Thermal management system

1 . A thermal management system adapted for use in a vehicle, the thermal management system comprising:

a main fluid circuit including a main conduit configured to conduct coolant fluid through the main fluid circuit and adapted to be in thermal communication with front and rear drives included in the vehicle to transfer heat between the front and rear drives and the coolant fluid,

a radiator fluid circuit including a radiator-circuit conduit configured to conduct the coolant fluid through the radiator fluid circuit and adapted to be in thermal communication with a radiator included in the vehicle to transfer heat between the radiator and the coolant fluid,

a battery fluid circuit including a battery-circuit conduit configured to conduct the coolant fluid through the battery fluid circuit and adapted to be in thermal communication with batteries included in the vehicle to transfer heat between the batteries and the coolant fluid and a heat exchanger in fluid communication with the battery-circuit conduit to transfer heat between the coolant fluid and a fluid in the heat exchanger, and

an integrated coolant controller comprising a coolant tank formed to define a coolant reservoir configured to store the coolant fluid, a first pump configured to pump a flow of the coolant fluid from the coolant tank through the main fluid circuit, a second pump configured to pump a flow of the coolant fluid through the battery fluid circuit, a multi-way valve configured to control the flow of the coolant fluid through the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit, and a manifold coupled to each of the coolant tank, the first and second pumps, and the multi-way valve to integrate the coolant tank, the first and second pumps, and the multi-way valve so that the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit flow through the manifold to eliminate the need for piping between the coolant tank, the first and second pumps, and the multi-way valve and to reduce the amount of power used by the pumps to supply the coolant fluid through the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit,

wherein the manifold includes a manifold body and a plurality of pipes that each extend from the manifold body, the manifold body shaped to define a plurality of fluid cavities and a plurality of valve ports that each open to one fluid cavity of the plurality of fluid cavities, and the plurality of pipes each defining a pipe passageway in fluid communication with one of the fluid cavity of the plurality of fluid cavities and one of the main conduit of the main fluid circuit, the radiator-circuit conduit of the radiator fluid circuit, and the battery-circuit conduit of the battery fluid circuit,

wherein the manifold body includes a first body section and a second body section that is separate from the first body section and coupled to the first body section, and

wherein the first and second body sections of the manifold body cooperate with each other to define the plurality of fluid cavities so that some fluid cavities included in the plurality of fluid cavities are only a part of one of the first body section and the second body section while the other fluid cavities included in the plurality of fluid cavities extend across both the first body section and the second body section.

2 . The thermal management system of claim 1 , wherein the manifold is shaped to include a plurality of temperature sensor docks each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid cavities to measure the temperature of the flow of coolant fluid.

3 . The thermal management system of claim 1 , wherein the manifold includes a tank dock configured to receive the coolant tank to mount the coolant tank on the manifold so that the coolant tank closes a top opening of the manifold and inlet and outlet ports included in the coolant tank align with tank ports on the manifold.

4 . The thermal management system of claim 3 , wherein the coolant tank is welded to the tank dock of the manifold.

5 . The thermal management system of claim 1 , wherein the manifold includes a first pump dock configured to receive the first pump to mount the first pump on the manifold so that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with the main fluid circuit.

6 . The thermal management system of claim 1 , wherein the manifold further includes a second pump dock configured to receive the second pump to mount the second pump on the manifold so that an inlet of the second pump is connected in fluid communication with the multi-way valve and an outlet of the second pump is connected in fluid communication with battery fluid circuit.

7 . The thermal management system of claim 1 , wherein the manifold includes a valve dock configured to receive the multi-way valve to mount the multi-way valve on the manifold so that a plurality of apertures included in the multi-way valve align with the plurality of valve ports on the manifold, and wherein each valve port of the plurality of valve ports is in the fluid communication with one of the fluid cavities of the plurality of fluid cavities.

8 . The thermal management system of claim 1 , wherein the coolant tank is integrally formed with the manifold so that the coolant tank and the manifold are a single-piece component.

9 . The thermal management system of claim 1 , wherein the manifold comprises:

a tank dock configured to receive the coolant tank to mount the coolant tank on the manifold so that the coolant tank closes a top opening of the manifold and inlet and outlet ports included in the coolant tank align with tank ports on the manifold,

a first pump dock configured to receive the first pump to mount the first pump on the manifold so that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with the main fluid circuit,

a second pump dock configured to receive the second pump to mount the second pump on the manifold so that an inlet of the second pump is connected in fluid communication with the multi-way valve and an outlet of the second pump is connected in fluid communication with battery fluid circuit, and

a valve dock configured to receive the multi-way valve to mount the multi-way valve on the manifold so that a plurality of apertures included in the multi-way valve align with the plurality of valve ports on the manifold.

10 . The thermal management system of claim 9 , wherein the first body section of the manifold defines the coolant tank dock and the first pump dock, and wherein the second body section of the manifold defines the second pump dock and the valve dock.

11 . The thermal management system of claim 1 , wherein the manifold body is shaped to define a first fluid cavity, a second fluid cavity, a third fluid cavity, a fourth fluid cavity, a fifth fluid cavity, a sixth fluid cavity, a seventh fluid cavity, an eighth fluid cavity, a ninth fluid cavity, a tenth fluid cavity, and a eleventh fluid cavity, wherein the first body section is shaped to define the first fluid cavity, a portion of the third fluid cavity, a portion of the fifth fluid cavity, a portion of the sixth fluid cavity, and a portion of the eleventh fluid cavity, and wherein the lower body section is shaped to define the second fluid cavity, a portion of the third fluid cavity, the fourth fluid cavity, a portion of the fifth fluid cavity, a portion of the sixth fluid cavity, the seventh fluid cavity, the eighth fluid cavity, the ninth fluid cavity, and the tenth fluid cavity.

12 . The thermal management system of claim 1 , wherein the multi-way valve includes a valve housing and a valve flow controller arranged in the valve housing to control the flow of the coolant fluid through a plurality of apertures formed in the valve housing to change the thermal management system between different modes.

13 . The thermal management system of claim 12 , wherein the different modes include:

(i) a system cooling mode in which the main fluid circuit is connected in fluid communication with the radiator fluid circuit so that the front and rear drives are cooled by the coolant fluid and heat is rejected by flowing the coolant fluid through the radiator and the battery fluid circuit is isolated from the main and radiator fluid circuits so that the batteries are cooled by the coolant fluid and heat is rejected by flowing the coolant fluid through the heat exchanger;

(ii) a system heating mode in which the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit are isolated from each other so that the front and rear drives in thermal communication with the man fluid circuit are heated, the radiator in the radiator fluid circuit is bypassed, and the batteries of the battery fluid circuit are heated;

(iii) a battery conditioning mode in which the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit are connected in fluid communication with each other so that the flow of coolant fluid flows from the main fluid circuit to the battery fluid circuit, from the battery fluid circuit to the radiator fluid circuit, and then from the radiator fluid circuit back to the main fluid circuit; and

(iv) a system cooling mode in which the main fluid circuit, the radiator fluid circuit, and the battery fluid circuit are connected in fluid communication with each other so that the flow of coolant fluid flows from the main fluid circuit to the radiator fluid circuit, from the radiator fluid circuit to the battery fluid circuit, and then from the battery fluid circuit back to the main fluid circuit.

14 . A thermal management system adapted for use in a vehicle, the thermal management system comprising:

a plurality of fluid circuits that each includes a conduit configured to conduct coolant fluid through the plurality of fluid circuits, and

an integrated coolant controller comprising:

a coolant tank formed to define a coolant reservoir configured to store the coolant fluid, the cooling tank including a plurality of outer walls and a bottom wall that extends between and interconnects the plurality of outer walls and is formed to define an inlet port and an outlet port,

a first pump configured to pump a flow of the coolant fluid from the coolant tank through the plurality of fluid circuits,

a multi-way valve configured to control the flow of the coolant fluid through the plurality of fluid circuits, and

a manifold coupled to each of the coolant tank, the first pump, and the multi-way valve to integrate the coolant tank, the first pump, and the multi-way valve so that each fluid circuit of the plurality of fluid circuits flows through the manifold to eliminate the need for piping between the coolant tank, the first pump, and the multi-way valve and to reduce the amount of power used by the first pump to supply the coolant fluid through the plurality of fluid circuits,

wherein the manifold comprises a tank dock configured to receive the coolant tank to mount the coolant tank on the manifold so that the bottom wall of the coolant tank closes a top opening of the manifold and the inlet and outlet ports formed in the bottom wall of the coolant tank align with tank ports on the manifold.

15 . The thermal management system of claim 14 , wherein the manifold includes a manifold body shaped to define a plurality of fluid cavities and a plurality of pipes that each extend from the manifold body, wherein the plurality of pipes each define a pipe passageway in fluid communication with one of the fluid cavities included in the plurality of fluid cavities and one conduit of the plurality of fluid circuits.

16 . The thermal management system of claim 15 , wherein the manifold is shaped to include a plurality of temperature sensor docks each configured to receive a temperature sensor to mount the temperature sensor in fluid communication with one of the plurality of fluid cavities to measure the temperature of the flow of coolant fluid.

17 . The thermal management system of claim 14 , wherein the coolant tank is welded to the tank dock of the manifold.

18 . The thermal management system of claim 15 , wherein the manifold includes a first pump dock configured to receive the first pump to mount the first pump on the manifold so that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits.

19 . The thermal management system of claim 15 , wherein the manifold includes a valve dock configured to receive the multi-way valve to mount the multi-way valve on the manifold so that a plurality of apertures included in the multi-way valve align with valve ports on the manifold, and wherein each of the valve ports is in the fluid communication with one of the fluid cavities of the plurality of fluid cavities.

20 . The thermal management system of claim 14 , wherein the manifold comprises:

a first pump dock configured to receive the first pump to mount the first pump on the manifold so that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with one of the plurality of fluid circuits, and

a valve dock configured to receive the multi-way valve to mount the multi-way valve on the manifold so that a plurality of apertures included in the multi-way valve align with valve ports on the manifold.

21 . The thermal management system of claim 15 , wherein the coolant tank is formed to include a lip that extends from the bottom wall of the coolant tank and is shaped to match the manifold body so that the coolant tank fits with the manifold body.

22 . An integrated coolant controller adapted for use in a thermal management system, the integrated coolant controller comprising:

a coolant tank formed to define a coolant reservoir configured to store a coolant fluid,

a first pump configured to pump a flow of the coolant fluid through the thermal management system,

a second pump configured to pump a flow of the coolant fluid through the thermal management system,

a multi-way valve configured to control the flow of the coolant fluid to different thermal fluid circuits of the thermal management system, the multi-way valve including a valve housing and a valve flow controller arranged in the valve housing to control the flow of the coolant fluid through a plurality of apertures formed in the valve housing to change the thermal management system between different modes, and

a manifold coupled to each of the coolant tank, the first pump, the second pump, and the multi-way valve to integrate the coolant reservoir of the coolant tank, the first pump, the second pump, and the multi-way valve in fluid communication with one another to eliminate the need for piping between the coolant tank, the first pump, the second pump, and the multi-way valve and to reduce the amount of power used by the first pump and the second pump to supply the coolant fluid through different fluid circuits of the thermal management system,

wherein the manifold includes a manifold body and a plurality of pipes that each extend from the manifold body, the manifold body shaped to define a plurality of fluid cavities and a plurality of valve ports that each open to one fluid cavity of the plurality of fluid cavities, and the plurality of pipes each defining a pipe passageway in fluid communication with one fluid cavity of the plurality of fluid cavities and the different fluid circuits, and

wherein the manifold includes a valve dock configured to receive the multi-way valve to mount the multi-way valve on an exterior of the manifold so that the plurality of apertures included in the valve housing of the multi-way valve align with the plurality of valve ports on the manifold.

23 . The integrated coolant controller of claim 22 , wherein the manifold is shaped to include a plurality of temperature sensor docks each adapted to receive a temperature sensor to mount the temperature sensor in fluid communication with the flow of coolant fluid to measure the temperature of the flow of coolant fluid.

24 . The integrated coolant controller of claim 22 , wherein the manifold includes a tank dock configured to receive the coolant tank to mount the coolant tank on the manifold so that the coolant tank closes a top opening of the manifold and inlet and outlet ports included in the coolant tank align with tank ports on the manifold.

25 . The integrated coolant controller of claim 22 , wherein the manifold includes a first pump dock configured to receive the first pump to mount the first pump on the manifold so that an inlet of the first pump is connected in fluid communication with the coolant reservoir of the coolant tank and an outlet of the first pump is connected in fluid communication with one of the different fluid circuits.

26 . The integrated coolant controller of claim 22 , wherein the manifold includes a second pump dock configured to receive the second pump to mount the second pump on the manifold so that an inlet of the second pump is connected in fluid communication with the multi-way valve and an outlet of the second pump is connected in fluid communication one of the different fluid circuits.

27 . The integrated coolant controller of claim 22 , wherein the valve housing of the multi-way valve defines a first valve cavity, a second valve cavity, and the plurality of apertures in fluid communication with at least one of the first valve cavity and the second valve cavity, wherein the valve flow controller includes a first valve rotor arranged in the first valve cavity of the valve housing to rotate relative to the valve housing about a first valve axis and a second valve rotor arranged in the second valve cavity of the valve housing to rotate relative to the valve housing about a second valve axis parallel to the first valve axis, and wherein the first valve rotor and the second valve rotor cooperate to define a plurality of different flow paths through the valve housing and the manifold to change the thermal management system between the different modes.

28 . The integrated coolant controller of claim 27 , wherein the first valve cavity and the second valve cavity are in in fluid communication through a connecting passageway defined by the valve housing.