Abstract: A heat exchanger has a core comprised of at least one core section defined by a plate stack comprising a plurality of core plates, each core plate having a plurality of spaced apart, raised openings surrounded by a flat area. The raised openings of adjacent plates are sealed together to define a plurality of tubular structures. Top and bottom manifolds are sealed to the top and bottom of the core, with continuous top and bottom end plates providing structurally rigid connections between multiple core sections of the heat exchanger. The heat exchanger may have numerous configurations, including stepped core, curved core, angled core, and/or a core having multiple sections of the same or different length, while minimizing the number of unique parts and/or parts of complex shape.

Abstract: A humidifier for transferring water vapor from a first gas stream to a second gas stream in a fuel cell system has a stack of thin plates joined together at their edges by planar sealing surfaces, with water permeable membranes between the plates. Each plate defines a gas flow passage along its top and bottom surfaces, with an inlet and outlet defined along edges of the plate, and a flow field extending between the inlet and outlet openings. Inlet and outlet passages connect the inlet and outlet openings to the flow field, with the planar sealing surfaces including bridging portions extending across these passages. Support structures are provided throughout the flow field to support the membrane and diffusion medium layer(s). Each support structure comprises a porous material which is sufficiently porous to permit gas flow through the flow field.

Abstract: A fitting assembly containing a fitting, a first plate and a second plate are provided. The first plate has a first plate wall and a first-plate aperture, the first-plate wall being positioned along an edge of the first plate defining the first-plate aperture. The second plate has a second-plate wall and a second-plate aperture, the second-plate wall being positioned along an edge of the second plate defining the second-plate aperture. The fitting assembly having the fitting being sandwiched between the first plate wall and the second plate wall. Also disclosed is a heat exchanger having the fitting assembly as described herein, and a method of forming the fitting assembly.

Abstract: A heat exchanger panel has a heat transfer surface with first and second heat transfer zones of different cooling capacities. Each zone has a subgroup of fluid flow passages having a flow capacity, each extending between a fluid inlet passage and a fluid outlet passage. Where one of the zones is adapted for cooling the tabs of a battery cell, the heat exchanger panel comprises at least one first header located at an end of the panel, including a fluid inlet header and/or a fluid outlet header, a second header at the opposite end of the panel, and a plurality of flow passages extending between the headers. At least one header has a height which is greater than the height of the flow passages, and is substantially the same as a spacing between tabs of adjacent batteries when separated by one of said heat exchanger panels.

Abstract: A heat exchanger assembly, having a heat exchanger having at least a plate pair, the plate pair defining a fluid passage for flow of fluid for heat exchange, and optionally coupled a base plate of the heat exchanger assembly. A component coupled to the heat exchanger or the base plate of the heat exchanger assembly, where the base plate is coupled to a bottom plate of the heat exchanger; the component having a plurality of parts, where one part of the plurality of parts has one or more protuberances, the one or more protuberances engaging a slit or cut-out for coupling the component.

Abstract: Disclosed is a heat exchanger having heat exchange plates and a base plate that can help to mitigate the thermal stresses encountered by a heat exchanger, particularly, around the peripheral edge portions of the heat exchanger and the base of heat exchanger. This is achieved by providing a channel of coolant fluid near the peripheral edge portions which is in between the peripheral edge portions and the manifold permitting flow of hot fluid. In addition, the base plate of the heat exchanger is protected from the hot fluid flowing through the manifold by providing deflectors that shield the base plate from the hot fluid.

Abstract: A heat exchanger has at least one plate pair comprising first and second plates with a fluid flow passage defined between the first plate and second plates. The inlet opening and the outlet opening in each plate pair are proximate to a first end and an elongate flow barrier separates the fluid flow passage into inlet and outlet portions, wherein a gap through and the flow barrier is provided proximate to the second end of each plate pair. A flow obstruction is located in the gap of each plate pair, the flow obstruction having first and second arcuate sides and being spaced from the terminal end of the flow barrier. The flow obstruction is substantially crescent-shaped, such that a middle portion of the flow obstruction is wider than the opposed ends.

Abstract: A heat exchanger for a battery has fluid-carrying panels and defines a multi-sided enclosure for enclosing at least two sides of the battery. The heat exchanger has first and second fluid-carrying panels defining first and second flow channels, where the first and second fluid-carrying panels are arranged at an angle to another. The heat exchanger may also include a third fluid-carrying panel defining a third flow channel, and being arranged at an angle to the second fluid-carrying panel. The heat exchanger has first and second plates sealingly joined together along their peripheries and defining a fluid flow passageway between their central fluid flow areas. The second plate may be compliant, its central fluid flow area being deformable away from the central fluid flow area of the first plate in response to a pressure of a fluid inside the fluid flow passageway.

Abstract: A heat exchanger for thermal management of battery units made-up of plurality of battery cells or battery cell containers is disclosed. The heat exchanger has a main body portion defining at least one primary heat transfer surface for surface-to-surface contact with a corresponding surface of at least one of the battery cells or containers. A plurality of alternating first and second fluid flow passages are formed within the main body portion each defining a flow direction, the flow direction through the first fluid flow passages being generally opposite to the flow direction through the second fluid flow passages providing a counter-flow heat exchanger. In some embodiments the heat exchanger has a two pairs of inlet and outlet manifolds, the heat exchanger providing a single-pass, counter-flow arrangement. In other embodiments the first and second fluid flow passages are interconnected by turn portions forming a U-flow, counter-flow heat exchanger.

Abstract: A heat exchanger module adapted for being mounted directly to the outer surface of the housing of an automobile system component, such as a transmission or engine housing, is provided. The heat exchanger module has a heat exchanger fixedly attached to an adapter module. The adapter module contains one of more fluid transfer channels, interface connectors, seals and mounting holes for screws and/or bolts. In one exemplary embodiment, the adapter module has an adapter plate that is sealed with one or more shim plates, the shim plates also providing a brazing surface for brazing the adapter module directly to the heat exchanger, the heat exchanger therefore being attached to the adapter module without the use of a base plate.

Abstract: A heat exchanger having a core defining a plurality of first fluid flow passages and a plurality of second fluid flow passages arranged in alternating order, and a housing enclosing the core. The housing has a top wall arranged opposite to the top of the core, and a bottom wall arranged opposite to the bottom of the core. A plurality of connecting structures which together provide a rigid connection between the core and the housing, wherein each of the connecting structures provides a connection between the top of the core and the top wall of the housing, or between the bottom of the core and the bottom wall of the housing. Wherein each of the connecting structures has a first connecting element and a second connecting element. The first connecting element is associated with the core and the second connecting element is associated with the housing.

Abstract: The invention relates to various ways in which to integrate control valves into the structure of a heat exchanger. The present disclosure relates to a heat exchanger assembly that includes a heat exchanger and a valve integration unit. The heat exchanger includes a plurality of alternating first and second fluid passages in heat exchange relation, and at least one inlet manifold and one outlet manifold interconnected by one of the plurality of first or second fluid passages. The valve integration unit is fixedly attached to heat exchanger and includes a fluid passage in fluid communication with at least one of the inlet and outlet manifolds. A valve mechanism is mounted within the valve integration unit in fluid communication with the fluid passage, the valve mechanism controlling the flow of a heat exchange fluid through said fluid passage.

Abstract: A heat exchanger for cooling batteries in hybrid or electric vehicles includes a plurality of spaced apart, discrete heat exchanger panels, each having a coolant inlet manifold section, a coolant outlet manifold section, and a plurality of coolant flow passages extending between the inlet and outlet manifold sections. The inlet and outlet manifold sections of the discrete panels are connected by tubes to define continuous coolant inlet and outlet manifolds, each having a coolant opening. The flow of coolant through discrete panels may be balanced by providing the fluid flow passages of the panels with various cross-sectional areas and/or hydraulic diameters, depending partly on the proximity of each panel to the coolant opening. In an embodiment, where the panels are formed from pairs of stamped plates, variation of the cross-sectional area and/or hydraulic diameter of the coolant flow passages may be achieved by deliberately offsetting the plates during assembly.

Abstract: A heat exchanger capable of conforming to expansion/contraction due to external stresses as well as adjusting/adapting to surface imperfections at the interface of the heat exchanger with additional components is disclosed. The heat exchanger is made up of various heat exchanger elements where the elements are interconnected in such a manner that they can shift relative to one another along and/or about different axes while maintaining fluid flow through the heat exchanger. Each element has a fluid inlet, fluid outlet and a flow passage extending therebetween, the elements being arranged such that the outlet of one element is fluidly connected to the inlet of the adjacent element. The individual elements are also physically interconnected to allow for longitudinal and/or lateral shifting in response to external expansion/contraction forces while maintaining fluid flow through the entire heat exchanger, as well as to tilting about each of these axes.

Abstract: A heat exchanger for battery thermal management applications is disclosed. The heat exchanger has at least one internal, two-pass flow passage, the at least one internal, two-pass flow passage having an inlet end and an outlet end and at least a first flow passage portion and at least a second flow passage portion interconnected by a generally U-shaped turn portion. An inlet manifold is in fluid communication with the inlet end of the internal flow passage for delivering an incoming fluid stream to the heat exchanger while an outlet manifold is in fluid communication with the outlet end of the internal flow passage for discharging an outgoing fluid stream from the heat exchanger. A bypass passage fluidly interconnects the incoming fluid stream and the outgoing fluid stream.

Abstract: A system for warming/cooling oil circulating within a power and torque transfer system of an automotive vehicle is disclosed. The system incorporates at least a first heat exchanger positioned between the inner wall of the outer housing and the outer surface of a gear forming part of the gear system enclosed within the housing, for instance a ring gear and/or pinion gear. The heat exchanger is generally formed as a single tubular member for conducting a first heat exchange fluid therethrough, the tubular member being curved to generally follow the curvature of the geometry of the inner wall of the housing and to fit within corresponding annular gaps. A second fluid channel is formed between the outer surface of the gear and the inner surface of the heat exchanger for bringing the oil into heat transfer relationship with the first heat exchanger fluid through rotation of the gear(s).

Abstract: A heat exchanger apparatus includes a housing that defines a flow passage for a first fluid. The housing has a housing fluid inlet and a housing fluid outlet communicating with the flow passage. A first heat exchanger is located within the flow passage of the housing between the housing fluid inlet and the housing fluid outlet. The first heat exchanger has a plurality of channels for transmitting a second fluid through the first heat exchanger. The heat exchanger apparatus also includes a flow diverter in the flow passage, between the housing fluid inlet and the first heat exchanger, for diverting some of the first fluid to a by-pass region of the flow passage that by-passes the first heat exchanger. As well, a flow control device is in communication with the housing fluid inlet and controls a volume and location of the first fluid entering the flow passage.

Abstract: A heat exchanger having a conical-shaped core is disclosed. A first set of flow passages is formed between mating conical-shaped core plates, the mating plates forming plate pairs that are spaced apart from each other forming a second set of flow passages therebetween. A pair of oppositely disposed fluid openings are provided for inletting/discharging a fluid to/from the heat exchanger in a co-axial manner, the fluid openings being interconnected by a pair of fluid manifolds formed in the outer perimeter of the core, the second set of flow passages and a fluid manifold formed centrally through the heat exchanger. A second set of inlet/outlet manifolds formed within the perimeter of the core are interconnected by the first set of flow passages. Flow through the first set flow passages is peripheral around the perimeter of the conically-shaped core plates while flow through the second set of flow passages is along the angle defined by the conical-shaped plates.

Abstract: A by-pass valve capable of activating at least two different temperatures is disclosed. The valve has a valve chamber housing a valve mechanism having a piston-cylinder arrangement. The cylinder defines two separate chambers therein for housing two different thermal materials each having a different activation temperature. A piston is arranged in each end of the cylinder operably coupled to the corresponding thermal material housed within the cylinder. A valve spool or valve sleeve is operably coupled to one of the pistons associated with the valve mechanism, the valve spool or sleeve adapted for sliding within the valve chamber for controlling flow to the fluid outlet ports formed in the valve. In some embodiments, the valve mechanism housing two different thermal materials can be arranged in combination with additional valve mechanism housing different thermal materials allowing for further multi-stage activation allowing for various flow arrangements through the valve.

Abstract: A manifold structure for re-directing a fluid stream between first and second ends of a manifold cavity for delivering or discharging a fluid to or from a corresponding fluid transmitting device, such as a heat exchanger is disclosed. In particular, a a flow box enclosing a fluid transmitting device is disclosed wherein an incoming or outgoing fluid is re-directed between first and second directions when being delivered to or discharged from the enclosed fluid transmitting device In one embodiment, the manifold structure includes a first curved surface having a concave curvature for redirecting a fluid stream from a first direction to a second direction. In another embodiment, the manifold structure includes a second curved surface having a convex curvature that is disposed in facing, spaced-apart relationship to the first curved surface, the first and second curved surfaces together inducing swirling movement into the incoming or outgoing fluid stream.