Heat management device and heat management system

Abstract

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

Description

[0001] Cross-references to related applications

[0002] This application claims priority and all benefits to U.S. Provisional Patent Application No. 63 / 562771, filed March 8, 2024. Technical Field

[0003] This disclosure generally relates to thermal management devices, thermal management systems, and methods for operating thermal management systems for hybrid and electric vehicles. Background Technology

[0004] Compared to traditional internal combustion engine vehicles, hybrid and electric vehicles have different thermal management requirements. Specifically, neither hybrid nor electric vehicles have an "always-on" internal combustion engine that continuously supplies heat for thermal management purposes. Furthermore, the optimized performance, durability, and safety of key components in hybrid and electric vehicles, such as the battery and electric motor, depend on operating temperatures. Current thermal management systems for hybrid and electric vehicles typically utilize electric heaters to heat working fluids (such as coolant) to assist in thermal management operations such as heating the passenger cabin and regulating battery temperature. However, these thermal management systems often lack the ability to independently control the temperature of multiple fluids or require an undesirable number of components to do so. Therefore, there remains a need for improved thermal management components and systems for hybrid and electric vehicles. Utility Model Content

[0005] One general aspect of the disclosure relates to a heat management device. The heat management device includes a manifold defining a first manifold flow path and a second manifold flow path. The first manifold flow path is configured to direct a first working fluid. The second manifold flow path is configured to direct a second working fluid. The second manifold flow path is not in fluid communication with the first manifold flow path. The heat management device also includes a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path. The first heating element is configured to generate heat in response to being energized to heat the first working fluid as the first working fluid flows through the first manifold flow path. The heat management device also includes a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path. The second heating element is configured to generate heat in response to being energized to heat the second working fluid as the second working fluid flows through the second manifold flow path. The second heating element is operable independently of the first heating element. The heat management device further includes a heat exchanger operatively attached to the manifold. The heat exchanger defines a first heat exchanger flow path in fluid communication with the first manifold flow path and a second heat exchanger flow path in fluid communication with the second manifold flow path. The first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid.

[0006] Another general aspect of the present disclosure relates to a heat management system. The heat management system includes a first fluid circuit for circulating a first working fluid, a second fluid circuit for circulating a second working fluid, and a manifold defining a first manifold flow path and a second manifold flow path. The first manifold flow path is in fluid communication with the first fluid circuit for directing the first working fluid. The second manifold flow path is in fluid communication with the second fluid circuit for directing the second working fluid. The second manifold flow path is not in fluid communication with the first manifold flow path. The heat management system further includes a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path for heating the first working fluid as it flows through the first manifold flow path. The heat management system further includes a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path for heating the second working fluid as it flows through the second manifold flow path. The second heating element is operable independently of the first heating element. The heat management system further includes a heat exchanger defining a first heat exchanger flow path interposed in fluid communication between the first manifold flow path and the first fluid circuit to facilitate flow of the first working fluid therebetween and a second heat exchanger flow path interposed in fluid communication between the second manifold flow path and the second fluid circuit to facilitate flow of the second working fluid therebetween. The first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with one another to facilitate heat transfer between the first working fluid and the second working fluid.

[0007] Another general aspect of the disclosure relates to a method of operating a heat management system, the heat management system including a manifold defining a first manifold flow path configured to direct a first working fluid and a second manifold flow path configured to direct a second working fluid, a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path to heat the first working fluid as the first working fluid flows through the first manifold flow path, a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path to heat the second working fluid as the second working fluid flows through the second manifold flow path, and a heat exchanger operatively attached to the manifold and defining a first heat exchanger flow path in fluid communication with the first manifold flow path and a second heat exchanger flow path in fluid communication with the second manifold flow path, wherein the first heat exchanger flow path and the second heat exchanger flow path are arranged in thermal communication with each other to facilitate heat transfer between the first working fluid and the second working fluid. The method includes circulating the first working fluid in one of a first direction and a second direction opposite the first direction through the first manifold flow path and the first heat exchanger flow path. The method also includes circulating the second working fluid in one of a third direction and a fourth direction opposite the third direction through the second manifold flow path and the second heat exchanger flow path. The method further includes operating the heat management system in a first operating mode in response to the first working fluid being circulated in the first direction and the second working fluid being circulated in the third direction, and operating the heat management system in a second operating mode in response to the first working fluid being circulated in the second direction and the second working fluid being circulated in the fourth direction. The step of operating the heat management system in the first operating mode includes operating the first heating element to heat the first working fluid, directing the first working fluid heated by the first heating element from the first manifold flow path through the first heat exchanger flow path, directing the second working fluid through the second heat exchanger flow path such that the first working fluid transfers heat to the second working fluid, and through the second manifold flow path, and operating the second heating element to further heat the second working fluid. The step of operating the heat management system in the second operating mode includes operating the second heating element to heat the second working fluid, directing the second working fluid heated by the second heating element from the second manifold flow path through the second heat exchanger flow path, directing the first working fluid through the first heat exchanger flow path such that the second working fluid transfers heat to the first working fluid, and through the second manifold flow path, and operating the first heating element to further heat the first working fluid.

[0008] Advantageously, based on the direction of the flow of the first working fluid and / or the second working fluid, the activation of the first heating element and / or the second heating element, and the heat transfer achieved by the heat exchanger between the first working fluid and the second working fluid, the heat management device / system according to the present disclosure acts to selectively prioritize heating one of the first working fluid and the second working fluid over the other of the first working fluid and the second working fluid. BRIEF DESCRIPTION OF DRAWINGS

[0009] Other advantages of the present disclosure will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0010] Figure 1 is a top perspective view of one example of a heat management device according to the present disclosure.

[0011] Figure 2 is a partial schematic exploded view of the heat management device of Figure 1

[0012] Figure 3 is a top perspective view of another example of a heat management device according to the present disclosure.

[0013] Figure 4 is a partial schematic exploded view of the heat management device of Figure 3

[0014] Figure 5 is a top perspective view of yet another example of a heat management device according to the present disclosure.

[0015] Figure 6 is a top perspective view of a manifold of the heat management device of Figure 5

[0016] Figure 7 is a cross-sectional view of the manifold of Figure 6

[0017] Figure 8 is a partial schematic exploded view of the heat management device of Figure 5

[0018] Figure 9 is a schematic view of a heat management system according to the present disclosure operating in a first mode of operation.

[0019] Figure 10 is a schematic view of the heat management system of Figure 9 operating in a second mode of operation.

[0020] Figure 11 is a schematic view of one embodiment of a heat management system according to the present disclosure operating in a first mode of operation.​​​​​

[0021] Figure 12 is operating in a second operating mode Figure 11 is a schematic view of a heat management system.

[0022] Figure 13 is a flowchart illustrating a method of operating a heat management system according to the present disclosure.

[0023] Figure 14 is a flowchart illustrating steps of operating a heat management system in a first operating mode.

[0024] Figure 15 is a flowchart illustrating steps of operating a heat management system in a second operating mode. DETAILED DESCRIPTION

[0025] Referring to the drawings, wherein like numerals indicate like components throughout the several views, Figures 1-8 various examples of a heat management device 50 according to the present disclosure are generally shown.

[0026] In each of the examples of Figures 1-8 the heat management device 50 includes a manifold 54. The manifold 54 defines a first manifold flow path 58 configured to direct a first working fluid WFl and a second manifold flow path 62 configured to direct a second working fluid WF2.

[0027] The first manifold flow path 58 can extend between a first port 58A and a second port 58B such that the first manifold flow path 58 is configured to direct the first working fluid WFl between the first port 58A and the second port 58B. It should be appreciated that in this context, the phrase “between the first port 58A and the second port 58B” is not limiting in direction. For example, the first working fluid WFl can flow from the first port 58A to the second port 58B, or from the second port 58B to the first port 58A. The second manifold flow path 62 can extend between a third port 62A and a fourth port 62B such that the second manifold flow path 62 is configured to direct the second working fluid WF2 between the third port 62A and the fourth port 62B. Similar to above, it should be appreciated that in this context, the phrase “between the third port 62A and the fourth port 62B” is not limiting in direction. For example, the second working fluid WF2 can flow from the third port 62A to the fourth port 62B, or from the fourth port 62B to the third port 62A. It should also be appreciated that the second manifold flow path 62 is not in fluid communication with the first manifold flow path 58.

[0028] The composition of the first working fluid WF1 and the second working fluid WF2 is not particularly limited for the purposes of the present disclosure. In some examples, the first working fluid WF1 and the second working fluid WF2 are the same composition, but in other examples, the first working fluid WF1 and the second working fluid WF2 are different compositions. The first working fluid WF1 and / or the second working fluid WF2 can be a cooling fluid suitable for use in vehicle applications, such as water, ethylene glycol, propylene glycol, etc. The first working fluid WF1 and / or the second working fluid WF2 can also be a refrigerant suitable for use in vehicle applications, such as 1,1,1,2-tetrafluoroethane (also known as R-134a), 2,3,3,3-tetrafluoropropene (also known as R1234yf), etc.

[0029] The construction of the manifold 54 is not particularly limited for the purposes of the present disclosure. From a materials perspective, the manifold 54 can be made from any suitable material that is compatible with the first working fluid WF1 and the second working fluid WF2, as well as their operating temperatures. For example, the manifold 54 can be made from a metal / metal alloy (such as steel, aluminum, etc.) or a plastic / composite material. Similarly, the shape of the manifold 54 is not particularly limited for the purposes of the present disclosure. Any shape / dimensions suitable for defining the first manifold flow path 58 and the second manifold flow path 62 are contemplated. In certain examples, the first manifold flow path 58 and the second manifold flow path 62 can have the same shape / dimensions, but in other constructions, the first manifold flow path 58 and the second manifold flow path 62 can have different shapes / dimensions. Example constructions of the manifold 54 are described in further detail below.

[0030] With continued reference to Figures 1-8 The heat management device 50 also includes a first heating element 66 and a second heating element 70. The first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58. Thus, the first heating element 66 is configured to generate heat in response to being energized to heat the first working fluid WF1 as the first working fluid WF1 flows through the first manifold flow path 58 of the manifold 54. The second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62. Thus, the second heating element 70 is configured to generate heat in response to being energized to heat the second working fluid WF2 as the second working fluid WF2 flows through the second manifold flow path 62 of the manifold 54.

[0031] The first heating element 66 and the second heating element 70 can be independently operable. In other words, the first heating element 66 can be energized without energizing the second heating element 70, the second heating element 70 can be energized without energizing the first heating element 66, or the first heating element 66 and the second heating element 70 can be simultaneously energized, etc. The independent operability of the first heating element 66 and the second heating element 70 permits the heat management device 50 to independently regulate the temperature of the first working fluid WF1 and the second working fluid WF2.

[0032] The first heating element 66 and the second heating element 70 are typically electrical heating elements, such as resistive heaters. The first heating element 66 and / or the second heating element 70 can be tube / jacket resistive heating elements, coil resistive heating elements, screen-printed resistive heating elements, thermal spray resistive heating elements, positive temperature coefficient (PTC) heating elements, etc., as well as combinations thereof. The first heating element 66 and / or the second heating element 70 can operate at high voltages, such as voltages typically associated with electric vehicle battery architectures (e.g., 400 volts, 800 volts, etc.). The arrangement of the first heating element 66 and the second heating element 70 relative to the first manifold flow path 58 and the second manifold flow path 62, respectively, is not necessarily limited for purposes of the present disclosure. In certain configurations, the first heating element 66 and / or the second heating element 70 are disposed within the first manifold flow path 58 and the second manifold flow path 62, respectively. In other examples, the first heating element 66 and / or the second heating element 70 are disposed on the manifold 54 (e.g., on a surface of the manifold 54), but are still in thermal communication with the first manifold flow path 58 and the second manifold flow path 62, respectively. Other configurations and arrangements of the first heating element 66 and the second heating element 70 are contemplated.

[0033] The heat management device 50 can also include a control module 74 in communication with the first heating element 66 and the second heating element 70 to energize the first heating element 66 and the second heating element 70 to heat the first working fluid WF1 and the second working fluid WF2, respectively. In Figures 1-8 In configurations, the control module 74 is coupled to, or integrated within, the manifold 54. In these examples, the control module 74 includes a plurality of connection ports for power / communication purposes (e.g., to connect the control module 74 to a wiring harness of a vehicle or system-level controller 144, described below). However, it is contemplated that in other examples, the hardware for energizing the first heating element 66 and the second heating element 70 can be positioned away from the heat management device 50 (e.g., within a separate electrical module of the vehicle).

[0034] Still referring to Figures 1-8The heat management device 50 further includes a heat exchanger 78 operatively attached to the manifold 54. The heat exchanger 78 defines a first heat exchanger flow path 82 and a second heat exchanger flow path 86. The first heat exchanger flow path 82 is in fluid communication with the first manifold flow path 58 (e.g., via at least one of the first and second ports 58A, 58B) such that the first heat exchanger flow path 82 is configured to direct the first working fluid WF1 therethrough. The second heat exchanger flow path 86 is in fluid communication with the second manifold flow path 62 (e.g., via at least one of the third and fourth ports 62A, 62B) such that the second heat exchanger flow path 86 is configured to direct the second working fluid WF2 therethrough. As described in further detail below, the first manifold flow path 58 and the first heat exchanger flow path 82 are configured to direct the first working fluid WF1 in a first direction D1 and a second direction D2 opposite the first direction D1, and the second manifold flow path 62 and the second heat exchanger flow path 86 are configured to direct the second working fluid WF2 in a third direction D3 and a fourth direction D4 opposite the third direction D3.

[0035] The first and second heat exchanger flow paths 82, 86 are arranged in thermal communication to facilitate heat transfer between the first and second working fluids WF1, WF2. By facilitating heat transfer between the first and second working fluids WF1, WF2, the heat exchanger 78 provides additional operational flexibility and advantages when using the heat management device 50 according to the present disclosure, as described in further detail below. More specifically, based on the direction of flow of the first and / or second working fluids WF1, WF2, the energization of the first and / or second heating elements 66, 70, and the heat transfer effected by the heat exchanger 78 between the first and second working fluids WF1, WF2, the heat management device 50 functions to selectively prioritize heating one of the first and second working fluids WF1, WF2 over the other of the first and second working fluids WF1, WF2.

[0036] In examples where the second working fluid WF2 is preferentially heated over the first working fluid WF1, in response to the first working fluid WF1 flowing in the first direction D1 and the second working fluid WF2 flowing in the third direction D3, the first heating element 66 can be energized to heat the first working fluid WF1, and the first working fluid WF1 heated by the first heating element 66 flows from the first manifold flow path 58 through the first heat exchanger flow path 82, and the second working fluid WF2 flows through the second heat exchanger flow path 86, such that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the second manifold flow path 62, such that the second heating element 70 further heats the second working fluid WF2. In examples where the first working fluid WF1 is preferentially heated over the second working fluid WF2, in response to the first working fluid WF1 flowing in the second direction D2 and the second working fluid WF2 flowing in the fourth direction D4, the second heating element 70 heats the second working fluid WF2, and the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 through the second heat exchanger flow path 86, and the first working fluid WF1 flows through the first heat exchanger flow path 82, such that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the first manifold flow path 58, such that the first heating element 66 further heats the first working fluid WF1.

[0037] The configuration of the heat exchanger 78 is not necessarily limited for purposes of the present disclosure. In Figures 1-8 In examples, the heat exchanger 78 is a plate heat exchanger, in which the first working fluid WF1 and the second working fluid WF2 exchange heat by flowing adjacent to one another between plates arranged parallel to one another (not shown in detail). However, it is also contemplated that the heat exchanger 78 can be other forms of heat exchangers, such as a tube heat exchanger, a spiral heat exchanger, etc. Moreover, the direction of flow of the first working fluid WF1 and the second working fluid WF2 through the heat exchanger 78 is not necessarily limited for purposes of the present disclosure. In other words, the first working fluid WF1 and the second working fluid WF2 can flow through the heat exchanger 78 in the same direction (i.e., concurrent flow), or the first working fluid WF1 and the second working fluid WF2 can flow through the heat exchanger 78 in opposite directions (i.e., countercurrent flow).

[0038] With reference to Figures 1-4 In configurations, in certain examples, the manifold 54 is defined by a pair of stamped metal plates that are coupled to one another to define the first manifold flow path 58 and the second manifold flow path 62. In Figures 1-4In the example of FIG. 1, the manifold 54 is made of aluminum plates that are brazed together and have corresponding stamped recesses that cooperate to define the first manifold flow path 58 and the second manifold flow path 62. In these examples, the first heating element 66 and the second heating element 70 are coupled to an outer surface of the manifold 54 to heat the first working fluid WFl and the second working fluid WF2, respectively. Also in these examples, the heat exchanger 78 is attached to one side of the manifold 54, and the control module 74 is coupled to the other side of the manifold 54 to energize the first heating element 66 and the second heating element 70 to heat the first working fluid WFl and the second working fluid WF2, respectively. On the other hand, in the example of FIG. 2, the heat exchanger 78 is attached to one side of the manifold 54, and the control module 74 is coupled to the other side of the manifold 54 to energize the first heating element 66 and the second heating element 70 to heat the first working fluid WFl and the second working fluid WF2, respectively. Figures 1-4 In the example of FIG. 1, the manifold 54 is made of aluminum plates that are brazed together and have corresponding stamped recesses that cooperate to define the first manifold flow path 58 and the second manifold flow path 62. In these examples, the first heating element 66 and the second heating element 70 are coupled to an outer surface of the manifold 54 to heat the first working fluid WFl and the second working fluid WF2, respectively. Also in these examples, the heat exchanger 78 is attached to one side of the manifold 54, and the control module 74 is coupled to the other side of the manifold 54 to energize the first heating element 66 and the second heating element 70 to heat the first working fluid WFl and the second working fluid WF2, respectively. On the other hand, in the example of FIG. 2, the heat exchanger 78 is attached to one side of the manifold 54, and the control module 74 is coupled to the other side of the manifold 54 to energize the first heating element 66 and the second heating element 70 to heat the first working fluid WFl and the second working fluid WF2, respectively. Figures 5-8 The example of FIG. 3 shows the manifold 54, the first heating element 66 and the second heating element 70, and the control module 74 integrated into one assembly (as best shown in Figures 6-8 The example of FIG. 3 shows the manifold 54, the first heating element 66 and the second heating element 70, and the control module 74 integrated into one assembly (as best shown in

[0039] With reference to Figure 9 and Figure 10 , the present disclosure is also directed to a heat management system 100 (e.g., for a hybrid or electric vehicle) that includes the heat management device 50 described above. The heat management system 100 includes a first fluid circuit 104 for circulating the first working fluid WFl and a second fluid circuit 108 for circulating the second working fluid WF2. The first fluid circuit 104 is configured to be in fluid communication with one or more components of the vehicle (schematically illustrated by the dashed box 112 in Figure 9 and Figure 10 ) for heat management of such component(s) 112 by the first working fluid WFl. Likewise, the second fluid circuit 108 is configured to be in fluid communication with one or more components of the vehicle (schematically illustrated by the dashed box 114 in Figure 9 and Figure 10 ) for heat management of such component(s) 114 by the second working fluid WF2.components 116 (illustrated schematically by dashed box 116) for heat management of such component(s) 116 by the second working fluid WF2. Exemplary component(s) 112, 116 include, but are not limited to, a vehicle battery, an electric motor, an inverter, power electronics, a compressor, an ambient air heat exchanger, and a cabin heat exchanger. It should be appreciated that more than one component 112, 116 can be arranged in fluid communication with the first fluid circuit 104 and the second fluid circuit 108, respectively. Using the first fluid circuit 104 as an example, multiple components 112 can be arranged in series such that the first working fluid WF1 flows between the components 112 via the first fluid circuit 104; however, in other examples, the first fluid circuit 104 branches such that multiple components 112 are arranged in parallel in that the first working fluid WF1 flows between the components 112 via the first fluid circuit 104. Of course, the same arrangements described with respect to the first fluid circuit 104 can be applicable to the second fluid circuit 108. In certain examples, the first working fluid WF1 is a coolant (as described above) and the first fluid circuit 104 is in communication with powertrain components of the vehicle (such as a battery, electric motor, inverter, etc.) and the second working fluid WF2 is a refrigerant (as described above) and the second fluid circuit 108 is in communication with HVAC components of the vehicle (such as a compressor, cabin heat exchanger, etc.). Other configurations of the first fluid circuit 104 and the second fluid circuit 108 are contemplated.

[0040] Both the first fluid circuit 104 and the second fluid circuit 108 are configured such that the first working fluid WF1 and the second working fluid WF2 are each configured to flow in two directions. More specifically, with reference to Figure 9 , the first fluid circuit 104 is configured to circulate the first working fluid WF1 in a first direction D1 (schematically depicted by arrow 120) and with reference to Figure 10 , the first fluid circuit 104 is also configured to circulate the first working fluid WF1 in a second direction D2 (schematically depicted by arrow 124) opposite the first direction D1. Similarly, with reference to Figure 9 , the second fluid circuit 108 is configured to circulate the second working fluid WF2 in a third direction D3 (schematically depicted by arrow 128) and with reference to Figure 10 , the second fluid circuit 108 is also configured to circulate the second working fluid WF2 in a fourth direction D4 (schematically depicted by arrow 132) opposite the third direction D3. As will be appreciated from the subsequent description, configuring both the first working fluid WF1 and the second working fluid WF2 to flow in two directions provides additional flexibility in transferring heat within the heat management system 100.

[0041] A variety of configurations are contemplated for circulating the first working fluid WF1 about the first fluid circuit 104 in both the first direction D1 and the second direction D2, and for circulating the second working fluid WF2 about the second fluid circuit 108 in both the third direction D3 and the fourth direction D4. In one non-limiting example, the heat management system 100 includes a first pump 136 in fluid communication with the first fluid circuit 104 and configured to circulate the first working fluid WF1 about the first fluid circuit 104 in the first direction D1 and the second direction D2, and a second pump 140 in fluid communication with the second fluid circuit 108 and configured to circulate the second working fluid WF2 about the second fluid circuit 108 in the third direction D3 and the fourth direction D4. The first pump 136 and the second pump 140 can be embodied as separate components coupled to the first fluid circuit 104 and the second fluid circuit 108, respectively. In other examples, such as schematically illustrated in Figure 9 and Figure 10 the first pump 136 and the second pump 140 are integrated within the component(s) 112, 116. The first pump 136 and / or the second pump 140 can be implemented as a bidirectional pump to enable bidirectional flow of the first working fluid WF1 and the second working fluid WF2 about the first fluid circuit 104 and the second fluid circuit 108, respectively. Other configurations can be implemented to achieve bidirectional flow of the first working fluid WF1 and the second working fluid WF2 about the first fluid circuit 104 and the second fluid circuit 108, respectively, through an actuable valve arrangement or other suitable component.

[0042] As schematically illustrated in Figure 9 and Figure 10 the first manifold flow path 58 of the manifold 54 is in fluid communication with the first fluid circuit 104 for directing the first working fluid WF1. In one configuration, at least one of the first port 58A and the second port 58B of the first manifold flow path 58 is in fluid communication with the first fluid circuit 104 such that the first manifold flow path 58 directs the first working fluid WF1 between the first port 58A and the second port 58B, although other configurations are contemplated. As also schematically illustrated in Figure 9 and Figure 10 the second manifold flow path 62 of the manifold 54 is in fluid communication with the second fluid circuit 108 for directing the second working fluid WF2. In one configuration, at least one of the third port 62A and the fourth port 62B is in fluid communication with the second fluid circuit 108 such that the second manifold flow path 62 directs the second working fluid WF2 between the third port 62A and the fourth port 62B, although other configurations are contemplated. As described above and in Figure 9 and Figure 10As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62.

[0043] As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62. Figure 9 and Figure 10 As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62. Figure 9 and Figure 10 As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62. Figure 9 and Figure 10 As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62.

[0044] As schematically illustrated in Figs. 1-3, the first heating element 66 is operatively attached to the manifold 54 and is in thermal communication with the first manifold flow path 58 for heating the first working fluid WF1 as it flows through the first manifold flow path 58, and the second heating element 70 is operatively attached to the manifold 54 and is in thermal communication with the second manifold flow path 62 for heating the second working fluid WF2 as it flows through the second manifold flow path 62. Figure 9 and Figure 10The heat management system 100 also includes a controller 144. The controller 144 is in communication with the first heating element 66 to selectively energize the first heating element 66 to heat the first working fluid WFi within the first manifold flow path 58 and the second heating element 70 to selectively energize the second heating element 70 to heat the second working fluid WF2within the second manifold flow path 62. The controller 144 is configured to operate the heat management system 100 between a plurality of modes, including but not limited to a first operating mode (illustrated in Figure 9 and described below) and a second operating mode (illustrated in Figure 10 and described below). In certain examples, as schematically illustrated in Figure 9 and Figure 9 the controller 144 is also in communication with the first fluid circuit 104 to control the direction of the first working fluid WFi (e.g., via the first pump 136) and / or the second fluid circuit 108 to control the direction of the second working fluid WF2(e.g., via the second pump 140). However, it should be appreciated that in other configurations, the direction of the first working fluid WFi and / or the direction of the second working fluid WF2may be controlled by other systems of the vehicle, and the controller 144 of the heat management system 100 can select the operating mode of the heat management system 100 in response to the direction of the first working fluid WFi and / or the direction of the second working fluid WF2. In other words, in certain examples, the controller 144 does not control the direction of the first working fluid WFi and / or the direction of the second working fluid WF2, but instead operates the heat management system 100 based on the direction of the first working fluid WFi and / or the direction of the second working fluid WF2.

[0045] Referring to Figure 9 , in the event the controller 144 operates the heat management system 100 in the first operating mode, the controller 144 operates the first heating element 66 to heat the first working fluid WFi while the first pump 136 circulates the first working fluid WFi in the first direction Di such that the first working fluid WFi heated by the first heating element 66 flows from the first manifold flow path 58 of the manifold 54 through the first heat exchanger flow path 82 of the heat exchanger 78 and to the first fluid circuit 104. In certain configurations, as schematically illustrated in Figure 9 , the controller 144 operates the first pump 136 to circulate the first working fluid WFi in the first direction Di such that the first working fluid WFi heated by the first heating element 66 flows from the first manifold flow path 58 of the manifold 54 through the first opening 82A of the heat exchanger 78, through the first heat exchanger flow path 82, to the second opening 82B, and through the second opening 82B to the first fluid circuit 104, although other configurations are contemplated.

[0046] Meanwhile, with continued reference to Figure 10 When the controller 144 operates the thermal management system 100 in the first mode of operation, the controller 144 operates the second pump 140 to circulate the second working fluid WF2 in the third direction D3 such that the second working fluid WF2 flows from the second fluid circuit 108 through the second heat exchanger flow path 86 of the heat exchanger 78 such that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the second manifold flow path 62 of the manifold 54 such that the second heating element 70 further heats the second working fluid WF2. In certain constructions, such as in the illustrative embodiment shown in Figure 10 the controller 144 operates the second pump 140 to circulate the second working fluid WF2 in the third direction D3 such that the second working fluid WF2 flows from the fourth opening 86B of the heat exchanger 78 and through the second heat exchanger flow path 86 such that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the third opening 86A to the second manifold flow path 62 of the manifold 54 such that the second heating element 70 further heats the second working fluid WF2, although other constructions are also contemplated.

[0047] In any case, when the controller 144 operates the thermal management system 100 in the first mode of operation, the first heating element 66 heats the first working fluid WF1, which then flows through the heat exchanger 78 and heats the second working fluid WF2, which is then subsequently further heated by the second heating element 70. Thus, in effect, the second working fluid WF2 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70.

[0048] With reference to Figure 10 When the controller 144 operates the thermal management system 100 in the second mode of operation, the controller 144 operates the second heating element 70 to heat the second working fluid WF2 while the second pump 140 circulates the second working fluid WF2 in the fourth direction D4 such that the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 of the manifold 54 through the second heat exchanger flow path 86 of the heat exchanger 78 and to the second fluid circuit 108. In certain constructions, such as in the illustrative embodiment shown in Figure 10In some configurations, for example in the configuration schematically illustrated in FIG. 6, the controller 144 operates the second pump 14 to circulate the second working fluid WF2 in the fourth direction D4 such that the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 of the manifold 54, through the third opening 86A of the heat exchanger 78, through the second heat exchanger flow path 86, to the fourth opening 86B, and through the fourth opening 86B to the second fluid circuit 108, although other configurations are contemplated.

[0049] Meanwhile, with continued reference to Figure 11 In the case where the controller 144 operates the thermal management system 100 in the second operating mode, the controller 144 operates the first pump 136 to circulate the first working fluid WF1 in the second direction D2 such that the first working fluid WF1 flows from the first fluid circuit 104, through the first heat exchanger flow path 82 of the heat exchanger 78, such that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the second manifold flow path 62 of the manifold 54, such that the first heating element 66 further heats the first working fluid WF1. In certain configurations, for example in the configuration schematically illustrated in FIG. 6, the controller 144 operates the first pump 136 to circulate the first working fluid WF1 in the second direction D2 such that the first working fluid WF1 flows from the second opening 82B of the heat exchanger 78, and through the first heat exchanger flow path 82, such that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the first opening 82A to the first manifold flow path 58 of the manifold 54, such that the first heating element 66 further heats the first working fluid WF1. Figure 12 In some configurations, for example in the configuration schematically illustrated in FIG. 6, the controller 144 operates the second pump 14 to circulate the second working fluid WF2 in the fourth direction D4 such that the second working fluid WF2 heated by the second heating element 70 flows from the second manifold flow path 62 of the manifold 54, through the third opening 86A of the heat exchanger 78, through the second heat exchanger flow path 86, to the fourth opening 86B, and through the fourth opening 86B to the second fluid circuit 108, although other configurations are contemplated.

[0050] In any case, as opposed to the first operating mode described above, in the case where the controller 144 operates the thermal management system 100 in the second operating mode, the second heating element 70 heats the second working fluid WF2, which then flows through the heat exchanger 78 to heat the first working fluid WF1, which is then further heated by the first heating element 66. Thus, in effect, the first working fluid WF1 reaps the benefits of being heated by both the first heating element 66 and the second heating element 70, either directly or indirectly.

[0051] It will be appreciated in view of the present disclosure that the heat management device 50 disclosed herein has particular operational advantages when employed in a heat management system 100 for a hybrid or electric vehicle. In particular, by including first and second heating elements 66, 70 that are independently operable from one another, and adjacently arranging a heat exchanger 78 for exchanging heat between first and second working fluids WF1, WF2, a variety of advantages are realized, including increased operational flexibility, reduced packaging footprint, etc. It will also be appreciated that additional operational modes of the heat management system 100 are contemplated. More particularly, any operational direction of circulation of the first working fluid WF1 around the first fluid circuit 104, any operational direction of circulation of the second working fluid WF2 around the second fluid circuit 108, and any excitation of the first and / or second heating elements are contemplated.

[0052] Figure 11 and Figure 12 A schematic example of one embodiment of a heat management system 100 is provided, the heat management system 100 operating in a first operational mode (shown in Figure 11 ) and a second operational mode (shown in Figure 12 ). In both Figure 11 and Figure 11 , the component(s) 112 in fluid communication with the first fluid circuit 104 include at least the vehicle battery 148, and the component(s) 116 in fluid communication with the second fluid circuit include the compressor 152, the vehicle passenger cabin heat exchanger 156, and the expansion valve 160, which are arranged in series with respect to one another. Of course, it will be appreciated that other components 116 can be in communication with the first fluid circuit 104.

[0053] Referring first to Figure 9 , the controller 144 (not shown in Figure 12 ) can be configured to operate the heat management system 100 in the first operational mode in response to a scenario in which the vehicle passenger cabin heat exchanger 156 has a high thermal demand. Here, there are at least three potential sources of heat for the vehicle passenger cabin heat exchanger 156— namely, the first heating element 66, the second heating element 70, and the compressor 152. Accordingly, as noted above in Figure 12In the context of the above description, the controller 144 can be configured to operate the thermal management system 100 in the first operating mode such that the first heating element 66 heats the first working fluid WFl, then the first working fluid WFl flows through the heat exchanger 78 to heat the second working fluid WF2, then the second working fluid WF2 is subsequently further heated by the second heating element 70, and finally provided to the passenger cabin heat exchanger 156. Again, in effect, the second working fluid WF2 reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70, allowing more heat to be provided to the passenger cabin heat exchanger 156 than would be possible without utilizing the higher capacity heating elements for the first fluid circuit 104 and the second fluid circuit 108.

[0054] Referring next to Figure 10 , the controller 144 (not shown in Figure 13 ) can be configured to operate the thermal management system 100 in the second operating mode in response to scenarios in which the vehicle battery 148 has a high thermal demand (e.g., in the case where the vehicle battery is provisioned to receive fast charging). Here, there are at least three potential sources of heat for the vehicle battery 148 — namely, the first heating element 66, the second heating element 70, and the compressor 152. Accordingly, similar to the above description in the context of Figure 14 , the controller 144 can be configured to operate the thermal management system 100 in the second operating mode such that the second heating element 70 heats the second working fluid WF2, then the second working fluid WF2 flows through the heat exchanger 78 to heat the first working fluid WFl, then the first working fluid WFl is subsequently further heated by the first heating element 66, and finally provided to the vehicle battery 148. Again, in effect, the first working fluid WFl reaps the benefits of being heated (directly or indirectly) by both the first heating element 66 and the second heating element 70, allowing more heat to be provided to the vehicle battery 148 than would be possible without utilizing the higher capacity heating elements for the first fluid circuit and the second fluid circuit.

[0055] The present disclosure also relates to a method 200 of operating the thermal management system 100. Referring to Figure 15The method 200 generally includes a step 202 of circulating the first working fluid WF1 in one of a first direction D1 and a second direction D2 opposite the first direction D1 through the first manifold flow path 58 and the first heat exchanger flow path 82. The method 200 also includes a step 204 of circulating the second working fluid WF2 in one of a third direction D3 and a fourth direction D4 opposite the third direction D3 through the second manifold flow path 62 and the second heat exchanger flow path 86. The method 200 also includes a step 206 of operating the heat management system 100 in a first operating mode in response to the first working fluid WF1 being circulated in the first direction D1 and the second working fluid WF2 being circulated in the third direction D3, and a step 208 of operating the heat management system 100 in a second operating mode in response to the first working fluid WF1 being circulated in the second direction D2 and the second working fluid WF2 being circulated in the fourth direction D4.

[0056] Referring to ​ The step 206 of operating the heat management system 100 in the first operating mode includes a sub-step 206a of operating the first heating element 66 to heat the first working fluid WF1, a sub-step 206b of directing the first working fluid WF1 heated by the first heating element 66 from the first manifold flow path 58 through the first heat exchanger flow path 82, a sub-step 206c of directing the second working fluid WF2 through the second heat exchanger flow path 86 such that the first working fluid WF1 transfers heat to the second working fluid WF2, and through the second manifold flow path 62, and a sub-step 206d of operating the second heating element 70 to further heat the second working fluid WF2. Here, the operation of the heat management system 100 in the first operating mode in accordance with the step 206 of the method 200 prioritizes the heating of the second working fluid WF2 over the first working fluid WF1.

[0057] Referring to ​ The step 208 of operating the heat management system 100 in the second operating mode includes a sub-step 208a of operating the second heating element 70 to heat the second working fluid WF2, a sub-step 208b of directing the second working fluid WF2 heated by the second heating element 70 from the second manifold flow path 62 through the second heat exchanger flow path 86, a sub-step 208c of directing the first working fluid WF1 through the first heat exchanger flow path 82 such that the second working fluid WF2 transfers heat to the first working fluid WF1, and through the second manifold flow path 62, and operating the first heating element 66 to further heat the first working fluid WF1. Here, the operation of the heat management system 100 in the second operating mode in accordance with the step 208 of the method 200 prioritizes the heating of the first working fluid WF1 over the second working fluid WF2.

[0058] It should also be appreciated that the method 200 can include operating the thermal management system 100 in additional operational modes. More specifically, it is contemplated that the direction of operation of any circulation of the first working fluid WF1 around the first fluid circuit 104, the direction of operation of any circulation of the second working fluid WF2 around the second fluid circuit 108, and the energization of the first heating element and / or the second heating element.

[0059] The application has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present application are possible in light of the above teachings. The application can be practiced otherwise than as specifically described.

Claims

1. A heat management device comprising: a manifold defining: a first manifold flow path configured to direct a first working fluid, and a second manifold flow path configured to direct a second working fluid, wherein the second manifold flow path is not in fluid communication with the first manifold flow path; a first heating element operatively attached to the manifold and in thermal communication with the first manifold flow path, wherein the first heating element is configured to generate heat in response to an excitation to heat the first working fluid as the first working fluid flows through the first manifold flow path; a second heating element operatively attached to the manifold and in thermal communication with the second manifold flow path, wherein the second heating element is configured to generate heat in response to an excitation to heat the second working fluid as the second working fluid flows through the second manifold flow path, and wherein the second heating element is operable independently of the first heating element; and a heat exchanger operatively attached to the manifold and defining: a first heat exchanger flow path in fluid communication with the first manifold flow path, and a second heat exchanger flow path in fluid communication with the second manifold flow path, wherein the first and second heat exchanger flow paths are arranged in thermal communication with one another to facilitate heat transfer between the first and second working fluids.

2. The heat management device of claim 1, wherein the first manifold flow path and the first heat exchanger flow path are configured to direct the first working fluid in a first direction and a second direction opposite the first direction; and wherein the second manifold flow path and the second heat exchanger flow path are configured to direct the second working fluid in a third direction and a fourth direction opposite the third direction. in response to the first working fluid flowing in the first direction and the second working fluid flowing in the third direction, the first heating element heats the first working fluid, and the first working fluid heated by the first heating element flows from the first manifold flow path through the first heat exchanger flow path, and the second working fluid flows through the second heat exchanger flow path, such that the first working fluid transfers heat to the second working fluid, and through the second manifold flow path, such that the second heating element further heats the second working fluid.

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

5. The heat management device of claim 1, wherein, A control module is also included in communication with the first heating element and the second heating element and configured to energize the first heating element to heat the first working fluid and energize the second heating element to heat the second working fluid.

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

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

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

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

10. A heat management system comprising: a first fluid circuit for circulating a first working fluid; a second fluid circuit for circulating a second working fluid; the heat management device of any one of claims 1-9, wherein the first manifold flow path is in fluid communication with the first fluid circuit, the second manifold flow path is in fluid communication with the second fluid circuit, the first heat exchanger flow path is in fluid communication between the first manifold flow path and the first fluid circuit, and the second heat exchanger flow path is in fluid communication between the second manifold flow path and the second fluid circuit; a first pump in fluid communication with the first fluid circuit and configured to circulate the first working fluid around the first fluid circuit in a first direction and a second direction opposite the first direction; a second pump in fluid communication with the second fluid circuit and configured to circulate the second working fluid around the second fluid circuit in a third direction and a fourth direction opposite the third direction; and a controller in communication with the first pump, the second pump, the first heating element, and the second heating element, wherein the controller is configured to operate the heat management system between a plurality of operating modes.

11. The heat management system of claim 10, wherein, The plurality of operating modes includes a first operating mode in which the controller: operates the first heating element to heat the first working fluid, operates the first pump to circulate the first working fluid in the first direction, such that the first working fluid heated by the first heating element flows from the first manifold flow path through the first heat exchanger flow path, and to the first fluid circuit, operating the second pump to circulate the second working fluid in the third direction such that the second working fluid flows from the second fluid circuit through the second heat exchanger flow path such that the first working fluid transfers heat to the second working fluid, and through the second manifold flow path, and operating the second heating element to further heat the second working fluid.

12. The heat management system of claim 10, wherein, the plurality of operating modes includes a second operating mode in which the controller: operates the second heating element to heat the second working fluid, operates the second pump to circulate the second working fluid in the fourth direction such that the second working fluid heated by the second heating element flows from the second manifold flow path through the second heat exchanger flow path, and to the second fluid circuit, operates the first pump to circulate the first working fluid in the second direction such that the first working fluid flows from the first fluid circuit through the first heat exchanger flow path such that the second working fluid transfers heat to the first working fluid, and through the second manifold flow path, and operates the first heating element to further heat the first working fluid. the plurality of operating modes includes a second operating mode in which the controller: operates the second heating element to heat the second working fluid, operates the second pump to circulate the second working fluid in the fourth direction such that the second working fluid heated by the second heating element flows from the second manifold flow path through the second heat exchanger flow path, and to the second fluid circuit, operates the first pump to circulate the first working fluid in the second direction such that the first working fluid flows from the first fluid circuit through the first heat exchanger flow path such that the second working fluid transfers heat to the first working fluid, and through the second manifold flow path, and operates the first heating element to further heat the first working fluid.

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