Coolant hub with integrated pump housing

Abstract

A thermal management module (100) includes a hub housing (10), and a first pump (20). The hub housing (10) includes a plurality of fluid flow channels (12) and a shaft (18). The hub housing (10) receives the first pump (20). A rotor assembly (222) of the first pump (20) is disposed inside a pump housing (14) which is integrally formed with the hub housing (10).

Description

TECHNICAL FIELD

[0001] The present invention relates to coolant hub, more specifically, one configured for use in a vehicle such as an electric or a hybrid vehicle.BACKGROUND OF THE INVENTION

[0002] Generally, a thermal management module includes a fluid hub, a reservoir, at least one fluid machine, for example, at least one fluid pump and at least one vehicle heat exchanger, for example, a chiller. Generally, the fluid hub is formed by joining two portions of plastic material by plastic welding, wherein at least one portion is configured with channels that define the fluid flow passages when the first and second portions are joined to each other. Further, the fluid hub configures multi-way valves controlled by a controller to selectively disrupt or establish fluid flow through the internal fluid flow passages for defining different cooling circuits and regulating fluid supply to the vehicle heat exchangers based on operating configuration of the multi-way valve that can be changed based on requirement. More specifically, the fluid hub configures several cooling circuits, wherein one or more cooling fluids are routed through the different cooling circuits to achieve different cooling based on requirements, while still maintaining fluid isolation between the cooling fluids flowing through the different cooling circuits. The fluid pumps drives the flow through the different cooling circuits that are configured based on operating configuration of the different valves configured in the fluid hub. The fluid hub receives fluid stored in the reservoir and selectively supplies the cooling fluids to the different heat exchangers through the different cooling circuits configured based on the operative configuration of the valves in the fluid hub. The fluid pumps are in fluid communication with the fluid flow channels to direct fluid to the heat exchangers.

[0003] Generally, the fluid pump comprises an electric motor. The motor includes a stator and a rotor. The rotor is fixedly connected to an impeller. The impeller abuts a volute portion of the fluid hub. The volute portion has an aperture connecting it to at least one fluid flow channel. As the rotor of the motor rotates, it also rotates the impeller driving fluid to at least one of the fluid flow channels through the aperture in the volute portion. The volute portion of the fluid hub has a centrally located receiving portion that houses a shaft. The rotor and the impeller have a central aperture configured to accommodate the shaft. Thus, when assembled, the shaft acts as a central axis of rotation for the rotor. During assembly of the fluid pump to the fluid hub, an operator first mounts the shaft to the receiving portion of the volute using any suitable fastening means. Subsequently, the operator mounts the impeller and rotor to the shaft, secures the rotor and impeller to the shaft using a nut, then the stator is mounted on the rotor. Subsequently, a stator and a pump housing is mounted to the hub. The pump housing is connected to the hub around the outer periphery of the volute, and encapsulates the rotor, stator, shaft and impeller circumferentially. Finally, a cover is mounted to an end face of the pump housing using suitable fastening means (such as bolts, screw, clip, weld etc.), to fluidically seal the enclosure accommodating the components of the fluid pump.

[0004] However, during the assembly process, centering of the pump housing and the stator with respect to the rotor and the volute may be misaligned. Due to such misalignment, the optimal functioning of the motor, and thus that of the fluid pump, is compromised resulting in efficiency losses and also causes vibrations, wear and tear.OBJECT OF THE INVENTION

[0005] An object of the invention is to allow proper centering of the pump housing and the stator with respect to the rotor and the volute.

[0006] Another objective of the invention is to reduce the steps required by an operator to assemble the fluid pump to the fluid hub.SUMMARY OF THE INVENTION

[0007] The present invention relates to hub housing that includes a plurality of fluid flow channels and a pump housing. The hub housing is adapted to receive in the pump housing at least a rotor assembly of a first pump. Particularly, the hub housing is adapted to receive in the pump housing the rotor assembly and a stator assembly of the first pump. The pump housing is integrally formed with the hub housing.

[0008] Generally, the hub housing includes a first hub housing portion and a second hub housing, the first hub housing portion and / or the second hub housing portion includes a volute portion.

[0009] Particularly, the pump housing is integrally formed with first hub housing portion.

[0010] Specifically, the pump housing is coaxial with of the volute portion.

[0011] Generally, at least one of the first hub housing portion and the second hub housing portion define a plurality of fluid flow channels to convey coolant fluid flow therein.

[0012] Particularly, the hub housing and the integrally formed pump housing are made of different materials.

[0013] Alternatively, the hub housing and the integrally formed with pump housing is made of the same material.

[0014] Generally, the hub housing and the pump housing are integrally formed using an overmolding process.

[0015] Specifically, the hub housing includes a shaft that is integrally formed with the hub housing, and said shaft configured to be received by the first pump, particularly by the rotor assembly of the first pump.

[0016] Generally, a thermal management module includes the hub housing and the first pump secured to the hub housing. The thermal management module further includes an electric motor that includes a rotor assembly. The rotor assembly further includes an impeller that is at least partially received within the hub housing. The rotor assembly comprises an axial aperture adapted to receive the shaft mounted to the hub housing. The shaft allows the rotor assembly to be mounted on the shaft. The electric motor also includes a stator assembly and a cover abutting an end face of the pump housing. The rotor assembly is mounted on the shaft by means of a fastener.

[0017] Particularly, a gasket is integrally formed on the cover facing the pump housing.

[0018] Additionally, the invention further relates to a method of assembling the first pump to the coolant hub housing of the thermal management module. The method of assembling includes the steps of aligning an axial aperture of the rotor assembly of the first pump with the shaft that is integrally formed on the coolant hub housing. The steps further include inserting the shaft into the axial aperture by movement of at least the rotor assembly and the hub housing relative to each other, to at least partially receive the rotor assembly within a pump housing that is integrally formed with the hub housing.

[0019] Further, the steps of assembly include restraining the relative axial motion of the rotor assembly with respect to the hub housing using the fastener.

[0020] Generally, the steps of assembly include assembling a stator assembly and a cover of the first pump.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Other characteristics, details and advantages of the invention may be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates a schematic representation depicting a thermal management module in accordance with an embodiment of the present invention. FIG. 2 illustrates an exploded view depicting elements of the thermal management module of FIG. 1. FIG 3 illustrates an exploded view depicting the components of a hub housing of the thermal management module of FIG. 1. FIG 4 illustrates an isometric view of a first pump of the thermal management module of FIG. 1. FIG 5 illustrates an exploded view depicting the components of the first pump and a fastener of the thermal management module of FIG. 1. FIG 6A illustrates an isometric view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG 6B illustrates a side view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG 6C illustrates a front view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG. 7 illustrates a sectional view of the thermal management module of FIG. 2 along a section line XX' depicted in FIG 2. FIG 8 illustrates an enlarged view of a region of the fluid hub and pump depicted within a dotted line box AA in FIG. 7. DETAILED DESCRIPTION

[0022] It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should, however, not be limited to the embodiments disclosed in the description.

[0023] The present invention envisages a hub housing for a thermal management module, more specifically, a coolant hub for the thermal management module for heating and / or cooling a plurality of fluids in vehicular environment. In conventional thermal management modules, a coolant pump is mounted to the hub housing of the coolant hub of the thermal management module. Usually this process includes mounting a rotor assembly on a shaft mounted on a volute portion of the hub housing, and subsequently mounting a pump housing (with or without a stator assembly) to the hub housing. However, during the assembly of the pump housing, the centering of the pump housing (and thus the stator) with respect to the volute portion and the rotor gets misaligned resulting in efficiency losses of the pump and also causes vibrations, wear and tear. The hub housing of the present invention overcomes the challenges of conventional hub housings in which the axis of the pump housing is prone to getting misaligned with respect to the axis of a volute portion of the hub during assembly.

[0024] The hub housing of the present invention includes a pump housing that is integrally formed along with the hub housing, thereby preventing misalignment of the pump housing with respect to the volute portion of the hub. The present invention is applicable to any coolant hub system used in automotive or non-automotive applications that is required to be efficient in operation and simple to assemble.

[0025] FIG. 1 illustrates an isometric view of a thermal management module 100 in accordance with an embodiment of the present invention.

[0026] In a preferred embodiment of the present invention, the thermal management module 100 comprises of a hub housing 10 and a first pump 20. The first pump 20 is secured to the hub housing 10, and adapted to drive flow of a coolant fluid within the hub housing 10. The first pump 20 is mounted on the hub housing 10 using suitable fasteners such as click-locking elements, screws, bolts, rivets, or the like.

[0027] FIG. 2 illustrates an exploded view depicting elements of the thermal management module 100. As depicted in the FIG.2, apart from the first pump 20, the thermal management module 100 further includes a second pump 40, an actuator 50, and a reservoir 60. The second pump 40 is also adapted to drive coolant fluid and the actuator 50 is adapted to control the direction of the coolant fluid flow. The reservoir 60 acts as a reservoir for coolant fluid. For the sake of conciseness, the structural details of the pump 40 and actuator 50 will not be discussed in further detail.

[0028] FIG. 3 illustrates an exploded view depicting the components of the hub housing 10 of the thermal management module 100. The hub housing 10 comprises a first hub housing portion 10a and a second hub housing portion 10b. At least one of the first hub housing portion 10a and the second hub housing portion 10b comprises a volute portion 16. In an embodiment, the first hub housing portion 10a includes the volute portion16. The hub housing 10 also comprises a plurality of fluid flow channels 12 protruding outward and adapted for fluid flow, such as a coolant fluid, therein. In an embodiment, the second hub housing portion 10b defines the plurality of fluid flow channels 12. However, it should be appreciated that either the first hub housing portion 10a or the second hub housing portion 10b or both may have projections to define the plurality of fluid flow channels 12. Together, the first hub housing portion 10a and the second hub housing portion 10b define a plurality of fluid flow channels 12. Alternatively, the first hub housing portion 10a and the second hub housing portion 10b can individually define the plurality of fluid flow channels 12.

[0029] Further, the hub housing 10 includes a shaft 18 that protrudes outward from the hub housing 10. The shaft 18 is centrally disposed with respect to the volute portion 16 receiving at least a portion of the pump 20, particularly, an impeller 222B (shown in FIG 6B) of a rotor assembly 222 (shown in FIG 5) of the pump 20. Specifically, the volute portion 16 of the hub housing 10 includes a plurality of joining legs 16a and a joining head 16b (shown in FIG. 8) adapted to accommodate the shaft 18. The enlarged view of the joining legs 16a and the joining head 16b have been further illustrated in FIG. 8. The shaft 18 has a threaded end 18a at its distal end to accommodate a fastener 30 (as shown in FIG. 5).

[0030] The hub housing 10 further includes a pump housing 14. Further, the hub housing 10 is configured to receive at least the rotor assembly 222 of the first pump 20. Particularly, the hub housing 10 is configured to receive the rotor assembly 222 and a stator assembly 224 of the first pump 20. The pump housing 14 is integrally formed with the hub housing 10. The pump housing 14 includes an end face 14a at its distal end (away from the hub housing 10).

[0031] In an embodiment, the pump housing 14 is integrally formed with first hub housing portion 10a. By way of example, and not limitation, the pump housing 14 is formed along with the first hub housing portion 10a as a single-piece using casting, injection molding, multi-shot molding, or the like.

[0032] In a preferred embodiment, the pump housing 14 is coaxial with of the volute portion 16. It must be understood, that since the pump housing 14 and the volute portion 16 are integral parts of the first hub housing portion 10a produced as a single casting, the pump housing 14 is, by design, coaxial with the volute portion 16. Thus any misalignment that would otherwise have resulted if the pump housing 14 had to be separately assembled is eliminated. This constitutes a key advantage of this invention as better axial alignment of the pump housing 14 with the volute 16 results in better alignment of the rotor assembly 222 (shown in FIG. 5) of the pump 20 with respect to the volute 16. Consequentially, this results in optimal functioning of the pump 20, increasing efficiency and also reducing vibrations, wear and tear.

[0033] In an embodiment, the pump housing 14 and the hub housing 10 are made of the same material. By way of example, the material may be a plastic, polymer, metal, alloy, or the like.

[0034] In one embodiment, the pump housing 14 and the hub housing 10 are integrally formed using an overmolding process. More specifically, the first hub housing portion 10a of the hub housing 10 and the pump housing 14 are integrally formed using an overmolding process.

[0035] It must be understood that any suitable process such as an insert molding process, encapsulation, press-fitting, ultrasonic friction, welding, or the like, or any combination thereof, may be used to integrally form the pump housing 14 and the hub housing 10.

[0036] In another embodiment, the pump housing 14 is made of a different material than that of the hub housing 10. By way of example and without limitation, the hub housing 10 is made of a plastic material while the pump housing 14 is made of a metal / alloy.

[0037] Alternatively, the hub housing 10 may also be made of stamped sheet metal / alloy or a cast metal / alloy, or a combination thereof.

[0038] FIG. 4 illustrates an isometric view of the first pump 20. The first pump 20 includes a centrally located aperture 28. As will be discussed in further details later, the aperture 28 of the first pump 20 is adapted to accommodate the shaft 18 of the hub housing 10.

[0039] Fig. 5 illustrates an exploded view depicting the components of the first pump 20 along with a fastener 30. The first pump 20 is secured to the hub housing 10 and comprises an electric motor 22 and a cover 24. The motor 22 further includes the rotor assembly 222 and a stator assembly 224. Generally, the rotor assembly 222 of the motor 22 is mounted on the shaft 18 and secured by means of the fastener 30.

[0040] In an embodiment, the fastener 30 is a threaded fastener such as a nut, cap nut, hex nut, or the like. Thus the fastener 30 is fastened to a threaded end 18a (shown in FIG. 3) of the shaft 18 by tightening the fastener 30 over the threaded end 18a. It should be understood that any suitable fastening means can be utilized by a person skilled in the art for retaining the rotor assembly 222 to the shaft 18.

[0041] The rotor assembly 222 is adapted to freely rotate over the shaft 18 based on interaction between the rotor assembly 222 and the stator assembly 224. The stator assembly 224 circumferentially surrounds the rotor assembly 222 and generally includes wire windings. The cover 24 is connected to the pump housing 14 using suitable fastening means such as threaded fasteners (screws, bolts, etc.), click locking fasteners, or the like. The cover 24 fluidically seals the motor 22 from the exterior. Specifically, the cover 24 abuts the end face 14a of the pump housing 14.

[0042] FIG. 6A, 6B and 6C illustrate an isometric view, side view and a front view, respectively of the rotor assembly 222. The rotor assembly 222 includes a rotor body 222a, an impeller 222b and a connection portion 222c connecting the rotor body 222a to the impeller 222b. Specifically, the rotor assembly 222 comprises the aperture 28 (also shown in shown in FIG. 4) which is located centrally along a rotational axis of the rotor assembly 222.

[0043] In an embodiment of the present invention, the shaft 18 is integrally formed with the hub housing 10 (such as the first hub housing portion 10a) and the shaft 18 is received by the first pump 20, particularly by the rotor assembly 222 of the first pump 20. Specifically, the axial aperture 28 of the rotor assembly 222 receives the shaft 18 mounted to the hub housing 10, to mount the rotor assembly 222 on the shaft 18.

[0044] In an alternative embodiment, the shaft 18 is separately attached to the hub housing 10 along with the rotor assembly 222 of the pump 20 using any suitable fastening means such as a threaded joint, or the like.

[0045] In an embodiment, the thermal management module 100 includes the hub housing 10, at least one first pump 20 secured to the hub housing 10, the electric motor 22, the cover 24. The electric motor 22 includes the rotor assembly 222 and the stator 224. The rotor assembly 222 includes the impeller 222b that is at least partially received within the hub housing 10. Particularly, the impeller 222b is partially received in the volute portion 16 of the hub housing 10. Generally, the surface of the impeller 222b facing the volute 16 of the first hub housing portion 10a has a curved conical surface and has a similar curvature as that of the volute 16. The rotor assembly 222 includes the axial aperture 28 configured to receive the shaft 18 mounted to the hub housing 10, to mount the rotor assembly 222 on the shaft 18. Further, the cover 24 abuts the end face 14a of the pump housing 14. Also, the rotor assembly 222 is mounted on the shaft 18 by means of a fastener 30 to secure the rotor assembly 222 to the shaft 18.

[0046] FIG. 7 is a sectional view of the thermal management module as shown in FIG. 2 along a section line XX' depicted in FIG 2, depicting the first hub housing portion 10a and the second hub housing portion 10b.

[0047] FIG. 8 shows an enlarged view of a portion of FIG. 7 bounded by dotted box AA. The figure illustrates that the pump housing 14 is integrally formed with the first hub housing portion 10a. As discussed earlier, the volute portion 16 of the hub housing 10, particularly the first hub housing portion 10a includes a plurality of joining legs 16a and a joining head 16b adapted to accommodate the shaft 18. The joining head 16b is overmolded over the shaft 18. Thus the joining head 16b encapsulates the outer surface of the shaft 18 at one end. A gasket 14b is disposed on the end face 14a of the pump housing 14, facing the cover 24. The gasket is made up of a resilient elastomeric material such as rubber. Thus the gasket enables a fluidically sealed connection between the pump housing 14 and the cover 24. This defines a fluidically sealed chamber for the motor 22 within the pump housing 14.

[0048] In an embodiment, the gasket 14b is integrally formed on the end face 14a of the pump housing 14.

[0049] In an alternate embodiment, the gasket 14b is integrally formed on the cover 24 facing the pump housing 14. More specifically, the gasket 14b is formed on the inner surface of the cover 24 that faces the pump housing 14. The gasket 14b is formed on the cover 24 such that there is a continuous interface of the gasket 14b with the complete circumference of the end face 14a of the pump housing 14, to ensure proper sealing.

[0050] In yet another embodiment, the gasket 14b is not integrated on either the pump housing 14 or the cover 24 and is separately placed thereon.

[0051] The invention further improves the assembly process of the first pump 20 to the hub housing 10. Since the pump housing 14 is integrated to the hub housing 10, the step of assembling the pump housing 14 to the hub housing 10 is eliminated.

[0052] In an embodiment, the method of assembly involves aligning the axial aperture 28 of the rotor assembly 222 of the first pump 20 with the shaft 18 mounted to the hub housing 10. Further, the method involves inserting the shaft 18 into the axial aperture 28 by movement of at least one of the rotor assembly 222 and the hub housing 10 relative to each other, so as to at least partially receive the rotor assembly 222 within the pump housing 14 that is integrally formed with the hub housing 10. Without limitation, the rotor assembly 222 may be fully inserted into the pump housing 14. The relative motion of the rotor assembly 222 with respect to the hub housing 10 is restrained using a fastener 30. Further, the method of assembly involves assembling at least one of a stator assembly 224 and a cover 24 of the first pump 20. Generally, the stator assembly is slid on to the rotor assembly 222 and hence forth the cover 24 is mounted to the pump housing 14. Without limitation, the cover 24 is fastened to the pump housing 14 with any suitable fastening means such as clip fasteners, threaded fasteners, or the like.

Examples

Embodiment Construction

[0022]It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should, however, not be limited to the embodiments disclosed in the description.

[0023]The present invention envisages a hub housing for a thermal management module, more specifically, a coolant hub for the thermal management module for heating and / or cooling a plurality of fluids in vehicular environment. In conventional thermal management modules, a coolant pump is mounted to the hub housing of the coolant hub of the thermal management module. Usually this process includes mounting a rotor assembly on a shaft mounted on a volute portion of the hub housing, and subsequently mounting a pump housing (with or without a stator assembly) to the hub housing. However, during the assembly of the pump housing, the centering of the pump housing (and thus the stator) with respect to the volute port...

TECHNICAL FIELD

[0001] The present invention relates to coolant hub, more specifically, one configured for use in a vehicle such as an electric or a hybrid vehicle.BACKGROUND OF THE INVENTION

[0002] Generally, a thermal management module includes a fluid hub, a reservoir, at least one fluid machine, for example, at least one fluid pump and at least one vehicle heat exchanger, for example, a chiller. Generally, the fluid hub is formed by joining two portions of plastic material by plastic welding, wherein at least one portion is configured with channels that define the fluid flow passages when the first and second portions are joined to each other. Further, the fluid hub configures multi-way valves controlled by a controller to selectively disrupt or establish fluid flow through the internal fluid flow passages for defining different cooling circuits and regulating fluid supply to the vehicle heat exchangers based on operating configuration of the multi-way valve that can be changed based on requirement. More specifically, the fluid hub configures several cooling circuits, wherein one or more cooling fluids are routed through the different cooling circuits to achieve different cooling based on requirements, while still maintaining fluid isolation between the cooling fluids flowing through the different cooling circuits. The fluid pumps drives the flow through the different cooling circuits that are configured based on operating configuration of the different valves configured in the fluid hub. The fluid hub receives fluid stored in the reservoir and selectively supplies the cooling fluids to the different heat exchangers through the different cooling circuits configured based on the operative configuration of the valves in the fluid hub. The fluid pumps are in fluid communication with the fluid flow channels to direct fluid to the heat exchangers.

[0003] Generally, the fluid pump comprises an electric motor. The motor includes a stator and a rotor. The rotor is fixedly connected to an impeller. The impeller abuts a volute portion of the fluid hub. The volute portion has an aperture connecting it to at least one fluid flow channel. As the rotor of the motor rotates, it also rotates the impeller driving fluid to at least one of the fluid flow channels through the aperture in the volute portion. The volute portion of the fluid hub has a centrally located receiving portion that houses a shaft. The rotor and the impeller have a central aperture configured to accommodate the shaft. Thus, when assembled, the shaft acts as a central axis of rotation for the rotor. During assembly of the fluid pump to the fluid hub, an operator first mounts the shaft to the receiving portion of the volute using any suitable fastening means. Subsequently, the operator mounts the impeller and rotor to the shaft, secures the rotor and impeller to the shaft using a nut, then the stator is mounted on the rotor. Subsequently, a stator and a pump housing is mounted to the hub. The pump housing is connected to the hub around the outer periphery of the volute, and encapsulates the rotor, stator, shaft and impeller circumferentially. Finally, a cover is mounted to an end face of the pump housing using suitable fastening means (such as bolts, screw, clip, weld etc.), to fluidically seal the enclosure accommodating the components of the fluid pump.

[0004] However, during the assembly process, centering of the pump housing and the stator with respect to the rotor and the volute may be misaligned. Due to such misalignment, the optimal functioning of the motor, and thus that of the fluid pump, is compromised resulting in efficiency losses and also causes vibrations, wear and tear.OBJECT OF THE INVENTION

[0005] An object of the invention is to allow proper centering of the pump housing and the stator with respect to the rotor and the volute.

[0006] Another objective of the invention is to reduce the steps required by an operator to assemble the fluid pump to the fluid hub.SUMMARY OF THE INVENTION

[0007] The present invention relates to hub housing that includes a plurality of fluid flow channels and a pump housing. The hub housing is adapted to receive in the pump housing at least a rotor assembly of a first pump. Particularly, the hub housing is adapted to receive in the pump housing the rotor assembly and a stator assembly of the first pump. The pump housing is integrally formed with the hub housing.

[0008] Generally, the hub housing includes a first hub housing portion and a second hub housing, the first hub housing portion and / or the second hub housing portion includes a volute portion.

[0009] Particularly, the pump housing is integrally formed with first hub housing portion.

[0010] Specifically, the pump housing is coaxial with of the volute portion.

[0011] Generally, at least one of the first hub housing portion and the second hub housing portion define a plurality of fluid flow channels to convey coolant fluid flow therein.

[0012] Particularly, the hub housing and the integrally formed pump housing are made of different materials.

[0013] Alternatively, the hub housing and the integrally formed with pump housing is made of the same material.

[0014] Generally, the hub housing and the pump housing are integrally formed using an overmolding process.

[0015] Specifically, the hub housing includes a shaft that is integrally formed with the hub housing, and said shaft configured to be received by the first pump, particularly by the rotor assembly of the first pump.

[0016] Generally, a thermal management module includes the hub housing and the first pump secured to the hub housing. The thermal management module further includes an electric motor that includes a rotor assembly. The rotor assembly further includes an impeller that is at least partially received within the hub housing. The rotor assembly comprises an axial aperture adapted to receive the shaft mounted to the hub housing. The shaft allows the rotor assembly to be mounted on the shaft. The electric motor also includes a stator assembly and a cover abutting an end face of the pump housing. The rotor assembly is mounted on the shaft by means of a fastener.

[0017] Particularly, a gasket is integrally formed on the cover facing the pump housing.

[0018] Additionally, the invention further relates to a method of assembling the first pump to the coolant hub housing of the thermal management module. The method of assembling includes the steps of aligning an axial aperture of the rotor assembly of the first pump with the shaft that is integrally formed on the coolant hub housing. The steps further include inserting the shaft into the axial aperture by movement of at least the rotor assembly and the hub housing relative to each other, to at least partially receive the rotor assembly within a pump housing that is integrally formed with the hub housing.

[0019] Further, the steps of assembly include restraining the relative axial motion of the rotor assembly with respect to the hub housing using the fastener.

[0020] Generally, the steps of assembly include assembling a stator assembly and a cover of the first pump.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Other characteristics, details and advantages of the invention may be inferred from the description of the invention hereunder. A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying figures, wherein: FIG. 1 illustrates a schematic representation depicting a thermal management module in accordance with an embodiment of the present invention. FIG. 2 illustrates an exploded view depicting elements of the thermal management module of FIG. 1. FIG 3 illustrates an exploded view depicting the components of a hub housing of the thermal management module of FIG. 1. FIG 4 illustrates an isometric view of a first pump of the thermal management module of FIG. 1. FIG 5 illustrates an exploded view depicting the components of the first pump and a fastener of the thermal management module of FIG. 1. FIG 6A illustrates an isometric view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG 6B illustrates a side view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG 6C illustrates a front view of a rotor assembly of the first pump of the thermal management module of FIG. 1. FIG. 7 illustrates a sectional view of the thermal management module of FIG. 2 along a section line XX' depicted in FIG 2. FIG 8 illustrates an enlarged view of a region of the fluid hub and pump depicted within a dotted line box AA in FIG. 7. DETAILED DESCRIPTION

[0022] It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should, however, not be limited to the embodiments disclosed in the description.

[0023] The present invention envisages a hub housing for a thermal management module, more specifically, a coolant hub for the thermal management module for heating and / or cooling a plurality of fluids in vehicular environment. In conventional thermal management modules, a coolant pump is mounted to the hub housing of the coolant hub of the thermal management module. Usually this process includes mounting a rotor assembly on a shaft mounted on a volute portion of the hub housing, and subsequently mounting a pump housing (with or without a stator assembly) to the hub housing. However, during the assembly of the pump housing, the centering of the pump housing (and thus the stator) with respect to the volute portion and the rotor gets misaligned resulting in efficiency losses of the pump and also causes vibrations, wear and tear. The hub housing of the present invention overcomes the challenges of conventional hub housings in which the axis of the pump housing is prone to getting misaligned with respect to the axis of a volute portion of the hub during assembly.

[0024] The hub housing of the present invention includes a pump housing that is integrally formed along with the hub housing, thereby preventing misalignment of the pump housing with respect to the volute portion of the hub. The present invention is applicable to any coolant hub system used in automotive or non-automotive applications that is required to be efficient in operation and simple to assemble.

[0025] FIG. 1 illustrates an isometric view of a thermal management module 100 in accordance with an embodiment of the present invention.

[0026] In a preferred embodiment of the present invention, the thermal management module 100 comprises of a hub housing 10 and a first pump 20. The first pump 20 is secured to the hub housing 10, and adapted to drive flow of a coolant fluid within the hub housing 10. The first pump 20 is mounted on the hub housing 10 using suitable fasteners such as click-locking elements, screws, bolts, rivets, or the like.

[0027] FIG. 2 illustrates an exploded view depicting elements of the thermal management module 100. As depicted in the FIG.2, apart from the first pump 20, the thermal management module 100 further includes a second pump 40, an actuator 50, and a reservoir 60. The second pump 40 is also adapted to drive coolant fluid and the actuator 50 is adapted to control the direction of the coolant fluid flow. The reservoir 60 acts as a reservoir for coolant fluid. For the sake of conciseness, the structural details of the pump 40 and actuator 50 will not be discussed in further detail.

[0028] FIG. 3 illustrates an exploded view depicting the components of the hub housing 10 of the thermal management module 100. The hub housing 10 comprises a first hub housing portion 10a and a second hub housing portion 10b. At least one of the first hub housing portion 10a and the second hub housing portion 10b comprises a volute portion 16. In an embodiment, the first hub housing portion 10a includes the volute portion16. The hub housing 10 also comprises a plurality of fluid flow channels 12 protruding outward and adapted for fluid flow, such as a coolant fluid, therein. In an embodiment, the second hub housing portion 10b defines the plurality of fluid flow channels 12. However, it should be appreciated that either the first hub housing portion 10a or the second hub housing portion 10b or both may have projections to define the plurality of fluid flow channels 12. Together, the first hub housing portion 10a and the second hub housing portion 10b define a plurality of fluid flow channels 12. Alternatively, the first hub housing portion 10a and the second hub housing portion 10b can individually define the plurality of fluid flow channels 12.

[0029] Further, the hub housing 10 includes a shaft 18 that protrudes outward from the hub housing 10. The shaft 18 is centrally disposed with respect to the volute portion 16 receiving at least a portion of the pump 20, particularly, an impeller 222B (shown in FIG 6B) of a rotor assembly 222 (shown in FIG 5) of the pump 20. Specifically, the volute portion 16 of the hub housing 10 includes a plurality of joining legs 16a and a joining head 16b (shown in FIG. 8) adapted to accommodate the shaft 18. The enlarged view of the joining legs 16a and the joining head 16b have been further illustrated in FIG. 8. The shaft 18 has a threaded end 18a at its distal end to accommodate a fastener 30 (as shown in FIG. 5).

[0030] The hub housing 10 further includes a pump housing 14. Further, the hub housing 10 is configured to receive at least the rotor assembly 222 of the first pump 20. Particularly, the hub housing 10 is configured to receive the rotor assembly 222 and a stator assembly 224 of the first pump 20. The pump housing 14 is integrally formed with the hub housing 10. The pump housing 14 includes an end face 14a at its distal end (away from the hub housing 10).

[0031] In an embodiment, the pump housing 14 is integrally formed with first hub housing portion 10a. By way of example, and not limitation, the pump housing 14 is formed along with the first hub housing portion 10a as a single-piece using casting, injection molding, multi-shot molding, or the like.

[0032] In a preferred embodiment, the pump housing 14 is coaxial with of the volute portion 16. It must be understood, that since the pump housing 14 and the volute portion 16 are integral parts of the first hub housing portion 10a produced as a single casting, the pump housing 14 is, by design, coaxial with the volute portion 16. Thus any misalignment that would otherwise have resulted if the pump housing 14 had to be separately assembled is eliminated. This constitutes a key advantage of this invention as better axial alignment of the pump housing 14 with the volute 16 results in better alignment of the rotor assembly 222 (shown in FIG. 5) of the pump 20 with respect to the volute 16. Consequentially, this results in optimal functioning of the pump 20, increasing efficiency and also reducing vibrations, wear and tear.

[0033] In an embodiment, the pump housing 14 and the hub housing 10 are made of the same material. By way of example, the material may be a plastic, polymer, metal, alloy, or the like.

[0034] In one embodiment, the pump housing 14 and the hub housing 10 are integrally formed using an overmolding process. More specifically, the first hub housing portion 10a of the hub housing 10 and the pump housing 14 are integrally formed using an overmolding process.

[0035] It must be understood that any suitable process such as an insert molding process, encapsulation, press-fitting, ultrasonic friction, welding, or the like, or any combination thereof, may be used to integrally form the pump housing 14 and the hub housing 10.

[0036] In another embodiment, the pump housing 14 is made of a different material than that of the hub housing 10. By way of example and without limitation, the hub housing 10 is made of a plastic material while the pump housing 14 is made of a metal / alloy.

[0037] Alternatively, the hub housing 10 may also be made of stamped sheet metal / alloy or a cast metal / alloy, or a combination thereof.

[0038] FIG. 4 illustrates an isometric view of the first pump 20. The first pump 20 includes a centrally located aperture 28. As will be discussed in further details later, the aperture 28 of the first pump 20 is adapted to accommodate the shaft 18 of the hub housing 10.

[0039] Fig. 5 illustrates an exploded view depicting the components of the first pump 20 along with a fastener 30. The first pump 20 is secured to the hub housing 10 and comprises an electric motor 22 and a cover 24. The motor 22 further includes the rotor assembly 222 and a stator assembly 224. Generally, the rotor assembly 222 of the motor 22 is mounted on the shaft 18 and secured by means of the fastener 30.

[0040] In an embodiment, the fastener 30 is a threaded fastener such as a nut, cap nut, hex nut, or the like. Thus the fastener 30 is fastened to a threaded end 18a (shown in FIG. 3) of the shaft 18 by tightening the fastener 30 over the threaded end 18a. It should be understood that any suitable fastening means can be utilized by a person skilled in the art for retaining the rotor assembly 222 to the shaft 18.

[0041] The rotor assembly 222 is adapted to freely rotate over the shaft 18 based on interaction between the rotor assembly 222 and the stator assembly 224. The stator assembly 224 circumferentially surrounds the rotor assembly 222 and generally includes wire windings. The cover 24 is connected to the pump housing 14 using suitable fastening means such as threaded fasteners (screws, bolts, etc.), click locking fasteners, or the like. The cover 24 fluidically seals the motor 22 from the exterior. Specifically, the cover 24 abuts the end face 14a of the pump housing 14.

[0042] FIG. 6A, 6B and 6C illustrate an isometric view, side view and a front view, respectively of the rotor assembly 222. The rotor assembly 222 includes a rotor body 222a, an impeller 222b and a connection portion 222c connecting the rotor body 222a to the impeller 222b. Specifically, the rotor assembly 222 comprises the aperture 28 (also shown in shown in FIG. 4) which is located centrally along a rotational axis of the rotor assembly 222.

[0043] In an embodiment of the present invention, the shaft 18 is integrally formed with the hub housing 10 (such as the first hub housing portion 10a) and the shaft 18 is received by the first pump 20, particularly by the rotor assembly 222 of the first pump 20. Specifically, the axial aperture 28 of the rotor assembly 222 receives the shaft 18 mounted to the hub housing 10, to mount the rotor assembly 222 on the shaft 18.

[0044] In an alternative embodiment, the shaft 18 is separately attached to the hub housing 10 along with the rotor assembly 222 of the pump 20 using any suitable fastening means such as a threaded joint, or the like.

[0045] In an embodiment, the thermal management module 100 includes the hub housing 10, at least one first pump 20 secured to the hub housing 10, the electric motor 22, the cover 24. The electric motor 22 includes the rotor assembly 222 and the stator 224. The rotor assembly 222 includes the impeller 222b that is at least partially received within the hub housing 10. Particularly, the impeller 222b is partially received in the volute portion 16 of the hub housing 10. Generally, the surface of the impeller 222b facing the volute 16 of the first hub housing portion 10a has a curved conical surface and has a similar curvature as that of the volute 16. The rotor assembly 222 includes the axial aperture 28 configured to receive the shaft 18 mounted to the hub housing 10, to mount the rotor assembly 222 on the shaft 18. Further, the cover 24 abuts the end face 14a of the pump housing 14. Also, the rotor assembly 222 is mounted on the shaft 18 by means of a fastener 30 to secure the rotor assembly 222 to the shaft 18.

[0046] FIG. 7 is a sectional view of the thermal management module as shown in FIG. 2 along a section line XX' depicted in FIG 2, depicting the first hub housing portion 10a and the second hub housing portion 10b.

[0047] FIG. 8 shows an enlarged view of a portion of FIG. 7 bounded by dotted box AA. The figure illustrates that the pump housing 14 is integrally formed with the first hub housing portion 10a. As discussed earlier, the volute portion 16 of the hub housing 10, particularly the first hub housing portion 10a includes a plurality of joining legs 16a and a joining head 16b adapted to accommodate the shaft 18. The joining head 16b is overmolded over the shaft 18. Thus the joining head 16b encapsulates the outer surface of the shaft 18 at one end. A gasket 14b is disposed on the end face 14a of the pump housing 14, facing the cover 24. The gasket is made up of a resilient elastomeric material such as rubber. Thus the gasket enables a fluidically sealed connection between the pump housing 14 and the cover 24. This defines a fluidically sealed chamber for the motor 22 within the pump housing 14.

[0048] In an embodiment, the gasket 14b is integrally formed on the end face 14a of the pump housing 14.

[0049] In an alternate embodiment, the gasket 14b is integrally formed on the cover 24 facing the pump housing 14. More specifically, the gasket 14b is formed on the inner surface of the cover 24 that faces the pump housing 14. The gasket 14b is formed on the cover 24 such that there is a continuous interface of the gasket 14b with the complete circumference of the end face 14a of the pump housing 14, to ensure proper sealing.

[0050] In yet another embodiment, the gasket 14b is not integrated on either the pump housing 14 or the cover 24 and is separately placed thereon.

[0051] The invention further improves the assembly process of the first pump 20 to the hub housing 10. Since the pump housing 14 is integrated to the hub housing 10, the step of assembling the pump housing 14 to the hub housing 10 is eliminated.

[0052] In an embodiment, the method of assembly involves aligning the axial aperture 28 of the rotor assembly 222 of the first pump 20 with the shaft 18 mounted to the hub housing 10. Further, the method involves inserting the shaft 18 into the axial aperture 28 by movement of at least one of the rotor assembly 222 and the hub housing 10 relative to each other, so as to at least partially receive the rotor assembly 222 within the pump housing 14 that is integrally formed with the hub housing 10. Without limitation, the rotor assembly 222 may be fully inserted into the pump housing 14. The relative motion of the rotor assembly 222 with respect to the hub housing 10 is restrained using a fastener 30. Further, the method of assembly involves assembling at least one of a stator assembly 224 and a cover 24 of the first pump 20. Generally, the stator assembly is slid on to the rotor assembly 222 and hence forth the cover 24 is mounted to the pump housing 14. Without limitation, the cover 24 is fastened to the pump housing 14 with any suitable fastening means such as clip fasteners, threaded fasteners, or the like.

Examples

Embodiment Construction

[0022]It must be noted that the accompanying figures disclose the invention in a detailed enough way to be implemented, said figures helping to better define the invention, if need be. The invention should, however, not be limited to the embodiments disclosed in the description.

[0023]The present invention envisages a hub housing for a thermal management module, more specifically, a coolant hub for the thermal management module for heating and / or cooling a plurality of fluids in vehicular environment. In conventional thermal management modules, a coolant pump is mounted to the hub housing of the coolant hub of the thermal management module. Usually this process includes mounting a rotor assembly on a shaft mounted on a volute portion of the hub housing, and subsequently mounting a pump housing (with or without a stator assembly) to the hub housing. However, during the assembly of the pump housing, the centering of the pump housing (and thus the stator) with respect to the volute port...

Claims

1. A hub housing (10) comprising a plurality of fluid flow channels (12) and a pump housing (14), said hub housing (10) being configured to receive in the pump housing (14), at least a rotor assembly (222) of a first pump (20), particularly the rotor assembly (222) and a stator assembly (224) of the first pump (20), characterized in that the pump housing (14) is integrally formed with the hub housing (10).

2. The hub housing (10) as claimed in the previous claim, wherein the hub housing (10) comprises a first hub housing portion (10a) and a second hub housing portion (1 0b), at least one of the first hub housing portion (10a) and the second hub housing portion (10b) comprises a volute portion (16).

3. The hub housing (10) as claimed in the previous claim, wherein the pump housing (14) is integrally formed with the first hub housing portion (10a).

4. The hub housing (10) as claimed in the previous claim, wherein the pump housing (14) is coaxial with of the volute portion (16).

5. The hub housing (10) as claimed in claim 2, wherein at least one of the first hub housing portion (10a) and the second hub housing portion (10b) define a plurality of fluid flow channels (12).

6. The hub housing (10) as claimed in any of the preceding claims, wherein the hub housing (10) and the pump housing (14) are made of different materials.

7. The hub housing (10) as claimed in any of the preceding claims, wherein the hub housing (10) and the pump housing (14) is made of a same material.

8. The hub housing (10) as claimed in any of the preceding claims wherein, the hub housing (10) and the pump housing (14) are integrally formed using an over molding process.

9. The hub housing (10) as claimed in any of the preceding claims wherein the hub housing (10) comprises a shaft (18), said shaft (18) being integrally formed with the hub housing (10), and said shaft (18) configured to be received by the first pump (20), particularly by the rotor assembly (222) of the first pump (20).

10. A thermal management module (100) comprising, • the hub housing (10) as claimed in any of the preceding claims, • at least one first pump (20) secured to the hub housing (10) and comprising an electric motor (22), the electric motor (22) comprising: ∘ a rotor assembly (222) comprising an impeller (222b) that is at least partially received within the hub housing (10), wherein the rotor assembly (222) comprises an axial aperture (28) configured to receive the shaft (18) mounted to the hub housing (10), to mount the rotor assembly (222) on the shaft (18) and, ∘ a stator assembly (224), • a cover (24) abutting an end face (14a) of the pump housing (14), wherein the rotor assembly (222) is mounted on the shaft (18) by means of a fastener (30).

11. A thermal management module (100) as described in the preceding claim in combination with claim 9 , wherein a gasket (14b) is integrally formed on the end face (14a) of the pump housing (14) facing the cover (24).

12. A thermal management module (100) as described in the preceding claim, wherein a gasket (14b) is integrally formed on the cover (24) facing the pump housing (14).

13. A method of assembling a first pump (20) to a hub housing (10) of a thermal management module (100), comprising the steps of : • aligning an axial aperture (28) of a rotor assembly (222) of the first pump (20) with a shaft (18) mounted to the hub housing (10), • inserting the shaft (18) into the axial aperture (28) by movement of at least one of the rotor assembly (222) and the hub housing (10) relative to each other, to at least partially receive the rotor assembly (222) within a pump housing (14) that is integrally formed with the hub housing (10).

14. The method of assembling as claimed in the previous claim comprising the steps of restraining the relative motion of the rotor assembly (222) with respect to the hub housing (10) using a fastener (30).

15. The method of assembling as claimed in claim 13 comprising the steps of assembling at least one of a stator assembly (224) and a cover (24) of the first pump (20).

Images