CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. provisional patent application no. 63/378,769, filed on October 7, 2022, the entire contents of which are incorporated by reference in this application, where permitted.

FIELD

[0002] The specification relates generally to thermal management systems for electric vehicles and more particularly to a valve for directing coolant flow in an electric vehicle.

BACKGROUND OF THE DISCLOSURE

[0003] It is known to provide thermal management systems for electric vehicles in which excess heat generated by one component is used by another component that requires heating. However, some such systems are complex and involve a large number of components such as valves and pumps, and have many seals and components, with associated complications in assembly, and high pressure drops. Improved valves and pumps are desirable.

SUMMARY OF THE DISCLOSURE

[0004] In an aspect, a valve-and-pump module for controlling a flow of coolant in a thermal management system for a vehicle. The valve-and-pump module includes a valve-and-pump module housing, a valve member, a valve actuator, a pump impeller and a pump driver. The valve-and-pump module housing defines a valve chamber, and has a plurality of valve inlet ports and a valve outlet port. The valve member is positioned in the valve chamber and has at least one pass-through aperture. The valve member is rotatable about a valve member axis between a first position in which the at least one pass-through aperture fluidically connects the plurality of valve inlet ports to the valve outlet port in a first way to provide a first flow arrangement through the coolant transport system, and a second position in which the at least one pass-through aperture fluidically connects the plurality of valve inlet ports to the valve outlet port in a second way to provide a second flow arrangement through the coolant transport system that is different than the first flow arrangement. The at least one pass-through aperture has at least one inlet end and at least one outlet end, and extends radially inward from the at least one inlet end towards the valve member axis and axially inward from the at least one outlet end. The valve actuator includes a valve actuator motor, and a valve actuator gear arrangement that includes a final gear that is positioned for rotation about the valve member axis and is operatively connected to the valve member to rotate the valve member between the first and second positions. The valve actuator is on a first axial side of the valve member. The valve-and-pump module housing defines a pump chamber having a volute. The valve-and-pump module housing has a pump inlet port that extends axially and a pump outlet port that extends tangentially. The pump inlet port is coaxial with and fluidically connected to the valve outlet port. The pump impeller is positioned in the pump chamber for rotation about a pump impeller axis that is coaxial with the valve member axis. The pump impeller is shaped so as to drive coolant from the pump inlet port through the volute to the pump outlet port. The pump driver includes an axial flux motor including a stator that is connected to the valve-and-pump module housing, and a rotor that is connected to and coaxial with the pump impeller. The rotor is rotatable by energizing the stator, to drive rotation of the pump impeller.

[0005] Other technical advantages may become readily apparent to one of ordinary skill in the art after review of the following figures and description.

BRIEF DESCRIPTIONS OF THE DRAWINGS

[0006] For a better understanding of the embodiment(s) described herein and to show more clearly how the embodiment(s) may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings.

[0007] Figure 1 is a schematic illustration of a thermal management system for an electric vehicle including a valve-and-pump module in accordance with a first embodiment of the present disclosure. [0008] Figure 2 is a perspective view of the valve-and-pump module shown in Figure 1.

[0009] Figure 3 is a sectional side view of the valve-and-pump module shown in Figure 2.

[0010] Figure 4 is a sectional perspective view of a portion of the valve-and-pump module shown in Figure 2.

[0011] Figure 5A is a perspective view of a valve member from the valve-and-pump module shown in Figure 2, in a first position.

[0012] Figure 5B is a perspective view of the valve member from the valve-and-pump module shown in Figure 2, in a second position.

[0013] Figure 6 is a plan view of a valve actuator from the valve-and-pump module shown in Figure 2.

[0014] Figure 7 is a magnified sectional side view of a seal member that forms a seal between the valve member and an associated valve inlet conduit from the valve-and- pump module shown in Figure 2.

[0015] Figure 8 is a perspective view of an alternative embodiment of the valve-and- pump module housing, showing three valve inlet ports that are each 120 degrees apart circumferentially.

[0016] Figure 9 is a side elevation view of an electric vehicle incorporating the valve and the thermal management system.

DETAILED DESCRIPTION

[0017] 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.

[0018] 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 so 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.

[0019] 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.

[0020] The indefinite article “a” is not intended to be limited to mean “one” of an element. It is intended to mean “one or more” of an element, where applicable, (i.e. unless in the context it would be obvious that only one of the element would be suitable).

[0021] Any reference to upper, lower, top, bottom or the like is intended to refer to an orientation of a particular element during use of the claimed subject matter and not necessarily to its orientation during shipping or manufacture. The upper surface of an element, for example, can still be considered its upper surface even when the element is lying on its side. [0022] Reference is made to Figure 9, which shows an electric vehicle 10. The term ‘electric vehicle’ is intended to include any vehicle that includes an electric motor 13 that drives one or more wheels 15 of the electric vehicle 10. The electric motor 13 may also be referred to as the traction motor 13, to distinguish it over other electric motors that may be present in the electric vehicle 10 for driving movement of minor elements of the electric vehicle 10 such as seats and windows and the like. The electric vehicle 10 includes a battery pack 11 for storing and releasing charge for use by the traction motor 13. The battery pack 11 may also be referred to as the battery 11 for simplicity. The battery pack 11 may incorporate a plurality of any suitable type of storage cells, such as pouch cells, cylindrical cells, other types of cells, or any combination thereof. The electric vehicle 10 may also include any other suitable type of energy storage device, in addition to the battery pack 10. The electric vehicle 10 further includes a passenger cabin shown at 16. The electric vehicle 10 further includes an ECU (electronic control unit) 18 that controls operation of various components of the electric vehicle 10. The ECU 18 may be part of a control system 19, that may include several additional controllers in addition to the ECU 18.

[0023] GENERAL DESCRIPTION OF THERMAL MANAGEMENT SYSTEM

[0024] Reference is made to Figure 1 , which shows a thermal management system 20 for the electric vehicle 10. The thermal management system 20 is used for controlling a temperature of a plurality of thermal loads 22 in an electric vehicle 10, including, for example the traction motor 13, and the battery pack 11 . For the purposes of the present disclosure, the traction motor 13 as a thermal load may include both the motor itself and the attendant power electronics including the inverter to convert DC current from the battery pack 11 to AC current for driving the traction motor 13.

[0025] The thermal management system 20 includes a refrigerant transport system 24 fortransporting refrigerant, and a coolant transport system 26 fortransporting coolant. The refrigerant is shown at by the conduits 28 in Figure 1 A and the coolant is represented by the conduits 30.

[0026] The refrigerant transport system 24 includes a chiller 32 with an expansion valve upstream therefrom, a cabin evaporator 36, and a condenser 40. The chiller 32 receives the refrigerant 28 and evaporates the refrigerant 30. The chiller 32 is also positioned to receive coolant 30 from the coolant transport system 26 and to cool the coolant 30 by the evaporation of the refrigerant 28 in the chiller 32.

[0027] Conversely, the condenser 40 is positioned to receive the coolant 30 from the coolant transport system 26 and to heat the coolant 30 by condensation of the refrigerant 28 in the condenser 40.

[0028] A compressor, shown at 41 , increases the pressure of the refrigerant 28 and drives the flow of refrigerant 28 through the refrigerant transport system 24.

[0029] The coolant transport system 26 further includes a cabin heater core 42 positioned to use the coolant 30 in order to heat an airflow to the passenger cabin 16 of the electric vehicle 10, a coolant heater 44 positioned to heat the coolant 30 by electric resistance heating, and a radiator 46 positioned to cool the coolant. The coolant heater 44 may be any suitable type of heater, such as a PTC heater and may be positioned immediately upstream from the cabin heater core 42. The radiator may be positioned near the front of the electric vehicle 10 so as to receive an air flow entering the electric vehicle 10 from the front end of the electric vehicle 10.

[0030] Degas tanks shown at 47 may be provided where suitable, as will be understood by one skilled in the art.

[0031] The thermal management system may include at least one valve-and-pump module 200. In the example embodiment shown in Figure 1 , there is a first valve-and- pump module 200a and a second valve-and-pump module 200b.

[0032] GENERAL DESCRIPTION OF VALVE-AND-PUMP MODULE

[0033] With reference to Figures 2 and 3, each valve-and-pump module 200 includes a valve 201 a and a pump 201 b. In the embodiment shown, the valve-and-pump module 200 includes a valve-and-pump module housing 202 (that is part of both the valve 201 a and the pump 201 b), and further includes a valve member 204, a valve actuator 206, a pump impeller 208 and a pump driver 210.

[0034] The valve-and-pump module housing 202 defines a valve chamber 212, and has a plurality of valve inlet ports 214 and a valve outlet port 216. In the example shown, the valve includes three valve inlet ports 214, shown individually at 214a, 214b, and 214c. For each of the valve inlet ports 214 there may be an optionally provided valve inlet conduit 217, and for the valve outlet port 216 there may be an optionally provided valve outlet conduit 219. As shown there are three valve inlet conduits 217a, 217b and 217c, which mate sealingly with the three valve inlet ports 214a, 214b, and 214c, respectively, and the valve outlet conduit 219, which mates sealingly with the valve outlet port 216.

[0035] The valve member 204 controls the flow of coolant through the valve 201 a and therefore through the valve-and-pump module 200. The valve member 204 is positioned in the valve chamber 212 and has at least one pass-through aperture 218. The at least one pass-through aperture 218 has at least one inlet end 220 and at least one outlet end 222, and may optionally extend radially inward from the at least one inlet end 220 towards the valve member axis Av and axially inward from the at least one outlet end 222.

[0036] The valve member 204 is rotatable about a valve member axis Av between a first position (Figure 5A) in which the at least one pass-through aperture 218 fluidically connects the plurality of valve inlet ports 214 to the valve outlet port 216 in a first way to provide a first flow arrangement through the coolant transport system 26, and a second position (Figure 5B) in which the at least one pass-through aperture 218 fluidically connects the plurality of valve inlet ports 214 to the valve outlet port 216 in a second way to provide a second flow arrangement through the coolant transport system 26 that is different than the first flow arrangement. An example is shown in Figures 5A and 5B. In Figure 5A, the valve member 204 connects the valve inlet port 214c with the valve outlet port 216. In Figure 5B, the valve member 204 connects the valve inlet port 214a with the valve outlet port 216. It will be noted that the valve inlet conduits 217a, 217b and 217c in Figures 5A and 5B are shown in transparent outline only, for illustrative purposes, and so as not to obscure the valve member 204 itself. The first and second positions for the valve member 204 as shown may wholly cut off flow from one of the valve inlet ports 214 and open flow from another one of the valve inlet ports 214. However, in some embodiments, the first and second positions for the valve member 204 may both permit some flow from a particular valve inlet port 214 to the valve outlet port 216, but may change the amount of flow that is permitted. Both of these examples of first and second positions constitute fluidically connecting the plurality of valve inlet ports 214 to the valve outlet port 216 in a second way to provide a second flow arrangement through the coolant transport system 26 that is different than the first flow arrangement.

[0037] The valve member 204 may have any suitable shape. For example, the valve member 204 may have an exterior surface 223 that is generally spherical. [0038] The valve actuator 206 includes a valve actuator motor 224, and a valve actuator gear arrangement 226 that includes a final gear 226a that is positioned for rotation about the valve member axis Av and is operatively connected to the valve member 204 to rotate the valve member 204 between the first and second positions. As can be seen in Figure 3, the valve actuator 206 is on a first axial side of the valve member 204.

[0039] The valve actuator gear arrangement 226 further includes an initial gear 226b, which may be a worm 233. The worm 233 includes a flight 235 that is shaped so as to be non-backdrivable so as to permit the valve actuator motor 224 to hold the valve member 204 in one of the first and second positions while the valve actuator motor 224 is deenergized.

[0040] The valve-and-pump module housing 202 further defines a pump chamber 230 having a volute 232. The valve-and-pump module housing 202 has a pump inlet port 234 that extends axially and a pump outlet port 236 that extends tangentially. The pump inlet port 234 is coaxial with and fluidically connected to the valve outlet port 236.

[0041] The pump impeller 208 is positioned in the pump chamber 230 for rotation about a pump impeller axis Ap that is coaxial with the valve member axis Av. The pump impeller 208 is shaped so as to drive coolant from the pump inlet port 234 through the volute to the pump outlet port 236. The pump impeller 208 may have any suitable shape for driving the coolant 30 in this manner.

[0042] The pump driver 210 may have any suitable structure for driving operation of the pump impeller 208. In the example shown, the pump driver 210 includes an axial flux motor 238 including a stator 240 that is connected to the valve-and-pump module housing 202, and a rotor 242 that is connected to and coaxial with the pump impeller 208. The rotor 242 is rotatable by energizing the stator 240, as is known in the art of motors, in order to drive rotation and therefore operation of the pump impeller 208. In the embodiment shown, there are two rotors 242, each of which is connected to and coaxial with the pump impeller 208. Thus, it can be said that the pump driver 210 includes at least one stator 240 and at least one rotor 242.

[0043] The at least one stator 240 and the at least one rotor 242 may be PCBs, which provides reduced axial length for the pump driver 210 as compared to some actuators of the prior art. Optionally, the at least one stator 240 and the at least one rotor 242 are positioned in the pump chamber 230 and are therefore exposed to the coolant 30.

[0044] The pump impeller 208 and the pump driver 210 are positioned on a second axial side of the valve member 204.

[0045] The valve-and-pump module housing 202 in the embodiment shown, includes a single contiguous valve-to-pump member 202a that defines at least part of the valve chamber 212, the valve inlet ports 214, the valve outlet port 216, at least part of the pump chamber 230, the pump inlet port 234, and the pump outlet port 236.

[0046] By providing the valve-and-pump module 200, a number of conduits (e.g. hoses), couplings, seal members and other components are eliminated. Additionally, the overall pressure drop that is present in the coolant system 26 is reduced as compared to a prior art system. By providing the single continuous valve-to-pump member 202a, even fewer components such as seals are needed, thereby reducing the assembly time for the thermal management system 20, and increasing its reliability.

[0047] In addition to the single contiguous valve-to-pump member 202a, the valve- and-pump module housing 202 may further include a valve chamber cover 202b, and a valve actuator housing 202c, that mounts to the single contiguous valve-to-pump member 202a and forms a seal against the valve chamber cover 202b to prevent leakage of coolant therebetween. The valve actuator housing 202c itself may include a plurality of housing member, such as a first valve actuator housing member 202d, and a second valve actuator housing member 202e which sealingly mate together. By providing the separate valve actuator housing 202c, it is possible to assemble the valve actuator 206 prior to installing it to other elements of the valve-and-pump module 200, such as to the single contiguous valve-to-pump member 202a.

[0048] A plurality of pumps 48 are provided for driving circulation of the coolant 30 in the coolant transport system 26. In the example shown there is a first pump 48a, a second pump 48b and a third pump 48c. The first pump 48a drives coolant flow through the traction motor 13 and the chiller 32. The second pump 48b drives coolant flow through the battery pack 11 . The third pump 48c drives coolant flow through the cabin heater core 42 and the coolant heater 44. [0049] In the embodiment shown in Figures 2-5B, the three valve inlet ports 214 are 90 degrees apart circumferentially about the valve member axis Av. In an alternative embodiment, shown in Figure 8, the three valve inlet ports 214 may be positioned 120 degrees apart circumferentially about the valve member axis Av. As a result, the forces acting on the valve member 204 by such causes as the coolant pressure, and any seals acting against the valve member 204 will be balanced, so as to reduce any net force acting on the valve member 204.

[0050] While the valve-and-pump module 200 is shown as having three valve inlet ports 214 and one valve outlet port 216, it is possible for the valve-and-pump module 200 to have any suitable number of valve inlet ports 214 that is a plurality of valve inlet ports 214. For example, the valve-and-pump module 200 may have two valve inlet ports 214 and one valve outlet port 216.

[0051] The valve-and-pump module 200 includes a sealing arrangement between the valve member 200 and between each of the valve inlet conduits 217. For each valve inlet conduit 217, there is a conduit outlet 250. The valve inlet conduit 217 further includes an outlet-surrounding surface 252 that surrounds the conduit outlet 250. A magnified view of the conduit outlet 250 is shown in Figure 7. The first outlet-surrounding surface 252 may be referred to as a seal support surface 252 and extends from a high region 254, and is sloped towards a low region 256. The low region 256 is at greater depth into the seal support surface 252 than is the high region 254, and is closer to the conduit outlet 250 than is the high region 254. A seal member 258 is provided and includes a seal member body 260 having a valve member engagement surface 262 positioned to slidingly engage the exterior surface 223 of the valve member 204. The seal member 258 further includes a leg 264. The leg 264 is engaged with the outletsurrounding surface 252 and is flexed in bending by engagement therewith.

[0052] Optionally, the seal member 258 is made from a first material at the valve member engagement surface 262, which has a first coefficient of friction Cf1 with the valve member 204, and the leg 264 is made from a second material, which has a second coefficient of friction Cf2 with the seal support surface 252. The second coefficient of friction Cf2 is higher than the first coefficient of friction Cf 1 , which helps to hold the seal member 258 in place on the first seal support surface 252 during movement of the valve member 204 between the first and second positions. [0053] Optionally, the seal member 258 is made from PTFE at the valve member engagement surface 262. For example, the seal member body 260 may include a layer of PTFE shown at 266, that defines the valve member engagement surface 262. For the purpose of sealing effectively and providing good grip on the seal support surface 252, the leg 264 may be made from a suitable sealing material such as, for example, a suitable rubber such as EPDM.

[0054] By flexing the leg 264 in bending as opposed to simple compression, the seal member 258 is much better able to accommodate tolerance stack up that may exist in the dimensions of the various components of the valve-and-pump module 200, without resulting in an impractically low or impractically high seal force against the seal support surface 252.

[0055] 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.