Thermal management system for electrified vehicle using power electronics heat for heating a battery

A thermal management system comprising:

• a heater loop, a battery loop, a radiator loop, and a power electronics loop operating within a glycol system;
• a first valve in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop;
• a second valve in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop;
• and
• wherein the second valve is fluidly connected to the first valve to provide at least one operational condition where waste heat from power electronics in the power electronics loop is used to heat a battery in the battery loop;
• wherein the at least one operational condition comprises a plurality of operational conditions, and including a system controller that controls the first valve and the second valve to manage heat transfer for the plurality of operational conditions;
• wherein the plurality of operational conditions includes at least a first operational condition where the waste heat from the power electronics is used to heat the battery independently or additively through a PTC heater to heat a cabin area;
• wherein during the first operational condition, the power electronics loop is used to heat a battery in the battery loop while bypassing the radiator loop;
• wherein, when in the first operational condition, the heater loop includes a PTC heater and a heater core, and wherein the first valve isolates the heater loop from all other loops such that the PTC heater and the heater core are directly looped together, and wherein when in the first operational condition, the first valve and the second valve cooperate with each other such that there is no flow through a radiator in the radiator loop and no flow through a battery chiller in the battery loop;
• and
• wherein each of the first valve and the second valve includes a first section, a second section, a third section, and a fourth section, and wherein each of the first section, the second section, the third section, and the fourth section include an outlet port A, an inlet port B, an outlet port C, an outlet port D, and an inlet port E, and wherein when in the first operational condition:
• an outlet from a battery heat exchanger in the battery loop connects to inlet port E in the third section of the first valve,
• flow to the battery chiller blocked via outlet port D in the third section of the first valve such that there is no flow through the battery chiller,
• inlet port E in the third section connects to outlet port A in the third section of the first valve such that flow can bypass the battery chiller,
• outlet port A in the third section of the first valve feeds into inlet port E of the first section of the second valve which fluidly connects to the outlet port D of the first section of the second valve,
• the outlet port D of the first section of the second valve connects to the power electronics loop,
• flow is blocked at outlet port A in the first section of the second valve such that all flow through the first section of the second valve bypasses the radiator,
• flow exiting power electronics in the power electronics loop feeds into the inlet port B of the first section of the second valve which connects to outlet port C of the first section of the second valve, and
• outlet port C of the first section of the second valve feeds back into the battery loop to heat the battery.

A thermal management system comprising:

• a heater loop, a battery loop, a radiator loop, and a power electronics loop operating within a glycol system;
• a first valve in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop;
• a second valve in fluid communication with one or more of the heater loop, the battery loop, the radiator loop, and the power electronics loop;
• wherein the second valve is fluidly connected to the first valve to provide at least one operational condition where waste heat from power electronics in the power electronics loop is used to heat a battery in the battery loop, and wherein each of the first valve and the second valve includes a plurality of discrete sections, with each discrete section having a plurality of ports;
• wherein the at least one operational condition comprises a plurality of operational conditions, and including a system controller that controls the first valve and the second valve to manage heat transfer for the plurality of operational conditions;
• wherein the plurality of operational conditions includes at least a first operational condition where the waste heat from the power electronics is used to heat the battery independently or additively through a PTC heater to heat a cabin area;
• wherein during the first operational condition, the power electronics loop is used to heat a battery in the battery loop while bypassing the radiator loop;
• and
• wherein when in a second operational condition, flow exiting the battery loop can have a portion directed into a radiator in the radiator loop and can have another portion directed to bypass the radiator, and wherein flow bypassing and exiting the radiator is then directed into the power electronics loop before being directed back into the battery loop.