F and the seventh hole 89G in fluid communication, as shown. Fig.17D In this way, the fluid flowing through the seventh hole 89G flows into the third chamber 95C of the third diverter housing 106C, and the third chamber 95C guides the fluid to flow through the sixth hole 89F, as shown. Fig.17D As shown by the arrow in FIG. 8 . The coolant fluid flows to the sixth hole 89F to flow back to the coolant tank 32 through the fifth fluid chamber 58F. Fig.15D and Fig.17D As indicated by the arrow in .

[0189] In the fourth position of the main valve rotor, the rotor through hole 94E is aligned with the fourth hole 89D, the rotor through hole 94F is aligned with the fifth hole 89E, and the second diverter housing 106B defining the second chamber 95B extends around the fourth hole 89D and the fifth hole 89E to connect the fourth hole 89D and the fifth hole 89E in fluid communication, as shown in FIG. Fig.17D Both the fourth hole 89D and the fifth hole 89E are in fluid communication with the fourth fluid chamber 58DE, so that this section of the manifold 40 is isolated from the other fluid chambers 58A-58L.

[0190] In some embodiments, the main valve rotor 90 can be in another suitable position to achieve the desired position of the flow path in different modes. For example, in some embodiments, when the thermal management system 20 is in Fig.17E The main valve rotor 90 may be in the fifth main valve rotor position when shown in mode D. When the main valve rotor 90 is in different positions, the same flow paths to the different circuits 22, 24, 26 are achieved, but the flow paths through the main valve rotor 90 are slightly different.

[0191] In the fifth position of the main valve rotor, the main valve rotor 90 connects the first main chamber hole 89A1 to the second hole 89B, the third hole 89C to the fourth hole 89D, the fifth hole 89E to the eighth hole 89H, and the sixth hole 89F to the seventh hole 89G, as shown in FIG. Fig.17E In the fifth position of the main valve rotor, the coolant fluid flows through the fourth hole 89D and the fifth hole 89E, using the fourth fluid cavity 58DE as part of the fluid flow path.

[0192] In the fifth position of the main valve rotor, the rotor through hole 94E is aligned with the first main cavity hole 89A1, the rotor through hole 94F is aligned with the second hole 89B, and the second diverter housing 106B defining the second chamber 95B extends around the first main cavity hole 89A1 and the second hole 89B to connect the first main cavity hole 89A1 and the second hole 89B in fluid communication, as shown in Figure 17. In this way, the fluid flowing through the first main cavity hole 89A1 flows into the second chamber 95B defined by the second diverter housing 106B, which guides the flow of the fluid through the second hole 89B, as shown in Figure 17. Fig.17E The fluid flowing through the first main cavity hole 89A1 flows into the second cavity 95B defined by the second diverter housing 106B, and flows out through the second hole 89B, as shown in FIG. Fig.17E As shown by the arrow in , the fluid flows into the second fluid chamber 58B which is connected to the second housing hole 89B in fluid communication.

[0193] The coolant fluid flows from the second fluid chamber 58B to the radiator fluid circuit 24 and returns to the manifold 40 through the third fluid circuit 58C. Fig.15D In the fifth position of the main valve rotor, the rotor through hole 94G is aligned with the third hole 89C, the rotor through hole 94H is aligned with the fourth hole 89D, and the third diverter housing 106C defining the third chamber 95C extends around the third hole 89C and the fourth hole 89D to connect the third hole 89C and the fourth hole 89D in fluid communication, as shown in FIG. Fig.17E As shown. The coolant fluid returning from the radiator fluid circuit 24 flows through the third fluid chamber 58C, passes through the third hole 89C, and enters the third chamber 95C defined by the third diverter shell 106C. The fluid flowing through the third hole 89C flows into the third chamber 95C defined by the third diverter shell 106C, and the third chamber 95C guides the fluid to flow out through the fourth hole 89D, as shown. Fig.17E As shown by the arrow in FIG. The fluid flowing out through the fourth hole 89D flows into the fourth fluid chamber 58DE, and the fourth fluid chamber 58DE is fluidically connected with the fifth hole 89E, so that the coolant fluid flows back to the multi-way valve 38 through the fifth hole 89E, as shown in FIG. Fig.17E shown.

[0194] In the fifth position of the main valve rotor, the rotor through hole 94A and the cover through hole 97B are aligned with the fifth hole 89E, and the rotor through hole 94D and the cover through hole 97A are aligned with the eighth hole 89H, so as to connect the fifth hole 89E and the eighth hole 89H in fluid communication, as shown in FIG. Fig.17E In this way, the fluid flowing through the fifth hole 89E flows through the rotor through hole 94A and the cover through hole 97B into the first valve chamber 86, and flows out of the first fluid chamber 86 through the rotor through hole 94D and the cover through hole 97A, as shown in FIG. Fig.17EAs shown by the arrow in the figure. The coolant fluid in the first valve chamber 86 flows through the eighth hole 89H aligned with the rotor through hole 94D and the cover through hole 97A, and flows through the seventh fluid chamber 58H connected to the battery fluid circuit 26, as shown in FIG. Fig.17E shown.

[0195] The coolant fluid flows through the battery fluid circuit 26 and returns to the manifold 40 through the sixth fluid cavity 58G. Fig.15D As shown. The sixth fluid chamber 58G is in fluid communication with the seventh housing hole 89G, so that the fluid flowing through the sixth fluid chamber 58G flows through the seventh housing hole 89G of the multi-way valve 38. In the fifth position of the main valve rotor, the rotor through hole 94B is aligned with the sixth hole 89F, the rotor through hole 94C is aligned with the seventh hole 89G, and the first diverter housing 106A defining the first chamber 95A extends around the sixth hole 89F and the seventh hole 89G to connect the sixth hole 89F and the seventh hole 89G in fluid communication, as shown. Fig.17E The coolant fluid flows to the sixth hole 89F to flow back to the coolant tank 32 through the fifth fluid chamber 58F, as shown. Fig.15D and Fig.17D As indicated by the arrow in .

Claims

1. A thermal management system suitable for use in a vehicle, characterized in that: The thermal management system comprises: a primary fluid circuit including a main conduit configured to direct a coolant fluid therethrough and adapted to be in thermal communication with front and rear drives included in the vehicle to transfer heat between the front and rear drives and the coolant fluid, a radiator fluid circuit including a radiator circuit conduit configured to direct the coolant fluid therethrough and adapted to be in thermal communication with a radiator included in the vehicle to transfer heat between the radiator and the coolant fluid, a battery fluid loop comprising a battery loop conduit configured to direct the coolant fluid therethrough and adapted to be in thermal communication with a battery included in the vehicle to transfer heat between the battery and the coolant fluid, and a heat exchanger in fluid communication with the battery loop conduit to transfer heat between the coolant fluid and a fluid in the heat exchanger, and 1. An integrated coolant controller, comprising: a coolant tank formed to define a coolant reservoir configured to store the coolant fluid; a first pump configured to pump the coolant fluid from the coolant tank through the flow of the main fluid circuit; a second pump configured to pump the coolant fluid through the flow of the battery fluid circuit; a multi-way valve configured to control the flow of the coolant fluid through the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit; and a manifold coupled to the coolant tank, the first pump and the second pump, and each of the multi-way valves to integrate the coolant tank, the first pump and the second pump, and the multi-way valve so that the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit flow through the manifold to eliminate piping between the coolant tank, the first pump and the second pump, and the multi-way valve, and reduce the amount of power used by the pumps to supply the coolant fluid through different fluid circuits.

2. The thermal management system according to claim 1, wherein: The manifold includes a manifold body shaped to define a plurality of fluid chambers and a plurality of tubes, each of the plurality of tubes extending from the manifold body, wherein each of the plurality of tubes defines a tube channel, the tube channel being in fluid communication with one of the plurality of fluid chambers and the main conduit of the main fluid circuit, the radiator circuit conduit of the radiator fluid circuit, and the battery circuit conduit of the battery fluid circuit.

3. The thermal management system according to claim 2, wherein: The manifold is shaped to include a plurality of temperature sensor interfaces each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid chambers to measure a temperature of the coolant fluid.

4. The thermal management system according to claim 2, wherein: The manifold includes a tank interface configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes a top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with tank ports on the manifold.

5. The thermal management system according to claim 4, wherein: The coolant tank is welded to the tank-butting portion of the manifold.

6. The thermal management system according to claim 2, wherein: The manifold includes a first pump interface configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and such that an outlet of the first pump is connected in fluid communication with the main fluid circuit.

7. The thermal management system according to claim 2, wherein: The manifold also includes a second pump dock configured to receive the second pump to mount the second pump on the manifold such that an inlet of the second pump is connected in fluid communication with the multi-way valve and such that an outlet of the second pump is connected in fluid communication with a battery fluid circuit.

8. The thermal management system according to claim 2, wherein: The manifold includes a valve interface configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold, and wherein each of the valve ports is in fluid communication with one of the plurality of fluid chambers.

9. The thermal management system according to claim 1, wherein: The coolant tank is integrally formed with the manifold such that the coolant tank and the manifold are a one-piece assembly.

10. The thermal management system according to claim 1, wherein: The manifold comprises: a tank docking portion configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes the top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with a tank port on the manifold, a first pump dock configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and such that an outlet of the first pump is connected in fluid communication with the primary fluid circuit, a second pump dock configured to receive the second pump to mount the second pump on the manifold such that an inlet of the second pump is connected in fluid communication with the multi-way valve and such that an outlet of the second pump is connected in fluid communication with the battery fluid circuit, and The valve interface is configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold.

11. The thermal management system according to claim 10, wherein: The manifold includes an upper body section and a lower body section, the lower body section being independent from and coupled to the upper body section, wherein the upper body section of the manifold defines the tank interface and the first pump interface, and wherein the lower body section of the manifold defines the second pump interface and the valve interface.

12. A thermal management system suitable for use in a vehicle, characterized in that: The thermal management system comprises: a plurality of fluid circuits, each of the plurality of fluid circuits comprising a conduit configured to direct a coolant fluid therethrough, and Integrated coolant controller, including: a coolant tank formed to define a coolant reservoir configured to store said coolant fluid, a first pump configured to pump coolant fluid from the coolant tank through the plurality of fluid circuits, a multi-way valve configured to control the flow of the coolant fluid through the plurality of fluid circuits, and a manifold coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate the coolant tank, the first pump, and the multi-way valve so that each of the plurality of fluid circuits flows through the manifold to eliminate piping between the coolant tank, the first pump, and the multi-way valve and to reduce an amount of power used by the first pump to supply the coolant fluid through different fluid circuits.

13. The thermal management system according to claim 12, wherein: The manifold includes a manifold body shaped to define a plurality of fluid chambers and a plurality of tubes each extending from the manifold body, wherein each of the plurality of tubes defines a tube channel in fluid communication with a conduit included in one of the plurality of fluid chambers and one of the plurality of fluid circuits.

14. The thermal management system according to claim 13, wherein: The manifold is shaped to include a plurality of temperature sensor interfaces each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid chambers to measure a temperature of the coolant fluid.

15. The thermal management system of claim 13, wherein: The manifold includes a tank interface configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes a top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with tank ports on the manifold.

16. The thermal management system of claim 15, wherein: The coolant tank is welded to the tank-butting portion of the manifold.

17. The thermal management system of claim 13, wherein: The manifold includes a first pump interface configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and such that an outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits.

18. The thermal management system of claim 13, wherein: The manifold includes a valve interface configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold, and wherein each of the valve ports is in fluid communication with one of the plurality of fluid chambers.

19. The thermal management system of claim 12, wherein: The coolant tank is integrally formed with the manifold such that the coolant tank and the manifold are a one-piece assembly.

20. The thermal management system of claim 12, wherein: The manifold comprises: a tank docking portion configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes the top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with a tank port on the manifold, a first pump dock configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and such that an outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits, and The valve interface is configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold.

21. An integrated coolant controller suitable for use in a thermal management system, characterized in that: The integrated coolant controller comprises: a coolant tank formed to define a coolant reservoir configured to store a coolant fluid, a first pump configured to pump the coolant fluid through the thermal management system, a multi-way valve configured to control the flow of the coolant fluid to different thermal fluid circuits of the thermal management system, and a manifold coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate a coolant reservoir of the coolant tank, the first pump, and the multi-way valve in fluid communication with each other to eliminate piping between the coolant tank, the first pump, and the multi-way valve and reduce an amount of power used by the first pump to supply the coolant fluid through different fluid circuits of the thermal management system.

22. The integrated coolant controller of claim 21, wherein: The manifold includes a manifold body shaped to define a plurality of fluid chambers and a plurality of tubes each extending from the manifold body, wherein each of the plurality of tubes defines a tube channel in fluid communication with one of the plurality of fluid chambers and the different fluid circuit.

23. The integrated coolant controller of claim 21, wherein: The manifold is shaped to include a plurality of temperature sensor interfaces each adapted to receive a temperature sensor to mount the temperature sensor in fluid communication with the coolant fluid to measure a temperature of the coolant fluid.

24. The integrated coolant controller of claim 21, wherein: The manifold includes a tank interface configured to receive the coolant tank to mount the coolant tank on the manifold such that the coolant tank closes a top opening of the manifold and such that an inlet port and an outlet port included in the coolant tank are aligned with tank ports on the manifold.

25. The integrated coolant controller of claim 21, wherein: The manifold includes a first pump interface configured to receive the first pump to mount the first pump on the manifold such that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and such that an outlet of the first pump is connected in fluid communication with one of the different fluid circuits.

26. The integrated coolant controller of claim 21, wherein: The manifold includes a valve interface configured to receive the multi-way valve to mount the multi-way valve on the manifold such that a plurality of holes included in the multi-way valve are aligned with valve ports on the manifold.

27. The integrated coolant controller of claim 21, wherein: The integrated coolant controller also includes a second pump configured to pump the coolant fluid to a different thermal fluid circuit of the thermal management system, and wherein the manifold is coupled to the second pump so that the second pump is integrated in fluid communication with the coolant tank, the first pump, and the multi-way valve.

28. The integrated coolant controller of claim 27, wherein: The manifold includes a second pump interface configured to receive the second pump to mount the second pump on the manifold such that an inlet of the second pump is connected in fluid communication with the multi-way valve and such that an outlet of the second pump is connected in fluid communication with one of the different fluid circuits.

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