Improvements to fluid heater

Abstract

In an aspect, a fluid heater includes a plurality of flow plates, a first end cover plate, a second end cover plate, an electric heater and a routing member. The flow plates are sealingly joined together to define a first flow path and a second flow path. The first and second end cover plates are at first and second ends of the flow plates. At least one of the first and second end cover plates defines a first flow path inlet, a first flow path outlet, a second flow path inlet and a second flow path outlet. The heater is positioned to heat both the first flow path and the second flow path. The heater extends along the peripheral edge of the flow plates. The routing member defines a routing member flow path, and fluidically connects the first flow path outlet to the second flow path inlet.

Description

[0001] IMPROVEMENTS TO FLUID HEATER

[0002] Cross-Reference to Related Applications

[0003] [1] This application claims the benefit of, and priority to, U.S. provisional patent application no. 63 / 557,449 filed on February 23, 2024, the entire contents of which are incorporated by reference in this application, where permitted.

[0004] Field of the Invention

[0005] [2] This disclosure relates generally to the field of thermal management systems for electric vehicles, and more particularly to a fluid heater that employs components from a heat exchanger, when only a single fluid is to be heated.

[0006] Background of the Invention

[0007] [3] Thermal management systems in electric vehicles (EVs) are known to employ heat exchangers for the purpose of transferring heat between two fluids, such as coolant and refrigerant, that are used in the thermal management of components of the EV such as the vehicle’s main battery pack, the traction motor and power electronics, and the vehicle cabin. It would be advantageous to expand the use of the components that form part of such heat exchangers.

[0008] Summary of the Disclosure

[0009] [4] In an aspect, a fluid heater for a thermal management system for a vehicle is provided and includes a plurality of flow plates, a first end cover plate, a second end cover plate, an electric heater and a routing member. The plurality of flow plates each have a plurality of faces and a peripheral edge. The plurality of flow plates are sealingly joined together to define a first flow path and a second flow path, such that the first flow path and the second flow path are positioned between mutually facing ones of the faces of adjacent ones of the plurality of flow plates. The first end cover plate is at a first end of the plurality of flow plates and the second end cover plate is at a second end of the plurality of flow plates. At least one of the first end cover plate and the second end cover plate defines a first flow path inlet, a first flow path outlet, a second flow path inlet and a second flow path outlet. The electric heater is positioned to heat both the first flow path and the second flow path. The electric heater extends along the peripheral edge of at least some of the plurality of flow plates. The routing member defines a routing member flow path, and is positioned to fluidically connect the routing member flow path to the first flow path outlet and to the second flow path inlet to fluidically connect the first flow path outlet to the second flow path inlet.

[0010] [5] In another aspect, a kit of parts for use in manufacturing a fluid heater and a heat exchanger for a thermal management system for a vehicle. The kit of parts includes a plurality of flow plates, a first end cover plate, a second end cover plate, an electric heater, and a routing member. The plurality of flow plates each have a plurality of faces and a peripheral edge. The plurality of flow plates are sealingly joinable together to define a first flow path and a second flow path, such that the first flow path and the second flow path are positioned between mutually facing ones of the faces of adjacent ones of the plurality of flow plates. The first end cover plate is connectable to a first end of the plurality of flow plates and the second end cover plate is connectable to a second end of the plurality of flow plates. At least one of the first end cover plate and the second end cover plate defines a first flow path inlet, a first flow path outlet, a second flow path inlet and a second flow path outlet. The electric heater is positionable along the peripheral edge of at least some of the plurality of flow plates to heat both the first flow path and the second flow path. The routing member defines a routing member flow path, and that is mountable to whichever of the first end cover plate and the second end cover plate defines the first flow path outlet and the second flow path inlet to fluidically connect the routing member flow path to the first flow path outlet and to the second flow path inlet so as to fluidically connect the first flow path outlet and to the second flow path inlet. The plurality of flow plates, the first end cover plate and the second end cover plate are connectable together to form a heat exchanger for a first fluid in the first flow path and a second fluid in the second flow path. The plurality of flow plates, the first end cover plate and the second end cover plate, the fluid heater and the routing member are connectable together to form a fluid heater.

[0011] [6] In another aspect, a fluid heater is provided and includes a plurality of flow plates, a first end cover plate, a second end cover plate, and an electric heater. The plurality of flow plates each have a plurality of faces and a peripheral edge. The plurality of flow plates are sealingly joined together to define a single flow path that extends along the faces of each of the plurality of flow plates. The first end cover plate is connected to a first end of the plurality of flow plates and a second end cover plate that is connected to a second end of the plurality of flow plates. At least one of the first end cover plate and the second end cover plate defines a single flow path inlet and a single flow path outlet. The electric heater is positionable along the peripheral edge of at least some of the plurality of flow plates to heat the single flow path.

[0012] Brief Description of the Drawings

[0013] [7] The foregoing and other aspects of the invention will be better appreciated with reference to the attached drawings, as follows:

[0014] [8] Figure 1 is a schematic view of a basic vehicular thermal management system using refrigerant, and coolant, in accordance with an embodiment of the present disclosure.

[0015] [9] Figure 2 is an elevation view of a vehicle which contains the thermal management system shown in Figure 1.

[0016]

[0010] Figure 3 is a perspective view of a heat exchanger that is part of the thermal management system shown in Figure 1.

[0017]

[0011] Figures 4A and 4B together are a perspective exploded view of the coolantrefrigerant heat exchanger shown in Figure 6.

[0018]

[0012] Figure 5 is a magnified perspective view of a portion of the coolant-refrigerant heat exchanger shown in Figure 3.

[0019]

[0013] Figure 6 is a perspective sectional view of the coolant-refrigerant heat exchanger shown in Figure 3.

[0020]

[0014] Figure 7 is a perspective, partially-exploded view of a portion of the heat exchanger shown in Figure 4, illustrating the flow of coolant and refrigerant therethrough.

[0015] Figure 8 is a schematic illustration showing the flow of coolant and refrigerant through the coolant-refrigerant heat exchanger shown in Figure 3.

[0021]

[0016] Figure 9 is a schematic illustration showing an alternative flow path for coolant and refrigerant through an alternative embodiment of the coolant-refrigerant heat exchanger shown in Figure 3.

[0022]

[0017] Figure 10 is a perspective view of an alternative embodiment of a heat exchanger.

[0023]

[0018] Figure 11 is a sectional elevation view of a portion of the heat exchanger shown in Figure 10.

[0024]

[0019] Figure 12 is a magnified sectional elevation view of a portion of a heater that is part of the heat exchanger shown in Figure 10.

[0025]

[0020] Figure 13 is a schematic view of a basic vehicular thermal management system using refrigerant, and coolant, in accordance with another embodiment of the present disclosure.

[0026]

[0021] Figure 14 is a perspective view of a fluid heater that may be assembled using parts of the heat exchanger shown in Figure 10.

[0027]

[0022] Figure 15 is a perspective sectional view of the fluid heater shown in Figure 14.

[0028]

[0023] Figure 16 is a perspective sectional view of a variant of the fluid heater shown in Figure 14 that includes more flow plates.

[0029]

[0024] Figure 17A is a perspective view of a flow plate from the fluid heater shown in Figure 14.

[0030]

[0025] Figure 17B is a perspective view of another flow plate from the fluid heater shown in Figure 14.

[0031]

[0026] Figure 17C is a perspective sectional view of flow plates that are part of the fluid heater shown in Figure 14.

[0032]

[0027] Figure 17D is another perspective sectional view of flow plates that are part of the fluid heater shown in Figure 14.

[0028] Figure 18 is a perspective view of another fluid heater that may be assembled using parts of the heat exchanger shown in Figure 10.

[0033]

[0029] Figure 19 is a perspective view of a fluid heater according to another embodiment.

[0034]

[0030] Figure 20 is a perspective sectional view of flow plates that are part of the fluid heater shown in Figure 19.

[0035] DETAILED DESCRIPTION OF THE DISCLOSURE

[0036]

[0031] PRELIMINARY STATEMENTS

[0037]

[0032] For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the Figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiment or embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. It should be understood at the outset that, although exemplary embodiments are illustrated in the figures and described below, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and described below.

[0038]

[0033] The terms ‘comprising’ and ‘including’ and their various conjugations (e.g. ‘comprises’) will be understood to be inclusive and open-ended, and not exclusive. This means that if an element A includes or comprises an element B, it will be understood that element A could include or comprise other elements in addition to including or comprising element B. The term ‘having’ and its various conjugations are also to be understood as being open-ended in the same way as ‘comprising’ and ‘including’. These terms are not to be interpreted to exclude the presence of other features, steps or components.

[0039]

[0034] As used herein, the terms “about” and “approximately” are meant to cover variations that may exist in the upper and lower limits of the ranges of values, such as variations in properties, parameters, and dimensions.

[0040]

[0035] Various terms used throughout the present description may be read and understood as follows, unless the context indicates otherwise: "or" as used throughout is inclusive, as though written "and / or"; singular articles and pronouns as used throughout include their plural forms, and vice versa; similarly, gendered pronouns include their counterpart pronouns such that pronouns should not be understood as limiting anything described herein to use, implementation, performance, etc. by a single gender; "exemplary" should be understood as "illustrative" or "exemplifying" and not necessarily as "preferred" over other embodiments. Further definitions for terms may be set out herein; these may apply to prior and subsequent instances of those terms, as will be understood from a reading of the present description. It will also be noted that the use of the term "a" or "an" will be understood to denote "at least one" in all instances unless explicitly stated otherwise or unless it would be understood to be obvious that it must mean "one".

[0041]

[0036] Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the components of the systems and apparatuses may be integrated or separated. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components and the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order. As used in this document, "each" refers to each member of a set or each member of a subset of a set.

[0042]

[0037] As used in this document, "attached" in describing the relationship between two connected parts includes the case in which the two connected parts are "directly attached" with the two connected parts being in contact with each other, and the case in which the connected parts are "indirectly attached" and not in contact with each other, but connected by one or more intervening other part(s) between.

[0038] As used in this document, terms describing relative positions of elements such as ‘top’, ‘upper1, ‘bottom’, ‘lower1, or other analogous terms will be understood to refer to the placement of the described element during use of the apparatus of which it is a part unless the context would make it clear that it is otherwise. It will be understood that the aforementioned placement of an element, for example, can still be considered its placement even when the object that it is a part of is lying in some position other than the position in which it will be used. As an example, if reference is made to a device having an upper member, it will be understood that the upper member is being described as having an upper position when the device that it is a part of is in use or is in position for use, unless the context would make it clear that it is otherwise. Further to this example, it will be understood that the aforementioned upper member of the object can still be considered its upper member even when the object is lying on its side, for storage, or for transport, or for some other reason.

[0043]

[0039] "Memory" refers to a non-transitory tangible computer-readable medium for storing information (e.g., data or data structures) in a format readable by a processor, and / or instructions (e.g., computer code or software programs or modules) that are readable and executable by a processor to implement an algorithm. The term "memory" includes a single device or a plurality of physically discrete, operatively connected devices despite use of the term in the singular. Non-limiting types of memory include solid-state semiconductor, optical, magnetic, and magneto-optical computer readable media. Examples of memory technologies include optical discs such as compact discs (CD-ROMs) and digital versatile discs (DVDs), magnetic media such as floppy disks, magnetic tapes or cassettes, and solid state semiconductor random access memory (RAM) devices, read-only memory (ROM) devices, electrically erasable programmable read-only memory (EEPROM) devices, flash memory devices, memory chips and combinations of the foregoing. Memory may be non-volatile or volatile. Memory may be physically attached to a processor, or remote from a processor. Memory may be removable or non-removable from a system including a processor. Memory may be operatively connected to a processor in such as way as to be accessible by a processor. Instructions stored by a memory may be based on a plurality of programming and / or markup languages known in the art, with non-limiting examples including the C, C++, C#, Python ™, MATLAB ™, Java ™, JavaScript ™, Perl ™, PHP ™, SQL ™, Visual Basic ™, Hypertext Markup Language (HTML), Extensible Markup Language (XML), and combinations of the foregoing. Instructions stored by a memory may also be implemented by configuration settings for a fixed-function device, gate array or programmable logic device.

[0044]

[0040] " Processor" refers to one or more electronic hardware devices that is / are capable of reading and executing instructions stored on a memory to perform operations on data, which may be stored on a memory or provided in a data signal. The term "processor" includes a single device or a plurality of physically discrete, operatively connected devices despite use of the term in the singular. The plurality of processors may be arrayed or distributed. Non-limiting examples of processors include integrated circuit semiconductor devices and / or processing circuit devices referred to as computers, servers or terminals having single or multi-processor architectures, microprocessors, microcontrollers, microcontroller units (MCU), central processing units (CPU), field-programmable gate arrays (FPGA), application specific circuits (ASIC), digital signal processors, and combinations of the foregoing.

[0045]

[0041] Any method, application or module herein described may be implemented using computer readable / executable instructions that may be stored or otherwise held by a memory, and executed by a processor. Aspects of the present disclosure may be described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems) and computer program products according to embodiments of the disclosure. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions may be provided to a processor, such that the processor, and a memory storing the instructions, which execute via the processor, collectively constitute a machine for implementing the functions / acts specified in the flowchart and / or block diagram block or blocks.

[0046]

[0042] The flowcharts and functional block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and / or flowchart illustration, and combinations of blocks in the block diagrams and / or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

[0047]

[0043] The embodiments of the disclosures described herein are exemplary (e.g., in terms of materials, shapes, dimensions, and constructional details) and do not limit by the claims appended hereto and any amendments made thereto. Persons skilled in the art will appreciate that there are yet more alternative implementations and modifications possible, and that the following examples are only illustrations of one or more implementations. The scope of the disclosure, therefore, is only to be limited by the claims appended hereto and any amendments made thereto.

[0048]

[0044] DESCRIPTION OF THERMAL MANAGEMENT SYSTEM

[0049]

[0045] Reference is made to Figure 1 , which shows a schematic diagram of a thermal management system 10 for a vehicle 50 shown in Figure 2, in accordance with an embodiment of the present disclosure. It will be noted that the thermal management system 10 shown in Figure 1 is simplified in the sense that several components that may be present, have been omitted here for simplicity.

[0050]

[0046] The vehicle 50 may be an electric vehicle, and may include a passenger cabin 52, a traction battery 54, and a traction motor 56 (for driving one or more of the wheels shown at 58). The vehicle 50 may employ a traction motor and a traction battery for supplying power to the traction motor. The vehicle 50 is shown as a sedan, but it could be an SUV, a light-duty truck, a heavy-duty truck, an off-road vehicle, a vehicle used in construction, an aircraft, or any other suitable type of vehicle. Furthermore, the vehicle 50 may contain only a traction motor (or several of them) for driving movement of the electric vehicle 50, or alternatively, it may contain an internal combustion engine, such as a range extender engine to assist in recharging the traction battery 54 when the traction battery 54 is at or near depletion. In yet other embodiments, the vehicle 50 may be a fuel-cell vehicle, generating electric power via a fuel cell, for powering the traction motor 56. The vehicle 50 shown in Figure 2 is shown charging at a charging station 60. In other embodiments the vehicle 50 may be an engine-driven vehicle, and may lack a traction motor.

[0051]

[0047] As shown in Figure 1 , the thermal management system 10 includes a refrigerant circuit 12 and a coolant circuit 14. The refrigerant circuit 12 includes a compressor 16, a condenser 18, an expansion valve 20; and an evaporator 22, which are arranged to compress, condense, expand, and evaporate a refrigerant, respectively. The compressor 16, the condenser 18, and the expansion valve 20 may be any suitable compressor, condenser and expansion valve, respectively. The coolant circuit 14 includes a pump 24, and a radiator 26.

[0052]

[0048] The evaporator 22 may be any suitable evaporator. In the embodiment shown, the evaporator 22 may be a coolant-refrigerant heat exchanger 100, that includes a coolant flow path 26 for transporting coolant therethrough, a refrigerant flow path 28 for transporting refrigerant therethrough. The coolant flow path 26 and the refrigerant flow path 28 are positioned in order to transfer heat from one of the coolant and the refrigerant to the other of the coolant and the refrigerant. The coolant-refrigerant heat exchanger 100 may be as shown and described in PCT patent publication W02023 / 060352 A1 , the contents of which are incorporated herein by reference in their entirety.

[0053]

[0049] The refrigerant circuit 12 may further include a heater 30 that is positioned to heat the refrigerant downstream from the expansion valve 20 and upstream from the compressor 16. The heater 30 is provided to heat the refrigerant in situations in which it is advantageous to do so. In some cases, the heater 30 may be operated to heat the refrigerant to ensure that the refrigerant is entirely in gas form when entering the compressor 16. In some cases, the heater 30 may be operated to accelerate the increase in pressure in the refrigerant in the refrigerant circuit 12 in situations where the pressure of the refrigerant in at least one area of the refrigerant circuit 12 is below 1 Bar, which increases the risk of leakage of air and contaminants into the refrigerant circuit 12 from outside of the refrigerant circuit 12. In other cases, the heater 30 may be operated for any other suitable purpose.

[0050] The heater 30 may be positioned anywhere suitable in the refrigerant circuit 12 for heating the refrigerant. In the embodiment shown, the heater 30 is mounted to the coolant-refrigerant heat exchanger 100 and is positioned to heat both the refrigerant and the coolant in the coolant-refrigerant heat exchanger 100.

[0054]

[0051] The thermal management system 10 may further include a control system 32, including a memory 32a and a processor 32b. The control system 32 may be configured to control the operation of the compressor 16, the pump 24, the heater 30 and other components of the thermal management system 10. Lines showing connections between the control system 32 and the components controlled by it are not shown so as not to make Figure 1 difficult to understand.

[0055]

[0052] The refrigerant circuit 12 and the coolant circuit 14 may be used to control the temperature of one or more thermal loads for the thermal management system 10. The thermal loads may include the vehicle’s passenger cabin 52, the traction battery 56 for the vehicle 50, and the power electronics for the traction motor 54 for the vehicle 50.

[0056]

[0053] DESCRIPTION OF STRUCTURE OF COOLANT-REFRIGERANT HEAT EXCHANGER

[0057]

[0054] Reference is made to Figures 3-7, which show the coolant-refrigerant heat exchanger 100 in further detail. Figure 3 is a perspective view of the coolant-refrigerant heat exchanger 100. Figures 4a and 4b together are a perspective exploded view of the coolant-refrigerant heat exchanger 100. Figure 5 is a magnified perspective view of a portion of the coolant-refrigerant heat exchanger 100. Figure 6 is a sectional view of the coolant-refrigerant heat exchanger 100, and Figure 7 is a partially exploded perspective view of a portion of the coolant-refrigerant heat exchanger 100.

[0058]

[0055] Referring to Figures 7 and 8, the coolant-refrigerant heat exchanger 100 includes a first flow path 101 (which may be a coolant flow path 102) for transporting a first fluid (e.g. coolant, represented by arrows 104) therethrough, and a second flow path 105 (which may be a refrigerant flow path 106) for transporting a second fluid (e.g. refrigerant, represented by arrows 108) therethrough. The coolant flow path 102 and the refrigerant flow path 106 are positioned so as to transfer heat from one of the coolant 104 and the refrigerant 108 to the other of the coolant 104 and the refrigerant 108. In the example, shown, the coolant-refrigerant heat exchanger 100 includes a plurality of flow plates 110. Each flow plate 110 has a first face 112a and a second face 112b shown in Figures 4b and 6, and a peripheral edge 114 (Figure 4b). The plurality of flow plates 110 are connected together such that the coolant flow path 102 and the refrigerant flow path 106 are defined between mutually facing ones of the faces of adjacent ones of the plurality of flow plates 110. More specifically, with reference to Figures 6 and 7, in the embodiment shown, the coolant flow path 102 is defined between the second face 112b of the first plate (shown at 110a) and the first face 112a of the second plate (shown at 110b), between the second face 112b of a third plate (shown at 110c) and the first face 112a of a fourth plate (shown at 110d), between the second face 112b of a fifth plate (shown at 110e) and the first face 112a of a sixth plate (shown at 110f), and so on. Analogously, the refrigerant flow path 106 is defined between the first face 112a of the second flow plate 110b and the second face 112b of the third flow plate 110c, between the first face 112a of the fourth plate (shown at 110d) and the second face 112b of the fifth flow plate 110e, and so on. In the embodiment shown, there are 32 flow plates 110 which are sealingly joined together.

[0059]

[0056] The flow plates 110 may be made from any suitable material, such as, for example, aluminum. While it is known that aluminum has a higher thermal conductivity than certain materials such as stainless steel, aluminum is not the typical material used for coolant or refrigerant conduits in coolant-refrigerant heat exchangers in vehicles.

[0060]

[0057] INSTALLATION OF HEATER

[0061]

[0058] As shown in Figures 4B and 5, the heater 30 may include a band heater 122a that extends around substantially the entire length of the peripheral edges 114 of the flow plates 110. Additionally, the heater 30 may include a first end heater 122b that is engaged with the first flow plate 110a for imparting heat into the plurality of flow plates 110 through the thickness of the first flow plate 110a, and a second end heater 122c for imparting heat into the plurality of flow plates 110 through the thickness of the second end cover plate 111 . A heat spreader plate 125 may be provided between the second end heater 122c and the second end cover plate 111.

[0059] In the embodiments shown in Figures 10, 11 and 12, the heater 30 may be a thick film heater 400. The thick film heater 400 may be positioned on a heat transfer plate 402, that is in turn positioned to transfer heat into the flow plates 110. The thick film heater 400 includes an electrical trace 404. The electrical trace 404 is positioned for carrying a current for resistively heating the heat transfer plate 402, and heating the flow plates 110 via the heat transfer plate 402, in order to transfer heat to any coolant and / or refrigerant in the coolant-refrigerant heat exchanger 100. A portion of the electrical trace 404 is represented as a simple rectangle in Figure 10, in order to illustrate a boundary of an area of the heat transfer plate 402 that is covered by that represented portion of the electrical trace 404. The specific routing of the electrical trace 404 may be any suitable routing (e.g. a serpentine routing) that permits the electrical trace 404 to heat the heat transfer plate 402, preferably generally uniformly.

[0062]

[0060] The electrical trace 404 may end at first and second electrical terminals shown at 408 and 410, respectively.

[0063]

[0061] The thick film heater 400 further includes a base electrical insulation layer 403 (shown in Figure 12) positioned between the electrical trace 404 and the heat transfer plate 402. Atop electrical insulation layer (shown at 405 in Figure 12) may be provided to cover the electrical trace 404. It will be noted that Figure 12 is intended to be a schematic representation of the layers 403, 404 and 405, and their relative thicknesses will vary from what is represented here.

[0064]

[0062] The thick film heater 400 may be affixed to the heat transfer plate 402 in any suitable way. For example, the various layers making up the thick film heater 400 (e.g. the base electrical insulation layer 403, the electrical trace 404 and the top electrical insulation layer 405) may be applied sequentially by printing. For example, the base electrical insulation layer 403 may be printed directly onto the heat transfer plate 402; the electrical trace 404 may be printed directly onto the base electrical insulation layer 403; and the top electrical insulation layer 405 may be printed over the electrical trace 404 and onto the base electrical insulation layer 403 so as to cover the electrical trace 404.

[0065]

[0063] The heat transfer plate 402 may be made from any suitable material, such as aluminum or stainless steel. In embodiments in which the thick film heater 400 is to receive current at 800V, it is preferable for the heat transfer plate 402 to be made from a material such as stainless steel, due to its relatively high melting temperature. A reason for this is related to the base electrical insulation layer 403. The base electrical insulation layer 403 is, in some embodiments, made from a material that is initially applied to the heat transfer plate 402 in a form that is not solid. The base electrical insulation layer is then heated (e.g. cured) in order to solidify it. For certain types of material for the base electrical insulation layer 403, it has been found that, if the temperature at which it is heated is too low, it does not solidify in a way that provides good performance as an electrical insulator. By contrast, if it is heated to a temperature that is at least about 800 degrees Celsius (e.g. 850 degrees Celsius), and held there for a suitable amount of time (e.g. about 10 minutes), the base electrical insulation layer 403 solidifies in a way that provides strong performance as an electrical insulator. As a result, the base electrical insulation layer 403 may be sufficiently insulative to prevent conduction of a current thereacross at 800V from the electrical trace 404 into the heat transfer plate 4O2.f

[0066]

[0064] In embodiments in which the thick film heater 400 is to receive current at 400V, the heat transfer plate 402 may be made more easily from a material such as aluminum. It will be noted that, in either case, (i.e. whether the heat transfer plate 402 is aluminum or stainless steel, the thick film heater 400 is preferably applied to it prior to joining of the heat transfer plate 402 to the flow plates 110.

[0067]

[0065] The heat transfer plate 402 may be positioned to transfer heat into the flow plates 110 in any suitable way. For example, as shown in Figure 16, the flow plates 110 may have plate peripheral edges shown at 412. The flow plates 110 may be arranged to alternate between a first type of flow plate shown at 414a, which has a first plate peripheral edge 412a, and a second type of flow plate shown at 414b, which has a second plate peripheral edge 412b, which nests laterally inside the first peripheral edge 412a of the subsequent first type of flow plate 414a. As a result, the peripheral edge (shown at 117a) of the flow plate subassembly 117 may be uneven and can include a plurality of peaks and a plurality of valleys, such that the valleys may be referred to as spaces 422 between the flow plates 110 at the peripheral edge 117a of the flow plate subassembly 117. Furthermore, there may be a relatively large tolerance in the exact positions of the peripheral edges 412, thereby contributing further to the unevenness of the peripheral edge 114. In order to provide good heat transfer from the heat transfer plate 402 into the flow plates 110, a suitable form-fitting heat transfer material 420 can be used to at least partially fill at least some of the spaces 422 between the heat transfer plate 402 at the plate peripheral edges 412. For example, the form-fitting heat transfer material 420 may include a suitable soldering material or a brazing material. The suitable soldering material or brazing material has a melting temperature that is lower than that of the flow plates 110, lower than that of the brazing material that is used to join the flow plates 110 together, and lower than that of the heat transfer plate 402. In an example, the soldering or brazing material may have a melting temperature that is between about 350 and 400 degrees C. Once in flowable form, the soldering material or brazing material may flow via capillary action through all of the spaces 422 between the heat transfer plate 402 and the plate peripheral edges 412. The soldering material or brazing material may be any suitable soldering material or brazing material, such as, but not limited to, an alloy of tin that includes any suitable alloy materials including for example silver. A person skilled in the art will understand what material to use for the soldering material or brazing material based on the materials to be joined, and based on the temperature restraints and the cost restraints of the application.

[0068]

[0066] In some other embodiments, the form-fitting heat transfer material 420 may include a thermal paste, a cement, and / or an adhesive.

[0069]

[0067] More specifically, the form-fitting heat transfer material 420 is positioned in the spaces 422. The form-fitting heat transfer material 420 is thermally conductive, and joins the heat transfer plate 402 to the peripheral edge 117a of the flow plate subassembly 117. Worded another way, the form-fitting heat transfer material 420 is provided between a first heat transfer plate face 402a and the flow plates 110, such that the form-fitting heat transfer material 420 at least partially fills in the spaces 422 between the heat transfer plate 402 and the peripheral edge 117a of the flow plate subassembly 117, and joins the heat transfer plate 402 to the flow plates 110. The thick film heater 400 is positioned on a second heat transfer plate face 402b, which is opposite the first heat transfer plate face 402a.

[0070]

[0068] It will be noted that, while the terms brazing and soldering may generally be understood to apply in certain temperature ranges, the term ‘soldering or brazing material’ is intended to mean a material that may be soldered, depending on the material selected for the application, or a material that may be brazed, depending on the material selected for the application. In other words, in some embodiments, the soldering or brazing material is a material that can be soldered. In other embodiments, the soldering or brazing material is a material that can be brazed. In some embodiments, the soldering or brazing material is a material that can be brazed or soldered.

[0071]

[0069] In a particular embodiment, the soldering or brazing material may be heated to 480 degrees C in order to ensure that it is sufficiently flowable to suitably fill the spaces 422 between the heat transfer plate 402 and the plate peripheral edges 412.

[0072]

[0070] It will be noted that the spaces 422 between the heat transfer plate 402 and the plate peripheral edges 412 need not be fully filled so as to be completely without any voids. It is entirely possible for the spaces 422 between the heat transfer plate 402 and the plate peripheral edges 412 to be mostly filled, and to have sufficient heat transfer from the heat transfer plate 402 into the flow plates 110 so as to avoid the presence of hot spots that could result in damage and failure of the thick film heater 400 (or more broadly worded, damage and failure of the heater 30).

[0073]

[0071] As can be seen in Figure 4A, the peripheral edge 114 of the flow plates 110 is rectangular with rounded corners (a rounded rectangle) in the embodiment shown. However, it will be understood that the peripheral edge 114 could have any other suitable shape, such as a circular shape, an elliptical shape, a regular or irregular polygonal shape with rounded corners having more or fewer than four sides or any other suitable shape. The shape of the peripheral edge 114 preferably has rounded corners where corners are present, however, corners that have substantially no rounding may be provided instead.

[0074]

[0072] With reference to Figure 4A, in the embodiment shown, a first end cover plate 109 is sealingly joined to a first end of the plurality of flow plates 110 and includes a first flow path inlet 116a (which may be a refrigerant inlet), a first flow path outlet 116b (which may be a refrigerant outlet), a second flow path inlet 118a (which may be a coolant inlet) and a second flow path outlet 118b (which may be a coolant outlet). The first end cover plate 109 may be joined to the flow plates 110 in the same way that the flow plates 110 are joined to one another. In embodiments in which the first flow path inlet 116a is a refrigerant inlet, a refrigerant filter 119 may be provided at the refrigerant inlet to filter contaminants from the refrigerant 108 before it passes through the flow plates 110.

[0075]

[0073] A second end cover plate 111 (Figure 6) is sealingly joined to a second end of the plurality of flow plates 110. The second end cover plate 111 may be joined to the flow plates 110 in the same way that the flow plates 110 are joined to one another.

[0076]

[0074] With reference to Figures 7B and 8, each of the flow plates 110 has a plurality of ridges 120 thereon on each of the first and second faces 112a and 112b, which define grooves which act as channels for the flow of refrigerant 108 or coolant 104 as the case may be. In the embodiment shown, the ridges 120 on each flow plate 110 form a pattern that alternates with the pattern of the ridges 120 on each adjacent flow plate 110. In other words, the ridges on the odd-numbered flow plates 110, (i.e., the first plate, the third plate, the fifth plate, etc.), form a pattern that alternates with the pattern on the even-numbered flow plates 110, (i.e. the second plate, the fourth plate, the sixth plate, etc.). The patterns of the ridges 120 on both the odd-numbered flow plates 110 and the even-numbered flow plates 110 may be herringbone patterns.

[0077]

[0075] Figure 9 shows a sectional view of the coolant-refrigerant heat exchanger 100. As can be seen, the flow plates 110 have first and second refrigerant pass-through apertures 113 (which may more broadly be referred to as first and second pass- through apertures 113 for a first fluid) and first and second coolant pass-through apertures 115 (which may more broadly be referred to as first and second pass- through apertures 115 for a second fluid). The space between the second flow plate 110b and the third flow plate 110c is a first refrigerant space 123 (which may more broadly be referred to as a second space 123 for the first fluid). The space between the first flow plate 110a and the second flow plate 110b is a first coolant space 121 (which may more broadly be referred to as a first space 121 for the second fluid). The space between the fourth flow plate 110d and the fifth flow plate 110e is a second space 123 for the first fluid. The space between the third flow plate 110c, the fourth flow plate 110d is a second space 121 for the second fluid, and so on. The spaces between the flow plates 110 alternate between spaces 121 and spaces 123 throughout the series of flow plates 110. As can be seen, in the region of the pass-through apertures 113, the first flow plate 110a is sealingly engaged with the second flow plate 110b, the second flow plate 110b is spaced from the third flow plate 110c, the third flow plate 110c is sealingly engaged with the fourth flow plate 110d, and the fourth flow plate 110d is spaced from the fifth flow plate 110e, and so on. Thus, the refrigerant 108 can flow in the spaces 123. Additionally, in the region of the pass- through apertures 115, the first flow plate 110a is spaced from the second flow plate 110b, the second flow plate 110b is sealingly engaged with the third flow plate 110c, the third flow plate 110c is spaced from the fourth flow plate 110d, the fourth flow plate 110d is sealingly engaged with the fifth flow plate 110e, and so on. Thus, the coolant 104 can flow in the spaces 121.

[0078]

[0076] The coolant-refrigerant heat exchanger 100 further includes the heater 30 that is positioned to heat both the refrigerant 108 and the coolant 104 (or more broadly, the first fluid and the second fluid) while in the coolant-refrigerant heat exchanger 100. More broadly, the coolant-refrigerant heat exchanger 100 may be referred to as a multi-fluid heat exchanger 100.

[0079]

[0077] The heater 30 may extend along the peripheral edge 114 of substantially all of the plurality of flow plates 110 so as to impart heat into each of the flow plates 110 through the height and the width of each of the flow plates 110. The heater 30 may be an electrical resistance heater, such as, for example a PTC heater. Alternatively, the heater 30 may be any other suitable kind of heater, such as, but not limited to, an induction heater, an infrared heater, a microwave heater, or any other kind of heater.

[0080]

[0078] The heater 30 may include a band heater 122a that extends around substantially the entire length of the peripheral edges 114 of the flow plates 110. Additionally, the heater 30 may include a first end heater 122b that is engaged with the first flow plate 110a for imparting heat into the plurality of flow plates 110 through the thickness of the first flow plate 110a, and a second end heater 122c for imparting heat into the plurality of flow plates 110 through the thickness of the second end cover plate 111 . A heat spreader plate 125 may be provided between the second end heater 122c and the second end cover plate 111.

[0081]

[0079] Optionally, the heater 30 may be sized to evaporate all of the refrigerant 108 passing through the coolant-refrigerant heat exchanger 100 (i.e. all the refrigerant 108 in the refrigerant flow path 106), so as to ensure that substantially all of the refrigerant 108 can be evaporated in the coolant-refrigerant heat exchanger 100 without any heat input to the refrigerant 108 from the coolant 104 in the coolant flow path 102. In some embodiments, the heater 30 is sized to superheat all the refrigerant in the refrigerant flow path 106 in order to ensure that all of the refrigerant 108 is evaporated and that substantially none of the refrigerant 108 remains in its liquid phase.

[0082]

[0080] A controller 124 may be provided for controlling the operation of the heater 30. Electrical connections shown at 126 and 128 are provided for providing power to the heater 30 and for providing power to the controller 124.

[0083]

[0081] A heat exchanger housing 130 may be provided for housing the abovedescribed components. The housing 130 may include a first housing portion 130a and a second housing portion 130b that is sealingly connected to the first housing portion 130a. O-rings 132 may be provided for sealing around the apertures shown at 134 in the housing 130 that permit the pass-through of the coolant inlet 118a, the coolant outlet 118b, the refrigerant inlet 116a and the refrigerant outlet 116b. Another seal member 136 is provided between the refrigerant filter 119 and the refrigerant inlet 116a.

[0084]

[0082] Figure 8 shows a schematic representation of the coolant spaces 121 and the refrigerant spaces 123 and the routing of the first flow path 106 and the second flow path 102 in the embodiment shown in Figures 3-7. As can be seen, the coolant 104 travels from the coolant inlet 118a, through to the coolant spaces 121 and then along the coolant spaces 121 and back to the coolant outlet 118b. Similarly, the refrigerant 108 travels from the refrigerant inlet 116a, through to the refrigerant spaces 123 and then along the refrigerant spaces 123 and back to the refrigerant outlet 116b. Thus, in the embodiment shown in Figure 8 (and Figures 3-7), the coolant outlet 118b and the refrigerant outlet 116b are both at the same end of the plurality of flow plates 110 as the coolant inlet 118a and the refrigerant inlet 116a. In an alternative embodiment shown in Figure 9, the first end cover plate 109 and the second end cover plate 111 are configured to each have one inlet and one outlet. For example, the first end cover plate 109 may have the coolant inlet 118a and the refrigerant outlet 116b, and the second end cover plate 111 may have the coolant outlet 118b and the refrigerant inlet 116a. Thus, the coolant 104 may flow across the flow plates 110 from the first end to the second end, and the refrigerant 108 may flow across the flow plates 110 from the second end to the first end.

[0085]

[0083] Regardless of whether the coolant flow path 102 and the refrigerant flow path 106 are as shown in Figures 3-7, or are as shown in Figure 8, the coolant flow path 102 and the refrigerant flow path 106 may be said to be positioned in order to transfer heat from one of the coolant 104 and the refrigerant 108 to the other of the coolant 104 and the refrigerant 108, and the heater 30 may be said to be positioned to heat both the refrigerant 108 and the coolant 104 in the coolant-refrigerant heat exchanger 100.

[0086]

[0084] Several advantageous features of the coolant-refrigerant heat exchanger 100 are described as follows: The coolant-refrigerant heat exchanger 100 includes a plurality of flow plates 110. It has been found to be effective to provide the heater 30 in the form of a band heater 122a that extends along substantially all of the peripheral edges of the flow plates 110, and also to provide the first end heater 122b, and to provide the second end heater 122c, such that heat is transferred through the height, the width, and through the thickness of the flow plates 110. The peripheral edge heater 122a and the first and second end heaters 122b and 122c may be solid elements formed from sheet material that is joined to the flow plates 110 or to the first and second end cover plates 109 and 111 respectively in any suitable way such as by a suitable adhesive. In some embodiments, one or more of the peripheral edge heater 122a and the first and second end heaters may be in the form of a film heater that is printed directly onto the surface on which it is intended to transfer heat to.

[0087]

[0085] MODIFICATION FOR OPERATION AS FLUID HEATER

[0088]

[0086] In some embodiments, it may be useful to provide a fluid heater for a thermal management system for a vehicle, where there is only a single fluid that passes through it. For example, in a thermal management system shown at 500 in Figure 13, a coolant-refrigerant heat exchanger may be provided (shown at 502) but may lack a heater. A fluid heater shown at 504 may be provided for the coolant. Additionally or alternatively, a fluid heater 504 may be provided for the refrigerant. In the thermal management system 500 shown in Figure 13, a fluid heater 504 is provided for each of the coolant the refrigerant.

[0087] The fluid heater 504 is shown in more detail in Figures 14 and 15. Advantageously, the fluid heater 504 may be made using the components from the coolant-refrigerant heat exchanger 100. For example, the fluid heater 504 may be made from the plurality of flow plates 110, the first end cover plate 109, the second end cover plate 111 , the heater 30, and a routing member 506. The plurality of flow plates 110 are sealingly joined together (as described elsewhere herein) to define the first flow path 101 and the second flow path 105, such that the first flow path 101 and the second flow path 105 are positioned between mutually facing ones of the faces 112a, 112b of adjacent ones of the plurality of flow plates 110.

[0089]

[0088] In the embodiment shown, the first end cover plate 109 defines the first flow path inlet 116a, the first flow path outlet 116b, the second flow path inlet 118a, and the second flow path outlet 118b. However, it will be understood that it is possible for the second end cover plate 111 to define one or more of the first flow path inlet 116a, the first flow path outlet 116b, the second flow path inlet 118a, and the second flow path outlet 118b. For example, in an embodiment where the first and second flow paths 101 and 105 are as shown in Figure 9, the second end cover plate 111 may include the first flow path inlet 116a and the second flow path outlet 118b. Accordingly, more broadly worded, it may be said that at least one of the first end cover plate 109 and the second end cover plate 111 defines the first flow path inlet 116a, the first flow path outlet 116b, the second flow path inlet 118a, and the second flow path outlet 118b.

[0090]

[0089] The heater 30 may be referred to as an electric heater 30 as it is configured to receive electric current to heat both the first flow path 101 and the second flow path 105. In the embodiment shown in Figure 13, the heater 30 may be similar to that shown in Figure 10, and may include a first thick film heater 400 and a second thick film heater 400 (shown individually at 400a and 400b). In Figure 13, only the thick film heater 400a is shown as the thick film heater 400b is obscured from view. Alternatively, the heater 30 may include one or more of any suitable kind of electric heater, such as an induction heater, or a thin film heater.

[0091]

[0090] The routing member 506 defines a routing member flow path 508 (Figure 15), and is positioned to fluidically connect the routing member flow path 508 to the first flow path outlet 116b and to the second flow path inlet 118a to fluidically connect the first flow path outlet 116b to the second flow path inlet 118a.

[0091] The routing member 506 may be made in any suitable way. In the embodiment shown, the routing member 506 may be made by boring first, second and third apertures 510, 512 and 514. Optionally, the first and second apertures 510 and 512 may be pass-through apertures, which are sealed at a first end thereof by a plug. The plug for the first aperture 510 is shown at 516 and the plug for the second aperture 512 is shown at 518. The third aperture 514 may be a blind aperture that intersects the first and second apertures 510 and 512. A plug 520 may be inserted at a first end of the third aperture 514 so as to seal the first end thereof. The first, second, and third apertures 510, 512 and 514 thereby form the routing member flow path 508.

[0092]

[0092] The routing member 506 may be joined to the first end cover plate 109 in any suitable way such as by welding, brazing or by fasteners and flexible seal members.

[0093]

[0093] By forming the fluid heater 504 from the components that make up the coolantrefrigerant heat exchanger 100 the manufacturer requires fewer parts in inventory. Additionally, the fluid heater 504 is advantageous over some other fluid heaters of the prior art in that it is easy to increase its capacity to introduce heat into the fluid that passes through it. For example, in order to increase its capacity, one merely has to add more flow plates 110, and either increase the size of the heater 30, or add an additional heater that is sized to cover the additional flow plates 110. By contrast, with some fluid heaters of the prior art, expanding such a heater involves manufacturing entirely new parts. Thus, by providing the fluid heater 504 one can easily and inexpensively customize the capacity of the fluid heater 504 to different applications.

[0094]

[0094] Figure 15 shows a first fluid heater 504a that is formed by connecting together a first plurality of flow plates 110, the first and second end cover plates 109 and 111 , and a first electric heater 30. The first fluid heater 504a has a first fluid capacity. Figure 16 shows a second fluid heater 504b that is formed by connecting together a second plurality of flow plates 110, the first and second end cover plates 109 and 111 , and a second electric heater 30. The second fluid heater 504b has a second fluid capacity. In the embodiment in Figure 16, the second plurality of flow plates 110 is larger than the first plurality of flow plates 110. In other words, there are more flow plates 110 in the fluid heater 504b than there are in the fluid heater 504a. Consequently, the second fluid capacity is larger than the first fluid capacity. In the embodiment shown, the second electric heater 30 in Figure 16 is larger than the first electric heater 30 in the embodiment in Figure 15, though it is alternatively possible for the second electric heater 30 to the same size as the first electric heater 30. It is also alternatively possible for the second electric heater 30 to include more than two of the heaters 400.

[0095]

[0095] The routing member 506 may be made from any suitable material such as the same material as the flow plates 110.

[0096]

[0096] It will be noted that the fluid generally increases in temperature throughout its passage through the fluid heater 504. Thus, the fluid in the portion of the first flow path 101 that is closest to the first flow path inlet 116a is the coldest fluid in the fluid heater 504, and the fluid in the portion of the second flow path 105 that is closest to the second flow path outlet 118b is the hottest fluid in the fluid heater 504. As the spaces for the first flow path 101 and the spaces for the second flow path 105 are interleaved in the assembly of flow plates 110, the hottest fluid in the fluid heater 504 transfers heat to the coldest fluid in the fluid heater 504, thereby helping to ‘pre-heat’ the fluid entering the fluid heater 504. Worded another way, fluid in the second flow path 105 adjacent the second flow path outlet 118b is in a space adjacent to fluid in the first flow path 101 adjacent the first flow path inlet 116a so as to generate heat exchange therebetween.

[0097]

[0097] Figures 17A-17D show several views of alternative flow plates 110 that may be used instead of the flow plates 110 shown in Figures 4A-7. The flow plates 110 shown in Figures 17A-17D incorporate a similar pattern of apertures 113 and 115 to the apertures 113 and 115 in the flow plates 110 in Figures 4A-7, and which seal with the apertures 113 and 115 of the adjacent flow plate 110 so as to provide the first flow path 101 and the second flow path 105 as shown in Figure 17D. As shown in Figures 17A, 17B and 17C, each flow plate 110 may include a central divider shown at 550, which drives the fluid to flow in a U-shape about the flow plate 110. Figure 17A shows a first flow plate 110a, and Figure 17B shows a second flow plate 110b. The central divider 550 extends downwards in Figures 17A and 17B, and extends upwards in Figures 17C. A difference in the flow plates 110 in Figures 17A-17D from the flow plates 110 in Figures 4A-7 is that the flow plates 110 in Figures 17A-17D omit the chevron pattern that is present in the flow plates 110 in Figures 4A-7.

[0098] Reference is made to Figure 18, which shows the fluid heater 504 with an optional discharge valve 522. The discharge valve 522 may be any suitable type of valve such as a proportional valve with a motorized control member (not shown), that permits the flow of fluid at the second flow path outlet 118b to be divided into a plurality of fluid flows via a plurality of valve outlets 523. In such an embodiment, the motorized control member may be controlled by the control system 32 In the example shown, the discharge valve 522 divides the flow of fluid into a first outlet fluid flow and a second outlet fluid flow (via a first valve outlet 523a and a second valve outlet 523b), so as to direct coolant to two different thermal loads in parallel. In some embodiments, the discharge valve 522 may be a fixed configuration that simply diverts fluid discharged from the second flow path outlet 118b in a fixed ratio into first and second outlet fluid flows based on relative pressure drops through the first and second valve outlets 523a and 523b.

[0098]

[0099] Reference is made to Figure 19, which shows a fluid heater 530 that is similar to the fluid heater 504 but does not include a routing member. Instead the first end cover plate 109 may be provided with only a single flow path inlet 532a and a single flow path outlet 532b. The flow plates 110 that are included in the fluid heater 530 may optionally be identical to the flow plates 110 shown in Figures 17A-17D as shown in Figure 20. In such an embodiment, the flow path 101 may exist and communicates with the single flow path inlet 532a and the single flow path outlet 532b, such that there may be flow only through every second pair of adjacent flow plates 110 and an airspace between every other second pair of adjacent flow plates 110. Since the first and second end cover plates 109 and 111 sealingly engage the flow plates there is no flow in the airspaces that would otherwise define the second flow path 105.

[0099]

[0100] Optionally, the discharge valve 522 may be provided for the embodiment of the fluid heater shown in Figure 19.

[0100]

[0101] Advantageously, in an alternative embodiment (not shown), the flow plates 110 in the embodiment shown in Figure 19 may be modified so as to direct flow between all the flow plates 110 and not only through every second pair of adjacent flow plates 110. This could be achieved by changing half of the apertures 113 to seal against an opposing flow plate 110 and changing half of the apertures 115 to seal against an opposing flow plate 110, thereby permitting fluid communication between all of the flow plates while still having only a single flow path.

[0101]

[0102] Those skilled in the art will appreciate that the embodiments disclosed herein can be modified or adapted in various other ways whilst still keeping within the scope of the appended claims.

Claims

Claims1 . A fluid heater for a thermal management system for a vehicle, comprising: a plurality of flow plates each having a plurality of faces and a peripheral edge, wherein the plurality of flow plates are sealingly joined together to define a first flow path and a second flow path, such that the first flow path and the second flow path are positioned between mutually facing ones of the faces of adjacent ones of the plurality of flow plates; a first end cover plate at a first end of the plurality of flow plates and a second end cover plate at a second end of the plurality of flow plates, wherein at least one of the first end cover plate and the second end cover plate defines a first flow path inlet, a first flow path outlet, a second flow path inlet and a second flow path outlet; an electric heater that is positioned to heat both the first flow path and the second flow path, wherein the electric heater extends along the peripheral edge of at least some of the plurality of flow plates; and a routing member that defines a routing member flow path, and is positioned to fluidically connect the routing member flow path to the first flow path outlet and to the second flow path inlet to fluidically connect the first flow path outlet to the second flow path inlet.

2. A fluid heater as claimed in claim 1 , wherein the electric heater is a thick film heater.

3. A fluid heater as claimed in claim 1 , wherein fluid in the second flow path adjacent the second flow path outlet is in a space adjacent to fluid in the first flow path adjacent the first flow path inlet so as to generate heat exchange therebetween.

4. A fluid heater as claimed in claim 1 , further comprising a discharge valve connected to the second flow path outlet that includes a plurality of valve outlets, and which controls fluid flow to each of the plurality of valve outlets.

5. A kit of parts for use in manufacturing a fluid heater and a heat exchanger for a thermal management system for a vehicle, the kit of parts comprising: a plurality of flow plates each having a plurality of faces and a peripheral edge, wherein the plurality of flow plates are sealingly joinable together to define a first flowpath and a second flow path, such that the first flow path and the second flow path are positioned between mutually facing ones of the faces of adjacent ones of the plurality of flow plates; a first end cover plate that is connectable to a first end of the plurality of flow plates and a second end coverplate that is connectable to a second end of the plurality of flow plates, wherein at least one of the first end cover plate and the second end cover plate defines a first flow path inlet, a first flow path outlet, a second flow path inlet and a second flow path outlet; an electric heater that is positionable along the peripheral edge of at least some of the plurality of flow plates to heat both the first flow path and the second flow path; and a routing member that defines a routing member flow path, and that is mountable to whichever of the first end cover plate and the second end cover plate defines the first flow path outlet and the second flow path inlet to flu idically connect the routing member flow path to the first flow path outlet and to the second flow path inlet so as to f luid ically connect the first flow path outlet and to the second flow path inlet, wherein the plurality of flow plates, the first end cover plate and the second end cover plate are connectable together to form a heat exchanger for a first fluid in the first flow path and a second fluid in the second flow path, and wherein the plurality of flow plates, the first end cover plate and the second end cover plate, the fluid heater and the routing member are connectable together to form a fluid heater.

6. A kit of parts as claimed in claim 5, wherein the heat exchanger further includes the electric heater.

7. A kit of parts as claimed in claim 5, wherein the electric heater is a thick film heater.

8. A kit of parts as claimed in claim 5, further comprising a discharge valve connected to the second flow path outlet that includes a plurality of valve outlets, and which controls fluid flow to each of the plurality of valve outlets.

9. A fluid heater, comprising:a plurality of flow plates each having a plurality of faces and a peripheral edge, wherein the plurality of flow plates are sealingly joined together to define a single flow path that extends along the faces of each of the plurality of flow plates; a first end cover plate that is connected to a first end of the plurality of flow plates and a second end cover plate that is connected to a second end of the plurality of flow plates, wherein at least one of the first end cover plate and the second end cover plate defines a single flow path inlet and a single flow path outlet; and an electric heater that is positionable along the peripheral edge of at least some of the plurality of flow plates to heat the single flow path.

10. A fluid heater as claimed in claim 9, wherein the electric heater is a thick film heater.

11. A fluid heater as claimed in claim 9, further comprising a discharge valve connectable to the single flow path outlet that includes a plurality of valve outlets, and which controls fluid flow to each of the plurality of valve outlets.

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