Abstract: A heating system for a vehicle having a power plant with a power plant coolant loop, and a method of operation, is disclosed. The heating system may include a HVAC module and a heater core coolant loop. The HVAC module includes a heater core. The heater core coolant loop includes a three-way valve having an inlet engaging the heater core for receiving a coolant, a first outlet that directs the coolant back into the heater core coolant loop, and a second outlet that directs the coolant into the power plant; a coolant pump for pumping the coolant through the heater core coolant loop; and a coolant heater located upstream of the heater core that selectively heats coolant flowing therethrough. Also, a coolant line receives the coolant from a heater core outlet of the power plant and directs the coolant into the heater core coolant loop.

Abstract: A method of operating a RESS thermal system in a vehicle having a coolant loop for directing a coolant through a RESS and a refrigerant loop configured to selectively cool the coolant flowing through a chiller in the coolant loop, including: determining a current target temperature range for the RESS based on a current vehicle operating mode and ambient temperature; determining a temperature of the RESS; determining if the temperature of the RESS needs to increase or decrease to be within the current target temperature range; if the determination is made that the temperature of the RESS needs to increase, determining if an active heating or a passive heating of the coolant will be employed, the active heating using a greater amount of energy over a shorter time period than the passive heating; and activating the determined active heating or passive heating of the coolant.

Abstract: A coolant system and method of operating the coolant system for a vehicle having a battery pack is disclosed. A method may include detecting a mountain grade descent condition; detecting a battery limit condition; and, if the mountain grade descent condition and the battery limit condition are detected, activating a coolant heater and a coolant pump to thereby accomplish an electric load shed. A method may include detecting a fuel cell stack warm up condition; and, if the fuel cell stack warm up condition is detected, activating a fuel cell coolant heater, a cabin coolant heater and a pump, and directing a coolant flowing through the cabin coolant heater through the fuel cell coolant heater and through a fuel cell stack to thereby warm the fuel cell stack.

Abstract: A method of operating a RESS thermal system in a vehicle having a coolant loop for directing a coolant through a RESS and a refrigerant loop configured to selectively cool the coolant flowing through a chiller in the coolant loop, including: determining a current target temperature range for the RESS based on a current vehicle operating mode and ambient temperature; determining a temperature of the RESS; determining if the temperature of the RESS needs to increase or decrease to be within the current target temperature range; if the determination is made that the temperature of the RESS needs to increase, determining if an active heating or a passive heating of the coolant will be employed, the active heating using a greater amount of energy over a shorter time period than the passive heating; and activating the determined active heating or passive heating of the coolant.

Abstract: A HVAC and RESS thermal management system and a method of operation for a vehicle having a passenger compartment, a power plant and a battery pack is disclosed. The system comprises a RESS coolant circuit and a power plant coolant circuit. The RESS coolant circuit directs a coolant through the battery pack and includes a pump, a coolant heating branch has a coolant-to-coolant heat exchanger, and a coolant routing valve that will selectively direct the coolant through the coolant heating branch. The power plant coolant circuit includes a heater core branch having a HVAC pump, a coolant heater, a heater core located in a HVAC module to provide heat to the passenger compartment, and the coolant-to-coolant heat exchanger, with the coolant-to-coolant heat exchanger providing heat transfer between the coolant in the coolant heating branch and the coolant in the heater core branch.

Abstract: A heater control system is provided that comprises a plurality of n banks of heating elements H1, H2, H3, H4, . . . , Hn each containing at least one heating element. Each one of a plurality of switches Q1, Q2, Q3, Q4, . . . , Qn is coupled to a respective one of the plurality of banks for selectively activating the plurality of banks. Each one of a plurality of control inputs is coupled to a different one of the plurality of switches to selectively activate the plurality of switches.

Abstract: A coolant system and method of operating the coolant system for a vehicle having a battery pack is disclosed. A method may include detecting a mountain grade descent condition; detecting a battery limit condition; and, if the mountain grade descent condition and the battery limit condition are detected, activating a coolant heater and a coolant pump to thereby accomplish an electric load shed. A method may include detecting a fuel cell stack warm up condition; and, if the fuel cell stack warm up condition is detected, activating a fuel cell coolant heater, a cabin coolant heater and a pump, and directing a coolant flowing through the cabin coolant heater through the fuel cell coolant heater and through a fuel cell stack to thereby warm the fuel cell stack.

Abstract: A HVAC and RESS thermal management system and a method of operation for a vehicle having a passenger compartment, a power plant and a battery pack is disclosed. The system comprises a RESS coolant circuit and a power plant coolant circuit. The RESS coolant circuit directs a coolant through the battery pack and includes a pump, a coolant heating branch has a coolant-to-coolant heat exchanger, and a coolant routing valve that will selectively direct the coolant through the coolant heating branch. The power plant coolant circuit includes a heater core branch having a HVAC pump, a coolant heater, a heater core located in a HVAC module to provide heat to the passenger compartment, and the coolant-to-coolant heat exchanger, with the coolant-to-coolant heat exchanger providing heat transfer between the coolant in the coolant heating branch and the coolant in the heater core branch.

Abstract: A heating system for a vehicle having a power plant with a power plant coolant loop, and a method of operation, is disclosed. The heating system may comprise a HVAC module and a heater core coolant loop. The HVAC module includes a heater core. The heater core coolant loop includes a three-way valve having an inlet engaging the heater core for receiving a coolant, a first outlet that directs the coolant back into the heater core coolant loop, and a second outlet that directs the coolant into the power plant; a coolant pump for pumping the coolant through the heater core coolant loop; and a coolant heater located upstream of the heater core that selectively heats coolant flowing therethrough. Also, a coolant line receives the coolant from a heater core outlet of the power plant and directs the coolant into the heater core coolant loop.

Abstract: A HVAC and battery thermal system and method for a vehicle having a passenger cabin and a battery pack is disclosed. The system may comprise a refrigerant loop and a coolant loop. The refrigerant loop includes a first leg and a second leg, the first leg including an expansion device and an evaporator, and the second leg including an expansion device and a chiller. The coolant loop directs coolant through the battery pack and includes a controllable coolant routing valve, a bypass branch and a chiller branch, with the chiller in the chiller branch. The coolant routing valve has a bypass outlet that directs the coolant into the bypass branch and a chiller outlet that directs the coolant into the chiller branch. The coolant loop may also include a radiator branch and battery radiator, with the coolant routing valve including a radiator outlet that directs the coolant into the radiator branch.

Abstract: An HVAC system for a vehicle having a battery pack, and a method of operation, is disclosed. The HVAC system may comprise a refrigerant loop having a first leg and a second leg, and a refrigerant compressor in the refrigerant loop. In the first leg, an evaporator provides cooling to a passenger cabin of the vehicle, an evaporator shut-off valve selectively blocks the flow of refrigerant through the evaporator, and an evaporator thermal expansion valve is upstream from the evaporator. In the second leg, a battery heat exchanger receives the refrigerant, a battery thermal expansion valve is located upstream from the battery heat exchanger, and a battery cooling shut-off valve selectively blocks the flow of refrigerant through the battery heat exchanger. The shut-off valves and compressor are controlled to control the cooling of the passenger cabin and the battery pack.